Alfain ALFIN 161 W MG120-1 User manual

MG120-1 SERVISNÍ MANUÁL / SERVICE MANUAL ALFIN 161 W page 1
ALFA IN a. s. © SERVISNÍ TECHNICKÁ DOKUMENTACE
SERVISNÍ MANUÁL ALFIN 161 W SERVICE MANUAL ALFIN 161 W
1. VAROVÁNÍ WARNING
UPOZORNĚNÍ – Pouze osoba splňující
kvalifikaci danou zákonem je oprávněna
opravovat stroj.
PŘED OTEVŘENÍM KRYTU STROJE JEJ
ODPOJTE VYTAŽENÍM SÍŤOVÉ VIDLICE ZE
SÍTĚ.
Každé 4 měsíce otevřete stroj a jemněho
vyfoukejte stlačeným suchým vzduchem
POZOR, NEPOUŽÍVEJTE STLAČENÝ
VZDUCH O PŘÍLIŠ VYSOKÉM TLAKU, ABY
NEDOŠLO K MECHANICKÉMU POŠKOZENÍ
ELEKTROSOUČÁSTEK.
Každé 4 měsíce zkontrolujte řádný stav
svařovacích kabelůa síťových kabelů.
Není povolena žádná modifikace
svařovacího stroje.
Pro Vaši bezpečnost je nutné posečkat se
sundáním krytu ze stroje po odpojení ze
sítěpo dobu minimálně5 minut, kdy klesne
napětí na kondenzátorech na hodnotu pod
36 V.
NOTE Only trained personnel are
permitted to work inside the machine.
BEFORE OPENING THE MACHINE, CUT
OFF ITS ELECTRICAL POWER BY
REMOVING THE PLUG FROM THE MAINS
SUPPLY SOCKET.
Every six months, open the machine and
clean it inside, using compressed
dehumidified air.
CAUTION. DO NOT USE COMPRESSED
AIR AT TOO HIGH A PRESSURE. YOU
COULD DAMAGE THE ELECTRONIC
COMPONENTS.
With the same frequency, check the
welding cables and the supply cables.
No modification, of any type, may be
made to the welding machine.
For safety while maintaining the
machine, please shut off the supply
power and wait for 5 minutes, until
capacity voltage already drops to safe
voltage 36V.
2. BLOKOVÉ SCHÉMA ELECTRICAL PRINCIPLE DRAWING

MG120-1 SERVISNÍ MANUÁL / SERVICE MANUAL ALFIN 161 W page 2
ALFA IN a. s. © SERVISNÍ TECHNICKÁ DOKUMENTACE

MG120-1 SERVISNÍ MANUÁL / SERVICE MANUAL ALFIN 161 W page 3
ALFA IN a. s. © SERVISNÍ TECHNICKÁ DOKUMENTACE
3. NÁHRADNÍ DÍLY SPARE PARTS

