Cebora POWER SPOT 5500 User manual

CEBORA S.p.A. 1
POWER SPOT 5500
POWER SOURCE art. 2153
SERVICE MANUAL
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CEBORA S.p.A. 2
CONTENTS
1- GENERAL INFORMATION..........................................................................................................................3
1.1 - Introduction. .................................................................................................................................................3
1.2 - General service policy. .................................................................................................................................3
1.3 - Safety information........................................................................................................................................3
1.4 - Electromagnetic compatibility......................................................................................................................3
2- SYSTEM DESCRIPTION ..............................................................................................................................4
2.1 - Introduction. .................................................................................................................................................4
2.2 - Technical specifications................................................................................................................................4
2.3 - Description of power source art. 2153..........................................................................................................4
3- MAINTENANCE............................................................................................................................................6
3.1 - Periodic inspection, cleaning........................................................................................................................6
3.2 - Sequence of operations (fig. 3.2.1)...............................................................................................................6
3.2.1 - Power source commands and signals.........................................................................................................6
3.2.2 - Starting the power source...........................................................................................................................7
3.3 - Troubleshooting............................................................................................................................................9
3.3.1 - The power source does not start, led (C) on control panel unlit. ...............................................................9
3.3.2 - Power source powered, fan (34) stopped.................................................................................................11
3.3.3 - Power source powered, the start button produces no effect.....................................................................11
3.3.4 - In open circuit operation, the voltage at the DC-capacitors (24) is not regular. ......................................12
3.3.5 - In resistive load operation, the output voltage is not regular. ..................................................................13
3.3.6 - In actual working conditions (thus with high currents), the welding quality is not satisfactory..............14
3.4 - Error codes..................................................................................................................................................15
3.4.1 - E1 - Transformer (31) temperature above limits......................................................................................15
3.4.2 - E2 - Scr (3) short-circuited. .....................................................................................................................15
3.4.3 - E3 - Dc voltage on the DC-capacitors (24) irregular...............................................................................15
3.4.4 - E4 - DC-capacitor (24) irregular charge. .................................................................................................15
3.4.5 - E5 - DC-capacitors (24) irregular discharge............................................................................................15
4- COMPONENTS LIST...................................................................................................................................16
4.1 - Power source art. 2153: see file ESP2153.pdf enclosed at the end of the manual......................................16
4.2 - Components table: see file ESP2153.pdf enclosed at the end of the manual..............................................16
4.3 - List of spare parts. ......................................................................................................................................16
5- ELECTRICAL DIAGRAMS ........................................................................................................................16
5.1 - Power source art. 2153: see file SCHE2153.pdf enclosed at the end of the manual. .................................16
5.2 - Waveforms. ................................................................................................................................................16
5.2.1 - Output voltage upon scr (3) engagement (par. 3.3.5)...............................................................................16
5.3 - Power board (12) code 5.602.169...............................................................................................................17
5.4 - Control board (2) code 5.602.168...............................................................................................................18
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1- GENERAL INFORMATION
1.1 - Introduction.
The purpose of this manual is to train personnel assigned to carry out maintenance on the
power source art. 2153 for welding systems of threaded stud bolts and rivets.
1.2 - General service policy.
It is the responsibility of the customer and/or operator to use the equipment appropriately, in
accordance with the instructions in the Manual, as well as to maintain the equipment and related
accessories in good working condition, in compliance with the instructions provided in the
Service Manual.
Any internal inspection or repairs must be carried out by qualified personnel who are
responsible for any intervention on the equipment.
It is forbidden to attempt to repair damaged electronic boards or modules; replace them with
original Cebora spare parts.
1.3 - Safety information.
The safety notes provided in this manual are an integral part of those given in the Instruction
Manual. Therefore, before working on the machine, please read the paragraph on safety
instructions in the aforementioned manual.
Always disconnect the power cord from the mains, and wait for the internal capacitors to
discharge before accessing the interior of the equipment.
WARNINGS
The discharge time of the DC-capacitors (24) depends on the status of the power source.
In normal situations it takes approximately 1 MINUTE, while in the event of a malfunction or
in the presence of error code “E5”, it may take as long as several hours.
