Language: English

.CITIG 1500 ACDC Date creation: Mar 2008

Rev.: 00

Service Manual

CITIG 1500 ACDC

Designed by Mario Jurik

 Tig Unit 150A AC/DC

1.0 REPAIR INSTRUCTIONS

A

1.1 GENERAL CLEANING 1-2-3

Remove the power source body sides and clean

with compressed air.

1-2-3
1.2 POWER SOURCE: VISUAL INSPECTION
Check the general conditions of the power source, B
particularly:
fig. 3 ref. 21
1. on the electronic circuit board ref. 21:
if there are short circuits in any of the tested com-
• the state of the input power capacitors (fig.
ponents, replace board ref. 21
1) and check if there are swellings or cracks
on the body 2. On the electronic circuit board ref. 22 test the
• check for the presence of burn tracks or IGBT of the secondary circuit between points
electric discharge marks on the printed cir- 1 and 3, 2 and 3 (fig. 4); if short circuits are
cuit board. p re se n t, re p la ce th e fau lt co mp o ne n ts ,
remove first the primary power circuit ref. 21
2. Check insulation on all the wire harnesses and the diode module of the secondary cir-
and inspect the harness connection points. cuit.

1
fig. 1 ref. 21 3

fig. 4 ref. 22
1.3 CHECK OF THE MAIN COMPONENTS
WITH A TESTER (OHMMETER) 3. Diodes of the secondary circuit: test between
1. On the electronic circuit board ref. 21 check: points 1,2,3,4 and the diode heatsink (fig. 5);
if there are short circuit replace them.
• For the presence of short circuits on the
rectifier bridge and the correct value of the
Ptc precharge (fig. 2)
• points 1-2, 1-3, 2-3 of mosfet A and B (fig. 2
1
3):

HEATSINK

3 4

fig. 5 DIODES OF THE SECUNDARY CIRCUIT

fig. 2 ref. 21

1305 Pag. 12
 Tig Unit 150A AC/DC

1.4 CHECK THE POWER SOURCE OPERA-

TION WITH OSCILLOSCOPE AND VOLT-
METER
Disconnect on circuit board ref. 21 the faston of the
positive of the rectifier bridge; set the oscilloscope
on a time base of 5 uS and a range of 0.5 V/Div
with probe x10; connect the generator to the power
supply, set it in MMA and DC with the pulse selec-
tor at zero, turn on the power source and verify:
1. The presence on the electronic circuit board
ref. 20 between points 1 and 2(negative) of
fig. 9
+15Vdc voltage, and between points 3 and
2(negative) of -15Vdc voltage (fig. 17); in
• if the wave form differs from the one in the
there is lower readings disconnect the circuit
figure, the electronic circuit board ref. 21 is
ref. 20 from the circuit ref. 21 and check:
broken (mosfet of the primary circuit).
• if the correct voltage is restored this means
3. Set the oscilloscope in DUAL mode on a time
that the electronic circuit board ref. 21 is
base of 10uS and a range of 0.5 V/Div, pre-
broken
trigger at 4 div and GND of the two channels
• if the wrong voltage is still there, the fault is are coincident; on the circuit board ref. 22
on the electronic circuits ref. 1 or ref. 36 or connect the probe of channel 1 between
ref. 20 points A (probe) and B (GND) and the probe
of channel 2 between points C (probe) and
D(GND) (fig. 10) and check for:

1 B

A
3

C
2
fig. 7 ref. 20

2. 2. Check for the presence on circuit board ref. fig. 10 ref. 21

21 between points E (GND) - A (Probe) and F
(GND) - B (probe) (fig. 8) of the wave form as • a wave form as shown in fig. 11 with the AC/
shown in fig. 9: DC selector in DC

