CEA DIGITECH vision PULSE Series User manual

DIGITECH vision PULSE
3300 - 4000 - 5000
1020H991F-EN-12/2013
CEA COSTRUZIONI ELETTROMECCANICHE ANNETTONI S.p.A.
C.so E. Filiberto, 27 - 23900 Lecco - Italy
Tel. ++39.0341.22322 - Fax ++39.0341.422646
Cas. Post. (P.O.BOX) 205
E-mail: [email protected] - web: www.ceaweld.com
EN Operator’s manual READ
CAREFULLY

2
ENGLISH
EN
Introduction
Thank you for having purchased our product. Please read in-
structions on use in this manual as well as the safety rules
given in the attached booklet and follow them carefully to get
the best performance from the equipment and be sure that the
parts have the longest service life possible. This manual will
show you the best way to do any maintenance jobs or repairs
eventually needed by your equipment to resolve any eventu-
al problems, we do however recommend our customers to ar-
range to have maintenance and eventual repairs done at our
servicing centres as they have the right equipment and the
highly qualified personnel is constantly updated. All our ma-
chinery and systems are subject to continual development.
We must therefore reserve the right to modify their construc-
tion and properties.
Description
MULTI-FUNCTION INVERTER GENERATOR FOR MIG-MAG,
MMA, and TIG WELDING
The DIGITECH vision PULSE series of multi-function equip-
ments are characterised by cutting edge, attractive design
combined with latest generation inverter technology and digi-
tal welding control. Innovative, technologically advanced, ro-
bust, and easy to use, they can be used for very high quality
MIG-MAG and Pulse MIG welding for all materials and espe-
cially stainless steel and aluminium, reducing repeat work due
to spray to a minimum, using electrodes, and in TIG with “Lift”
type ignition, and they represent the best solution for all indus-
trial fields and all specialist welding purposes that call for high
precision and repeatable results. DIGITECH vision PULSE
equipments, fitted with an innovative synergic digital control,
colour display, and the extraordinary VISION-ARC meet the
needs of those that wish to combine synergy with complete
control of all welding parameters.
They come in a version with a separate feeder (HT4).
These are systems open to the future evolution of technology -
the control software can be kept up to date with the latest ver-
sions with the help of a personal computer.
Operating features
The main feature of the welding unit DIGITECH vision PULSE
3300-4000-5000 are:
• Metallic main structure with shockproof plastic front frames.
• Controls protected by a visor.
•
Spatter free exceptional welding characteristics in both MIG/
MAG, MIG Pulsed and MIG Dual Pulsed on any material and
with any gas.
•
High welding performance in both MMA and TIG by “Lift”
mode striking.
•
Synergic digital control (DH) of all welding parameters, dis-
played via the innovative colour display, also featuring the
following functions:
-
Allows less expert operators to regulate all welding param-
eters in a user-friendly way and extremely easily, choos-
ing the type of program on the basis of the material, wire
diameter, and gas used.
- Innovative “VISION ARC” software for controlling all weld-
ing parameters.
-
With the special MIG torches you can adjust the welding
parameters at a distance straight from the torch.
- BURN BACK control. At the end of each weld, in any con-
dition and with any material, the digital control ensures a
perfect wire cut, prevents the typical “wire globule” from
forming and ensures correct arc restriking.
Introduction 2
Description 2
Operating features 2
Technical data 3
Usage limits (IEC 60974-1) 3
How to lift up the system 4
Opening the packaging 4
Installation and connections 4
Connection to the electrical supply 4
Usage norms 4
MIG-MAG / PULSE MIG / DOUBLE PULSE MIG
Welding 5
Spot welding 7
Interval welding 7
Aluminium welding 7
Electrode welding (MMA) 7
TIG welding with “Lift” 8
Maintenance 8
Optional 9
The pointing out of any difficulties
and their elimination 9
Replacing the digital interface PCB 9
Wiring diagram 10
Key to the electrical diagram 11
Colour key 11
Meaning of graphic symbols on machine 11