Therefore, MEASURE THE VOLTAGE ON THE DC-CAPACITORS (24) EVERY TIME
YOU ACCESS THE INTERIOR OF THE POWER SOURCE, AND DISCHARGE THEM
MANUALLY IF NECESSARY BY TEMPORARILY APPLYING A 470 OHM 50 W
RESISTOR IN PARALLEL TO THE DC-CAPACITORS (24).
NEVER SHORT-CIRCUIT THE TERMINALS OF THE DC-CAPACITORS (24).
The large capacity of the DC-capacitors (24) may produce very high currents, even with just a
few volts, with serious danger to the operator.
Some internal parts, such as terminals and dissipaters, may be connected to mains or
otherwise hazardous potentials. It is therefore forbidden to work with the safety guards removed
from the machine unless strictly necessary. In this case, take special precautions such as wearing
insulating gloves and footwear, and working in a perfectly dry environment with dry clothing.
1.4 - Electromagnetic compatibility.
Please read and observe the instructions provided in the paragraph “Electromagnetic
compatibility” of the Instruction Manual.
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2- SYSTEM DESCRIPTION
2.1 - Introduction.
The POWER SPOT 5500 is a system for welding ferrous and non-ferrous threaded stud bolts
or rivets, on various types of sheet metal.
It is made up of an electronic power source (art. 2153), and a set of accessories to adapt to
various applications and tasks (see Sales Catalogue).
The power source is controlled by microprocessor-controlled electronic circuits that manages
the operator interface and operation.
2.2 - Technical specifications.
To verify the technical specifications, see the machine plate, Instruction Manual, and Sales
Catalogue.
2.3 - Description of power source art. 2153.
Art. 2153 is a capacitor discharge power source made up of a single-phase transformer, a
rectifier bridge, a battery of capacitors and a scr static switch.
It may be powered at either 115 or 230 Vac; the unit adapts automatically based on the
voltage applied to the power source input.
Referring to fig. 3.2.1, the electrical diagram in par. 5.1, drawing 4.1 and table 4.2, you can
identify the main blocks that make up the unit.
The operating principle is based on the effects of the passage of high current, supplied by the
DC-capacitors (24) (capacitor discharge), onto the small contact surface offered by rivets or bolts
with the sheet metal to which they are being welded. The amount of energy needed at the
welding point is adjusted by checking the dc voltage on the DC-capacitors (24). This adjustment
is made by means of a “triac” that partializes the supply voltage provided by the 190 Vac
secondary circuit of the transformer (31).
The DC-capacitors (24) that create the welding point are discharged by means of a “scr” (3)
static switch on the high current circuit, which becomes conductive and directly connects the
DC-capacitors (24) to the output terminals (F) and (G) of the power source.
The main switch (21) powers the power board (12), which contains:
-the filter to reduce conducted interference reflected in the mains;
-the circuits to select the supply voltage via the relay RL1;
-the “triac” to adjust the voltage on the DC-capacitors (24);
-the rectifier bridge that keeps the voltage adjusted by the “triac” continuous.
The power board (12) is connected to the transformer (31) that generates the supply voltages
for the power (190 Vac) and control circuits (18 Vac), and galvanically isolates the output and
control circuits from the input circuits linked to mains potential.
The control board (2), powered by the same service voltages generated on the power board
(12), also acts as a control panel as it contains both the control circuits and the command and
signaling circuits, and is mounted on the front panel of the power source.
Depending on the supply voltage applied to the power source input, the check either does or
does not activate relay RL1 on power board (12), which adapts the power source operation to the
mains voltage by connecting in series (for 230 Vac main) or parallel (for 115 Vac mains) the two
primary windings at 115 Vac of the transformer (31). In this way both the control and power
circuits are always powered by the same secondary voltages.
Once the power source is powered, the control checks the triac on power board (12), which
partializes the voltage supplied by the secondary circuit at 190 Vac of the transformer (31) to
slowly charge the DC-capacitors (24) until the programmed voltage shown on display (E) is
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reached. Normally the programmed voltage that appears upon start-up matches the voltage used
the last time welding was performed.
This voltage may be changed using the keys on the control panel. If the accessory (gun)
connected to the connector (H) changes, the programmed voltage becomes the standard voltage
for the connected accessory. The check recognizes the accessory connected to the power source
by means of a special signal in connector (H), and based on that signal activates a working
program with a voltage specific to the type of accessory. The working program is shown on
display (E) (ex.: P_0) during start-up.
