REPAIR MANUAL - · PDF file1.3 The diagram of AC/DC200P’s top PCB PM-03-A2, center PCB PD-08-B0, bottom PCB PZ-06-B4, control panel PK-31-A0, low-voltage control PCB

Riland Welder

REPAIR MANUAL

MIG SERIES

SHENZHEN RILAND ELECTRIC MFG. CO., LTD.

CONTENTS -FOREWORD…………………………………………………………………………………………. 2

-SAFETY………………………………………………………………………………………………. 3

1. AC/DC200P………...……….…..……...……..……….…………………….…..……....……….. 4

1.1 The structure drawing of AC/DC200P………………………………………………………. 4

1.2 The general connection diagram of AC/DC200P………………………………………….. 4

1.3 The PCB diagram of AC/DC200P…………………………………………………………… 5

1.4 Troubleshooting of AC/DC200P……………………………………………………………... 10

2. AC/DC200Ⅱ……………...…….....………..……………….…….………...…………....………. 17

2.1 The structure drawing of AC/DC200Ⅱ……………………………………………………… 17

2.2 The general connection diagram of AC/DC200Ⅱ…………………………………………. 17

2.3 The PCB diagram of AC/DC200Ⅱ………………………………………………………….. 18

2.4 Troubleshooting of AC/DC200Ⅱ…………………………………………………………….. 18

3. WSE200……….…………...…...........…….....………………………………….…..……….….. 25

3.1 The structure drawing of WSE200…………………………………………………………... 25

3.2 The general connection diagram of WSE200………………………………………………. 26

3.3 The PCB diagram of WSE200……………………………………………………………….. 26

3.4 Troubleshooting of WSE200…………………………………………………………………. 30

4. AC/DC315P/250P…...…..…….............……………………………………..…..………………. 35

4.1 The structure drawing of AC/DC315P/250P………………………………………………... 35

4.2 The general connection diagram of AC/DC315P/250P…………………………………… 36

4.3 The PCB diagram of AC/DC315P/250P…………………………………………………….. 36

4.4 Troubleshooting of AC/DC315P/250P………………………………………………………. 41

5. WSE250/315...……………….…….……..…………...…..……….…………………….…….…. 48

5.1 The structure drawing of WSE250/315……………………………………………………… 48

5.2 The general connection diagram of WSE250/315…………………………………………. 49

5.3 The PCB diagram of WSE250/315………………………………………………………….. 50

5.4 Troubleshooting of WSE250/315……………………………………………………………. 51

6. AC/DC160…….……..…..............…....................……………………….………..………….…. 56

6.1 The structure drawing of AC/DC160………………………………………………………… 56

6.2 The general connection diagram of AC/DC160……………………………………………. 57

6.3 The PCB diagram of AC/DC160……………………………………………………………... 58

6.4 Troubleshooting of AC/DC160……………………………………………………………….. 61

REPAIR MANUAL·AC/DC SERIES

1

FOREWORD This manual is only fit for the repairer, who has only digital or pointer multi-meter but special instrument or equipment, to analyze the cause of malfunction, judge which parts of the machine are damaged, and find the right solution through malfunction phenomenon and measure data. When malfunction occurs, uncover the case of machines and check if there is some part burned out or not. Mainly check the following parts:

A. Top PCB: MOSFET, control module, drive module, auxiliary power supply B. Center PCB: rectifying diode, transformer C. Bottom PCB: electrolytic capacitor, thermal resistor, voltage-sensitive resistor

If there is, replace the PCB directly. ◆How to use this manual? This manual is provided to help you locate and repair possible machine malfunctions. Simply

follow the three-step procedure listed below. Step 1. Trouble (symptom) Look under the column labeled “Trouble” (symptom). This column describes possible

symptoms that the machine may exhibit. Find the listing that best describes the symptom that the machine is exhibiting.

Step 2. Analysis (possible cause) The second column labeled “Analysis”(possible cause) lists the possibilities that may

contribute to the machine symptom. Step 3. Solution This column provides a course of action for the possible cause. If you do not understand or are unable to perform the recommended solution, contact your local

dealer or supplier for further advice. ◆Note: ● Please read and understand the instruction manual carefully before the operation of this

equipment to ensure safety. ● Please read and understand this repair manual carefully before the maintenance of this

equipment to ensure safety. ● Have a qualified electrician to do the maintenance and troubleshooting work. ● Save this manual and keep it handy for quick reference. ● The contents of this manual may be revised without prior notice. ● This repair manual is issued on 1st August 2006.


2

SAFETY Welding and cutting is dangerous to the operator, people in or near the working area, and the surrounding, if the equipment is not correctly operated. Therefore, the performance of welding/cutting must only be under the strict and comprehensive observance of all relevant safety regulations. Please read and understand the instruction manual carefully before the installation and operation.


·The switching of function modes is possibly damaging to theequipment, while the welding operation is performed. ·Do disconnect the electrode-holder cable with the equipment,

before the performance of welding. ·A safety switch is necessary to prevent the equipment fromelectric leakage. ·Welding tools should be of high quality. ·Operators should be qualified. Electric shock: It can kill. ·Connect the earth cable according to standard regulation. ·Avoid all contact with live electrical parts of the welding circuit,electrodes and wires with bare hands. It is necessary for theoperator to wear dry welding gloves while he/she performs thewelding task. ·The operator should keep the work piece insulating fromhimself/herself. Smoke and gas generated while welding or cutting: harmfulto people’s health. ·Avoid breathing the smoke and gas generated while welding orcutting. ·Keep the working area in good ventilation. Arc rays: harmful to people’s eyes and skin. ·Wear welding helmet, anti-radiation glasses and work clothes

while the welding operation is performed. ·Measures also should be taken to protect people in or near theworking area. . Fire hazard ·The welding splash may cause fire, thus remove flammable

material away from the working place. ·Have a fire extinguisher nearby, and have a trained person

ready to use it. Noise: possibly harmful to people’s hearing. ·Noise is generated while welding/cutting, wear approved ear

protection if noise level is high. Machine fault: ·Consult the instruction manual and this repair manual. ·Contact your local dealer or supplier for further advice.

3

1. AC/DC200P 1.1 The structure drawing of AC/DC200P: The structure of AC/DC200P is similar to that of AC/DC315P. (See the structure drawing of AC/DC315P on page 35.) 1.2 The general connection diagram of AC/DC200P:

CONTROL MODULE

ELECTRIC DIAGRAM

Top Board

DRIVE MODULE

PK-03-A1

DC24V

AC/DC200P

VH

-03

VH-02

VH-02

THERMAL SWITCH

PK-05-A4Control Board

VH-03

14V

14V

0 0

AC380V

AC220V

(VH-04)*2

DRIVE LINE

XH

-02

XH

-03

VH-02XH-03

DC12V

VH-02

XH-04 XH-03VH-03 XH-04

CON11

CON6CON1

CON3 CON5CON8CON7CON10

CON2

CON4

CON9CON14

CON15 CON12 CON13

METER CONTROL SIGNALREMOTE RESISTANCE

PK-08-A1

PM-03-A2

CON

4

CON

1

Port

Port

CP3

CP4

INPUT AC220V

CON

6

CO

N11 CO

N1

DC308V

CON7 CON8

CON2

AC220V

CO

N5PH-20-A1

CO

N4

CO

N6A

C22

0V

FA

N *

2

PZ-06-B4

BOTTOM BOARD

CON3

CON2

CON

10

CON2

CO

N9

CENTER BOARD

PD-08-B0VH

-07(

6)

