Cebora POWER ROD 1565 Cell User manual

CEBORA S.p.A. 1
3.302.113 20/11/02
POWER ROD 1565 Cell
POWER SOURCE art. 255
SERVICE MANUAL

CEBORA S.p.A. 2
3.302.113 20/11/02
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. 255...................................................................................................... 4
2.3.1 - Operating mode setting.......................................................................................................................... 4
2.3.2 - Internal/external welding current setting............................................................................................. 5
3- MAINTENANCE......................................................................................................................................... 6
3.1 - Periodic inspection, cleaning. .................................................................................................................. 6
3.2 - Operating sequence (fig. 3.2.1). .............................................................................................................. 6
3.2.1 - Power source commands and signals................................................................................................... 6
3.2.2 - Power source operation.......................................................................................................................... 7
3.3 - Troubleshooting......................................................................................................................................... 8
3.3.1 - The power source does not start, panel off. ........................................................................................ 8
3.3.2 - Power source powered, fan (9) stopped............................................................................................... 9
3.3.3 - Power source powered, signals do not indicate the correct values.................................................. 9
3.3.4 - In TIG mode, the start button does not generate output voltage.................................................... 10
3.3.5 - In open circuit operation, the output voltage is not regular............................................................ 10
3.3.6 - In resistive load operation, the output voltage is not regular.......................................................... 11
3.3.7 - In TIG, arc unstable, welding irregular. ............................................................................................ 12
3.3.8 - In MMA, difficulty striking the arc, welding irregular. .................................................................. 13
3.4 - Error codes. .............................................................................................................................................. 14
3.4.1 - Yellow led (B) lit steadily. .................................................................................................................. 14
3.4.2 - Yellow led (B) flashing (4 rapid flashes with interval of 5” of steady light)............................... 14
3.4.3 - Yellow led (B) flashing (2 rapid flashes with interval of 2” of steady light)............................... 14
3.4.4 - Yellow led (B) flashing (1 rapid flash with interval of 2” of steady light). ................................. 14
3.4.5 - Yellow led (B) off during the first 5 seconds upon start-up (no lamp-test). ................................ 14
4- COMPONENTS LIST............................................................................................................................... 15
4.1 - Power source art. 255: see file ESP255.pdf enclosed at the end of the manual. ............................ 15
4.2 - Components table: see file ESP255.pdf enclosed at the end of the manual.................................... 15
4.3 - List of spare parts. ................................................................................................................................... 15
5- ELECTRICAL DIAGRAMS.................................................................................................................... 15
5.1 - Power source art. 255: see file SCHE255.pdf enclosed at the end of the manual.......................... 15
5.2 - Power board (11) code 5.602.125. ........................................................................................................ 15
5.3 - Panel board (16) code 5.602.126........................................................................................................... 17