When lowering the direct current, the check automatically inserts the discharge resistor (7) in
parallel to the DC-capacitors (24), to discharge them until they reach the programmed voltage.
Once the programmed voltage is reached, the power source awaits the start command via the
gun trigger.
The start signal may be provided from the gun only when the start button (trigger) is pressed
and with the gun pressed against the sheet metal. There is a spring inside the gun whose force
must be adjusted based on the type of rivet being used (see Instruction Manual), which activates
an interface switch serially connected to the start button.
In addition, the check carries out the start command only if a voltage of 0 Vdc is detected, on
output terminals (F) and (G) of the power source, to enable welding only if the high current
circuit is actually closed, thus if the rivet is truly in contact with the workpiece, with clamps
firmly grasping the sheet metal.
When the start command reaches control board (2), the scr (3) connecting the DC-capacitors
(24) to the output terminals (F) and (G) of the power source is engaged. This allows the rapid
discharge of the DC-capacitors (24) on the point of contact between rivet and workpiece,
essentially welding the rivet to the sheet metal.
When you have finished welding, the check pauses for approximately 1 second, after which it
recharges the DC-capacitors (24) for a new welding cycle. During this pause the gun must be
removed from the welded rivet, thus open the high current circuit; if the gun remains in contact
with the newly welded rivet for longer, this may block the power source with message “E2” on
the display (E) (see Error codes par. 3.4). To reset you must shut down the power source then
switch it back on.
On the transformer (31) is a thermostat that blocks operation of the power source in case of
overtemperature, showing the corresponding alarm code on the display (E) (see Error codes par.
3.4).
The signals processed by the electronic boards and present at their connectors are listed in the
table in chapter five of this manual.
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3- MAINTENANCE WARNINGS
ANY INTERNAL INSPECTIONS OR REPAIRS MUST BE CARRIED OUT BY QUALIFIED
PERSONNEL.
BEFORE BEGINNING MAINTENANCE OPERATIONS, UNPLUG THE MACHINE FROM
THE MAINS AND WAIT FOR THE INTERNAL CAPACITORS TO DISCHARGE.
MEASURE THE VOLTAGE ON THE DC-CAPACITORS (24) EVERY TIME YOU
ACCESS THE INTERIOR OF THE POWER SOURCE, AND DISCHARGE THEM
MANUALLY IF NECESSARY BY TEMPORARILY APPLYING A 470 OHM 50 W
RESISTOR IN PARALLEL TO THE DC-CAPACITORS (24) (see warnings par. 1.3).
NEVER SHORT-CIRCUIT THE TERMINALS OF THE DC-CAPACITORS (24).
3.1 - Periodic inspection, cleaning.
Periodically remove any dirt or dust from the air vents to ensure smooth air flow, and thus
adequate cooling of the internal parts of the power source.
Check the condition of the output terminals, output and power supply cables of the power
source; replace if damaged.
Check the condition of the internal power connections and connectors on the electronic
boards; if you find “loose” connections, tighten or replace the connectors.
3.2 - Sequence of operations (fig. 3.2.1).
The following sequence represents correct functioning of the machine. It may be used as a
guiding procedure for troubleshooting.
It must be carried out after each repair without any errors.
3.2.1 - Power source commands and signals.
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NOTE
Operations preceded by this symbol refer to operator actions.
♦Operations preceded by this symbol refer to machine responses that must occur following an
operator action.
3.2.2 - Starting the power source.
System shut off and unplugged from the mains.
Connect the cable with the gun to terminal (G) of the power source.
Connect the start signal cable of the gun to connector (H).
Connect the cable with earth clamps to terminal (F) of the power source, and the earth clamps
to the metal workpiece (see the Instruction Manual on how to fasten them).
Close the switch (I).
♦System powered, green led (C) lit, fan (34) running.
♦Display (E) reads “P_0”, thus the working program for the gun provided.
Correct?
♦After two seconds display (E) shows the programmed voltage for the DC-
capacitors (24).
NO (see 3.3.1, 3.3.2).
YES
Press the tip of the gun to an insulating surface, with no rivets inserted in the mandrel, and
press the start button of the gun (trigger).
Holding down the start button on the gun, lift the gun from the surface against which the tip
was pressed.
Correct?
