ALFIN 150 TIG HF User manual

MG014-2 SERVISNÍ MANUÁL / SERVICE MANUAL ALFIN 150 TIG HF page 1
ALFA IN a. s. © SERVISNÍ TECHNICKÁ DOKUMENTACE
SERVISNÍ MANUÁL ALFIN 150 TIG
HF SERVICE MANUAL ALFIN 150 TIG HF
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

MG014-2 SERVISNÍ MANUÁL / SERVICE MANUAL ALFIN 150 TIG HF page 2
ALFA IN a. s. © SERVISNÍ TECHNICKÁ DOKUMENTACE

MG014-2 SERVISNÍ MANUÁL / SERVICE MANUAL ALFIN 150 TIG HF page 3
ALFA IN a. s. © SERVISNÍ TECHNICKÁ DOKUMENTACE
3. NÁHRADNÍ DÍLY SPARE PARTS

MG014-2 SERVISNÍ MANUÁL / SERVICE MANUAL ALFIN 150 TIG HF page 4
ALFA IN a. s. © SERVISNÍ TECHNICKÁ DOKUMENTACE
POZ. CODE NAZEV DESCRIPTION
1 003.002.0001 ventilátor FAN 1
2 005.001.0001 popruh BELT 1
3 011.000.0052 kryt vrchní CASE 1
4 012.001.0000 držák vnitřní INTERNAL
FRAMEWORKS 1
5 012.002.0001 kryt spodní BASE 1
6 012.002.0052 panel přední FRONT 1
7 012.001.0102 panel zadní BACK 1
8 014.002.0000 Knoflík+ krytka knoflíku HANDLE WITHOUT
POINTER+ COVER
FOR HANDLE
1
9 015.001.0001 chladičL-107 DISSIPATER L=107mm
1
10 015.001.0002 chladičL-50 DISSIPATER L=50mm 2
11 015.001.0003 chladičL-75 DISSIPATER L=75mm 1
12 AO-20510 rychlosp. samice FIXED SOCKET 200A 2
13 032.002.0255 usměrňovačvýstupní ISOTOPE DIODE 1
14 040.001.0001 vypínačhlavní ISOTOPE DIODE 1
15 040.001.0002 chráničhl.vyp. TWO-POLE SWITCH 1
16 040.003.1080 termostat THERMAL CUT-OUT 1
17 042.003.0001 trafo PLANAR
TRANSFORMER 1
18 045.000.0001 vývodka 1 CABLE GRIP 1 1
19 045.000.0002 matice vývodky 2 CABLE GRIP 2 1
20 045.002.0001 kabel přívodní 3x2,5 NEOPRENE CABLE 1
21 045.005.0005 bočník SHUNT 1
22 045.006.0005 propoj kl. pólu SHUNT 1
23 046.002.0002 vložka slídová SHEET OF MYLAR 1
24 046.003.0401 vložka isolační SHEET OF SIL-PAD 2
25 050.001.0004 PCB HF start HF BOARD 1
26 050.002.0001 PCB silová POWER BOARD 1
27 050.001.0003 PCB RC-člen SNUBBER BOARD 1
28 050.517.1400 PCB řídící A150T s pan FRONT PANEL 1
29 044.003.0001 cívka HF startu HF TRANSFORMER 1
30 022.002.0002 kabel propoj ovl. TORCH CONNECTOR
WIRING 1
31 022.002.0003 kabel propoj 24V 24V CONTROL
WIRING 1
32 022.002.0004 kabel propoj HF SHUNT 1
33 017.001.5512 Ventil SOLENOID VALVE 1
34 021.000.0000 sada pro příp. plynu KIT FOR GAS
CONNECTORS 1

MG014-2 SERVISNÍ MANUÁL / SERVICE MANUAL ALFIN 150 TIG HF page 5
ALFA IN a. s. © SERVISNÍ TECHNICKÁ DOKUMENTACE
35 021.004.3360 konektor ovl. hořáku TORCH CONNECTOR 1
36 046.004.0003 izolátor pod HF PCB HF BOARD
INSULATION 1
4. KONTROLA SILOVÉ PCB CHECKING THE POWER PCB

MG014-2 SERVISNÍ MANUÁL / SERVICE MANUAL ALFIN 150 TIG HF page 6
ALFA IN a. s. © SERVISNÍ TECHNICKÁ DOKUMENTACE
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.
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

MG014-2 SERVISNÍ MANUÁL / SERVICE MANUAL ALFIN 150 TIG HF page 7
ALFA IN a. s. © SERVISNÍ TECHNICKÁ DOKUMENTACE
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
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

MG014-2 SERVISNÍ MANUÁL / SERVICE MANUAL ALFIN 150 TIG HF page 8
ALFA IN a. s. © SERVISNÍ TECHNICKÁ DOKUMENTACE
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
Digitální multimetr. "OL" označuje
přerušený obvod

150 T / 150 W
Ultima modifica/ Last Modify: 18/03/2008 Rev0 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 cir-
cuits 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
Ultima modifica/ Last Modify: 18/03/2008 Rev0 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 +/- out-
put outlets and that the 6-path connector
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 re-
quire 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
Ultima modifica/ Last Modify: 18/03/2008 Rev0 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
Ultima modifica/ Last Modify: 18/03/2008 Rev0 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
Ultima modifica/ Last Modify: 18/03/2008 Rev0 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
Ultima modifica/ Last Modify: 18/03/2008 Rev0 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
Ultima modifica/ Last Modify: 18/03/2008 Rev0 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

MG014-2 SERVISNÍ MANUÁL / SERVICE MANUAL ALFIN 150 TIG HF
Vypracoval:
Worked out: DJ 15/4/2010 Přezkoumal: In pected: DJ 15/4/2010 Schválil: Approved: VS 15/4/2010