E
A
fig. 11

fig. 8 ref. 21 • a wave form as shown in fig. 12 with the

AC/DC selector in AC

1305 Pag. 14
 Tig Unit 150A AC/DC

4. Set the function selector in TIG 2T, short-cir-

cuit points E and G of the remote receptacle
(ref. 51) and check:
• the release of the solenoid valve
• the appearance on the oscilloscope of the
wave form of fig. 14
• a high voltage noise for approx. 2 seconds
if there isn’t noise or if in GTAW (Tig) welding there
is a less discharge, replace the electronic circuit
ref. 32, if the fault appears again replace the cou-
fig. 12
pler ref. 33
Carry out the final test after the repair.
• Switch off the power source, restore the
positive connection on the bridge; set the
oscilloscope only with channel 1 with a 2.0 FINAL TEST
range of 1V/Div with a probe x100; on the
circuit board ref. 21 connect the probe
between points M (GND) and P (probe) (fig. 1. Carry out the safety test according to our
13) and verify: operative instruction N. SLL12, before pro-
ceeding, act as follows:
• Disconnect the faston connector at 90° and
the shunt harness on the circuit board ref.
20 (fig. 15)
• Turn on the power switch
• short circuit the primary power
• disconnect the two cables connecting the
rectifier bridge with the circuit board ref. 21
M (positive and negative)

fig. 13 ref. 21

• that approx. 2 seconds after turn on, a wave

appears as shown in fig. 14
• check with a voltmeter, that the open circuit
voltage (OCV) is approx. 62 Vdc
If the waveform does not appear or the OCV is not
present, replace circuit ref. 01

fig. 15 ref. 20

• short-circuit the mosfet on the circuit board

ref. 21 (fig. 16)

fig. 14 ref. 21

1305 Pag. 16
 Tig Unit 150A AC/DC

loscope shows a waveform as in fig. 18.

SHORT-CIRCUIT

fig. 18
SHORT-CIRCUIT
• if the voltage on the load it isn’t within the
fig. 16 ref. 21
tolerance (25-26Vdc) adjust the trimmer T1
• short-circuit the heatsink of diodes of the on circuit ref. 01 (fig. 19).
secondary circuit with the heatsink of circuit 4. Regulate the resistive load bank to measure
board ref. 22 the minimum current (5A - 20V), set the mini-
• on circuit board ref. 22 short-circuit the point mum current on the frontal panel and check
1-2-3 (fig. 17) that the amperometer shows a value included
within 4 and 6A.

2 • if the voltage differs from the value within

the tolerance, adjust the trimmer T2 on cir-
cuit ref. 01 (fig. 19).

T1

T2
1
3
fig. 17 ref. 22

After the test remove all the short circuits and turn
off the switch. fig. 20 ref. 1

5. Now short-circuit the outputs and check that

2.1 FUNCTIONAL TEST
by the output potentiometer, the amperometer
1. Connect the power source to the power sup- changes from approx. 5A to 150A; switch off
ply (230 Vac), set it in DC and SMAW (Stick) the power source.
turn on and check if the open circuit voltage
6. Set the AC/DC selector to AC, set the load
(OCV) is 62Vdc (+/- 5%): turn off the power
bank so that the voltage on the load, with
source.
maximum current, is between 24 and 26Vdc.;
2. Connect the generator to the resistive load turn on the power source and check that the
bank must be regulated so that his voltage, output current is within 125 and 145 Aac; turn
with maximum current, is between 24 and off the power source.
26Vdc. Apply oscilloscope probe as in fig. 13
3. Set the output potentiometer knob to the cen- 2.2 WELDING TEST
tre of the dial, switch on the generator, turn
the knob to the maximum welding current and 1. Connect the GTAW (tig) torch for DC welding
check with an amperometer that the reading to the power source, set the AC/DC selector
corresponds with the maximum current indi- in DC; the function selector in GTAW (Tig) 2T
cated on the data plate. Check that the oscil- and the pulser selector at 0 Hz:

1305 Pag. 18
 Tig Unit 150A AC/DC

• carry out welding tests at maximum current

and check for the correct striking at high
voltage
• verify that the machine is working correctly
either with the function selector in GTAW
(Tig) 4T and in Spot
• check that the pulser selector is working
correctly by testing the weld at various fre-
quencies
2. Now set the AC/DC selector in AC, the func-
tions selector in TIG 2T and the pulser selec-
tor at 25 Hz (attention: equip the torch with
the electrode for AC weld):
• carry out welding test at approx. 100 Aac on
aluminium, check for the correct striking at
high voltage
• check that the pulser selector is working
correctly by testing in weld the various
working frequencies.
3. Turn off the power source and equip it for
SMAW (Stick) weld; set the function selector
in SMAW (Stick), the AC/DC selector in DC
and the pulser selector at 0 Hz; turn on the
generator:
• carry out SMAW (Stick) welding test at max-
imum current (one electrode)

2.3 THERMAL TEST

1. Turn off the power source and close it up
again, connect it to the load bank regulated
for the maximum current; turn on the power
source:
• let it work until the thermal protection inter-
venes (yellow led turns on)
• wait until the thermal protection led turns off
and in the meanwhile change the AC/DC
selector to AC
• run through a new work cycle in AC until the
thermal protection intervenes.