♦Led (D) on control panel lights for as long as the start button is held down and the
tip of the gun pressed against the test surface. Release the start button or lift the
gun from the test surface. The led (D) shuts off to indicate that the start command
is no longer present.
NO (see 3.3.3).
YES
Press and hold down the key (A).
Press and hold down the key (B).
♦The programmed voltage on display (E) increases (with key (A)) or decreases
(with key (B)).
Correct?
♦When the buttons are released, display (E) flashes to indicate that the voltage on
the DC-capacitors (24) is reaching the new programmed value. When the flashing
stops, the voltage on the DC-capacitors (24) has reached the new programmed
value.
NO (see 3.3.4).
YES
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Use the (A) or (B) keys to set a voltage on display (E) suitable for the welding to be done.
Insert a rivet in the mandrel of the gun and press the tip of the rivet against the surface of the
sheet metal to which it is to be welded; press the gun start trigger.
Correct?
♦Current output is activated for a few tenths of a second, during which time the
rivet is welded to the sheet metal.
NO (see 3.3.5, 3.3.6).
YES
As soon as you have finished welding, release the torch trigger and immediately move the gun
away from the sheet metal.
Correct?
♦The power source is awaiting a new start command for a new welding cycle (if
you pause with the torch in contact with the workpiece, you will cause a block and
message “E2” will appear on display (E) (see Error codes, par. 3.4).
NO (see 3.4.2).
YES
REGULAR OPERATION.
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3.3 - Troubleshooting. WARNINGS
ANY INTERNAL INSPECTIONS OR REPAIRS MUST BE CARRIED OUT BY QUALIFIED
PERSONNEL.
BEFORE BEGINNING MAINTENANCE OPERATIONS, UNPLUG THE MACHINE FROM
THE MAINS AND WAIT FOR THE INTERNAL CAPACITORS TO DISCHARGE.
MEASURE THE VOLTAGE ON THE DC-CAPACITORS (24) EVERY TIME YOU
ACCESS THE INTERIOR OF THE POWER SOURCE, AND DISCHARGE THEM
MANUALLY IF NECESSARY BY TEMPORARILY APPLYING A 470 OHM 50 W
RESISTOR IN PARALLEL TO THE DC-CAPACITORS (24) (see warnings par. 1.3).
NEVER SHORT-CIRCUIT THE TERMINALS OF THE DC-CAPACITORS (24).
NOTE
Items in boldface describe problems that may occur on the machine (symptoms).
Operations preceded by this symbol refer to situations that the operator must verify (causes).
♦Operations preceded by this symbol refer to actions the operator must perform in order to
solve the problems (solutions).
3.3.1 - The power source does not start, led (C) on control panel unlit.
MAINS SUITABILITY TEST.
Correct?
No voltage due to tripped mains protection.
NO
YES
♦Eliminate any short-circuits on the connections between power cable, switch (21),
fuse (J) and power board (12).
♦Make sure that terminals L1 and L2 of CN1 on power board (12) are not short-
circuited between themselves or towards earth.
♦Mains not suitable to power the power source (ex.: insufficient installed power).
MAINS CONNECTION TEST.
Terminals L1 and L2 on power board (12) = 115 or 230 Vac, with switch (21) closed.
Correct?
YES
NO
♦Check power cable and plug and replace if necessary.
♦Make sure the fuse (J) is intact on the rear panel of the power source.
♦Check switch (21), and replace if defective.
♦Check the mains voltage conditions.
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SERVICES POWER SUPPLY TEST.
Correct?
Power board (12), rectifier bridge W1, negative terminal (-) and diode D2 cathode (+) = +25
Vdc, with switch (21) closed and mains voltage 230 Vac.
YES
NO
♦Check the wiring between CN3 of power board (12) and transformer (31).
♦With power source powered check the following voltages at the primary circuit of
transformer (31):
−CN3, terminals 8 and 10 = 115 Vac;
−CN3, terminals 7 and 9 = 115 Vac;
−CN3, terminals 7 and 10 = 0 Vac with mains 230 Vac; 115 Vac with mains 115
Vac.
If incorrect replace relay RL1 on power board (12) or complete power board (12).
If correct, make sure the following voltages are present on the secondary circuits
of the transformer (31):
−CN3, terminals 1 and 2 = 190 Vac; terminals 4 and 5 = 18 Vac.