CON1

+

-

+-

OU

T1

OU

T2

INVERTER BOARD

PN-0

7-A

1PN

-08-

B0

CO

N11

CON1

ARC FORCE

CON

12

PRO

TE

CT L

ED

CU

RR

EN

T

CON13CON14

THERMAL SWITCH

CONTROL BOARD

PK-31-A0

CON

1V

H-0

5V

H-0

4

50W

450R

*2

CON1 CON5

PK-09-A3

DRIVE BOARD

CON

15

CON

3AC2

0V*4

0

AC

380V

AC

220V

T

T

CO

N2

O

R

C

ON

4

XH-03(2)

PH-10-A2Gun Switch Board

Gun switch

CON

9

CON10

2T/4T

CON5

AC/DC

CON

TRO

L G

AS

CONTROL HF

CON6 CON7

ARC/TIG CONTROL GAS

CON8

CONTROL HF

CON2 CON3

CONTROL PULSE

CON4

PH-10-A01

CON15 DC12VPK-05-A4

PK-31-A0CONTROL BOARD


4

1.3 The diagram of AC/DC200P’s top PCB PM-03-A2, center PCB PD-08-B0, bottom PCB PZ-06-B4, control panel PK-31-A0, low-voltage control PCB PK-05-A4, control module PK-03-A1, secondary drive PCB PK-09-A3, secondary inverter PCB PN-07-A1, PN-08-B0, power supply conversion PCB PH-20-A1, meter display preset PCB PH-10-A01:

C12.4

C12.3

C12.2

C12.1

CON1

CON4

CON5

1

CON3

C5

C6

R10.1 R10.2

R9.2R9.1

R12.5R12.4R12.3R12.2R12.1R10.5R10.4R10.3

C8 C10

C11C9 R13

R14R7

R8

R9.3 R9.4 R9.5 R11.1 R11.2 R11.3 R11.4 R11.5

C7.2

C7.1

C7.3

VT4.3 VT4.4 VT4.5VT4..2VT4.1VT2.5VT2.4VT2.3VT2.2VT2.1

VT3.3 VT3.4 VT3.5VT3.2VT3.1VT1.5VT1.4VT1.3VT1.2VT1.1

T1

CON2

2006.02.08

PM-03-A2

VH-03(2)

CON2

R18 R17 R18 R17 R18 R17 R18 R17

R17R18R17R18R17R18R17R18

C16C15

CON1

T2.2 T2.3 T2.4

C14C13 C13 C14 C14C13

C14C13C13 C14C14C13C13 C14

C13 C14

T2.1

D2D1D2D1 D2D1

D1 D2 D1 D2 D1 D2D1 D2

D1 D2

CON3

R23

L2.5X31.0

RT4

R02

R01

AC/DC.ARC.MIG.TIG(T) 2005.09PD-08-B0

+


5

P1 P2

Q1

+

+

+ +

+

+ +RELAY1

D10

D7

C17

CON5

RELAY4

CON9

CON1

C12C13

C6

R11

C18VT2

C8C7

RV2 RV3

RV5RT1

D5

CP3

CP4

RELAY3VT3

U1

CON4

C11

C5

C10

C4

RELAY2

CP1

CP2

R9

CON11

CON6

RV4

CON8

C19

R1

R4

C20

CON3

D4

D2

D1

D9

D11

R7

R5

D6

C15

T1

CON10

Z2

Z1

Z3

CON7

C14

RV1

C9

C16

R8

R6

CON2

R2

R3

C3

D3

C2

C1

VT1

R10 D8

PZ-06-B4

2005.11.30

- +

-++-

+ -

- +

D18

D22

D1

D2

Z1

D24

D26

D25

D23Z5

D6

D11

D8

D16

D14D12

Z4

D9

Z3 D7

D5

D13

D10

D15

D20

D17

D21

D27

D4

D3

Z2

D19

D28

D30

D29

C18

R32

R45

R72

Q1

R15

C1

C17

C8

R1

C9

R4

CON5

Q3 Q4

R35

R37

R41

C29

R70 C26

C27

R6

R13

R18

R59

R62

R64

R65

R68

R58

R61

VR4

U7U6U5 U8

U3

CON6

CON10

CON9

CON7

CON11 CON12 LED1LED2

VR7

VR1

VR6VR8 VR9

VR2 VR3

VR5

U4

R12R9 R10

R2

R5

R19

R21 R22 R23 R24

R27 R29 R30

R33

R34

R38R39

R42

R25

R43 R44

R46 R47 R48

R50

R54

R51 R52

R56 R55

R57

R60

R69

R71

R73

R74

R76

CON13 CON15

D32D31 D34D33

C23

C22

U9

U2

R7

R11

CON8

L2L1

U1

C3

C5

L6L5

C2

R53

C15

C16

R63

R66

C21

C28

R67

C25

CON4

R8

CON3CON2CON1 R3

Q2

C10R17

R40

R36

R31

C4

L4

L3

C12

R20

R26

Q5 Q6

C24

C19

R14

R16

C6

C20

R75

L7

R28

C13

R49

C7

CON14

C14

C11

PK-31-A02006.02.08


6

+ +

+ +

+

CON12

CON3CON6

R2

R3

C9

R11

R12

R5

C1

C19R30

z1

R29

D7Z2

D1

D3

D4

D11 D12U6 Q2

CON1

C21

C14

CON10

C11

C5

CON15CON14

CON5

C3

CON13

R27R31

R23R26

C15

C22

R33

R22

R25

R4

U3 U5U4

U2

Q1

C28

C29

C24

R17

CON11

C2

CON2

C4

C6

R6R7

R9

CON4

LED1 R8

R32

U1U9

D6D5

CON9

C8

C18

L1

U7 C34C33

C26

C13

C27

C16

C25

C12

C20

U8

R19D8

D10

R10

R13

C31

CON7 CON8

R14

R20

R18R16

R15

R24R28

R35

R1

C32

C23

C17

R34

C10

C30

R21

PK-05-A4 2006.02.08

C13

D1

C12

C7

LED2

LED1

R4

P1

R14

R17

R29

R16

R31

R25

R21

R19 D5

R28

C8

R15

C15

Z2 Z3

R7R6

C4

R23

R32

D4

D3D2

Z1R12

R13

R9

R1

R2

R8

C6

C9

C5

C18 C1 C2

R30

U2

Q5

Q8Q7

Q4

C16

Q9

Q1

Q3

C14U3

C17

C10

C11

Q2

R24R22

R18

R3

R27

R5

R11R10

Q6

R26

C3

R20

U1

PK-03-A1 2006.02.08


7

+

+

+

C13

C12

C5

C17

C2

C8

CON3

CON2

R5

U1

C7

D1

C6

Q3

Q4

U4U5

C1

C4

R1

U3

U2Q2

Q1C3

C10 Q5

Q6

U8

U6

R10

U7

D5

C11

C9

C16

CON1

U10

U9

Q8

Q7 C14

D7

C15

U11

R13

CON5

CON4

R3

R7

R11

R15

D2

Z1Z2

Z3

Z4

D6

D3

D4

R14

R6

R2R4

R8

R12

R16

R9

2006.02.08PK-09-A3

VT10

R10

VT9

R9

VT8

R8

VT7

R7

VT6

R6

VT5

R5

VT4

R4

VT3

R3

VT2

R2

VT22

R23

VT21

R22

VT20

R21

VT19

R20

VT18

R19

VT17

R18

VT16

R17

VT15

R16

VT14

R15

VT1

R1

Z2

Z1

VT13

13

4

9

C4

D1

5

2

1

C3

3

7

12

C1

C2

C5

Z5

Z4

R14

VT11

VT12

CON1

R12

R11

C6Z3R13

11

14

15

6

8

10

AC/DC200/200II/200P(T)

