Pegasus 200 ACDC PULSE User manual

MG125-4 PEGAS 200 AC-DC PULSE SERVICE MANUAL page 1
ALFA IN a. s. © 2012 SERVISNÍ TECHNICKÁ DOKUMENTACE
SERVISNÍ MANUÁL PEGAS 200 AC-
DC PULSE SERVICE MANUAL PEGAS 200 AC- DC PULSE
1. VAROVÁNÍ WARNING
UPOZORNĚNÍ – Pouze osoba splňující
kvalifikaci danou zákonem je oprávněna
opravovat stroj.
PŘED OTEVŘENÍM KRYTU STROJE JEJ
ODPOJTE VYTAŽENÍM SÍŤOVÉ VIDLICE ZE
SÍTĚ.
Každé 4 měsíce otevřete stroj a jemněho
vyfoukejte stlačeným suchým vzduchem
POZOR, NEPOUŽÍVEJTE STLAČENÝ
VZDUCH O PŘÍLIŠ VYSOKÉM TLAKU, ABY
NEDOŠLO K MECHANICKÉMU POŠKOZENÍ
ELEKTROSOUČÁSTEK.
Každé 4 měsíce zkontrolujte řádný stav
svařovacích kabelůa síťových kabelů.
Není povolena žádná modifikace
svařovacího stroje.
Pro Vaši bezpečnost je nutné posečkat se
sundáním krytu ze stroje po odpojení ze sítě
po dobu minimálně5 minut, kdy klesne
napětí na kondenzátorech na hodnotu pod
36 V.
NOTE Only trained personnel are
permitted to work inside the machine.
BEFORE OPENING THE MACHINE, CUT
OFF ITS ELECTRICAL POWER BY
REMOVING THE PLUG FROM THE MAINS
SUPPLY SOCKET.
Every six months, open the machine and
clean it inside, using compressed
dehumidified air.
CAUTION. DO NOT USE COMPRESSED
AIR AT TOO HIGH A PRESSURE. YOU
COULD DAMAGE THE ELECTRONIC
COMPONENTS.
With the same frequency, check the
welding cables and the supply cables.
No modification, of any type, may be
made to the welding machine.
For safety while maintaining the machine,
please shut off the supply power and wait
for 5 minutes, until capacity voltage
already drops to safe voltage 36V.
2. BLOKOVÉ SCHÉMA ELECTRICAL PRINCIPLE DRAWING

MG125-4 PEGAS 200 AC-DC PULSE SERVICE MANUAL page 2
ALFA IN a. s. © 2012 SERVISNÍ TECHNICKÁ DOKUMENTACE

MG125-4 PEGAS 200 AC-DC PULSE SERVICE MANUAL page 3
ALFA IN a. s. © 2012 SERVISNÍ TECHNICKÁ DOKUMENTACE
3. NÁHRADNÍ DÍLY SPARE PARTS
Pos
. Item No Popis Description Quantit y
1
8.253.020
Držák - madlo P250 Handle P250
1
2
8.301.099
Kryt horní P250 Upper Cover P250
1
3
8.062.543
PCB Installation Panel P200AC-
DC PCB Installation Panel P200AC-DC
1
4
7.202.123
Pojistka 3A Fuse 3A
1
5
7.202.029
Držák pojistek P200AC-DC Fuse Holder P200AC-DC
1
6
5.496.931
PCB EMC P200AC-DC PCB EMC P200AC-DC
1
7
5.496.526-B
Spínaný zdroj PCB P200AC-DC SWITCH POWER PCB P200AC-
DC
1
8
5.496.875-E
PCB měření napětí Voltage test PCB P200AC-DC
1
9
5.496.415-E
PCB řídící P200P AC-DC Control PCB P200P AC-DC
1
10
5.496.373-C
PCB HF P200AC-DC PCB HF P200AC-DC
1
11
6.185.515
Hlavní transformátor P200AC-
DC Main transformer P200AC-DC
1
12
6.271.515
Tlumivka P200AC-DC Choke P200AC-DC
1