If incorrect, with power source off temporarily disconnect CN3 from power board
(12) and check the resistance between the following terminals of CN3:
−CN3, terminals 1 and 2 = approximately 1.7 ohm; terminals 4 and 5 =
approximately 0.7 ohm.
If incorrect replace the power board (12). If correct, replace transformer (31).
CONTROL BOARD (2) POWER SUPPLY TEST.
Correct?
Control board (2), connector CN2, terminals 14 (–) and 1 (+) = + 5 Vdc, with switch (21)
closed.
YES
NO
♦Check the wiring between CN2 control board (2) and CN4 power board (12).
♦With power source off, temporarily disconnect connector CN4 from power board
(12) and turn the power source back on. Make sure that on CN4 of power board
(12), terminals 14(-) and 1(+) = +5 Vdc. If correct, check the wiring between CN2
control board (2) and CN4 power board (12), and replace control board (2) if
necessary. If incorrect replace the power board (12).
♦Replace the control board (2).
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3.3.2 - Power source powered, fan (34) stopped.
FAN TEST.
Correct?
Fast-on terminals fan (34) = 115 Vac (with mains 115 or 230 Vac).
NO
YES
♦Make sure that there are no mechanical impediments blocking the fan.
♦Replace the fan (34).
♦Check the wiring between fan (34) and terminals 8 and 10 of CN3 on power board (12).
♦See SERVICE POWER SUPPLY TEST, par. 3.3.1.
♦Replace the power board (12).
3.3.3 - Power source powered, the start button produces no effect.
START COMMAND TEST.
Correct?
Control board (2), connector CN1, terminals 3(+) and 1(-) = 0 Vdc, led (D) lit, with start
button and gun tip pressed (approximately +4 Vdc, led (D) off, with start button and gun tip
resting).
YES
NO
♦Check the wiring between terminals 1 - 3 of CN1 control board (2), connector
(38)(H) on the front panel of the power source, start button and interface switch in
the gun.
♦Check the conditions and operation of the start button, interface switch in the gun,
and gun patch connector. Replace if defective.
♦See CONTROL BOARD (2) POWER SUPPLY TEST par. 3.3.1.
♦Replace the control board (2).
♦Regular operation.
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3.3.4 - In open circuit operation, the voltage at the DC-capacitors (24) is not regular.
NOTE
To check the open circuit operation of the power source, you must measure the output voltage
directly on the DC-capacitors (24), since the output terminals (F) and (G) of the power source are
connected to this potential only at the moment of welding.
WARNINGS
DC-capacitors (24) are normally discharged by the control, which inserts the discharge resistor
(7) in parallel until the programmed voltage is reached.
If this circuit does not work the DC-capacitors (24) remain charged for several hours.
TO DISCHARGE THEM MANUALLY, TEMPORARILY APPLY A RESISTANCE OF 470
OHM 50 W IN PARALLEL TO THE DC-CAPACITORS (24).
NEVER SHORT-CIRCUIT THE TERMINALS OF THE DC-CAPACITORS (24).
The large capacity of the DC-capacitors (24) may produce very high currents, even with just a
few volts, with serious danger to the operator.
VOLTAGE ON THE DC-CAPACITORS (24) ADJUSTMENT TEST.
Terminals of the DC-capacitors (24) = same voltage used the last time welding was
performed, or standard voltage for the type of accessory applied to the power source (ex.: 40
Vdc for the gun provided).
Correct?
Adjust the keys (A) or (B) to increase or decrease the programmed voltage, shown on display
(E). When the keys are released, display (E) flashes to indicate that the voltage on the DC-
capacitors (24) is changing to reach the programmed value. When the flashing stops, the
voltage on the DC-capacitors (24) has reached the programmed value.
YES
NO
♦Check the flat cable between CN4 power board (12) and CN2 control board (2).
♦Check the status of the relay RL2 on power board (12). In normal conditions it
must not be powered and its NC contact actually closed.
♦With the power source off, check on CN2 of power board (12) to make sure
resistance of terminals 5 and 6 = approximately 60 ohm. If >Mohm (circuit
broken) replace discharge resistor (7). If 0 ohm (short-circuit) replace discharge
resistor (7) and power board (12).
♦See POWER SUPPLY AND CONTROL BOARD (2) TEST and SERVICES
POWER SUPPLY TEST par. 3.3.1.