3
-
WSC Wire start control. This arc striking control device pre-
vents wire from sticking to the workpiece or torch nozzle
and ensures precise and smooth arc striking, particularly
when welding aluminium.
-
Welding parameters that are controlled digitally by a micro-
processor, are monitored and modified in just a few sec-
onds, maintaining a consistently precise and stable arc as
the welding conditions continue to vary due to the move-
ment of the torch and the irregularities of the parts to be
welded.
-
Exclusive SWS “Smart Welding Stop” system at the end of
TIG welding. Lifting up the torch without switching off the
arc will introduce a slope down and it will switch off auto-
matically.
-
“Energy Saving” function to operate the power source cool-
ing fan and the torch water cooling only when necessary.
- Auto-diagnostic feature for trouble shooting.
- Password-controlled total or partial equipment access.
• High electrical performance resulting in a reduction in ener-
gy consumption.
• Remote parameter adjustment directly from HT4 feeder.
Technical data
The general technical data of the system are summarized in
table 1.
Usage limits (IEC 60974-1)
The use of a welder is typically discontinuous, in that it is made
up of effective work periods (welding) and rest periods (for the
positioning of parts, the replacement of wire and underflush-
ing operations etc. This welder is dimensioned to supply a I
2
max nominal current in complete safety for a period of work of
40/50% of the total usage time. The regulations in force estab-
lish the total usage time to be 10 minutes. The work cycle is
considered to be 40/50% of this period of time. Exceeding the
work cycle allowed could cause a trip switch to trip (for further
information see the DH control panel manual), which protects
the components inside the welding machine against dangerous
overheating. After several minutes the overheat cut-off rearms
automatically and the welder is ready for use again.
Table 1
Model
DIGITECH vision PULSE
3300
DIGITECH vision PULSE
4000
DIGITECH vision PULSE
5000
MIG-MAG welding
Three-phase input 50/60 Hz V 400 ± 20% 400 ± 20% 400 ± 20%
Mains supply: Zmax Ω0,037 0,028 0,017
Input power @ I2Max kVA 18,8 25,5 32
Delayed fuse (I2@ 60%) A253040
Power factor / cosφ0,64 / 0,99 0,66 / 0,99 0,66 / 0,99
Efficiency degree η0,83 0,86 0,89
Open circuit voltage V637070
Current range A 10 ÷ 330 10 ÷ 400 10÷500
Duty cycle @ 100% (40°C) A 280 330 380
Duty cycle @ 60% (40°C) A 300 370 460
Duty cycle @ X% (40°C) A 330 (40%) 400 (50%) 500 (50%)
Wires diameter (*) mm 0,6 ÷ 1,2 (*) 0,6 ÷ 1,6 (*) 0,6 ÷ 1,6 (*)
N° rollers (*) 4 (*) 4 (*) 4 (*)
Power output of feeder motor (*) W 100 (*) 100 (*) 100 (*)
Rated wire feeding speed (*) m/min 0,5 ÷ 25 (*) 0,5 ÷ 25 (*) 0,5 ÷ 25 (*)
Spool (*)
Diameter
Weight
mm
kg
Ø300 (*)
15 (*)
Ø300 (*)
15 (*)
Ø300 (*)
15 (*)
Standards IEC 60974-1 - IEC 60974-5 (*) - IEC 60974-10
Protection class IP 23 S IP 23 S IP 23 S
Insulation class HHH
Dimensions mm 660 - 515 - 290 660 - 515 - 290 660 - 515 - 290
Weight kg 35 40 44
(*) On the HT4 feeder, fitted separately.
WARNING: This equipment complies with EN//IEC 61000-3-12 provided that the maximum permissible system impedance Zmax is less than or
equal to 0,037 ΩDIGITECH vision PULSE 3300 - 0,028 ΩDIGITECH vision PULSE 4000 - 0,017 ΩDIGITECH vision PULSE 5000 at the in-
terface point between the user’s supply and the public system. It is the responsibility of the installer or user of the equipment to ensure, by con-
sultation with the distribution network operator if necessary, that the equipment is connected only to a supply with maximum permissible system
impedance Z
max
less than or equal to 0,037 ΩDIGITECH vision PULSE 3300 - 0,028 ΩDIGITECH vision PULSE 4000 - 0,017 ΩDIGITECH
vision PULSE 5000.
This system, tested according to EN/IEC 61000-3-3, meets the requirements of EN/IEC 61000-3-11.