2.5X191.8

2.5X191.8

2.5X191.8

2.5X81.2

2.5X81.2

2.5X81.2

2.5X127.8

2.5X127.8

2.5X127.8

PN-07-A1

2005.09


8

VT11

12

14

16

R11

R1

VT1

CON1

6

5

2

11

1

Z1

Z2

Z4

Z3

9

VT12

R12

VT13

R13

VT14

R14

VT15

R15

VT16

R16

VT17

R17

VT18

R18

VT19

R19

VT20

R20

R2

VT2

R3

VT3

R4

VT4

R5

VT5

R6

VT6

R7 R8

VT8VT7

R9

VT9

R10

VT10

AC/DC200/200II/200P(T)

PN-08-B0

2005.09

2.5X81.2

2.5X127.8

2.5X191.8

2.5X81.22.5X127.8

2.5X191.8

2.5X81.2

2.5X127.8

2.5X191.8

CON1

CON3

CON6CON5CON4

CON2

2005.09

PH-20-A1


9

+12V

CON2

CON1

VR1

R1

D1 U1

PH-10-A01

1.4 Troubleshooting of AC/DC200P:

Trouble Analysis Solution 1. Turn on the machine, no display of the meter, the fan doesn’t work, no no-load voltage output in TIG/ARC mode.

a. The input voltage is abnormal. b. The power supply cable matching

CP3/CP4 on bottom PCB PZ-06-B4 is disconnected, or the tie-in is damaged.

c. The power supply switch may be damaged.

d. The connecting cable matching socket CON1 — CON6 on power supply conversion PCB is in loose connection.

a. Check if the input voltage is AC 220V.

b. Check. c. Replace the power supply switch

if it’s damaged. d. Check.


10

2. Turn on the machine, the meter displays, press the welding torch switch in TIG mode, there is gas out and no HF, no no-load voltage output in ARC mode.

a. The connecting cable matching socket CON1 on bottom PCB PZ-06-A3 is in loose connection.

b. The prime relay RELAY3 on bottom PCB PZ-06-A3 doesn’t close well; the value of thermal resistor RT1 increases.

c. The connecting cable matching rectifying bridge with socket CON11/CON6 is in loose connection.

d. Some part on control module PK-03-A1 is damaged.

e. Some part on control PCB PK-05-A4 is

damaged.

a. Check if the voltage of socket CON1 is DC308V.

b. Check and replace if necessary. c. Check. d. Check with a multi-meter if chip

U1 is damaged. Check if the 16th pin of U1 is 5V. If it’s not, replace the chip because U1 is damaged. Check if resistor R32, diode D2/D3/D4, zener diode Z1/Z2/Z3, audion Q2/Q3/Q4/Q5/Q6/Q7/Q9, thyristor Q1 or capacitor C17 is damaged.

e. Check if MOSFET U2/U3/U4/U5 or resistor R32 is damaged.

3. Turn on the machine, the meter displays, but the thermal resistor RT1/RT2/RT3/RT5 on bottom PCB PZ-06-B4 heats and smokes after a while.

a. The connecting cable (+24V) matching socket CON10 on bottom PCB PZ-06-A4 with socket CON14 on control PCB PK-05-A4 is in loose connection.

b. The relay RELAY3 on bottom PCB PZ-06-A4 is damaged.

c. The auxiliary power supply part on control PCB PK-05-A4 is damaged.

a. Check. b. Check. c. Check with a multi-meter if chip

U6, audion Q2, MOSFET U1, capacitor C23 or resistor R35 on control PCB PK-05-A4 is damaged.


11

4. Turn on the machine and it appears normal, there is no-load voltage output in ARC mode, press the welding torch in TIG mode and there is gas out, the malfunction LED is not on, no HF.

a.

b.

c.

d.

e.

f.

The connecting cable matching socket CON3 on top PCB PM-03-A2 with socket CON3 on bottom PCB PZ-06-B4 is in loose connection. High voltage silicon granule D1/D2/D4/D5 or high voltage output capacitor C12/C13 on bottom PCB PZ-06-B4 is damaged. The connecting cable is in loose connection with CP1/CP2 on bottom PCB. The discharge nozzle P1/P2 on bottom PCB has conglutination, excessive clearance or serious oxidation problem. The ARC/TIG conversion switch on the panel or chip U7 on control panel PK-31-A0 is damaged. The connecting cable matching socket CON8 on control PCB PK-31-A0 with socket CON2 on bottom PCB PZ-06-B4 is in loose connection, or HF relay RELAY1, audion Q1, MOSFET VT1 or diode D3 on bottom PCB is damaged.

a. Check. b. Check. c. Check. d. Adjust or replace it if necessary. e. Check and replace it if necessary. f. Check. Short-circuit socket CON2

on bottom PCB PZ-06-B4, then turn on the machine and press the manual switch. If there is no HF, there is something wrong with the HF circuit on bottom PCB. If there is, the inductor L1/L2, chip U1/U3 or resistor R6 on control PCB PK-31-A0 is damaged.


12

5. Turn on the machine and it appears normal, press the welding torch switch and there is gas out, the malfunction LED is on, turn to ARC mode, the malfunction LED turns on.

a. Over-current protection occurs when welding is carried out.

b. Over-heating protection occurs when welding is carried out.

c. Some parts on top PCB, center PCB, or

bottom PCB are damaged.

a. Turn off the machine for 5mins and restart.

b. Stop the welding operation for 5mins, or the secondary inverter thermal switch is damaged.

c. Check. Turn off the machine, pull out the connecting cable matching the socket CON3 on top PCB PM-03-A2 with the socket CON3 on bottom PCB PZ-06-B4, turn on the machine. If the malfunction LED is off, the transformer T1 is short-circuited or damaged. If it’s on, turn off the machine, pull out the connecting cable matching socket CON1 on top PCB PM-03-A2, turn on the machine. If the malfunction LED is on, MOSFET VT1.1—/VT4.5 on top PCB or some parts on drive module PK-08-A1 are damaged; if it’s off, transformer T2.1/T2.2/ T2.3/T2.4 or rectifying diode D1/D2 on PCB PD-08-B0 is damaged.

6. Turn on the machine and it appears normal, it can start arc in TIG mode, but the welding point appears black.

a. The magnet valve or the gas tube is blocked.

b. The magnet valve is damaged. c. The connecting cable matching socket

CON10 on bottom PCB PZ-06-A4 with socket CON7 on control panel PK-31-A0 is in loose connection.

d. Some parts in magnet valve control circuit on bottom PCB PZ-06-B4 or some parts in magnet valve control circuit on control panel PK-31-A0 are damaged.

e. The welding torch is damaged. f. The tungsten is of bad quality or the

argon is impure.

a. Clear. b. Replace. c. Check. d. Check with a multi-meter if the

MOSFET VT1, resistor R3/R2, diode D3 or audion Q1 on bottom PCB or audion Q1 on control PCB PK-31-A0 is damaged or if the magnet valve control cable matching the socket CON4 is disconnected.

e. Remove the welding torch and the gas-electricity tie-in, and press the welding torch switch. If there is gas out, the welding torch is damaged. Replace it.

f. Check and replace it if necessary.


13

7. The cutting current is unstable and out of control.

a. The connecting cable matching socket CON2 on control PCB PK-05-A4 with socket CON11 on control panel PK-31-A0 is in loose connection.

b. The capacitor C14/C15/C16/C9/C7/C8 on bottom PCB PZ-06-B4 leaks or is damaged.

c. The input cable or output cable is too slim and too long.

d. Loose connection exists inside the machine, e.g. the remote control connecting cable matching socket CON4 on control panel.

a. Check and replace it if necessary. b. Check and replace it if necessary. c. Enlarge the cross section area of

the cable. d. Check.