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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. 255 for MMA and TIG welding systems.
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 Instruction 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 (2 minutes) before accessing the interior of the equipment.
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 ROD 1565 Cell is a system for MMA, MMA Cellulosic and TIG welding with
strike starting of the arc.
It is made up of an electronic power source (art. 255), and a set of accessories to adapt to
various types of applications (see list in Sales Catalogue).
The power source is controlled by a microprocessor circuit, which manages the operative
functions of the welding system and the operator interface.
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. 255.
Art. 255 is a direct current power source with controlled current, consisting of a single-phase
rectifier bridge, a DC/AC mosfet converter (inverter), and an additional single-phase rectifier
bridge.
Referring to the electrical diagram in par. 5.1, drawing 4.1 and table 4.2, we can identify the
main blocks that make up the power source.
The main switch (5) powers the power board (11), which contains the power circuits and
control circuits to manage the functions of the power source art. 255. It converts the alternating
voltage of the network into direct current, adjusted according to welding needs. The welding
current is adjusted by the microprocessor based on the signals received from the panel board
(16).
The microprocessor also checks the condition of the supply voltage, to implement the
protections needed to protect the power source (see Error codes, par. 3.4).
The panel board (16) represents the power source control panel and depends entirely on the
power board (11), from which it receives supply voltages.
The panel board (16) contains the signaling leds (see Error codes, par. 3.4), the potentiometers
for setting the operating parameters, and the connector to connect external control devices to the
power source.
The fan (9), connected to the power board (11), is actually connected directly in parallel to the
board mains input terminals, for which it is subjected to all variations in the mains voltage,
without any control by the power board (11).
The power source requires only the mains voltage supply in order to operate. Once powered,
the power source performs the “lamp-test”, during which the microprocessor analyzes the mains
voltage. If the voltage is found suitable, the microprocessor then prepares the power source for
the type of operation, based on the level of the START Signal (terminal 7 of CN1 on power
board (11)), which in turn is determined by the jumper on terminals 8 and 3 of the connector (H),
as illustrated in table 2.3.1.
2.3.1 - Operating mode setting.
Accessories
connected
to the connector H
Jumper 8-3
connector H
Operating mode Start
button
Signal
START
Output
voltage
None / art. 187 Open MMA/MMA cell Absent 1.5 – 4 Vdc YES
Released >4 Vdc NOTIG torches / art.
181 Closed TIG
Pressed <1.5 Vdc YES

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Note that the type of operation depends on the jumper on terminals 8 and 3 of the connector
(H), and thus the accessory connected to the power source, while the output voltage generated
depends on the operating mode set and/or the start button.
Similarly to what occurs for the start command, the welding current adjustment takes into
account the accessory connected to the power source, according to the procedure in table 3.2.2.
2.3.2 - Internal/external welding current setting.
Accessories connected
to the connector H
Jumper 8-4
connector H
Operating mode Setting the welding
current using
TIG torches with
potentiometer / art181 TIG
Art. 187
Closed
MMA/MMA cell
Knob A + external
None / TIG torches
without potentiometer Open MMA/MMA cell TIG Knob A only
Note that the jumper on terminals 8 and 4 of the connector (H) also determines the possibility
of adjusting the welding current by adjusting connected external accessories. Their setting range
is between 0 and the value set using the knob (A) of the panel board (16).
In TIG mode the arc must be started through contact between electrode and workpiece. The
power source does not manage the gas circuit, thus a torch must be used with gas valve built into
the grip (ex.: torch T150, arts. 1567.02 or 1567.20 Cebora).
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 (2
MINUTES).
3.1 - Periodic inspection, cleaning.
Periodically make sure that air is flowing properly within the aeration tunnel.
Remove any dirt or dust to ensure 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 - Operating sequence (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.
NOTE
Steps marked with this symbol refer to actions by the operator.
♦The operations marked with this symbol refer to machine responses that must occur following
an operator action.
3.2.1 - Power source commands and signals.

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Correct?
Correct?
Correct?
3.2.2 - Power source operation.
System shut off and disconnected from the mains.
In MMA mode, connect the electrode clamp to the positive pole of the power source, and the
negative pole cable of the power source to the workpiece.
In TIG mode, connect the cable of the positive pole of the power source to the workpiece, the
TIG torch (Cebora torch T150 recommended) to the negative pole of the power source, and
the torch control cable to the connector (H) on the front of the power source.
In TIG mode, connect the gas supply to the specific fitting on the TIG torch.
Plug the power source into the mains and turn on the switch (F).
♦System powered, lamp on switch (F) lit.
♦Fan (9) running, yellow (B) and green (C) leds lit (lamp-test).
♦Yellow led (B) off after five seconds. Voltage begins to be generated at the power
source output (without accessories connected to the connector (H), or with art.
187 connected. With the other accessories connected to the connector (H) the
power source awaits the start signal, without generating output voltage).
NO (see 3.3.1, 3.3.2, 3.3.3).
YES
WARNING
DURING THE TIG MODE TEST, DO NOT POINT THE TORCH AT PEOPLE OR PARTS
OF THE BODY, BUT ALWAYS TOWARDS AN OPEN SPACE OR THE WORKPIECE.
Press the start button of the accessories connected to the connector (H), if present.
♦Voltage begins to be generated at the power source output, for as long as the
button is held down.
NO (see 3.3.4, 3.3.5).
YES
Use the knob (A) and the current settings of any accessories connected to the connector (H) to
adjust the welding current based on the electrode to be used, or based on the TIG welding to
be carried out.
Move the clamp with electrode or TIG torch with start button pressed near the workpiece.
♦Begin welding. Adjust the knob (A) or the current settings of the accessories, to
maximize the welding quality.
NO (see 3.3.6, 3.3.7, 3.3.8).
YES
After welding, release the start button and/or move the electrode clip or TIG torch away from
the workpiece.
♦The welding arc is interrupted, the power source returns to its initial condition
with yellow led (B) off and green led (C) on.
NO (see 3.3.4, 3.3.5).
YES
REGULAR OPERATION.