4
How to lift up the system
Strap the system safely and securely in the slings working from
the bottom, then lift up from the ground.
This welding machine has a robust handle built into the frame
for moving the equipment.
NOTE: These hoisting and transportation devices conform to
European standards. Do not use other hoisting and transpor-
tation systems.
Opening the packaging
The system essentially consists of:
• DIGITECH vision PULSE 3300 or 4000 or 5000 weld unit.
• Separately:
- HT4 wire-feeder unit (supplied separately).
- MIG-MAG welding torch (optional).
-
Wire-feeder/generator interconnection cable (supplied sep-
arately).
- Coolant unit for welding torch (optional).
- Trolley to carry it around (optional).
Perform the following operations on receiving the apparatus:
•
Remove the welding generator and all accessories and com-
ponents from the packaging.
•
Check that the welding apparatus is in good condition; other-
wise immediately inform the retailer or distributor.
• Check that all the ventilation grilles are open and that there
is nothing to obstruct the correct air flow.
Installation and connections
The installation site for the system must be carefully chosen
in order to ensure its satisfactory and safe use. The user is re-
sponsible for the installation and use of the system in accord-
ance with the producer’s instructions contained in this manual.
Before installing the system the user must take into consider-
ation the potential electromagnetic problems in the work area.
In particular, we suggest that you should avoid installing the
system close to:
• Signalling, control and telephone cables.
• Radio and television transmitters and receivers.
• Computers and control and measurement instruments.
• Security and protection instruments.
Persons fitted with pace-makers, hearing aids and similar
equipment must consult their doctor before going near a ma-
chine in operation. The equipment’s installation environment
must comply to the protection level of the frame.
The welding unit is characterized by the following classes:
• IP 23 S protection class indicates that the generator can be
used in both interior and exterior environments.
•
The “S” usage class indicates that the generator can be em-
ployed in environments with a high risk of electrical shocks.
This system is cooled by means of the forced circulation of air,
and must therefore be placed in such a way that the air may
be easily sucked in and expelled through the apertures made
in the frame.
Assemble the system in the following way:
• Assemble the trolley.
• Fixing the cooling unit to the trolley.
•
Fixing of the welding machine to the trolley and the cooling
unit (electrical and plumbing connections).
• Fitting the feeder unit to the generator.
• Connect up the welder to the mains.
•
Connect up the wire-feeder/generator interconnection cable.
• Connect up the welding cables.
Instructions for fitting the individual components / optional ex-
tras are contained in the relevant packaging.
Connection to the electrical supply
Connection of the machine to the user line (electrical cur-
rent) must be performed by qualified personnel.
Before connecting the welding machine to the mains pow-
er supply, make sure that rated voltage and frequency cor-
respond to those provided by the mains power supply and
that the welding machine’s power switch is turned to “O”.
Use the welder’s own plug to connect it up to the main pow-
er supply. Proceed as follows if you have to replace the plug:
•
3 conducting wires are needed for connecting the machine
to the supply.
•
The fourth, which is YELLOW GREEN in colour is used for
making the “GROUND” connection.
Connect a suitable load of normalised plug (3P+T) to the
power cable and provide for an electrical socket complete
with fuses or an automatic switch. The ground terminal
must be connected to the ground conducting wire (YEL-
LOW-GREEN) of the supply.
Table 2 shows the capacity values that are recommended for
fuses in the line with delays.
NOTE: Any extensions to the power cable must be of a suita-
ble diameter, and absolutely not of a smaller diameter than the
special cable supplied with the machine.
Usage norms
CONTROL APPARATUS (Fig. A)
Pos. 1 “DH” control panel.
Pos. 2 Fast coupling positive polarity.
Pos. 3 Fast coupling negative polarity.
Pos. 4 Mains switch. In the “O” position the welder is off.
Pos. 5 Connector for connecting the interconnection cable
or auxiliary welding controls.
Pos. 6 Fast coupling reverse polarity.
Pos. 7 Connector for connecting the cooling system.
Pos. 8 Mains cable.
Table 2
Model
DIGITECH vision PULSE
3300
DIGITECH vision PULSE
4000
DIGITECH vision PULSE
5000
MIG-MAG welding
Input power @ I2Max V 18,8 25,5 32
Delayed fuse (I2@ 60%) Ω25 30 40
Duty cycle @ X% (40°C) kVA 330 (40%) 400 (50%) 500 (50%)
Mains cable
Length
Section
mm
kg
4
4 × 2,5
4,5
4 × 4
4,5
4 × 6
Ground cable kg 50 50 70

5
MIG-MAG / PULSE MIG / DOUBLE
PULSE MIG Welding
To begin MIG-MAG / PULSE MIG / DOUBLE PULSE MIG weld-
ing, carry out the following tasks (with the machine switched
off).
1 - Connecting the gas hose and torch (Fig. B1-B2)
• Connect the gas hose to the pressure reducer fitted on the
cylinder beforehand.
• Screw the torch onto the centralised connection on the front
panel of the feeder and connect the feed (blue) and return
(red) water hoses for cooling the torch to the respective (blue
and red) rapid couplings on the front panel of the feeder.
2A - Connecting the cables - Welding with a POSITIVE
POLE TORCH (Fig. B1)
1) The feeder - generator connecting cable is used to connect
the welding machine to the feeder.
WARNING: Do not disconnect the wire-feeder until the ma-
chine has been switched off.
Connect up the interconnection cables (power cable, an-
cillary wiring and gas tube) to the special attachments and
couplings shown in Fig. B1.
The delivery (blue coloured) and return (red coloured) wa-
ter tubes, used for cooling the torch of the welding machine,
are part of the interconnection cable and should be con-
nected as follows:
4
1
5
6
7
8
32
FIG. A
FIG. B1