8. Turn on the machine but it strips.

a. The rectifying bridge matching the socket CON6/CON11 on bottom PCB PZ-06-B4 is damaged.

b. The power supply cable is disconnected or short-circuited.

a. Replace. b. Check.

9. Adjust the decay potentiometer to the max value and release the welding torch switch, the gas shuts off and then no current output.

a. The diode D1/D2 or chip U3 on control panel PK-10-A1 is damaged.

a. Check and replace it if necessary.

10. Press the welding torch switch, there is HF discharge buzz, but no welding voltage output.

a. The earth cable of welding torch is in loose connection.

b. The output terminal of the earth cable is in loose connection with gas-electricity tie-in or with center PCB PD-01-A2.

a. Check and replace it if necessary. b. Check and replace it if necessary.

11. The arc starting is bad in TIG mode.

a. The space between discharge nozzles P1 and P2 on bottom PCB PZ-06-B4 is too big or small, or their surface is badly oxidized.

b. The high-voltage capacitor C12/C13 on bottom PCB is damaged, or the capacitance becomes smaller.

c. The tungsten is of bad quality or the argon is impure.

d. The welding torch is in loose connection.e. Incorrect turn rate or turn-to-turn

electricity leakage problem exists in arc-starting coil matching CP1/CP2 on bottom PCB.

a. Adjust the space between them, or clear their surface.

b. Check and replace it if necessary. c. Check and replace it if necessary. d. Check. e. Check.


14

12. Turn on the machine, and it appears normal, but the malfunction LED turns on once welding is carried out.

a. The connecting cable matching socket CON11 on control PCB PK-05-A4 with the output bypass is in loose connection.

b. Loose contact exists in MOSFET VT1.1— VT4.5 on top PCB PM-03-A2 or rectifying diode D1/D2 on center PCB PD-08-B1.

c. Some parts on control module PK-03-A1 are damaged.

a. Check. b. Check with a multi-meter. c. Check if the chip U2 or audion Q9

on PK-03-A1 is damaged. 13. Turn on the machine, and there is HF.

a. Some parts in manual switch control circuit are damaged.

b. The connecting cable matching socket

CON8 on control panel PK-31-A0 with socket CON2 on bottom PCB PZ-06-B4 is in loose connection, or chip U1 on control panel PK-31-A0 is damaged.

a. Check with a multi-meter if chip U8 or diode D14/D18 on control panel PK-31-A0 is damaged. Disconnect the connecting cable matching socket CON9, and short-circuit both terminal of CON9, then check if the manual switch board PH-10-A1 is short-circuited.

b. Check.

14. Incessant HF exists when welding is carried out.

a. The relay RELY1, audion Q1, diode D3, MOSFET VT1 on bottom PCB PZ-06-B4 or chip U1 on control panel PK-31-A0 is damaged.

b. The connecting cable matching socket CON13 on control panel PK-31-A0 with socket CON5 on control PCB PK-05-A4.

a. Check and replace it if necessary. b. Check.

15. There is deviation between the preset value and real value of the show value of the meter.

a. The value of the variable resistor R9 on control PCB PK-05-A4 or VR1 on preset PCB PH-10-A01 changes.

a. Adjust. Methods: 1. Turn to ARC mode, adjust the value of variable resistor R9 on control PCB PK-05-A4 to make the show value of the meter is 200. 2. Turn to TIG mode, do not press the manual switch, adjust the value of variable resistor VR1 on preset PCB to make the show value of the meter is 200.

16. No pulse in the pulse mode.

a. The pulse conversion switch on the panel is damaged.

b. The connecting cable matching socket CON2/CON3 on control panel PK-31-A0 with the pulse conversion switch is short-circuited, or chip U4, capacitor C4/C11, potentiometer VR2/VR3 or diode D24 is damaged.



15

17. When no-load in ARC mode, it appears normal in DC mode, but there is abnormal sound in AC mode.

a. Some of the MOSFET on the secondary inverter PCB PN-07-A1/PN-08-B0 is damaged.

a. Check. Method: Turn to ARC mode, then AC mode, turn off the machine after 3mins of no-load, touch the MOSFET on the secondary inverter PCB with your hand one by one. The extra hot ones are damaged.

18. No 4T state or 4T is inaccurate.

a. The 2T/4T conversion switch on the panel is damaged, or the connecting cable matching it with socket CON10 on control panel PK-31-A0 is in loose connection.

b. Some part on control panel PK-31-A0 is damaged.

a. Check. b. Check if chip U8/U2, diode D6 or

capacitor C2 on control panel is damaged.

19. No AC output in AC mode. a. The AC/DC conversion switch on the panel is damaged.

b. Some part on the control panel PK-31-A0 is damaged.

c. Some part on the secondary drive PCB PK-09-A3 is damaged.

a. Check. b. Check if the diode D9/D2/D1,

audion Q2, chip U6 or potentiometer VR4 on control panel is damaged.

c. Check with a multi-meter if chip U2/U4/U8/U9/U3, audion Q1—Q8 or zener diode Z1/Z2/Z3/Z4 on drive PCB is damaged.

20. No AC sound when welding in AC mode.

a. The value of the resistor matching socket CON1 on inverter PCB PN-07-A1 varies.

b. The MOSFET VT1, rectifying diode VT11, diode D1 or zener diode Z3 on inverter PCB PN-07-A1 is damaged.


21. Press the welding torch switch, there is gas out, the show value of the meter is invariable, there is only small current, and the pre-flow time is variable.

a. The connecting cable matching socket CON11 on control panel PK-31-A0 with socket CON2 on control PCB PK-05-A4 is in loose connection.


a. Check. b. Check if chip U5, audion Q3/Q4 or

potentiometer VR7 on control panel PK-31-A0 is damaged.

22. When the pulse conversion switch is in no-pulse mode, in ARC or TIG mode, the welding current is invariable, and there is only maximum current.

a. The diode D24 on control panel PK-31-A0 is damaged.

a. Check.


16

23. Turn on the machine, the indicator of protection status is on because the voltage is too low.

a. The input voltage is too low or is unstable.

b. The thermal switch matching socket CON14 on control panel PK-31-A0 is damaged.

c. The connecting cable matching socket CON15 on control panel PK-31-A0 is in loose connection.

d. The resistor R51/R44 or chip U6 on control panel PK-31-A0 is damaged.

a. Check. b. Check. c. Check. d. Check. Method: properly reduce

the value of resistor R44.

2. AC/DC200Ⅱ 2.1 The structure drawing of AC/DC200Ⅱ: (Lack for the moment) 2.2 The general connection diagram of AC/DC200Ⅱ:

CONTROL MODULE

ELECTRIC DIAGRAM

Top Board

DRIVE MODULE

PK-03-A1

DC24V

AC/DC200

VH

-03

VH-02

VH-02

THERMAL SWITCH


VH-03

14V

14V

0 0

AC380V

AC220V

(VH-04)*2

DRIVE LINE

XH

-02

XH

-03

VH-02XH-03

DC12V

VH-02

XH-04 XH-03VH-03 XH-04

CON11

CON6CON1


CON2

CON4

CON9CON14

CON15 CON12 CON13


PK-08-A1

PM-03-A2

CON

4

CON

1

Port

Port

CP3

CP4

INPUT AC220V

CON

6

CO

N11 CO

N1

DC308V

CON7 CON8

CON2

AC220V

CO

N5PH-20-A1

CON

4C

ON

6AC2

20V

F

AN

*2

PZ-06-B4

BOTTOM BOARD

CON3

CON2

CON

10

CON2

CO

N9

CENTER BOARD

PD-08-B0VH

-07(

6)