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3.3 - Troubleshooting.
WARNINGS
ANY INTERNAL INSPECTIONS OR REPAIRS MUST BE CARRIED OUT BY QUALIFIED
PERSONNEL.
BEFORE REMOVING THE PROTECTIVE GUARDS AND ACCESSING INTERNAL
PARTS, DISCONNECT THE POWER SOURCE FROM THE MAINS AND WAIT FOR THE
INTERNAL CAPACITORS TO DISCHARGE (2 MINUTES).
NOTE
Items in boldface describe problems that may occur on the machine (symptoms).
Steps marked with this symbol refer to situations for which the operator must determine the
causes (causes).
♦Steps marked with this symbol refer to actions that the operator must carry out to solve the
problem (solutions).
3.3.1 - The power source does not start, panel off.
MAINS SUITABILITY TEST.
No voltage due to tripped mains protection.
NO
YES
♦Eliminate any short-circuits on the connections between power cable, switch (5)
and power board (11).
♦Make sure that the mains input terminals F5 and F6 on power board (11) are not
short-circuited between them or towards earth.
♦Mains not suited to power the power source (ex.: insufficient installed power).
MAINS CONNECTION TEST.
Power board (11), terminals F5 and F6 = 230 VAC, with switch (5) closed.
YES
NO
♦Check power cable and plug and replace if necessary.
♦Check switch (5), and replace if defective.
♦Check the mains voltage conditions.
PANEL BOARD (16) POWER SUPPLY TEST.
Panel board (16), connector CN1, terminals 2 (+) and 10 (-) = +5 Vdc; terminals 3 (+) and 1
(-) = +13.8 Vdc.
YES
NO

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♦Check the wiring between CN1 power board (11) and CN1 panel board (16).
♦With the power source off, temporarily disconnect connector CN1 on panel board
(16), and make sure that terminals 2 and 10 and terminals 3 and 1 of CN1 on
panel board (16) are not short-circuited. If necessary, replace the panel board (16),
and power the power source with the connector CN1 disconnected to make sure
that the correct voltages are present on terminals 2 and 10 and terminals 3 and 1 of
the patch connector CN1, left free. If missing, also replace power board (11).
♦Replace the panel (16) and/or power (11) boards.
3.3.2 - Power source powered, fan (9) stopped.
FAN TEST.
Fast-on terminals for fan (9) = 230 Vac, with switch (5) closed.
NO
YES
♦Make sure that there are no mechanical impediments blocking the fan.
♦Replace fan (9).
♦Check the wiring between fan (9) and CN11 on power board (11). Connect the fan (9) directly
downstream from the switch (5) if necessary.
3.3.3 - Power source powered, signals do not indicate the correct values.
LAMP-TEST AND ERROR CODE.
Upon start-up, yellow (B) and green (C) leds lit for the first 5 seconds after closing the switch
(5), then green led (C ) = on, yellow led (B) = off.
YES
NO
♦See Error codes, par. 3.4.
♦Check panel board (16) power supply, (see PANEL BOARD (16) POWER
SUPPLY TEST, par. 3.3.1).
♦Replace the display (16) and/or power (11) boards.
♦Correct operation.