6
•
Interconnection cable on generator side: connect up
tubes to their rapid couplings (blue and red coloured) at
the back of the coolant system.
• Wire feeder side connecting cable: connect the red and
blue pipes to their respective bulkhead grommets on the
rear panel of the feeder.
2) Connect up the earthing system cable to the rapid cou-
pling marked by a - (negative) symbol and then the rel-
evant ground clamps to the piece being welded or to its
support in an area free from rust, paint and grease. Using
particularly long earthing cables reduces the voltage and
causes some problems from increased resistance and in-
ductance of the cables that could cause faulty welding. Fol-
low instructions to avoid these problems:
•
Use earthing and extension cables with appropriate sec-
tion.
• Lay out the cables as a flat as possible to prevent them
from coiling up.
2B - Connecting the cables - Welding with a
NEGATIVE POLE TORCH (Fig. B2)
1) Connect the generator - feeder connection cable using the
extension cable in addition to invert the polarity (optional).
WARNING: Do not disconnect the wire-feeder until the ma-
chine has been switched off.
Connect up the interconnection cables (power cable, an-
cillary wiring and gas tube) to the special attachments and
couplings shown in Fig. B2.
The delivery (blue coloured) and return (red coloured) wa-
ter tubes, used for cooling the torch of the welding machine,
are part of the interconnection cable and should be con-
nected as follows:
•
Interconnection cable on generator side: connect up
tubes to their rapid couplings (blue and red coloured) at
the back of the coolant system.
• Wire feeder side connecting cable: connect the red and
blue pipes to their respective bulkhead grommets on the
rear panel of the feeder.
2) Connect up the earthing system cable to the rapid cou-
pling marked by a + (positive) symbol and then the relevant
ground clamps to the piece being welded or to its support in
an area free from rust, paint and grease. Using particularly
long earthing cables reduces the voltage and causes some
problems from increased resistance and inductance of the
cables that could cause faulty welding. Follow instructions
to avoid these problems:
•
Use earthing and extension cables with appropriate sec-
tion.
• Lay out the cables as a flat as possible to prevent them
from coiling up.
3 - Welding
1) Switch the welding machine on by moving the power sup-
ply switch to I(Pos. 4, Fig. A).
2) Make the adjustments and do the parameter settings on
the control panel (for further information see the DH con-
trol panel manual).
3) Load the wire (see the relevant paragraph in the feeder
manual) using the motor test button, after having removed
the wire guide nozzle from the torch to allow the wire to
come out freely during loading (remember that the wire
guide nozzle must correspond to the diameter of the wire
used).
4) Open the tap on the cylinder slowly and adjust the reduc-
er knob to obtain a pressure of about 1,3 to 1,7 bar, and
then activate the gas test button and regulate the flow to
a value between 14 and 20 lit/min to suit the current used
for welding.
5) The welding machine is ready to weld. Make the adjust-
ments and select the parameters for the feeder or, if se-
lected, on the control panel (for further information see the
DH control panel manual). Start welding by moving close
to the welding point and press the torch button.
FIG. B2