CON1

+

-

+-

OU

T1

OU

T2

INVERTER BOARDPN

-07-

A1

PN-0

8-B0

CON

8

CON1

ARC FORCE

CON

9

PRO

TEC

T L

EDCU

RREN

T

CON10CON11

THERMAL SWITCH

CONTROL BOARD

PK-30-A0

CON

1V

H-0

5V

H-0

4

50W

450R

*2

CON1 CON5

PK-09-A3

DRIVE BOARD

CON

12

CON

3AC2

0V*4

0

AC

380V

AC

220V

T

T

CO

N2

O

R

CO

N4

XH-03(2)


Gun switch

CON

5

CON6

2T/4T

CON7

AC/DC

CON

TRO

L G

AS

CONTROL HF

CON2 CON3

ARC/TIG CONTROL GAS

CON4

CONTROL HF

CON1

PH-10-A01

CON15 DC12VPK-05-A4



17

2.3 The diagram of AC/DC200Ⅱ’s control panel PK-30-A0:

-+

+-

D13

D3

D25

D12

D14

D33

D31

Z2

D32

D1

D2

D4

D5

D6

Z3

D18

D21

D23

D19 D17

D20

D22

D24

D26

D16

D15

D7 D11D10D8 D9

Z1

L6

L5

R4

R7

L7

R56

R66

C15

R30

C4

R23 R24

C19

R33C20

C3

D28D27 D30D29

L4L3

R67

C26

C23

C25

C21

Q6

C16

U3

R41

C2

R13

R11

C11

U5

C12CON5

U1 U2

VR1

VR4

VR5

VR2 VR3

LED2LED1

R12

R1

R58R49

R46

R29

R27

R25

R21

R57

R48

R45

R38

R32

R28

R8

R6

R65

R9

R55

R42

R40

R60

R51

U7

CON4

CON12

CON8 CON9 CON11

CON1

0

CON7

CON6

U6

C13

C17

U8

R47

R44

R43

R37

R34

U4

CON3

R39

Q2

Q3

R36

C10C8 C9

Q1

C6

C1

C22

Q4 Q5

R54

R64

R59

R52 R53

R63R62R61

R50

C14

R19R18R17R15 R16 R20

C7

R22

R35

CON1

R5

R3

R2

C5

L2L1CON2

R26

R10

R14

C24

R31C18

PK-30-A02006.02.08

2.4 Troubleshooting of AC/DC200Ⅱ:

Trouble Analysis Solution 1. Turn on the machine, there is no display of the meter, the fan doesn’t work, no no-load voltage output in ARC/TIG mode.

a.

b.

c.

d.

The input voltage is abnormal.

The power supply cable matching CP3/CP4 on bottom PCB PZ-06-B4 is disconnected, or the tie-in is damaged. The power supply switch may be damaged, or it’s not closed. The connecting cable matching socket CON1-CON6 on power supply conversion PCB PH-20-A1 is in loose connection.


b. Check. c. Check. d. Check.


18

2. Turn on the machine, the meter displays, press the welding torch switch in TIG mode, there is gas out and no HF, no no-load voltage output in ARC mode.

a. The connecting cable matching socket CON1 on bottom PCB PZ-06-B4 is in loose connection.

b. The prime relay RELY3 on bottom PCB PZ-06-B4 doesn’t close well; the value of thermal resistor RT1 increases.

c. The connecting cable matching socket CON11/CON6 on bottom PCB PZ-06-B4 with the rectifying bridge is in loose connection.



damaged.

a. Check. Make sure the voltage of socket CON1 is DC308V.


U1 on PK-03-A1 is damaged. Method: Check if the output voltage of the 16th pin of U1 is 5V. If it’s not, U1 is damaged. Check if audion Q2/Q3/Q4/Q5/Q6/Q7/Q9, thyristor Q1, diode D2/D3/D4, zener diode Z1/Z2/Z3, capacitor C17 or resistor R32 is damaged.


3. Turn on the machine, the meter displays, but the thermal resistor RT1/RV2/RV3/RV5 on bottom PCB PZ-06-B4 heats and smokes after a while.

a.

b.

c.

The connecting cable (+24V) matching socket CON10 on bottom PCB PZ-06-A4 with socket CON14 on control PCB PK-05-A4 is in loose connection. The relay RELAY3 on bottom PCB PZ-06-A4 is damaged. The auxiliary power supply part on control PCB PK-05-A4 is damaged.

a. Check. b. Check. c. Check with a multi-meter if chip

U6, audion Q2, MOSFET U1, capacitor C23 or resistor R35 on control PCB PK-05-A4 is damaged.


19


a.

b.

c.

d.

e.

f.

The connecting cable matching socket CON3 on top PCB PM-03-A2 with socket CON3 on bottom PCB PZ-06-B4 is in loose connection. High voltage silicon granule D1/D2/D5/D4 or high voltage output capacitor C12/C13 on bottom PCB PZ-06-B4 is damaged. CP1/CP2 is disconnected with the bottom PCB. The discharge nozzles P1/P2 on bottom PCB have conglutination, excessive clearance or serious oxidation problem. The ARC/TIG conversion switch on the panel or the chip U4 on control panel PK-30-A0 is damaged. The connecting cable matching socket CON4 on control PCB PK-30-A0 with socket CON2 on bottom PCB PZ-06-B4 is in loose connection, or HF relay RELAY1, audion Q1, MOSFET VT1 or diode D3 on bottom PCB is damaged.

a. Check. b. Check. c. Check. d. Adjust or replace it if necessary. e. Check and replace it if necessary. f. Check. Method: short-circuit the

socket CON2 on bottom PCB PZ-06-B4, turn on the machine, and press the manual switch. If there isn’t HF, the HF circuit on bottom PCB goes wrong. If there is, the inductor L3/L4, chip U5/U3 or resistor R9 on control PCB PK-30-A0 is damaged.


20

5. Turn on the machine and it appears normal, press the welding torch switch and there is gas out, the malfunction LED is on, the malfunction LED turns on when turning to ARC mode.







c. Check. Method: turn to TIG mode, turn off the machine, and pull out the connecting cable matching the socket CON3 on top PCB PM-03-A2 with the socket CON3 on bottom PCB PZ-06-B4, then turn on the machine. If the malfunction LED is off, the transformer T1 is short-circuited or damaged. If it’s on, turn off the machine, pull out the connecting cable matching socket CON1 on top PCB PM-03-A2, turn on the machine. If malfunction LED is on, MOSFET VT1.1—/VT4.5 on top PCB or some part on drive module PK-08-A1 is damaged; if off, transformer T2.1/T2.2/T2.3/T2.4 or rectifying diode D1/D2 on PCB PD-08-B0 is damaged.




CON10 on bottom PCB PZ-06-B4 with socket CON3 on control panel PK-30-A0 is in loose connection.

d. Some part in magnet valve control circuit on bottom PCB PZ-06-B4 or some part in magnet valve control valve circuit on control panel PK-30-A0 is damaged.


argon is impure.


MOSFET VT1, resistor R3/R2, diode D3 or audion Q1 on bottom PCB or audion Q1 on control PCB PK-30-A0 is damaged or if the magnet valve control cable matching the socket CON4 is disconnected.


f. Check and replace it if necessary.


21

7. The welding current is unstable and out of control.

a. The connecting cable matching the socket CON2 on the control PCB PK-05-A4 with socket CON8 on control panel PK-30-A0 is in loose connection.



d. Loose connection exists inside the machine, e.g. the connecting cable matching socket CON1 with the remote control.




a. The rectifying bridge matching the socket CON6/CON11 on bottom PCB PZ-06-B4 is damaged.