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3.3.4 - In TIG mode, the start button does not generate output voltage.
START COMMAND TEST.
Power board (11), connector CN1, terminals 7 (+) and 10 (-) = voltage of the START Signal
as shown in the table.
Accessories
connected
to the connector H
Jumper 8-3
connector H
Operating mode Start
button
Signal
START
Output
voltage
None / art. 187 Open MMA/MMA cell Absent 1.5 – 4 Vdc YES
Released >4 Vdc NOTIG torches / art.
181 Closed TIG
Pressed <1.5 Vdc YES
YES
NO
♦Check the wiring between CN1 power board (11) and CN1 panel board (16).
♦Check the status of the jumper on terminals 8 and 3 of the connector of the
accessory connected to the connector (H), according to table conditions (see
description in par. 2.3).
♦Check the cable and start button of the accessory being used. If defective, replace.
♦With power source off, temporarily disconnect connector CN1 on power board
(11) and make sure that the terminals 7 and 10 of CN1 on power board (11) are
not short-circuited. If necessary replace the power board (11).
♦Check the supply voltages for the panel board (16), performing the PANEL
BOARD (16) POWER SUPPLY TEST, in par. 3.3.1, if necessary.
♦Replace the power (11) and/or panel (16) boards.
♦Check the wiring between CN1 power board (11) and CN1 panel board (16).
♦Replace the power board (11).
3.3.5 - In open circuit operation, the output voltage is not regular.
OPEN-CIRCUIT OUTPUT VOLTAGE TEST.
Output terminal – power source (-) and output terminal + power source (+) = +96 Vdc
approximately, in MMA without accessories connected to the connector (H), or in TIG mode
with start button pressed.
YES
NO
♦Check connections between terminals “-V” and “+V” of the power board (11) and
output terminals “-” and “+”of the power source. If you find loose connections,
tighten and replace any damaged terminals.
♦Make sure that both the internal and external start commands are working
properly, by carrying out the test in par. 3.3.4.
♦Replace the power board (11).
♦Correct operation.

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Correct?
Correct?
Correct?
3.3.6 - In resistive load operation, the output voltage is not regular.
NOTE
For the following tests use a resistive load capable of withstanding the maximum power
source current. The appropriate values are shown in the table.
Process Resistive load
resistance
Maximum output
current
Power source
output voltage
Condition
TIG 0.117 ohm 130 Adc +15 Vdc Start button pressed
MMA 0.194 ohm 130 Adc +25 Vdc Power source powered
OUTPUT VOLTAGE TEST ON RESISTIVE LOAD.
Turn knob (A) in max. clockwise (to maximum), and adjust the current on any accessory
connected to the connector (H) to the maximum current value.
Output terminal – power source (-) and output terminal + power source (+) = voltage and
current values as shown in the table, adjustable both with knob (A) and by adjusting on the
accessory connected to the connector (H).
NO
YES
♦Correct operation.
♦Make sure that open circuit operation is working properly, performing the OPEN-CIRCUIT
OUTPUT VOLTAGE TEST, in par. 3.3.5, if necessary.
INTERNAL CURRENT REFERENCE TEST.
Temporarily disconnect any accessories from the connector (H). Power board (11), connector
CN1, terminals 5 (+) and 1 (-) = voltage adjustable from 0 to maximum (approximately +3.9
Vdc), by turning knob (A).
YES
NO
♦Check the wiring between CN1 power board (11) and CN1 panel board (16).
♦Check the supply voltages for the panel board (16), performing the PANEL
BOARD (16) POWER SUPPLY TEST, in par. 3.3.1, if necessary.
♦With power source off, temporarily disconnect connector CN1 on power board
(11) and check the resistance between terminals 5 and 1 of CN1 on power board
(11). Correct value = approximately 200 Kohm. If 0 ohm (short-circuit) or
>Mohm (circuit broken), check the resistive network RR2 and its connection with
CN1 terminal 5, or replace the power board (11).
♦Replace the panel board (16).
EXTERNAL CURRENT REFERENCE TEST.
Temporarily connect an accessory with potentiometer to adjust the current at the connector
(H). Power board (11), connector CN1, terminals 5 (+) and 1 (-) = voltage adjustable from 0
up to the value set with knob (A) (max. +3.9 Vdc), by turning the potentiometer on the
connected accessory.
NO
YES