7
6) Once welding has been completed remove any slag, switch
off the machine (which is only to be done when the fan is
not running), and close the gas cylinder.
Spot welding
The substantial difference with MIG-MAG welding is essential-
ly related to the torch and the adjustments that must be made
on the DH control panel.
•
The gas guide nozzle specifically for spot welding must be
fitted on the torch (see Fig. C).
• On the DH control panel, select the spot welding mode and
set the time.
To begin spot welding:
•
Press the torch button to start the welding current and wire
feed.
• When the spot welding time expires, the wire feed stops au-
tomatically.
•
When the torch button is pushed again a new welding cy-
cle starts.
• Release the torch button.
FIG. C
Interval welding
The basic difference from spot welding is the addition of an ad-
ditional time known as the “stitch pause”.
On the DH control panel, select the interval welding mode and
then set the following times for it:
• Stitch time.
• Stitch pause.
To begin interval welding:
•
Press the torch button to start the welding current and wire
feed.
•
At this point the welding machine automatically carries out a
succession of welded portions followed by a pause, accord-
ing to the times entered previously. This procedure stops au-
tomatically only when the torch button is released.
•
When the torch button is pushed again the torch begins a
new interval welding cycle.
Aluminium welding
To weld with aluminum wire proceed as follows:
• Replace the drive rolls with special ones for aluminium wire.
• Use a torch with a 3M cable and a carbon Teflon sheath.
•
Set the pressure between the drive rollers at the minimum,
by turning the screw provided.
•
Use argon gas at a pressure of 1,3 - 1,7 bar and regulate
the flow to a value between 14 and 20 lit/min to suit the cur-
rent used for welding.
Electrode welding (MMA)
On the DIGITECH vision PULSE 3300-4000-5000 machine,
electrode welding is used to weld most metals (different types
of steel, etc.) using coated rutilic and basic electrodes with di-
ameters ranging from Ø 1.6 mm to Ø 6 mm, and devices that
the user can adjust for “Arc Force”, “Hot Start”, and Anti-stick-
ing functions to avoid the electrodes sticking.
1) Connecting the welding cables (Fig. D):
Disconnect the machine from the mains power supply and
connect the welding cables to the output terminals (Posi-
tive and Negative) of the welding machine, attaching them
to the clamp and ground with the polarity specified for the
type of electrode being used (Fig.D). Always follow the
electrode manufacturer’s instructions. The welding cables
must be as short as possible, they must be near to one
another, positioned at or near floor level. Do not touch the
electrode clamp and the ground clamp simultaneously.
2) Switch the welding machine on by moving the power sup-
ply switch to I(Pos. 3, Fig. A).
3) Make the adjustments and do the parameter settings on
the control panel (for further information see the DH con-
trol panel manual).
4) Carry out welding by moving the torch to the workpiece.
Strike the arc (press the electrode quickly against the met-
al and then lift it) to melt the electrode, the coating of which
forms a protective residue. Then continue welding at an in-
clination of about 60° compared with the metal in relation
to the direction of welding.
PART TO BE WELDED
The part to be welded must always be connected to ground
in order to reduce electromagnetic emission. Much attention
must be afforded so that the ground connection of the part to
be welded does not increase the risk of accident to the user or
the risk of damage to other electric equipment. When it is nec-
essary to connect the part to be welded to ground, you should
make a direct connection between the part and the ground
shaft. In those countries in which such a connection is not al-
lowed, connect the part to be welded to ground using suitable
capacitors, in compliance with the national regulations.
FIG. D
FIG. E
FIG. C

8
WELDING PARAMETERS
Table 3 shows some general indications for the choice of elec-
trode, based on the thickness of the parts to be welded. The
values of current to use are shown in the table 5 with the re-
spective electrodes for the welding of common steels and
low-grade alloys. These data have no absolute value and are
indicative data only. For a precise choice follow the instructions
provided by the electrode manufacturer.
Table 3
Welding thickness (mm) Ø electrode (mm)
1,2 ÷ 2
1,5 ÷ 3
3 ÷ 5
5 ÷ 12
≥12
≥20
1,6
2
2,5
3,25
4
≥5
Table 4
Ø electrode (mm) Current (A)
1,6
2
2,5
3,25
4
5
6
30 ÷ 60
40 ÷ 75
60 ÷ 110
95 ÷ 140
140 ÷ 190
190 ÷ 240
220 ÷ 330
The current to be used depends on the welding positions and
the type of joint, and it increases according to the thickness and
dimensions of the part.
The current intensity to be used for the different types of weld-
ing, within the field of regulation shown in table 4 is:
• High for plane, frontal plane and vertical upwards welding.
• Medium for overhead welding.
•
Low for vertical downwards welding and for joining small pre-
heated pieces.
A fairly approximate indication of the average current to use in
the welding of electrodes for ordinary steel is given by the fol-
lowing formula:
I = 50 × (Øe - 1)
Where:
I = intensity of the welding current
Øe = electrode diameter
Example:
For electrode diameter 4 mm
I = 50 × (4 - 1) = 50 × 3 = 150A
TIG welding with “Lift”
In the TIG process welding is achieved by melting the two metal
pieces to be joined, with the possible addition of material from
the outside, using an arc ignited by a tungsten electrode. The
“Lift” type ignition used in DIGITECH vision PULSE equip-
ments makes it possible to reduce tungsten inclusions on ig-
nition to a minimum. The molten bath and the electrode are
protected by and inert gas (for example, Argon). This type of
welding is used to weld thin sheet metal or when elevated qual-
ity is required.
1) Connecting the welding cables (Fig. E):
•
Connect one end of the gas hose to the gas connecter on
the TIG torch and the other end to the pressure reducer
on the inert gas cylinder (Argon or similar).
• With the machine switched off:
-
Connect the ground cable to the snap-on connector
marked + (positive).
-
Connect the relative ground clamp to the workpiece or
to the workpiece support in an area free of rust, paint,
grease, etc..
-
Connect the TIG torch power cable to the snap-on con-
nector marked - (negative).
2) Switch the welding machine on by moving the power sup-
ply switch to I(Pos. 3, Fig. A).
3) Make the adjustments and do the parameter settings on
the control panel (for further information see the DH con-
trol panel manual).
4) Open the gas cylinder and regulate the flow by adjusting
the valve on the TIG torch by hand.
5) Ignite the electric arc by contact, using a decisive, quick
movement without dragging the tungsten electrode on the
piece to be welded (“Lift” type ignition).
6) The welder has a SWS “Smart Welding Stop” system for
the end of TIG welding. Lifting up the torch without switch-
ing off the arc will introduce a slope down and it will switch
off automatically.
7) When you have finished welding remember to shut the
valve on the gas cylinder.
Table 5 shows the currents to use with the respective elec-
trodes for TIG DC welding. This input is not absolute but is for
your guidance only; read the electrode manufacturers’ instruc-
tions for a specific choice. The diameter of the electrode to use
is directly proportional to the current being used for welding.
Table 5
Ø ELECTRODE
(mm)
ELECTRODE TYPE
Current adjustment field (A)
TIG DC
Tungsten
Ce 1%
Grey
Tungsten
Rare ground 2%
Turchoise
1 10-50 10-50
1,6 50-80 50-80
2,4 80-150 80-150
3,2 150-250 150-250
4 200-400 200-400
Maintenance
ATTENTION: Cut off the power supply to the equipment be-
fore effecting any internal inspection.
DIGITECH vision PULSE 3300-4000-5000
IMPORTANT: For fully electronic welding machines, remov-
ing the dust by sucking it into the machine by the fans, is of ut-
most importance.
In order to achieve correct functioning of the machine, pro-
ceed as described:
•
Periodic removal of accumulations of dirt and dust inside the
equipment using compressed air. Do not point the jet of air
directly at the electrical parts as this could damage them.
•
Periodical inspection for worn cables or loose connections
that could cause overheating.
TORCH
The torch is subjected to high temperatures and is also stressed
by traction and torsion. We recommend not to twist the wire and
not to use the torch to pull the welder. As a result of the above
the torch will require frequent maintenance such as:
• Cleaning welding splashes from the gas diffuser so that the
gas flows freely.
• Substitution of the contact point when the hole is deformed.
•
Cleaning of the wire guide liner using trichloroethylene or
specific solvents.
• Check of the insulation and connections of the power cable;
the connections must be in good electrical and mechanical
condition.
SPARE PARTS
Original spares have been specifically designed for our equip-
ment. The use of spares that are not original may cause vari-