1305 Pag. 20
 SPARE PARTS LIST - PIÈCES DÉTACHÉES - LISTA DE LAS PIEZAS DE RECAMBIO - LISTA PEZZI DI RICAMBIO
WISSELSTUKKEN - LISTA PIESE COMPONENTE - ZOZNAM NÁHRADNÝCH DIELOV

38
56.1
11
56
13.1
13
52
08
12
51

57
26

14
20
75
01
76
21
46
18
41
22
69
24
72
36
72.2
48
32
33
72.1

I
 SPARE PARTS LIST - PIÈCES DÉTACHÉES - LISTA DE LAS PIEZAS DE RECAMBIO - LISTA PEZZI DI RICAMBIO
WISSELSTUKKEN - LISTA PIESE COMPONENTE - ZOZNAM NÁHRADNÝCH DIELOV

R. CODE DESCRIPTION DESCRIPTION DESCRIPCIÓN DESCRIZIONE

01 W000233944 CIRCUIT BOARD CE 22604 CIRCUIT ÉLECTRONIQUE CE 22604 CIRCUITO ELECTRÓNICO CE 22604 CIRCUITO ELETTRONICO CE 22604

08 W000254539 POWER CABLE CÂBLE ALIMENTATION CABLE DE ALIMENTACIÓN CAVO ALIMENTAZIONE

11 W000070027 SWITCH INTERRUPTEUR INTERRUPTOR INTERRUTTORE

12 W000231163 DINSE COUPLING RACCORD SORTIE RACOR DE SALIDA RACCORDO USCITA

13 W000070032 KNOB BOUTON PERILLA MANOPOLA

13.1 W000070029 HOOD CAPUCHON CAPUCHÓN CAPPUCCIO

14 W000227848 FAN VENTILATEUR VENTILADOR VENTOLA

18 W000070034 CIRCUIT BOARD CE 22661 CIRCUIT ÉLECTRONIQUE CE 22661 CIRCUITO ELECTRÓNICO CE 22661 CIRCUITO ELETTRONICO CE 22661

20 W000070035 CIRCUIT BOARD CE 22617 CIRCUIT ÉLECTRONIQUE CE 22617 CIRCUITO ELECTRÓNICO CE 22617 CIRCUITO ELETTRONICO CE 22617

21 W000050172 CIRCUIT BOARD CE 22678 CIRCUIT ÉLECTRONIQUE CE 22678 CIRCUITO ELECTRÓNICO CE 22678 CIRCUITO ELETTRONICO CE 22678

22 W000050171 CIRCUIT BOARD CE 22675 CIRCUIT- ÉLECTRONIQUE CE 22675 CIRCUITO ELECTRÓNICO CE 22675 CIRCUITO ELETTRONICO CE 22675

24 W000070038 TRANSFORMER COIL BOBINE TRANSFORMATEUR BOBINA TRANFORMATOR BOBINA TRASFORMATORE

26 W000227848 FAN VENTILATEUR VENTILADOR VENTOLA

32 W000070040 CIRCUIT BOARD HF 317 CIRCUIT ÉLECTRONIQUE HF 317 CIRCUITO ELECTRÓNICO HF 317 CIRCUITO ELETTRONICO HF 317

33 W000070041 COIL COUPLER BOBINE COUPLEUR BOBINA ACOPLADOR BOBINA ACCOPPIATORE

36 W000070042 CIRCUIT BOARD CE 22624 CIRCUIT ÉLECTRONIQUE CE 22624 CIRCUITO ELECTRÓNICO CE 22624 CIRCUITO ELETTRONICO CE 22624