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♦Check the connection between terminals “-V” and “+V” on the power board (11),
with the output terminals – and + of the power source. If you find loose
connections, tighten and replace any damaged terminals.
♦Replace the power board (11).
EXTERNAL CURRENT REFERENCE ENABLE TEST.
Panel board (16), connector J1, terminals 4 (+) and 8 (-) = +13.8 Vdc, external reference
disabled, without accessories connected to the connector (H), or with art. 1567.20 connected
(TIG torch with start button only); 0 Vdc, external reference enabled, (with arts. 181, or 187,
or 1567.02 connected to the connector (H).
YES
NO
♦Check the wiring between CN1 power board (11) and CN1 panel board (16).
♦Check the wiring of the accessory connected to the connector (H), especially the
presence, where necessary, of the jumper between terminals 4 and 8 of the
connector of the accessory being used.
♦Make sure that the accessory being used is compatible with the power source art.
255 (see tables 2.3.1 and 2.3.2, and electrical diagram in par. 5.1 for connections,
or Sales Catalogue, and the power source Instruction Manual).
♦Replace the panel board (16).
♦Check cable and potentiometer of the accessory being used. If defective, replace.
♦Make sure that the accessory being used is compatible with the power source art. 255 (see
tables 2.3.1 and 2.3.2, and electrical diagram in par. 5.1 for connections, or Sales Catalogue,
and the power source Instruction Manual).
♦Replace the panel board (16).
3.3.7 - In TIG, arc unstable, welding irregular.
NOTE
In TIG, the welding quality may not be acceptable due to current instability. In this case we
recommend carrying out MMA welding tests.
WELDING QUALITY TEST IN MMA.
Power source in MMA, welding tests = good welding quality.
YES
NO
♦Perform the tests “open circuit operation” (par. 3.3.5) and “operation on resistive
load” (par. 3.3.6).
♦Replace the power board (11).
♦Check the condition of the torch and electrode. If necessary, sharpen the tip of the electrode.
♦Check for the presence and continuous flow of gas in output from the torch.
♦Check the operation of the gas valve in the torch.
♦Replace the power board (11).

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3.3.8 - In MMA, difficulty striking the arc, welding irregular.
NOTE
The power source art. 255 offers the functions HOT-START, to assist striking the arc in both
MMA and TIG modes, and ARC-FORCE, to maximize transferring the electrode drop to the
workpiece in MMA welding.
ARC-FORCE AND HOT-START REFERENCES TEST.
NOTE
The ARC-FORCE function is timed (maximum duration = 400 msec.) and begins when the
output voltage, during MMA welding, exceeds a certain threshold (not adjustable). Therefore,
for the following test we recommend temporarily setting up a jumper on terminals 8 and 3 of
the connector (H), to prevents the output voltage from being generated and thus stabilizing the
welding test condition. Without the jumper on the connector (H), the test voltage may be
measured only during the initial “lamp-test” and the subsequent 400 msec, or during MMA
welding.
ARC-FORCE FUNCTION REFERENCE. Power board (11), connector CN1, terminals 4 (+)
and 1 (-) = voltage adjustable from 0 to maximum (approximately +4 Vdc), using the knob
(L), with open-circuit power source.
HOT-START FUNCTION REFERENCE. Power board (11), connector CN1, terminals 8 (+)
and 1 (-) = voltage adjustable from 0 to maximum (approximately +4 Vdc) using the knob (I),
with open-circuit power source.
YES
NO
♦Check the wiring between CN1 power board (11) and CN1 panel board (16).
♦Check the supply voltages for the panel board (16), performing the PANEL
BOARD (16) POWER SUPPLY TEST, in par. 3.3.1, if necessary.
♦With the power source off, temporarily disconnect connector CN1 on power board
(11) and check the resistance between terminals 8 and 1 and between terminals 4
and 1 of CN1 on power board (11). Correct value = approximately 200 Kohm for
both measurements. If 0 ohm (short-circuit) o >Mohm (circuit broken), check the
resistive network RR2 and its connection with CN1 terminals 8 and 4, or replace
the power board (11).
♦Make sure that the potentiometers PT1 and PT3 on panel board (16) are intact.
Replace if defective, or replace the panel board (16).
♦Replace the power board (11).