♦Replace the control (2) and/or power (12) boards.
♦Regular operation.
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3.3.5 - In resistive load operation, the output voltage is not regular.
NOTE
For the following test use a resistive load capable of circulating a current greater than 100
Adc, at a maximum voltage of 210 Vdc (for example 0.5 ohm).
OUTPUT VOLTAGE TEST ON RESISTIVE LOAD.
With power source powered, connect the resistive load to terminals (F) and (G) of the power
source and the gun signals connector to connector (H) of the power source.
Press the start button. Terminals (F) and (G) (gnd) = fig. 5.2.1 in the table conditions.
Programmed voltage
(display (E). Resistive load resistance. Output voltage pulse.
210 Vdc 0.5 ohm fig 5.2.1.
NOTE
In this test, at the end of each pulse it may be necessary to disconnect the load (as occurs
normally when the rivet is changed in the gun), to avoid an “E2” block of the power source.
If blocked, shut off and restart the power source without connecting any charge.
Correct?
YES
NO
♦Check the flat cable between CN4 power board (12) and CN2 control board (2).
♦Check voltages on the windings of the transformer (31) see SERVICES POWER
SUPPLY TEST in par. 3.3.1.
♦Check the wiring between terminal (+) on power board (12), positive terminal of
the DC-capacitors (24), and output terminal (F) of the power source; between
terminal 2 of CN2 on power board (12) and scr (3) cathode (equivalent to the
negative terminal of the DC-capacitors (24)), and between scr (3) anode and
output terminal (G) of the power source. If you find loose or burnt connections,
clean thoroughly and tighten, or replace any damaged terminals or components.
♦Check operation of the start command, if necessary performing the START
COMMAND TEST in par. 3.3.3.
♦Replace the control (2) and/or power (12) boards.
♦Replace scr (3).
♦Regular operation.
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3.3.6 - In actual working conditions (thus with high currents), the welding quality is not
satisfactory.
In actual working conditions, thus with high currents, the welding quality may not be
satisfactory even if the “no-load operating test” par. 3.3.4 and “resistive load operating test” par.
3.3.5 were successful.
To check whether the problem depends on the power source or any accessories connected to it
(cables, clamps, gun, rivets or sheet metal), we recommend that you carefully check the
operating conditions of the accessories and sheet metal, to make sure they are not responsible.
Should you determine that the cause lies in the power source you must consider the following:
−the DC-capacitors (24) may lose their efficiency over time, and no longer deliver the
currents needed for welding. This decline may be detected by using an instrument to
measure the capacity, checking the waveform of the output voltage pulse in the test in par.
3.3.5 (fig. 5.2.1), or checking the automatic discharge time if charges are left at the
maximum voltage (210 Vdc). With new and efficient capacitors you may notice an
automatic discharge of approximately 10 - 20 Vdc every hour.
−In certain applications the welding current may reach peak values of around 5 kA, for a
duration of 2 - 3 msec. Any extension cords at the power source output, as well as partially
rusted contacts in the internal power wiring and in the output terminals (F) and (G) of the
power source, may make it impossible to attain these currents.
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3.4 - Error codes.
3.4.1 - E1 - Transformer (31) temperature above limits.
The power source delivers no current, but the fan continues running; we therefore recommend
leaving the power source powered to ensure rapid cooling.
This is reset automatically when the temperature returns within the allowed limits.
The thermostat is inserted on the windings of the transformer (31); its contact must be closed
at ambient temperature.
If the alarm persists even with the power source powered and without welding, check the
voltages on the windings of the transformer (31), performing the SERVICES POWER SUPPLY
TEST in par. 3.3.1.. If the alarm occurs only when welding, make sure that the working cycle is
not above specifications, or that the ambient temperature is not too high.
3.4.2 - E2 - Scr (3) short-circuited.
To allow the clamps, gun and rivet to be positioned, the output terminals (F) and (G) of the
power source must be free from voltage until the moment of welding. In the event the scr (3) is
short-circuited, there would be voltage on the output terminals (F) and (G), and this positioning
would be difficult and hazardous. This check therefore makes sure there is no voltage on the
output terminals (F) and (G); otherwise it blocks the unit and activates E2.