9
ations in the performance and reduce the safety level of the
equipment. We are not liable for damage due to use of spare
parts that are not original.
Optional
NOTE: The digital control unit of the generator is fitted with a
control recognition device which allows it to identify which de-
vice is connected and take action accordingly.
REMOTE CONTROL ANALOGIC RC
This command (that must be plugged into the relevant connec-
tor on the front panel of the HT4 drawing unit):
•
Completely replaces the ENCODER - A knob on the HT4
feeder’s front panel.
•
Partially (depending on the welding process selected) replac-
es the ENCODER - V knob on the HT4 feeder’s front pan-
el (for further information see the DH control panel manual).
AIR AND/OR WATER COOLED UP/DOWN TORCH
This command (that must be plugged into the relevant con-
nector on the front panel of the HT4 drawing unit) works as an
alternative to:
• The ENCODER - A knob on the HT4 feeder’s front panel. In
“synergic” MIG MAG and “manual” MIG MAG welding pro-
cesses, by pressing the two right (+) and left (-) buttons you
can regulate the values for the synergic welding parameters.
• The ENCODER - V knob on the HT4 feeder’s front panel. In
the JOB welding process, by pressing the two right (+) and
left (-) buttons you can scroll the welding points set previ-
ously.
The pointing out of any difficulties
and their elimination
The supply line is attributed with the cause of the most com-
mon difficulties. In the case of breakdown, proceed as follows:
1) Check the value of the supply voltage.
2) Check that the power cable is perfectly connected to the
plug and the supply switch.
3) Check that the power fuses are not burned out or loose.
4) Check whether the following are defective:
• The switch that supplies the machine
• The plug socket in the wall
• The generator switch
NOTE: Given the required technical skills necessary for the re-
pair of the generator, in case of breakdown we advise you to
contact skilled personnel or our technical service department.
Replacing the digital interface PCB
Proceed as follows:
• Unscrew the 4 screws fastening the front rack panel.
• Remove both the adjustment knobs.
• Extract wiring connectors from the digital interface PCB.
• Unscrew the nuts and washers on the support.
•
Remove the digital interface PCB by lifting it out of its sup-
ports.
•
Proceed vice versa to assemble the new digital interface
PCB.