38 W000237974 PROFILE FRAME PROFIL ARÊTE PROFIL ÂRETE PROFILO CORNICE

41 W000227794 AUXILIARY TRANSFORMER TRANSFORMATEUR AUXILIAIRE TRANSFORMADOR AUXILIAR TRASFORMATORE AUSILIARIO

46 W000070045 SOLENOID VALVE ÉLECTROVANNE ELECTROVALVULA ELETTROVALVOLA

48 W000050179 LONG TRIMMER PIN ARBRE POUR TRIMMER EJE DEL TRIMMER ALBERINO PER TRIMMER

51 W000070019 CONNECTOR CONNECTEUR CONECTOR CONNETTORE

52 W000070047 GAS CONNECTION RACCORD GAZ RACOR GAS RACCORDO GAS

56 W000070049 KNOB BOUTON PERILLA MANOPOLA

56.1 W000070048 HOOD CAPUCHON CAPUCHÓN CAPPUCCIO

57 W000231572 SOCKET REMOTE PRISE REMOTE TOMA REMOTE CONNESSIONE REMOTE

69 W000050201 CHOKE ASSEMBLY IMPEDANZ IMPEDANCIA GRUPPO IMPEDENZA SECONDARIO

72 W000070053 RHMOUNT SUPPORT DROIT SOPORTE DERECHO SUPPORTO DESTRO

72.1 W000070052 LH MOUNT SUPPORT GAUCHE SOPORTE IZQUIERDO SUPPORTO SINISTRO

72.2 W000050178 INSULATOR ENTRETOISE ESPACIADOR DISTANZIALE

75 W000070054 FAN ATTACHMENT ASSISE DE VENTILATEUR ASIENTO DEL VENTILADOR SELLA PER VENTILATORE

76 W000070055 CHOKE ASSEMBLY IMPEDANZ IMPEDANCIA GRUPPO IMPEDENZA PRIMARIO

II
 SPARE PARTS LIST - PIÈCES DÉTACHÉES - LISTA DE LAS PIEZAS DE RECAMBIO - LISTA PEZZI DI RICAMBIO
WISSELSTUKKEN - LISTA PIESE COMPONENTE - ZOZNAM NÁHRADNÝCH DIELOV

R. CODE BESCHRIJVING DESCRIERE POPIS

01 W000233944 ELEKTRONISK CIRCUIT CE 22604 CIRCUIT ELECTRONIC CE 22604 DOSKA PLOŠNÝCH SPOJOV CE 22604

08 W000254539 VOEDINGSKABEL CABLU DE ALIMENTARE NAPÁJACÍ VODIČ

11 W000070027 SCHAKELAAR •NTRERUP®TOR VYPÍNAČ

12 W000231163 AANSLUITSTUK RACORD IE≤IRE VÝSTUPNÁ PRÍPOJKA

13 W000070032 KNOP BUTON RUKOVAŤ

13.1 W000070029 DOPJE CAPAC KRYTKA

14 W000227848 MOTORVENTILATOR VENTILATOR VRTUĽA

18 W000070034 ELEKTRONISK CIRCUIT CE 22661 CIRCUIT ELECTRONIC CE 22661 DOSKA PLOŠNÝCH SPOJOV CE 22661

20 W000070035 ELEKTRONISK CIRCUIT CE 22617 CIRCUIT ELECTRONIC CE 22617 DOSKA PLOŠNÝCH SPOJOV CE 22617

21 W000050172 ELEKTRONISK CIRCUIT CE 22678 CIRCUIT ELECTRONIC CE 22678 DOSKA PLOŠNÝCH SPOJOV CE 22678

22 W000050171 ELEKTRONISK CIRCUIT CE 22675 CIRCUIT ELECTRONIC CE 22675 DOSKA PLOŠNÝCH SPOJOV CE 22675

24 W000070038 TRANSFORMATORSPOEL BOBIN® TRANSFORMATOR CIEVKA TRANSFORMÁTORA

26 W000227848 VENTILATOR VENTILATOR VRTUĽA

32 W000070040 ELEKTRONISK CIRCUIT HF 317 CIRCUIT ELECTRONIC HF 317 DOSKA PLOŠNÝCH SPOJOV HF 317
CIEVKA VYSOKOFREKVENŚNÉHO
33 W000070041 KOPPELSTUKSPOEL BOBINA DE CUPLAJ
TRANSFORMÁTORA
36 W000070042 ELEKTRONISK CIRCUIT CE 22624 CIRCUIT ELECTRONIC CE 22624 DOSKA PLOŠNÝCH SPOJOV CE 22624