9. In TIG mode, adjust the decay potentiometer to the max value and release the welding torch switch, the gas shuts off and then no current output.

a. The audion Q4, resistor R54/R59/R63 or chip U8 on control PCB PK-30-A0 is damaged.




b. The output terminal of the earth cable is in loose connection with gas-electricity tie-in.



a. The space between discharge nozzles P1 and P2 on bottom PCB PZ-06-B4 is too big or small, or their surface is badly oxidized.

b. The high-voltage capacitor C12/C13 on bottom PCB is damaged, or the capacitance becomes smaller.

c. The tungsten is of bad quality or the argon is impure.

d. The welding torch is in loose connection.e. Incorrect turn rate or turn-to-turn





22



b. Loose contact exists in MOSFET VT1.1-VT4.5 on top PCB PM-03-A2 or rectifying diode D1/D2 on center PCB PD-08-B0.

c. Some part on control module PK-03-A1 is damaged.



a. Some parts in manual switch control circuit on bottom PCB are damaged.


CON4 on control panel PK-30-A0 with socket CON2 on bottom PCB PZ-06-B4 is short-circuited or in loose connection, or chip U3 on control panel PK-30-A0 is damaged.

a. Check with a multi-meter if chip U1 or diode D1/D2 on control panel PK-30-A0 is damaged. Disconnect the connecting cable matching socket CON5, short-circuit both terminal of socket CON5 and check if the manual switch board PH-10-A1 is short-circuited.

b. Check.


a. The relay RELAY1, audion Q1, diode D3, MOSFET VT1 on bottom PCB PZ-06-B4 or chip U3 on control panel PK-30-A0 is damaged.

b. The connecting cable matching socket CON10 on control panel PK-30-A0 with socket CON5 on control PCB PK-05-A4 is in loose connection.




a. Adjust. Methods: 1. Turn to ARC mode, adjust the value of variable resistor R9 on control PCB PK-05-A4 to make the show value of the meter is 200. 2. Turn to TIG mode, do not press the manual switch, adjust the value of variable resistor VR1 on preset PCB to make the show value of the meter is 200.

16. No welding voltage output in ARC mode, but it’s normal in TIG mode.

a. The ARC/TIG conversion switch on the panel is damaged.

b. The connecting cable matching socket CON2/CON3 on control panel PK-30-A0 with ARC/TIG conversion switch is in loose connection, or chip U4, resistor R7 or diode D3 is damaged.



23


a. Some of the MOSFET on the secondary inverter PCB PN-07-A1/PN-08-B0 is damaged.





c. Interfered by the manual switch PCB.



c. The porcelain capacitor 102/2KV on the manual switch PCB is damaged.



c. Some part on the secondary drive PCB

PK-09-A3 is damaged.

a. Check. b. Check if the diode D18/D11/D10,

audion Q6, chip U8 or potentiometer VR2 on control panel PK-30-A0 is damaged.

c. Check with a multi-meter if chip U2/U4/U8/U9/U3, audion Q1-Q8 or zener diode Z1/Z2/Z3/Z4 on drive PCB is damaged.



b. The MOSFET VT1, rectifying diode VT11, diode D1 or zener diode Z3 on inverter PCB PN-07-A1 is damaged.








24







the value of resistor R47.

3. WSE200 3.1 The structure drawing of WSE200:

The structure of WSE200 is similar to that of RILTIG315AC/DC. (See the above structure drawing.)

No. Description No. Description No. Description 1 Cover 9 Pilot-socket (2 pins) 17 Center PCB 2 Handle 10 Pilot-socket (3 pins) 18 Inverter PCB 2 3 Button 11 Rubber foot 19 Fan 4 Function switch 12 Coupling socket 20 HF PCB 5 Function switch 13 Panel PCB 21 Heat sink 6 Main switch 14 Control PCB 22 Input cable 7 Front panel 15 Top PCB (left) 23 Digital meter 8 Fast-socket 16 Inverter PCB 1

Note: WSE200 is without No.20 HF PCB.


25

3.2 The general connection diagram of WSE200:

ELECTRIC DIAGRAM

Top Board

DRIVE MODULE

WSE200

REMOTE RESISTANCE

PK-07-B0

PM-01-A3

CON

4---

CO

N3

CON

8

Port

Port

CP3

CP4

INPUT AC220V

CON

5 C

ON

9

CON

1

DC308V

CON2 CON8

CON2

AC220V

CO

N5PH-20-A1

CO

N4

CO

N6A

C22

0V

FA

N *

2

PZ-27-A0

BOTTOM BOARD

CON3

CON

2

CO

N10

CON7

CO

N3

CENTER BOARD

PD-06-A2VH

-07(

6)

CON2

+

-

+-

OU

T1

OU

T2

INVERTER BOARD

PN-0

2-A

2PN

-01-

A1

CON10CON8 OR CON9

CON

12

PROTECT LEDCURRENT R

CON6

CON11

THERMAL SWITCH

CONTROL BOARD

PK-10-A1

CON

1V

H-0

5V

H-0

4

50W

160R

CON1 CON5

PK-09-A3

DRIVE BOARD

CON

3

CON

3AC2

0V*4

0

AC

380V

AC

220V

T

CO

N2

O

R

C

ON

4

XH-03(2)


Gun switch

CON

4

CON7

CON

5

AC/DC

CON

TRO

L H

F

CON1

CON6

CO

N8HF

CONTROL MODULE

PK-02-A1

+24V

CON

6

FEED BACK

CON

1

CONTROL GAS TIME

CON2

REMOTE SWITCH

CO

NT

RO

L M

ETE

R

CON5 CON2CON2

THERMAL SWITCH

CON9

3.3 The diagram of WSE200’s top PCB PM-01-A3, control module PK-02-A1, center PCB PD-06-A2, bottom PCB PZ-27-A0 and secondary inverter PCB PN-01-A1 and PN-02-A2:

+

+

+

+

C4

VT7

VT9

VT8

VT10

PK-07-B0 PK-02-A1(C)

P1

VR4

T2

VT4.1

VT6.1

VT2

R35

C10.3

C10.2

C10.1

CON8

C19

Q1

C1

C20

D6

R25

R26

R27R32

R23

R22

R24

C27

R33

C21.2

LED2C18

CON6

CON5

C24

CON2

R34

R37

CON3---CON4

R10

C16

R30

R15

R13

R11

C3

U2

R38

R29

R5

R14

C8

C7

R31

C29

R20.1

R19.1

U3

C32

C28

D5.2

D5.1

R36

Q2

C33

C31

CON10

CON9

103C21

CON1

C21.1

C17

C23

C5.1 C5.2

R28

LED1

R12

Z6Z5

BR2.1

Z3

BR2.2

BR2.3

BR2.4

D9D10

Z4

D7

D8

C25

C22

P1

R39

L1

300:1:1

T3

C14

VT4.2 VT4.3

R20.3R20.2

VT3.1

R17.1

VT3.2 VT3.3

R17.3R17.2

VT6.2

R19.2

VT6.3

R19.3

VT5.1

R18.1

VT5.2

R18.2

VT5.3

R18.3

R16

C9

R4

C6

CON7

2006.02.08

PM-01-A3

X4


26

++

R19 R20

R25

C10

R22

R27

C15

Q2

U2

C9

C7

D4

R29

Q4

Q1

R16

R18

C3

R24

Q3

Q8

Q9

Q6U1

C13

LED1

LED2

D1 D2

R8

Z4

R28

C5

C6

C2

C8

C14

Z2

R23

C1

C11

D3

Z1

C16

R9

R17

R3

R10

R13

R2R12

R14

R11

R4R5 R6

R15

R26

R30

Q7

Q5

R7

Z3

C4

C12

R1

R21

2006.02.08PK-02-A1

CON1

L2.5X31.0

T1-1

D3.1 D2.2 D3.2 D2.3 D3.3

D3.6D2.6D3.5D2.5D3.4D2.4

C14

C13

L3.0X99.8

D12

D13

Z01

hz

R21

R7.5 R6.5 R7.6 R6.6

R6.3R7.3R6.2R7.2R6.1R7.1

R6.4R7.4

C11.1C12.1

C11.4C12.4 C12.5 C11.5 C12.6 C11.6

C12.3 C11.3C12.2 C11.2

T1-2 T1-3

CON2

R8

L1-1

L1-2

RV5

RV4

RV3 C01

D2.1

2005.09PD-06-A2AC/DC200.ARC160/200 (T)