MG125-4 PEGAS 200 AC-DC PULSE SERVICE MANUAL page 4
ALFA IN a. s. © 2012 SERVISNÍ TECHNICKÁ DOKUMENTACE
13
5.496.204-B
HF filtr PCB P200P AC-DC HF filter PCB P200P AC-DC
1
14
6.174.515
Trafo HF P200AC-DC Transformer HF P200AC-DC
1
15
7.321.002
Sonda Hall 200A Pegas Hall sensor 200A Pegas
1
16
8.055.543
Kryt spodní P200AC-DC Bottom Plate P200AC-DC
1
17
8.050.099
Kryt boční P250 Side Cover P250
2
18
5.496.416-B
PCB přední P200P AC-DC Front PCB P200P AC-DC
1
19
8.068.099
Panel přední/zadní plast P250 Plastic Front/Rear Panel P250
1
20
8.306.441
Panel přední kov P200P AC-
DC+fólie Metal Front Panel P200P AC- DC+folie
1
21
7.458.053
Knoflík Pegas černý P200P Knob Pegas black P200P
1
22
8.065.570
Panel přední kov spodní
P200AC-DC Metal Front Panel For Output P200AC-DC
1
23
7.152.312
Rychlosp. 35-70mm P250 35-70mm Socket P250
2
24
7.132.114
Konektor zásuvka P250 14-Pin Socket P250
1
25
8.462.104
Konektor plyn Pegas P200AC-
DC Gas Connector Pegas P200AC- DC
1
26
8.307.634
Panel zadní kov P200AC-DC Metal Rear Panel For Output
P200AC-DC
1
27
7.232.022
VypínačPegas P200AC-DC Switch On/OFF Pegas P200AC-
DC
1
28+
29
7.155.001
Průchodka P250 Cable Connector P250
1
30
8.122.366
Panel pro ventilátor P200AC-
DC Metal Panel For Fan P200AC- DC
1
31
7.253.013
Ventil Pegas Solenoid Valve Pegas
1
32
7.720.030
Ventilátor P250 Fan P250
1
A-1 8.425.502
Chladič3 P200AC-DC Heat Sink 3 P200AC-DC
1
A-2 8.746.030
Box chladiče 2 P200AC-DC Heat Sink Box 2 P200AC-DC
1
A-3 8.425.503
Chladič4 P200AC-DC Heat Sink 4 P200AC-DC
1
A-4 7.445.311
Rezistor 6ohm P200AC-DC Rezistor 6ohm P200AC-DC
2
A-5 7.231.275
Termostat PEGAS Thermo switch
2
A-6 7.425.631
Tranzistor IGBT Discrete1 P40 Discrete1 IGBT P40
8
A-6 7.425.631
Tranzistor IGBT Discrete1 P40 Discrete1 IGBT P40
4
A-7 7.421.681
Dioda P200AC-DC Diode P200AC-DC
2
A-8 5.496.674-C
PCB silová P200AC-DC PCB Power P200AC-DC
1
A-9 8.306.301
Krycí deska 1 P200AC-DC Blanking plate 1 P200AC-DC
1
B-1 8.425.500
Chladič2 P200AC-DC Heat Sink 2 P200AC-DC
1
B-2 8.425.501
Chladič1 P200AC-DC Heat Sink 1 P200AC-DC
1
B-3 8.746.029-D
Box chladiče 1 P200AC-DC Heat Sink Box 1 P200AC-DC
1
B-4 7.411.010
UsměrňovačPEGAS 160 E Rectifier Bridge
2
B-5 5.496.527-B
Vstupní usměrňovačPCB
P200AC-DC Input rectifier PCB P200AC-DC
1

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ALFA IN a. s. © 2012 SERVISNÍ TECHNICKÁ DOKUMENTACE
B-6 7.460.801
Kondenzátor kapacitní P200P
AC-DC Capacitor P200P AC-DC
6
B-7 8.052.500
Krycí deska 2 P200AC-DC Blanking plate 2 P200AC-DC
1
4. TROUBLESHOOTING
S/N
Troubles Reasons Solutions
The power light
damaged or connection
is not good Check and repair Pr7
The transformer of
power is broken Repair or change the transformer
1 Turn on the power source, and fan works,
but the power pilot lamp is not on.
Control PCB failures Repair or change the control Pr4
There is something in
the fan Clear out
The start capacitor of
fan damaged Change capacitor
2 Turn on the power source, and the power
pilot lamp is on, but fan doesn’t work The fan motor
damaged Change fan
No power supply input Check whether there is power
supply
3 Turn on the power source, the power pilot
lamp is not on, and fan doesn’t work The fuse inside the
machine damaged Change it (3A)
4 The number on the display is not intact. The LED in the display
is broken Change the LED
The max value is not
accordant (refer to
§3.1)
Adjust potentiometer Imin on the
power board.
5 The max and min value displayed doesn’t
accord with the set value. The min value is not
accordant (refer to
§3.1)
Adjust potentiometer Imaxin the
current meter.
6 No no-load voltage output (MMA) The machine is
damaged Check the main circuit and the Pr4.
The welding cable is
not connected with the
two output of the
welder.
Connect the welding cable to the
welder’s output.
The welding cable
damaged. Repair or change it.
The earth cable
connected unstably. Check the earth cable.
The welding cable is
too long. Use an appropriate welding cable.
There is oil or dust on
the workpiece. Check and remove it.
There is spark on the HF
igniting board.
The distance between
tungsten electrode
and workpiece is too
long.
Reduce the distance (about 3mm).
The HF igniting board
does not work. Repair or change Pr8
The distance between
the discharger is too
short. Adjust this distance (about 0.7mm).
7
Arc can
not be
ignited
(TIG)
There is not spark on the HF
igniting board.
The malfunction of the
welding gun switch. Check the welding gun switch, control cable and aero socket.