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3.4 - Error codes.
3.4.1 - Yellow led (B) lit steadily.
Alarm for temperature above limits.
The thermostat is located on the dissipater of the power mosfets of the power board (11).
The power source delivers no current, but the fan remains in operation; we therefore
recommend leaving the power source powered in case of alarm for overtemperature.
Check the temperature of the power module dissipaters on the power board (11), and wait for
them to cool completely if necessary. If the alarm persists, replace power board (11). If the alarm
is reset, check the efficiency of ventilation, make sure the ambient temperature is not too high,
and that the working cycle is not greater than the one specified.
3.4.2 - Yellow led (B) flashing (4 rapid flashes with interval of 5” of steady light).
Alarm for high supply voltage, greater than approximately 260 Vac, at the start-up.
The power source delivers no current.
Proper operation returns when the voltage falls below 260 Vac.
This system also protects the power source against accidental power supply at 400 Vac. In
this condition the electronic circuits are protected, but the fan subjected to the mains voltage may
be damaged in just a few seconds.
3.4.3 - Yellow led (B) flashing (2 rapid flashes with interval of 2” of steady light).
Alarm for excessive supply voltage of the internal driver circuits. Generally, something has
occurred which may damage the power source if the activity continues.
To restore operation, shut off the power source, wait for the capacitors inside to discharge
completely (4 minutes), and restart the power source at the rated voltage. If the alarm persists,
the power board (11) may be faulty, and it is therefore recommended to replace it.
3.4.4 - Yellow led (B) flashing (1 rapid flash with interval of 2” of steady light).
Alarm for low supply voltage, below approximately 160 Vac, both at start-up and while
operating.
The power source delivers no current.
Proper operation returns when the voltage rises above approximately 160 Vac, remaining at
reduced performance levels until the voltage reaches values close to the rated value.
3.4.5 - Yellow led (B) off during the first 5 seconds upon start-up (no lamp-test).
Alarm for low supply voltage, less than approximately 150 Vac, at start-up.
The power source delivers no current, even though the signals are the same as for normal
operation after the lamp-test.
Proper operation returns when the voltage rises above approximately 160 Vac, remaining at
reduced performance levels until the voltage reaches values close to the rated value.

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4- COMPONENTS LIST
4.1 - Power source art. 255: see file ESP255.pdf enclosed at the end of the manual.
4.2 - Components table: see file ESP255.pdf enclosed at the end of the manual.
4.3 - List of spare parts.
Essential spare parts.
Ref. Code Description Qty.
11 5602125 power board 1
Recommended spare parts.
Ref. Code Description Qty.
5 3190014 switch 1
9 3165075 fan 1
16 5602126 panel board 1
5- ELECTRICAL DIAGRAMS
5.1 - Power source art. 255: see file SCHE255.pdf enclosed at the end of the manual.
5.2 - Power board (11) code 5.602.125.
5.2.1 - Connector table.
Connector Terminals Function
CN1 2(+) – 1(-) 5Vdc power supply output for panel board (16).
CN1 3(+) – 10(-) 13.8 Vdc power supply output for panel board (16).
CN1 4 ARC-FORCE reference input.
CN1 5 welding current reference input.
CN1 6 power source blocked signaling output.
CN1 7 start command input (from external button or internal command).
CN1 8 HOT-START reference input.
CN1 9 HOT-START enable output.
CN11 - output for fan (9).
F3 - F4 earth connections of the power board (11).
F5 - F6 230 Vac power supply input for power board (11).
+V - -V power circuit output of power board (11).