MG120-1 SERVISNÍ MANUÁL / SERVICE MANUAL ALFIN 161 W page 4
ALFA IN a. s. © SERVISNÍ TECHNICKÁ DOKUMENTACE
Pos. Code Popis Description Quantity
1 003.002.0001 Ventilátor Alfin
KD1209PTBX 6A Fan Alfin KD1209PTBX 6A 1
2 7.511.249 Popruh Pegas Belt Pegas 1
3 011.000.0052 Kryt horní Alfin140T Upper Cover
Alfin140T 1
4 012.001.0000 Držák vnitřní 140ET Inner Support 140ET 1
5 012.002.0001 Kryt spodní
Alfin140T Cover Lower Alfin140T 1
6 012.002.0052 Panel přední
Alfin140T Front Panel Alfin140T 1
7 012.001.0102 Panel zadní Alfin
140-150 M Back Panel Alfin140ET 1
8+8b 014.001.0002 Knoflík Alfin kodér
bez šipky Knob Alfin encoder 1
9 015.001.0001 ChladičL-107
Alfin140ET Cooler L-107 Alfin140ET 1
10 015.001.0002 ChladičL-50
Alfin140ET Cooler L-50 Alfin140ET 2
11 015.001.0003 ChladičL-75
Alfin140ET Cooler L-75 Alfin140ET 1
12 021.001.1022 Rychlosp. samice
Alfin140ET Quick Connector Female Alfin140ET 2
13 032.002.0255 Usměr. výstupní
Alfin Rectifier Outlet Alfin 1
14 040.001.0001 Vypínačhlavní
Alfin140ET Switch ON/OFF Alfin140ET 1
16 040.003.1080 Termostat
Alfin140ET Thermostat Alfin140ET 1
17 010.0007.0005 Trafo Alfin161 Transformer Alfin161 1
18 045.000.0001 Vývodka Alfin Outlet Alfin 1
20 045.002.0001 Kabel přívodní Alfin
140ET Mains Cable Alfin 140ET 1
21 045.005.0005 Bočník Alfin140T Shunt Alfin140T 1
23 046.002.0002 Vložka slídová
Alfin140ET Insulator Alfin140ET 1
24 046.003.0401 Vložka izolační
Alfin140ET Insultaor Alfin140ET 2
25 050.001.0004 PCB HF start A140T PCB HF start A140T 1
25 050.R01.0004 PCB HF start A140T
REPAS PCB HF start A140T REPAS 1
26 050.0014.0001 PCB silová ALFIN
161 TIG HF PCB power board ALFIN 161 TIG HF 1
26 050.R014.0001 PCB silová ALFIN
161 TIG HF repas PCB power board ALFIN 161 TIG HF
used
1

MG120-1 SERVISNÍ MANUÁL / SERVICE MANUAL ALFIN 161 W page 5
ALFA IN a. s. © SERVISNÍ TECHNICKÁ DOKUMENTACE
27 050.001.0003 PCB RC-člen
A140ET PCB RC Circuit A140ET 1
28 050.5022.9900 PCB řídící ALFIN
161 TIG HF PCB Control board ALFIN 161 TIG HF 1
28 050.R522.9900 PCB řídící ALFIN
161 TIG HF repas PCB Control board ALFIN 161 TIG HF
used
1
29 044.003.0001 Cívka start HF Coil Start HF 1
30 022.002.0002 Konektor
panel.zásuvka
ALFIN
Torch connection
ALFIN
1
31 022.002.0003 Kabel propoj. 24V
Alfin140T Cable Bundle 24V Alfin140T 1
33 017.001.5512 Ventil 24V DC
D=2,7mm Solenoid Valve 24V DC D=2,7mm 1
34 3210 Sada kon. na ALFIN
3 dílce M10X1 Connector Set na ALFIN 3 Parts
M10X1CONNECTORS
1
35 021.004.3360 Konektor ovl.
hořáku Alfin orig. Connector Alfin Orig. 1
36 046.004.0003 Izolátor pod PCB HF
Gasket under PCB HF 1

MG120-1 SERVISNÍ MANUÁL / SERVICE MANUAL ALFIN 161 W page 6
ALFA IN a. s. © SERVISNÍ TECHNICKÁ DOKUMENTACE
4. KONTROLA SILOVÉ PCB CHECKING THE POWER PCB
Pozice kontaktův konektoru
•teplotní čidlo (žluté dráty):
pozice 2,5
•drát pro snímání výstupního
napětí (červený): pozice 3
•dráty bočníku: pozice 1,4
Zkontrolujte spojení kontaktů
tepelné ochrany pomocí testeru
diod, teplota chladiče nesmí být
vyšší než 40°C.
Zkontrolujte spojení mezi: +
objímkou a červeným drátem
Zkontrolujte průchodnost mezi: -
objímkou a vodiči bočníku.