27

P1 P2 + +

+

+ +

R8

C10

C11

T1

Z4

Z3

R1

R5

R6

CON6

RV1

R9

C17 VT1

CON1

C5C4

RT2 RT3

RT4RT1

CP3

CP4RELAY3

VT2

U1

CON4

R7

CON9

CON5

RV2

CON8

C19C18

D7

D8

D6

C13

D1

CON10

CON

7

C12

C14 C15

D5

CON2

C8

C6

C7

C2

CP1

CP2

R2

R4

D4

D3

D2

C16

C1

C9

CON3

C3

Z1Z2

R3

Z5

RELAY1

RELAY2

AC/DC200(D)

L1

R101K 5W

2005.09

PZ-27-A0

+-- +

-++ -

-+-+

-+

-+

+ --+

CON12

R11

D25

C23

C24

R23C18

C1

C5

C16

D18

R10

U4

D13

D10

D8

R14

D23D22

D12

D11

CON2CON1

D14

R19

R17

C6

C8

C15

C10

C13

R22

C4

Q1 Q2

C22

R5

R1

R3

R25

R7

R4

R13

R12

C9

C2

D9

D1

C14

C20

C11

R31

R2

R32

R35

R28

R6

R16

Q4

Q3

R18

R15

R20

C3

C19

C21

C7

R29

D15

D3

D19

U3

R24

R34

R26

CON7 CON8CON5CON4 CON6 CON11

VR4

VR5

VR2VR1 VR3

LED2LED1

CON3 CON9 CON10

D20

D16

D21

D17

C12

D5

D4

R8

D2

R27R30

R33

R21

D24

R9

C17

D6

U1

U2

D7

PK-10-A1 2006.02.09


28

C1

Z4

Z3

Z2

Z1 R3 R4

R12R11R10R9

R5 R6

R7 R8

R2R1

VT1 VT2 VT3 VT6

VT7 VT9 VT10 VT11

35

32

34

37

VT5

VT12

VT4

VT8

AC/DC200(D)

2005.09

PN-01-A1

R8

R7

Z5

Z4

Z2

Z1

R3 R4

R15R14R13R12

R5 R6

R10 R11

R2R1

VT1 VT2 VT3 VT6

VT8 VT9 VT10 VT12

VT5

VT13

VT4

VT11

C5

CON1

C6

Z3R9

D1

VT7

D1

C3

C1

C4

C2

AC/DC200(D)

PN-02-A2

2005.09


29

3.4 Troubleshooting of WSE200: Trouble Analysis Solution

1. Turn on the machine, the power indicator is not on, the fan doesn’t work, no no-load voltage output.

a. The input voltage is abnormal. b. The power supply cable is not in good

connection with CP3/CP4 on bottom PCB PZ-27-A0, or the tie-in is damaged.

c. The power supply switch may be damaged or unclosed.

d. The connecting cable matching socket CON1-CON6 on power supply conversion PCB PH-20-A1 is in loose connection.


b. Check. c. Check and replace it if necessary. d. Check.

2. Turn on the machine, the power indicator is on, press the welding torch switch in TIG mode, there is gas out, no HF, and no no-load voltage output.


b. The prime relay RELAY3 on bottom PCB PZ-27-A0 doesn’t close well; the value of resistor RT1-RT4 increases.

c. The connecting cable matching socket CON5/CON9 on bottom PCB PZ-27-A0 with rectifying bridge is in loose connection.


e. Some part on top PCB PM-01-A3 is

damaged.

a. Check and make sure the voltage of socket CON1 is DC308V.


U1 on PK-02-A1 is damaged. Check if the 16th pin of U1 is 5V. If it’s not, replace the chip because U1 is damaged. Check if diode D1/D2/D3, audion Q1/Q2/Q3/Q4/ Q5/Q6/Q7/Q8/Q9 or zener diode Z1/Z2/Z3/Z4 is damaged.

e. Check if MOSFET VT7-VT10, resistor R15 or manostat U3 is damaged.

3. Turn on the machine, the power indicator turns on, but the thermal resistor RT1-RT4 on bottom PCB PZ-27-A0 heats and smokes after a while.

a. The connecting cable (+24V) matching socket CON10 on bottom PCB PZ-27-A0 with socket CON10 on top PCB PM-01-A3 is in loose connection.


c. The auxiliary power supply part on top PCB PM-01-A3 is damaged.

a. Check. b. Check. c. Check with a multi-meter if

resistor R22/R24, MOSFET VT2, diode D6/D8/D7/D9/D10, zener diode Z3/Z4, OC U2 or audion Q1 on top PCB PM-01-A3 is damaged.


30

4. Turn on the machine and it appears normal, press the welding torch and there is gas out, the malfunction LED is not on, no HF, and there is no-load voltage output.

a. The connecting cable matching socket CON7 on top PCB PM-01-A3 with socket CON3 on bottom PCB PZ-27-A0 is in loose connection.

b. High voltage silicon granule D3/D2/D5/D4 or high voltage output capacitor C14/C15/C16 on bottom PCB PZ-27-A0 is damaged.

c. CP1/CP2 is disconnected with the bottom PCB.

d. The discharge nozzles P1/P2 on bottom PCB have conglutination, excessive clearance or serious oxidation problem.

e. The connecting cable matching socket CON2 on bottom PCB PZ-27-A0 with both output terminal is in loose connection, or HF relay RELAY1, zener diode Z1/Z2, bridge D1 or resistor R1/R3 on bottom PCB is damaged.

a. Check. b. Check. c. Check. d. Adjust or replace it if necessary. e. Check.

5. Turn on the machine, and it appears normal, press the welding torch switch and there is gas out, the malfunction LED is on.







c. Check. Turn off the machine, pull out the connecting cable matching the socket CON7 on top PCB PM-01-A3 with the socket CON3 on bottom PCB PZ-27-A0, turn on the machine. If the malfunction LED is off, the transformer T1 is short-circuited or damaged. If it’s on, turn off the machine, pull out the connecting cable matching socket CON8 on top PCB PM-01-A3, turn on the machine. If the malfunction LED is on, MOSFET VT3.123/VT4./VT5./ VT6. on top PCB or some part on drive module PK-07-B0 is damaged; if it’s off, transformer T1-1/T1-2/T1-3 or rectifying diode D2.1/D3.5/D3.6 on center PCB PD-05-A2 is damaged.


31

6. Turn on the machine and it appears normal, it can start arc, but the welding point appears black.



CON4 on bottom PCB PZ-27-A0 with socket CON8/CON9 on control panel PK-10-A1 is in loose connection.

d. Some part in the magnet valve control circuit on bottom PCB PZ-27-A0 or on control panel PK-10-A1 is damaged.


argon is impure.


relay RELAY4, MOSFET VT1, resistor R8, diode D7 or zener diode Z3 on bottom PCB or audion Q3 on control PCB PK-10-A1 is damaged or if the magnet valve control cable matching the socket CON4 is disconnected.


f. Replace them if necessary.


a. The connecting cable matching socket CON10 on control panel PK-10-A1 with socket CON5 on top PCB PM-01-A3 is in loose connection.

b. The capacitor C4/C5/C12/C13 on bottom PCB PZ-27-A0 leaks or is damaged.


d. Loose connection exists inside the machine.




a. The rectifying bridge matching the socket CON5/CON9 on bottom PCB PZ-27-A0 is damaged.



