ALFIN 150 TP User manual

MG062-2 SERVISNÍ MANUÁL / SERVICE MANUAL ALFIN 150 TP page 1
ALFA IN a. s. © SERVISNÍ TECHNICKÁ DOKUMENTACE
SERVISNÍ MANUÁL ALFIN 150 TP SERVICE MANUAL ALFIN 150 TP
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 sítě
po 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

MG062-2 SERVISNÍ MANUÁL / SERVICE MANUAL ALFIN 150 TP page 2
ALFA IN a. s. © SERVISNÍ TECHNICKÁ DOKUMENTACE

MG062-2 SERVISNÍ MANUÁL / SERVICE MANUAL ALFIN 150 TP page 3
ALFA IN a. s. © SERVISNÍ TECHNICKÁ DOKUMENTACE
3. NÁHRADNÍ DÍLY SPARE PARTS

MG062-2 SERVISNÍ MANUÁL / SERVICE MANUAL ALFIN 150 TP page 4
ALFA IN a. s. © SERVISNÍ TECHNICKÁ DOKUMENTACE
Poz.
Kód / CODE Název DESCRIPTION
1 005.001.0002 Popruh Alfin150
BELT
2 011.001.0001 Kryt horní Alfin150
UPPER COVER
3 015.001.0001 ChladičL-107 Alfin140ET
HEAT SINK L=107mm
4 015.001.0002 ChladičL-50 Alfin140ET
HEAT SINK L=50mm
5 050.010.0001 PCB silová A150
POWER BOARD
6 012.001.0000 Držák vnitřní 140ET
INTERNAL FRAMEWORKS
7 050.001.0018 PCB řídící A150 modrý
LOGIC FRONT PANEL
8 013.015.0001 Panel přední-nálepka A150
FRONT LABEL
9 AO-20510 Rychlosp. 10-25 panel samice
FIXED SOCKET 200A
10 012.001.0150 Panel přední Alfin150M
FRONT PLASTIC PANEL
11 014.002.0011 Knoflík ALFIN modrý 1980/M
KNOB
12 012.001.0006 Kryt spodní Alfin150
LOWER COVER
13 040.003.1080 Termostat Alfin140ET
TERMAL SWITCH
14 045.006.0002 Propoj kladného pólu Alfin140E
COPPER BRACKET
15 015.001.0003 ChladičL-75 Alfin140ET
HEAT SINK L=75mm
16 032.002.0255 Usměrňovačvýstupní Alfin
DIODE
17 050.001.0043 PCB 150TP
DOUBLER - OVERCUT
BOARD
18 003.002.0001 Ventilátor Alfin
FAN
19 046.004.0003 Izolátor pod PCB HF
ELECTRICAL INSULATION
20 012.001.0102 Panel zadní Alfin 140-150 M
REAR PLASTIC PANEL
21 045.000.0001 Vývodka Alfin
CABLE CLAMP
22 045.002.0001 Kabel přívodní Alfin 140ET
SUPPLY CABLE
23 040.001.0001 Vypínačhlavní Alfin140ET
TWO-POLE SWITCH
24 042.003.0001 Trafo Alfin140ET
PLANAR TRANSFORMER
25 045.005.0003 Bočník Alfin140E
SHUNT

MG062-2 SERVISNÍ MANUÁL / SERVICE MANUAL ALFIN 150 TP page 5
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.

MG062-2 SERVISNÍ MANUÁL / SERVICE MANUAL ALFIN 150 TP page 6
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

MG062-2 SERVISNÍ MANUÁL / SERVICE MANUAL ALFIN 150 TP page 7
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

MG062-2 SERVISNÍ MANUÁL / SERVICE MANUAL ALFIN 150 TP page 8
ALFA IN a. s. © SERVISNÍ TECHNICKÁ DOKUMENTACE
Digitální multimetr. "OL" označuje
přerušený obvod

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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 4). 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 5).
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 4);
- inverter (picture 3);
- Input bridge rectifier (picture 2);
switching power supply unit (picture 5).
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 5).
!"#$%&'(
)*+,-*( ./--0123( ,45( /20( 6,-7( ,2( 58*( 9/.812*(
9/7*( :4-*(15(1:( ,++(/2;(58*(<=43( 8/:( >**2(;1:?
.,22*.5*;@(
'(

150 TURBO / 150
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PROBLEM CASE SOLUTION
The MMA/TIG output
voltage is about 10V
and the machine does
not weld.
The output voltage cable that goes to the
Power Board is interrupted.
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 (picture
1).
Check for continuity between the +/- out-
put outlets and that the 6-path connector
is connected to the power board;
!The power board must be replaced.
The output voltage in
each procedure is about
14V 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 one of the protection devices 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 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 diodes;
Damaged voltage doubler;
Damaged inverter;
The inductive value of the Power Trans-
former is null.
Switch off the machine and disconnect the
plug. Remove the snubber board (above the
Power Transformer):
!check with a diode tester the status of the
diodes. If they are damaged, they must be
replaced;
!Check with a diode tester the status of the
voltage doubler , if it’s damaged it must be
replaced;
!Check the status of the Power Board
(picture 3);
!The Power Transformer must be replaced.
The output voltage in
MMA is not 90 V.
The voltage doubler is damaged.
The Power board 0001 is damaged.
The Front Panel is damaged.
The shunt wires are damaged or not cor-
rectly inserted in the 6-pin connector.
!Replace the damaged components or the
damaged boards.
!Connect the cables or if damaged replace
them.

150 TURBO / 150
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PROBLEM CASE SOLUTION
The welding is non opti-
mal.
Spattering occurs during welding. Make sure welding polarity is correct, the
earth clamp is fixed correctly.
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 machine always
welds at maximum cur-
rent.
The Front Panel is damaged.
The Power Board is damaged.
The shunt wires are damaged or not cor-
rectly inserted in the 6-pin connector.
The doubler board is damaged.
Switch off the machine and disconnect the
plug:
!The Front Panel must be replaced.
!The Power Board must be replaced.
!Connect the cables or if damaged replace
them (picture 1).
!The doubler board must be replaced.

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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 red wire; - so-
cket and the shunt.
Input bridge rectifier on the power board.
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.
Shunt
Output voltage
PICTURE 1
PICTURE 2
F+
DF-
D
Faston Probe Faston Probe Measure
F+ Rosso D Nero “OL”
FRosso D Nero >.450
6-pin connector
Thermal protection
device

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EXPLANATION
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.
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.
G D S
G D S
G D S G D S
PICTURE 3
Red Probe Black Probe Measure
S G 0.28
G S 0.6
Varistor
PICTURE 4
S D G
PICTURE 5
Red Probe Black Probe Measure
G D 0.5
D S “OL”
G S 0.6

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EXPLANATION
Tester or digital millimetre. “OL” means Open Loop.
PICTURE 6

MG062-2 SERVISNÍ MANUÁL / SERVICE MANUAL ALFIN 150 TP
Vypracoval:
Worked out: DJ 15/4/2010 Přezkoumal: In pected: DJ 15/4/2010 Schválil: Approved: VS 15/4/2010