10
2101EA86
Wiring diagram

11
Key to the electrical diagram
•1 •2 •3 •4 •5
C2 CCI CHR Cp D2
•6 •7 •8 •9 •10
F-EMC IL L2 MIH MIL
•11 •12 •13 •14 •15
MV1-2 P1 P2 R2 RP
•16 •17 •18 •19
RS S-INT DIG S-INV S-LINK
•20 •21 •22 •23 •24
S-PS TA TH2 TP VR
•1 SNUBBER capacitor for output diodes •2 Interconnec-
tion cable connector •3 Cooling system power connector •4
Quick connection protection capacitor •5 Secondary diode
•6 EMC filter •7 Mains switch •8 Secondary inductor •9 Pri-
mary upper IGBT •10 Lower primary IGBT •11 Fan motor
•12 Main primary transformer (start) •13 Main primary trans-
former (end) •14 Output diode snubber resistor •15 Prima-
ry rectifier •16 Secondary rectifier •17 Digital interface PCB
•18 Inverter PCB •19 Capacitors PCB •20 Power Source
PCB •21 Hall effect transformer •22 Secondary thermostat
•23 Main transformer •24 Output diodes snubber varistor
Colour key
Ar Orange
Az Sky Blue
Bc White
Bl Blue
Gg Grey
Gl Yellow
GV Yellow-Green
Mr Brown
NA Black-Sky Blue
Nr Black
RN Red-Black
Ro Pink
Rs Red
Vd Green
Vl Violet
Meaning of graphic
symbols on machine
9
8765
4321
10
•1 Power supply switch •2 System for use in environments
with increased risk of electroshock •3 Product suitable for
free circulation in the European Community •4 Danger! high
voltage •5 Grounding •6 Positive pole snap-in connector •7
Negative pole snap-in connector •8 Warning! •9 Before us-
ing the equipment you should carefully read the instructions
included in this manual •10 Special disposal

DIGITECH vision PULSE
3300 - 4000 - 5000
1020H991F-LR-12/2013
CEA COSTRUZIONI ELETTROMECCANICHE ANNETTONI S.p.A.
C.so E. Filiberto, 27 - 23900 Lecco - Italy
Tel. ++39.0341.22322 - Fax ++39.0341.422646
Cas. Post. (P.O.BOX) 205
e-mail: [email protected] - web: www.ceaweld.com
IT Lista ricambi LEGGERE ATTENTAMENTE
EN Spare parts list READ CAREFULLY

2
IT Lista ricambi EN Spare parts list
Pos.
DIGITECH
vision
PULSE
3300
Descrizione Description
1 352389 Pivot Pivot
2 352461 Visiera rack frontale Front rack visor
3 439383 Pannello rack, con adesivo
"DIGITECH", senza display Rack panel with "DIGITECH" sticker without display
4 378020 Display Display
5 438849 Manopola senza indice Ø22mm Ø22mm knob without index
6 438888 Manopola senza indice Ø29mm Ø29mm knob without index
7 468725 Adesivo logo CEA Ø30mm CEA logo sticker Ø30mm
8 352458 Pannello frontale senza adesivo logo CEA Ø30mm Front panel without CEA logo sticker Ø30mm
9 403611 Attacco rapido Quick connection
10 420685 Coperchio lato sinistro con adesivo logo CEA Left cover with CEA logo sticker
2
3
4
5
6
7
8
9
10
1

3
11 12
13
14
15
16
17
18
19
20
Pos.
DIGITECH
vision
PULSE
3300
Descrizione Description
11 420577 Coperchio superiore Top cover
12 438111 Maniglia Handle
13 438720 Manopola interruttore alimentazione Mains switch knob
14 427883 Pressacavo con ghiera Cable clamp with lock ring
15 235948 Cavo alimentazione Mains cable
16 352459 Pannello posteriore senza adesivo logo CEA Ø30mm Rear panel without CEA logo sticker Ø30mm
17 453145 Connettore cavo interconnessione Interconnection cable connector
18 403611 Attacco rapido Quick connection
19 419049 Connettore alimentazione impianto di raffreddamento Cooling system power connector
20 420686 Coperchio lato destro con adesivo logo CEA Right cover with CEA logo sticker

4
Pos.
DIGITECH
vision
PULSE
3300
Descrizione Description
21 435760 Interruttore alimentazione Mains switch
22 427667 Filtro EMC EMC Filter
23 449578 Pianale superiore Upper plate
24 377133 Scheda condensatori Capacitors PCB
25 478786 Termostato secondario Secondary thermostat
26 377113 Scheda power source Power source PCB
27 413499 Cablaggio ausiliario Auxiliary wiring
28 463215 Staffa fissaggio trasformatore Transformer support
29 481424 Trasformatore principale Main transformer
30 481954 Trasformatore ad effetto di Hall Hall effect transformer
31 418874 Condensatore di protezione attacco rapido Quick connection protection capacitor
32 247493 Induttore secondario Secondary inductor
33 404931 Basamento Base
34 478846 Termostato primario Primary thermostat
35 286019 IGBT primario Primary IGBT
36 240474 Complessivo inverter primario Primary inverter assembly
37 455512 Raddrizzatore primario Primary rectifier
38 486383 Motore ventilatore Fan motor
39 377105 Scheda di snubber secondaria Snubber secondary PCB
40 423236 Diodo secondario Secondary diode
41 377149F Scheda interfaccia digitale Digital Interface PCB
42 454150 Encoder Encoder
21 22 23 24 25 26
28
27
29
30
313233343536
37
38
39
40
42
41