MG120-1 SERVISNÍ MANUÁL / SERVICE MANUAL ALFIN 161 W page 7
ALFA IN a. s. © SERVISNÍ TECHNICKÁ DOKUMENTACE
Vstupní usměrňovačna silové
desce
Pro kontrolu můstku změřte tento
podle následující tabulky
testerem diod
Červený
vodičČerný vodičNaměřená
hodnota
F+ D OL
D F+ >0.450
D F- OL
F- D >0.450
Pro kontrolu tranzistorůzměřte
tyto podle následující tabulky
testerem diod
červený černý hodnota
S G 0,28
G S 0,6
Hodnoty jsou orientační.
Naměříte-li zkrat, nebo rozpojený
obvod (OL), je nutné PCB
vyměnit

MG120-1 SERVISNÍ MANUÁL / SERVICE MANUAL ALFIN 161 W page 8
ALFA IN a. s. © SERVISNÍ TECHNICKÁ DOKUMENTACE
Varistor je blízko vstupu
napájecího napětí na silovou
PCB. Toto zařízení slouží
k ochraněPCB před vstupním
přepětím. Při přepětí "exploduje"
a zkratuje vstup. Je-li rozsah
zkratu velmi
vysoký, obvod se přeruší
Pro kontrolu tranzistor změřte
podle následující tabulky
testerem diod
červený
černý hodnota
G D 0,5
D S OL
G S 0,6
Hodnoty jsou orientační.
Naměříte-li zkrat, nebo rozpojený
obvod (OL), je nutné PCB
vyměnit

MG120-1 SERVISNÍ MANUÁL / SERVICE MANUAL ALFIN 161 W page 9
ALFA IN a. s. © SERVISNÍ TECHNICKÁ DOKUMENTACE
Digitální multimetr. "OL" označuje
přerušený obvod

150 T / 150 W / 161T / 161W
Ultima modifica/ Last Modify: 03/11/2010 Rev1 pagina 10 di 17
PROBLEM CASE SOLUTION
The machine does not
switch on.
! Electrical power does not reach the ma-
chine.
! Voltage reaches the machine switch but
there is no voltage after the contacts.
! There is voltage after the disconnecting
switch but the machine does not go on.
"! Make sure the line switches are closed, the
protection devices (fuses) have not been
enabled and that the power supply cable is
intact.
"! Switch the machine off and disconnect the
plug. Make sure that when the switch is
closed, there is continuity between the
contact input and output and that the varis-
tor is not broken (picture 5). If it’s dama-
ged, the Power Board must be replaced.
"! Switch the machine off and disconnect the
plug. Check the mosfet of the switching
power supply unit on the power board
(picture 6). If it’s damaged, the Power
Board must be replaced.
The protection devices
of the line set off when
the switch is activated
and the machine does
not go on.
! Damaged power supply cable with short-
circuited wires.
! Inverter is damaged.
"! Switch off the machine and disconnect the
plug. Make sure that there are no short
circuits between the poles of the plug
caused by a damaged power supply cable.
"! Switch off the machine, disconnect the
plug and check:
- varistors (picture 5);
- l’inverter (picture 4);
- Input bridge rectifier (picture 3)
! switching power supply unit (picture 6).
If one of these components is damaged
replace the power board.
The front panel does
not switch on.
! The fan works but the front panel does
not go on.
! Both the fan and the front panel do not
work.
"! Switch off the machine and disconnect the
plug. Make sure the flat cable that con-
nects the front panel to the power board is
inserted correctly. If correctly inserted, re-
place the front panel. If the front panel
does not go on, one of the switching power
supply unit outputs is broken. Therefore
the power board must be replaced.
"! Switch off the machine, disconnect the
plug and check the mosfet of the switching
power supply unit (picture 6).
!"#$%&'(
)*+,-*( ./--0123( ,45( /20( 6,-7( ,2( 58*( 9/.812*(
9/7*(:4-*(15(1:(,++( /2;( 58*(<=43( 8/:( >**2( ;1:?
.,22*.5*;@(
'(