Check the wiring between cathode and gate of scr (3) and terminals 1 and 2 of CN2, power
board (12). With CN2 disconnected from power board (12) measure the resistance between the
anode and cathode of scr (3). Correct value = >Mohm in both measurement directions. If
incorrect, replace scr (3).
3.4.3 - E3 - Dc voltage on the DC-capacitors (24) irregular.
The dc voltage on the DC-capacitors (24) has risen beyond the maximum allowed limits.
This may be due to a defect in the regulating circuits or a short-circuit of the triac TR1 on
power board (12). This alarm also trips the relay RL2 on power board (12), which cuts off the
power circuit (190 Vac secondary circuit of transformer (31)), to avoid the risk of explosion in
the DC-capacitors (24).
To reset, shut off and restart the power source after removing the cause of the block.
Make sure that the triac TR1 on power board (12) is not short-circuited. Replace if necessary.
Replace the power (12) and/or control (2) boards.
3.4.4 - E4 - DC-capacitor (24) irregular charge.
Irregular (too slow) charge of the DC-capacitors (24). In this case the voltage regulator circuit
is no longer deemed efficient. This control thus blocks the power source to avoid welding with
potentially hazardous voltages.
To reset, shut off and restart the power source after removing the cause of the block.
Replace the power (12) and/or control (2) boards.
3.4.5 - E5 - DC-capacitors (24) irregular discharge.
To lower the voltage on the DC-capacitors (24), the check engages the discharge resistor (7)
in parallel to them until the programmed voltage is reached. If this circuit does not work or if the
discharge resistor (7) is interrupted, this control blocks the power source.
Check resistor (7), making sure whether on CN2 of power board (12), terminals 5 and 6,
resistance = approximately 60 ohm. If >Mohm (circuit broken) replace discharge resistor (7). If 0
ohm (short-circuit) replace discharge resistor (7) and power board (12).
Replace the control board (2).
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4- COMPONENTS LIST
4.1 - Power source art. 2153: see file ESP2153.pdf enclosed at the end of the manual.
4.2 - Components table: see file ESP2153.pdf enclosed at the end of the manual.
4.3 - List of spare parts.
Essential spare parts.
Ref. Code Description Qty
2 5602168 control circuit 1
3 5605538 scr group 1
12 5602169 power circuit 1
Recommended spare parts.
Ref. Code Description Qty
21 3190014 switch 1
24 3175775 capacitor 1
31 5610050 power transformer 1
34 3165094 motor-driven fan 1
5- ELECTRICAL DIAGRAMS
5.1 - Power source art. 2153: see file SCHE2153.pdf enclosed at the end of the manual.
5.2 - Waveforms.
5.2.1 - Output voltage upon scr (3) engagement (par. 3.3.5).
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5.3 - Power board (12) code 5.602.169.
5.3.1 - Topographical drawing.
5.3.2 - Connector table.
Connector Terminals Function
CN1 1 input earth connection.
CN1 2 - 3 mains power supply input (115 / 230 Vac).
CN2 1(+) – 2(-) scr (3) gate command output.
CN2 3 NU.
CN2 4 output voltage signal input.
CN2 5(+) – 6(-) voltage output for discharge resistor (7).
CN3 1 - 2 190 Vac voltage input for power circuit power supply.
CN3 3 NU.
CN3 4 - 5 18 Vac voltage input for services power supply.
CN3 6 NU.
CN3 7 - 9 115 Vac voltage output for primary winding 1 of transformer (31) power supply.
CN3 8 - 10 115 Vac voltage output for primary winding 2 of transformer (31) power supply.
CN4 1-2 +5 Vdc output for control board (2) power supply.
CN4 3 engage command input for scr (3).
CN4 4 charge command input for triac TR1.
CN4 5 discharge command input for discharge resistor (7).
CN4 6 RL1 command input (mains voltage selection).
CN4 7 mains voltage signal output.
CN4 8 mains synchronism signal output.
CN4 9 scr (3) engage enable signal output.
CN4 10 DC-capacitors (24) voltage signal output for alarm threshold E3.
CN4 11 DC-capacitors (24) voltage signal output to adjust dc voltage.
CN4 12-13-14 0 Vdc output for control board (2) power supply.
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5.4 - Control board (2) code 5.602.168.
5.4.1 - Topographical drawing.
5.4.2 - Connector table.
Connector Terminals Function
CN1 1 shared input for signals from outside.