38 W000237974 LIJSTROPOFIEL PROFIL CADRU RÁM

41 W000227794 HULP- TRANSF. TRANSFORMATOR AUXILIAR POMOCNÝ TRANSFORMÁTOR

46 W000070045 ELEKTROMAGNETISCHE KLEP ELECTROVALV® ELEKTROVENTIL

48 W000050179 AS VOOR TRIMMER AX PENTRU TRIMMER OS PRE TRIMMER

51 W000070019 CONNECTOR CONECTOR KONEKTOR

52 W000070047 GAS AANSLUITING RACORD GAZ PLYNOVÁ PRÍPOJKA

56 W000070049 KNOP BUTON RUKOVAŤ

56.1 W000070048 DOPJE CAPAC KRYTKA

57 W000231572 STOPCONTACT CONECTOR REMOTE KONEKTOR DIAĽKOVÉHO OVLÁDANIA

69 W000050201 SECUNDAIRE IMPEDANTIE GRUP IMPEDAN∂® SECUNDAR JEDNOTKA TLMIVKY SEKUNDÁR

72 W000070053 STEUN RECHTS SUPORT DREAPTA PRAVÝ DRŽIAK

72.1 W000070052 STEUN LINKS SUPORT ST>NGA ĽAVÝ DRŽIAK

72.2 W000050178 AFSTANDSTUK ≤AIB® IZOLATOARE NYLON NYLONOVÁ IZOLAŚNÁ PODLOŽKA

75 W000070054 VENTILATORZADEL SUPORT PENTRU VENTILATOR DRŽIAK PRE VENTILÁTOR

76 W000070055 PRIMAIR IMPEDANTIE GRUP IMPEDAN∂® PRIMAR JEDNOTKA TLMIVKY PRIMÁR

III
DUTY CYCLE - FACTEUR DE MARCHE - CICLO DE TRABALHO - CICLO DI LAVORO
BEDRIJFSCYCLUS - DUTY CYCLE
WELDING CURRENT - COURANT DE SOUDAGE - CORRIENTE DE SOLDADURA
CORRENTE DI SALDATURA - SNIJSTROOM - ZVÁRACÍ PRÚD

DUTY CYCLE - FACTEUR DE MARCHE - CICLO DE TRABAJO - CICLO DI LAVORO

CICLO DE TRABALHO - BEDRIJFSCYCLUS - DUTY CYCLE

VOLT/AMPERE CURVES - COURBES VOLT /AMPERE - CURVA VOLTIOS/AMPERIOS - CURVE VOLT/AMPERE

KURVOR VOLT/AMPERE - VOLT – AMPÉROVÉ KRIVKY

V out

V mma
VOLT

V tig

AMPERE
WIRING DIAGRAM - SCHÉMA ÉLECTRIQUE - ESQUEMA ELÉCTRICO - SCHEMA ELETTRICO
ELEKTRISCHE SCHEMA'S - SCHEMA ELECTRICA - ELEKTRICKÁ SCHÉMA

V
CIRCUIT BOARD CE 22604 (W000233944)
ELECTRONIC CIRCUIT BOARD CE 22604 (W000233944) page 1of4
ELECTRONIC CIRCUIT BOARD CE 22604 (W000233944) page 2of4
ELECTRONIC CIRCUIT BOARD CE 22604 (W000233944) page 3of4
ELECTRONIC CIRCUIT BOARD CE 22604 (W000233944) page 4of4
CIRCUIT BOARD CE 22661 (W000070034)
ELECTRONIC CIRCUIT BOARD CE 22661 (W000070034)
CIRCUIT BOARD CE 22617 (W000070035)
ELECTRONIC CIRCUIT BOARD CE 22617 (W000070035)
CIRCUIT BOARD CE 22678 (W000050172)
ELECTRONIC CIRCUIT BOARD CE 22678 (W000050172)
CIRCUIT BOARD CE 22675 (W000050171)
ELECTRONIC CIRCUIT BOARD CE 22675 (W000050171)
CIRCUIT BOARD CE 22437 (W000070040)
ELECTRONIC CIRCUIT BOARD CE 22437 (W000070040)
CIRCUIT BOARD CE 22624 (W000070042)
ELECTRONIC CIRCUIT BOARD CE 22624 (W000070042)
CIRCUIT BOARD CE 22614 (W000070050)
ELECTRONIC CIRCUIT BOARD CE 22614 (W000070050)