150 T / 150 W / 161T / 161W
Ultima modifica/ Last Modify: 03/11/2010 Rev1 pagina 11 di 17
PROBLEM CASE SOLUTION
The output voltage in
each procedure is about
9V and enabling of the
thermal protection de-
vice.
Wait a few minutes keeping the machine on
to favour cooling of the inverter. If the ma-
chine continues running with the protection
devices on, switch the machine off and dis-
connect the plug. Remove the hood and
make sure:
! the temperature of the heat sink tool is
less than 40°C;
! If it is less than 40°C, check whether the
thermal protective device contacts are
normally closed.
- If the protection device is always
opened it is defective, it must be
accordingly replaced.
- If it is closed, make sure the two terminals
are well inserted in the connector(picture 1).
- Power board feed problems, it must be
accordingly replaced.
The MMA/TIG output
voltage is about 10V
and the machine does
not weld.
! The output voltage cable of the Power
Board is damaged (picture 1).
! The primary current alarm on the power
board is activated.
"! Switch off the machine and disconnect the
plug:
! Make sure that the wiring contact is cor-
rectly inserted in the connector.
! Check for continuity between the +/-
output outlets and that the 6-path con-
nector is connected to the power board
(picture 1);
"! The power board must be replaced.
The output voltage in
MMA is zero.
Switch the machine off and disconnect the
plug. Check for a short circuit at the DINSE
plug with a diode tester. A short circuit may
be caused by :
! damaged transil on the snubber board;
! damaged diode;
! damaged inverter;
! The inductive value of the Power Trans-
former is null.
Switch off the machine and disconnect the
plug. Remove the snubber board:
"! check with a diode tester the status of the
transil on the snubber board (picture 2);
"! check with a diode tester the status of the
diode (picture 2);
"! check the status of the power board
(picture 4);
"! The Power Transformer must be replaced.
When welding the pro-
tection devices of the
line set off.
Make sure the welding current does not
require greater power than the one supplied
by the line.
Decrease the welding current.
The welding is non opti-
mal.
Spattering occurs during welding. Make sure welding polarity is correct, the
earth clamp is fixed correctly.

150 T / 150 W / 161T / 161W
Ultima modifica/ Last Modify: 03/11/2010 Rev1 pagina 12 di 17
PROBLEM CASE SOLUTION
The machine does not
strike in HF mode.
! The front panel could be damaged.
! The HF board could be damaged.
! HF board cable could be damaged or
disconnected.
"! Replace the front panel board; first verify
that the spare part has the right software.
"! The HF board must be replaced.
"! Connect the cables or, if damaged, replace
them (picture 8).
Gas does not come out
from solenoid valve.
! Excessive gas pressure.
! Damage solenoid valve wiring.
! The solenoid valve control relay on the
front panel is damaged.
! Feeding is missing.
! Solenoid valve is damaged.
"! Remove the gas connection. Carry out a
gas test on the front panel in the TIG pro-
cedure and check opening of the solenoid
valve. Reduce gas pressure. Restore con-
nections and carry out a gas test.
"! Switch off the machine and disconnect the
plug:
! Check the continuity of the solenoid
valve cable .If there’s no continuity, try
to repair the damaged cables;
! Check that the connectors are correctly
inserted (picture 8).
"! The front panel must be replaced.
"! The HF board could be damaged, in that
case it must be replaced.
"! Should the operations carried out not have
a positive outcome, replace the solenoid
valve.
The torch button does-
n’t work.
! The Torch could be damaged.
! There is no continuity between the
amphenol connector and the front panel.
! The front panel or the HF board are
damaged.
"! The Torch must be replaced.
"! Single out the interruption and replace the
wiring.
"! The damaged boards must be replaced.
The machine always
welds at maximum cur-
rent.
! The Torch could be damaged.
! The Front Panel could be damaged.
! The Power Board could be damaged.
! The shunt wires could be damaged or
not correctly inserted.
Switch off the machine and disconnect the
plug:
"! Replace the Torch;
"! Replace the Front Panel;
"! Replace the Power Board;
"! Connect the shunt wires or if damaged,
replace them.
Gas comes out but the
machine doesn’t weld.
Pre-gas settings are not correct. "! Regulate pre-gas settings.
The machine can’t stop
welding or the welding
current is not the one
set.
The slope up and slope down are not cor-
rectly set.
"! Regulate in the correct way the slopes.
"! Otherwise, reset the parameters and reset
the machine (picture 8).