CN1 2 temperature signal input from thermostat on transformer (31).
CN1 3 start signal input from gun button.
CN1 4 NU.
CN1 5 NU.
CN1 6 NU. (accessory connected recognition signal input).
CN1 7 NU.
CN1 8 earth connection.
CN2 1-2 +5 Vdc input for control board (2) power supply.
CN2 3 scr (3) engage command output.
CN2 4 charge command output for triac TR1.
CN2 5 discharge command output for discharge resistor (7).
CN2 6 RL1 command output (mains voltage selection).
CN2 7 mains voltage signal input.
CN2 8 mains synchronism signal input.
CN2 9 scr (3) engage enable signal output.
CN2 10 DC-capacitors (24) voltage signal input for alarm E3 threshold.
CN2 11 DC-capacitors (24) voltage signal input to adjust dc voltage.
CN2 12-13-14 0 Vdc input for control board (2) power supply.
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29

30
pos DESCRIZIONE DESCRIPTION
01 CORNICE FRAME
02 CIRCUITO PANNELLO PANEL CIRCUIT
03 GRUPPO SCR SCR UNIT
04 FASCIONE HOUSING
05 DIODO SKN SKN DIODE
06 IMANICO HANDLE
07 RESISTENZA RESISTANCE
08 DISSIPATORE SCR SCR RADIATOR
09 RADIATORE RADIATOR
10 DISTANZIALE SPACER
11 DISTANZIALE ISOLANTE INSULATING SPACER
12 CIRCUITO DI POTENZA POWER CIRCUIT
13 DISTANZIALE DISTANZIALE
14 CONNETTORE CONNECTOR
15 CONNESSIONE CONNECTION
16 RADIATORE RADIATOR
17 DISTANZIALE DISTANZIALE
18 PASSACAVO CABLE OUTLET
19 PORTA FUSIBILE FUSE HOLDER
20 FUSIBILE FUSE
21 INTERRUTTORE SWITCH
22 COPERTURA COVER
23 PANNELLO POSTERIORE BACK PANEL
24 CONDENSATORE CAPACITOR
25 CAVO RETE POWER CORD
26 TIRANTE TIE ROD
27 SUPPORTO CONDENSATORE CAPACITOR SUPPORT
28 PIANO INTERMEDIO INSIDE BAFFLE
29 FONDO BOTTOM
30 PIEDE IN GOMMA RUBBER FOOT
31 TRASFORMATORE TRANSFORMER
32 PRESA SOCKET
33 ISOLAMENTO INSULATION
34 VENTOLA FAN
35 SUPPORTO VENTOLA FAN SUPPORT
36 PROTEZIONE PROTECTION
37 PANNELLO ANTERIORE FRONT PANEL
38 CONNETTORE CONNECTOR
39 CORNICE FRAME
40 SUPPORTO MANICO HANDLE SUPPORT
When oordering sspare pparts pplease aalways sstate tthe mmachine iitem aand
serial nnumber aand iits ppurchase ddata, tthe sspare ppart pposition aand tthe
quantity.
La rrichiesta ddippezzi ddirricambio ddeve iindicare ssempre: nnumero ddiaarti-
colo, mmatricola eeddata ddiaacquisto ddella mmacchina, pposizione eeqquantità
del rricambio.
pos DESCRIZIONE DESCRIPTION
100 IMPUGNATURA HANDGRIP
102 ANELLO POSTERIORE BACK RING
103 REGOLAZIONE MOLLA SPRING ADJUSTMENT
104 INDICE DI REGOLAZIONE REGULATION POINTER
105 MOLLA SPRING
106 MANDRINO HOOK
107 BOCCOLA BUSH
108 PULSANTE SWITCH
109 CAMMA CAM
110 MICRO INTERRUTTORE MICRO SWITCH
111 MICRO INTERRUTTORE MICRO SWITCH
112 ROSETTA WASHER
113 SOFFIETTO BELLOWS
114 GHIERA MANDRINO HOOK RING NUT
115 GHIERA RING NUT
116 CAVO CABLE
117 PASSACAVO DOPPIO DOUBLE CABLE OUTLET
118 CAVO CABLE
119 SPINA VOLANTE WANDER PLUG
120 SPINA VOLANTE WANDER PLUG
130 KIT ACCESSORI ACCESSORIES KIT