5
IT Lista ricambi EN Spare parts list
Pos.
DIGITECH
vision
PULSE
4000
DIGITECH
vision
PULSE
5000
Descrizione Description
1 352389 352389 Pivot Pivot
2 352461 352461 Visiera rack frontale Front rack visor
3 439381 439382 Pannello rack, con adesivo
"DIGITECH", senza display
Rack panel with "DIGITECH"
sticker without display
4 378020 378020 Display Display
5 438849 438849 Manopola senza indice Ø22mm Ø22mm Knob without index
6 438888 438888 Manopola senza indice Ø29mm Ø29mm Knob without index
7 468725 468725 Adesivo logo CEA Ø30mm CEA logo sticker Ø30mm
8 352458 352458 Pannello frontale senza adesivo
logo CEA Ø30mm Front panel without CEA logo sticker Ø30mm
9 403617 403617 Attacco rapido Quick connection
10 420685 420685 Coperchio lato sinistro con adesivo logo CEA Left cover with CEA logo sticker
2
3
4
5
6
7
8
9
10
1

6
11
12
13
14
15
16
17
18
19
20
Pos.
DIGITECH
vision
PULSE
4000
DIGITECH
vision
PULSE
5000
Descrizione Description
11 420577 420577 Coperchio superiore Top cover
12 438111 438111 Maniglia Handle
13 438720 438720 Manopola interruttore alimentazione Mains switch knob
14 427883 427883 Pressacavo con ghiera Cable clamp with lock ring
15 235999 235943 Cavo alimentazione Mains cable
16 352459 352459 Pannello posteriore senza
adesivo logo CEA Ø30mm Rear panel without CEA logo sticker Ø30mm
17 453145 453145 Connettore cavo interconnessione Interconnection cable connector
18 403617 403617 Attacco rapido Quick connection
19 419049 419049 Connettore alimentazione
impianto di raffreddamento Cooling system power connector
20 420686 420686 Coperchio lato destro con adesivo logo CEA Right cover with CEA logo sticker
21 404931 404931 Basamento Base
22 286034 286042 IGBT primario Primary IGBT
23 455508 455508 Raddrizzatore primario Primary rectifier
24 240466 240468 Complessivo inverter primario Primary inverter assembly
25 377133 377133 Scheda condensatori Capacitors PCB
26 449578 449578 Pianale superiore Upper plate
27 427667 427667 Filtro EMC EMC Filter
28 435760 435760 Interruttore alimentazione Mains switch
29 486379 486379 Motore ventilatore Fan motor
30 377105 377105 Scheda di snubber secondaria Snubber secondary PCB
31 481954 481954 Trasformatore ad effetto di Hall Hall effect transformer
32 478786 478786 Termostato secondario Secondary thermostat
33 423236 423236 Diodo secondario Secondary diode
34 247494 247494 Induttore secondario Secondary inductor
35 418887 418887 Condensatore di protezione attacco rapido Quick connection protection capacitor
36 463215 463216 Staffa fissaggio trasformatore Transformer support
37 481421 481422 Trasformatore principale Main transformer
38 413499 413499 Cablaggio ausiliario Auxiliary wiring
39 377113 377113 Scheda power source Power source PCB
40 377149G 377149H Scheda interfaccia digitale Digital Interface PCB
41 454150 454150 Encoder Encoder

7
21
22
23
24
26
25
27
28
30
41
40
29
30
31
32
33
34
35
36
37
38
39
40

8
IT Ordinazione dei pezzi di ricambio
Per la richiesta di pezzi di ricambio indicare chiaramente:
1) Il numero di codice del particolare
2) Il tipo di impianto
3) La tensione e la frequenza che rileverete dalla targhetta
dei dati posta sull’impianto
4) Il numero di matricola
ESEMPIO
N° 2 pezzi, codice n. 420577 - per l’impianto DIGITECH 5000
PULSE - 400 V - 50/60 Hz - Matricola n° ....................................
EN Ordering spare parts
To ask for spare parts clearly state:
1) The code number of the piece
2) The type of device
3) The voltage and frequency read on the rating plate
4) The serial number of the same
EXAMPLE
N. 2 pieces code n. 420577 - for DIGITECH 5000 PULSE - 400
V - 50/60 Hz - Serial number ......................................................