150 T / 150 W / 161T / 161W
Ultima modifica/ Last Modify: 03/11/2010 Rev1 pagina 13 di 17
EXPLANATION
Position of the connector in which they are inserted:
"! thermal protection device (yellow wires): position 2, 5
"! Wire for the output voltage reading: position 3 (red)
"! Shunt wires: position 1, 4.
Check the continuity of contact of the thermal protection de-
vice with the diode tester, with the heat sink tool temperature
less than 40° C.
Check the continuity between: + socket and the shunt; - socket
and the output voltage wire.
Remove the snubber board and check with a diode tester the
stauts of the transil.
At the ends of the two transils (see below) positioned on the
snubber board, “OL” must always be measured.
Thermal protection device
Shunt
Output voltage
PICTURE 1
6 pin connector
Transil
PICTURE 2

150 T / 150 W / 161T / 161W
Ultima modifica/ Last Modify: 03/11/2010 Rev1 pagina 14 di 17
EXPLANATION
Input bridge rectifier .
To check the Input bridge rectifier , carry out the following
measurements with a diode tester:
Should there be a short circuit on one of these measurements,
the input bridge rectifier must be replaced.
To check the inverter, carry out the following measurements
with a diode tester:
Should there be a short-circuit on one of these measurements
or an “OL” instead of a numeric value, the power board must
be replaced.
The varistor is a blue disc near the ground wire of the power
board. This device is for protecting the board from input
overvoltage. When there is overvoltage it “explodes” causing a
short circuit most of the times. If the extent of the short circuit
is very high they become an open circuit.
Faston Probe Faston Probe Measure
F+ red D black “OL”
Fred D black >.450
F+ black D red “OL”
F- black D red >.450
PICTURE 3
F+
DF-
D
G D S
G D S
G D G D S
PICTURE 4
Red Probe Black Probe Measure
S G 0.28
G S 0.6
PICTURE 5
Varistor

150 T / 150 W / 161T / 161W
Ultima modifica/ Last Modify: 03/11/2010 Rev1 pagina 15 di 17
EXPLANATION
To check the mosfet of the switching power supply unit, carry
the following measurements with a diode tester:
Should there be a short-circuit on one of these measurements
or an “OL” instead of a numeric value, the power board must
be replaced.
Tester or digital millimetre. “OL” means Open Loop.
PICTURE 7
S D G
PICTURE 6
Red Probe Black Probe Measure
G D 0.5
D S “OL”
G S 0.6

150 T / 150 W / 161T / 161W
Ultima modifica/ Last Modify: 03/11/2010 Rev1 pagina 16 di 17
EXPLANATION
Check that the cable 24V that connect the Front Panel and the
HF board is whole and well inserted.
(for HF transformer and Solenoid Valve problem)
Check that the ampenol wiring are intact and well inserted.
In order to reset the parameters, switch the machine on while
the S1 and S3 buttons are being pressed.
24V 140 T
PICTURE 8
Amphenol wire
Amphenol Connector
S1 S3

MG120-1
SERVISNÍ MANUÁL ALFIN 161 W SERVICE MANUAL ALFIN 161 W
Vypracoval:
Worked out: DJ 24/1/2011 Přezkoumal: Inspected: DJ /11/2011 Schválil: Approved: DJ /11/2011