CEBORA S.p.A. 16
3.302.113 20/11/02
5.2.2 - Topographical drawing.

CEBORA S.p.A. 17
3.302.113 20/11/02
5.3 - Panel board (16) code 5.602.126.
5.3.1 - Connector table.
Connector Terminals Function
CN1 2(+) – 1(-) 5Vdc power supply input for panel board (16).
CN1 3(+) – 10(-) 13.8 Vdc power supply input for panel board (16).
CN1 4 ARC-FORCE reference output.
CN1 5 welding current reference output.
CN1 6 power source blocked signaling input.
CN1 7 start command output (from external button or internal command).
CN1 8 HOT-START reference output.
CN1 9 HOT-START enable input.
J1 1 - 9 input from external start button.
J1 2 + power supply output for external current potentiometer.
J1 3 - 8 external start button enable input.
J1 4 - 8 welding current reference enable input from external potentiometer.
J1 5 NU.
J1 6 NU.
J1 7 power supply output (-) for external current potentiometer.
J1 10 current reference input from external potentiometer cursor.
5.3.2 - Topographical drawing.

When ordering spare parts please always state the machine item
and serial number and its purchase data, the spare part position
and the quantity.
La richiesta di pezzi di ricambio deve indicare sempre: numero di
articolo, matricola e data di acquisto della macchina, posizione e
quantità del ricambio.
pos DESCRIZIONE DESCRIPTION
01 SUPPORTO MANICO HANDLE SUPPORT
02 MANICO HANDLE
03 FASCIONE HOUSING
04 COPERTURA IN GOMMA RUBBER MAT
05 INTERRUTTORE SWITCH
06 PRESSACAVO STRAIN RELIEF
07 PANNELLO POSTERIORE BACK PANEL
08 SUPPORTO VENTOLA FAN SUPPORT
09 MOTORE CON VENTOLA MOTOR WITH FAN
10 COPERTURA COVER
11 CIRCUITO DI POTENZA POWER CIRCUIT
12 PANNELLO ANTERIORE FRONT PANEL
pos DESCRIZIONE DESCRIPTION
13 MANOPOLA KNOB
14 CORNICE FRAME
15 PRESA SOCKET
16 CIRCUITO CONNETTORE CONNECTOR CIRCUIT
17 SUPPORTO SUPPORT
18 RETE METALLICA WIRE NETTING
19 CORNICE FRAME
20 PIEDE IN GOMMA RUBBER FOOT
21 FONDO BOTTOM
22 CAVO RETE POWER CORD
23 TAPPO CAP
24 MANOPOLA KNOB
CODIFICA COLORI WIRING DIAGRAM
CABLAGGIO ELETTRICO COLOUR CODE
A NERO BLACK
B ROSSO RED
C GRIGIO GREY
D BIANCO WHITE
E VERDE GREEN
F VIOLA PURPLE
G GIALLO YELLOW
H BLU BLUE
K MARRONE BROWN
J ARANCIO ORANGE
I ROSA PINK
CODIFICA COLORI WIRING DIAGRAM
CABLAGGIO ELETTRICO COLOUR CODE
L ROSA-NERO PINK-BLACK
M GRIGIO-VIOLA GREY-PURPLE
N BIANCO-VIOLA WHITE-PURPLE
O BIANCO-NERO WHITE-BLACK
P GRIGIO-BLU GREY-BLUE
Q BIANCO-ROSSO WHITE-RED
R GRIGIO-ROSSO GREY-RED
S BIANCO-BLU WHITE-BLUE
T NERO-BLU BLACK-BLUE
U GIALLO-VERDE YELLOW-GREEN
V AZZURRO BLUE