MG125-4 PEGAS 200 AC-DC PULSE SERVICE MANUAL page 6
ALFA IN a. s. © 2012 SERVISNÍ TECHNICKÁ DOKUMENTACE
Gas cylinder is close or
gas pressure is low Open or change the gas cylinder
Something in the valve Remove it
8 No gas flow (TIG)
Electromagnetic valve
is damaged Change it
The gas-test on the
front panel is on The gas-test on the front panel is off
Something in the valve Remove it
Electromagnetic valve
is damaged Change it9
Gas always flows
The adjustment knob of
pre-gas time on the
front panel is damaged Repair or change it
10 The welding current can not be adjusted
The welding current
potentiometer on the
front panel connection
is not good or damaged
Repair or change the potentiometer
The power PCB is in
trouble. Repair or change it.
The AC drive PCB
damaged. Change it.
11 No AC output while selecting “AC”
The AC IGBT module
damaged. Change it.
The min value
displayed isn’t
accordant with the
actual value. (Please
refer to §3.1)
Adjust potentiometer Imin on the
power board.
12 The welding current displayed isn’t
accordant with the actual value. The max value
displayed isn’t
accordant with the
actual value. (Please
refer to §3.1)
Adjust potentiometer Imax on the
power board.
The welding current is
adjusted too low Increase the welding current
13 The penetration of molten pool is not
enough. The arc is too long in
the welding process Use 2T operation
Two much
welding
current Reduce the welding current output
Over
heat
protecti
on Working time
too long Reduce the duty cycle (work intermittently)
Over-
voltage
protecti
on
Power
supply
fluctuates Using the stable power supply
Power
supply
fluctuates Using the stable power supply Low-
voltage
protecti
on
Too many
machines
using power
supply in the
same time
Reduce the machines using power
supply in the same time
14 The alarm light on the front panel is on
Over-
current
protecti
on
Unusual
current in the
main circuit
Check and repair the main circuit
and drive Pr6

MG125-4 PEGAS 200 AC-DC PULSE SERVICE MANUAL page 7
ALFA IN a. s. © 2012 SERVISNÍ TECHNICKÁ DOKUMENTACE
5. Konektor Connector
5.0189 Sada konektorů pro PEGAS AC/DC AERO 5.0189 Set of Connectors for PEGAS AC/DC AERO
I age Kód CZ EN Quantity
5.0181 PIN pro konektor PEGAS DOV Male AERO plug Male PIN 2
5.017 Konektor PEGAS AERO čelo AERO Plug PEGAS part#1 1
5.0180 Konektor PEGAS AERO kryt AERO plug PEGAS part 2 1
5.0182 Připojení plynu PEGAS AC/DC
matice převlečná
Gas fitting part 1 PEGAS AC/DC 1
5.0183 Připojení plynu PEGAS AC/DC
koncovka
Gas fitting part 2 PEGAS AC/DC 1
5.0184 Připojení plynu#PEGAS AC/DC
matice zajišťovací
Gas fitting part 3 PEGAS AC/DC 1
Sada 5.0198 obsahuje pouze dva piny. Pro
zapojení různých druhůdálkového ovládání
budete potřebovat více pinů. Viz schémata
níže.
The set 5.0198 content two pieces of PINs. In
order to connect different kinds of remote
controls you will need order more PINs. See
the schemas below.
6. Hořák Torch
7. Hořák s potenciometrem -
nepodporováno Torch with potentiometer – not supported

MG125-4 PEGAS 200 AC-DC PULSE SERVICE MANUAL page 8
ALFA IN a. s. © 2012 SERVISNÍ TECHNICKÁ DOKUMENTACE
8. Dálkové ovládání + hořák Remote Control + torch
9. Nožní dálkové ovládání-pedál Remote foot control
10. Hořák s UD & DOWN Torch with UD & DOWN
11. Zapojení plynového konektoru Gas connector

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ALFA IN a. s. © 2012 SERVISNÍ TECHNICKÁ DOKUMENTACE
1. Na plynovou hadici nasaďte dílec C
2. Sešroubujte dílec A a B
3. Nasaďte trn z dílce A do hadice
4. Pevněutáhněte dílec B, tak, že vznikne
mezera mezi osazením dílce A a dílcem
B. Tím se zajistí hadice (viz obr. Níže).
1. Fit C onto the hose
2. Screw A and B together
3. Fit the nipple of A into the hose
4. Firmly tighten B in the way that between
A and B appears a gap. That way you
fix the hose (see the image below)
Worked out: DJ 4/11/2011 Revision: Vh 4/7/2012 Approved: vh 4/7/2012