9. Adjust the value of the decay potentiometer to the maximum and release the welding torch switch, the gas valve shuts off, and no current output.








32

11. The arc starting is bad. a. The space between discharge nozzles P1 and P2 on bottom PCB PZ-27-A0 is too big or small, or their surface is badly oxidized.

b. The high-voltage capacitor C14/C15/C16 on bottom PCB is damaged, or the capacitance becomes smaller.

c. The tungsten is of bad quality or argon is impure.

d. The welding torch is loose or broken. e. Incorrect turn rate or turn-to-turn





a. The connecting cable matching socket CON6 on top PCB PM-01-A3 with socket CON2 on center PCB PD-06-A2 is in loose connection.

b. Loose contact exists in MOSFET VT1.1-VT4.5 on top PCB PM-01-A3 or rectifying diode D1/D2 on center PCB PD-06-A2.




a. Some parts in manual switch control circuit on bottom PCB are damaged.


CON3 on control panel PK-10-A0 with socket CON3 on AC drive PCB PK-09-A3 is in loose connection, or chip U3/U4 or diode D11/D12/D14/D15 on control panel PK-10-A1 is damaged.

c. Some MOSFET on inverter PCB PN-01-A1/PN-02-A2 is damaged.

a. Check with a multi-meter if chip U3, diode D18/D22 or audion Q4 on control panel PK-10-A1 is damaged. Disconnect the connecting cable matching socket CON5/4, and check if the manual switch board PH-10-A1 is short-circuited.

b. Check. c. Check with a multi-meter one by

one. 14. Incessant HF exists when welding is carried out.

a. The relay RELAY1or zener diode Z1/Z2 on bottom PCB PZ-27-A0 is damaged.

b. Some part on inverter PCB PN-02-A2 is damaged.

a. Check and replace it if necessary. b. Check if rectifying diode D1,

MOSFET VT7, zener diode Z3 or resistor matching socket CON1 on PN-02-A2 is damaged.


33

15. Press the manual switch, when no-load, it appears normal in DC mode, but there is abnormal sound in AC mode.

a. Some MOSFET on the secondary inverter PCB PN-01-A1/PN-02-A2 is damaged.

a. Check. Method: Press the manual switch, turn to AC mode, turn off the machine after 3mins of no-load, touch the MOSFET on the secondary inverter PCB with your hand one by one. The extra hot ones are damaged.





a. Check. b. Check if the diode D23/D24, chip

U4 or potentiometer VR2 on control panel PK-10-A1 is damaged.




b. The MOSFET VT7, rectifying diode D1 or zener diode Z3 on inverter PCB PN-02-A2 is damaged.


18. Press the welding torch switch, there is gas out, there is only small current, and the pre-flow time is variable.



c. The remote control conversion switch on

the panel is damaged.

a. Check. b. Check if audion Q1/Q2 or


c. Check.







the value of resistor R17. 20. The tungsten is badly burned out in ARC mode.

a. The value of clean width potentiometer VR2 on control panel PK-10-A1 is adjusted too big.

a. Adjust the clean width smaller, or parallel connect a resistor of 200K or so with resistor R3 on control panel PK-10-A1.


34

21. The manual control is normal, but the pedal control goes wrong.

a. The panel conversion switch is damaged.b. The inching switch inside the pedal

control is damaged. c. The potentiometer inside the pedal

control is damaged. d. The connecting cable matching socket

CON1/CON2 on control panel PK-10-A1 is in loose connection.

a. Check and replace it if necessary.b. Check and replace it if necessary. c. Check and replace it if necessary. d. Check.

22. The welding current is variable, but the maximum current is too big.

a. The audion Q1/12 on control panel PK-10-A1 is damaged.


4. AC/DC315P/250P 4.1 The structure drawing of AC/DC315P/250P 4.1.1 The structure drawing of AC/DC315P:

No. Description No. Description No. Description 1 Cover 9 Pilot-socket (2 pins) 17 Inverter PCB 2 2 Handle 10 Pilot-socket (3 pins) 18 AC Driver PCB 3 Button 11 Rubber foot 19 Fan 4 Function switch 12 Coupling socket 20 Inductance 5 Function switch 13 Panel PCB 21 Heat sink 6 Main switch 14 Control PCB 22 Input cable 7 Front panel 15 Top PCB (left) 23 Digital meter 8 Fast-socket 16 Inverter PCB 1

4.1.2 The structure drawing of AC/DC250P: The structure of AC/DC250P is similar to that of AC/DC315P. (See the structure drawing of AC/DC315P on page ) REPAIR MANUAL·AC/DC SERIES

35

4.2 The general connection diagram of AC/DC315P/250P:

CONTROL MODULE

ELECTRIC DIAGRAM

Top Board

DRIVE MODULE

PK-03-A1

DC24V

AC/DC315P

VH

-03

VH-02

VH-02

THERMAL SWITCH


VH-03

14V

14V

0 0

AC380V

AC220V

(VH-04)*2

DRIVE LINE

XH

-02

XH

-03

VH-02XH-03

DC12V

VH-02

XH-04 XH-03VH-03 XH-04

CON11

CON6CON1


CON2

CON4

CON9CON14

CON15 CON12 CON13


PK-08-A1

PM-04-A3

CON

3

CON

1Port

Port

CP3

CP2

INPUT AC380V

CON

6 2

CO

N4

CO

N5

CON

8/C

ON

7

DC532V

CON6CON3

CON2

AC220V

CO

N5PH-20-A1

CO

N4

CO

N6A

C22

0V

FA

N *

2

PZ-03-B0

BOTTOM BOARD

CON3

VH-04

CON

1

CENTER BOARD

PD-13-B0

VH

-09(

8)

CON3

+

-

+-

OU

T1

OU

T2

INVERTER BOARD

PN-0

5-A

2PN

-06-

A1

CO

N11

CON1

ARC FORCE

CON

12

PRO

TE

CT L

ED

CU

RR

EN

T

CON13CON14

THERMAL SWITCH

CONTROL BOARD

PK-31-A0

CON

1V

H-0

5V

H-0

4

50W

450R

*4

CON1 CON5

PK-09-A3

DRIVE BOARD

CON

15

CON

3AC2

0V*4

0

AC

380V

AC

220V

T

T

CO

N2

O

R

C

ON

4

XH-03(2)


Gun switch

CON

9

CON10

2T/4T

CON5

AC/DC

CON6 CON7

ARC/TIG CONTROL GAS

CON8

CONTROL HF

CON2 CON3

CONTROL PULSE

CON4

PH-10-A01

CON15 DC12VPK-05-A4


CP1

Port

DC+24V

HF BOARD

PZ-35-A0C

ON

2

HF

CON1

CO

N4

CON2

GAS

+24V

CON3

+24V CONTROL GAS（PK-31-A0 CON7）

4.3 The diagram of AC/DC315P/250P’s top PCB PM-04-A3, center PCB PD-13-B0, bottom PCB PZ-03-B0, HF PCB PZ-35-A0, control panel PK-31-A0, control PCB PK-05-A4, control module PK-03-A1, AC drive PCB PK-09-A3 and inverter PCB PN-05-A2 and PN-06-A1:

R1 R4 R6 R10 R14 R17 R19 R21 R23 R27 R30 R33

R32R31R26R22R20R18R16R15R9R5R3R2

R12

R13 R25

CON3 C14C13

C2 C8

C9C1R29

R28

R8

R7 R24

C10

C11

C12

C7

C6

C5

C4

R11RT1

CON1

CON2

U2 U4 U6 U8 U10 U12 U14 U16 U18 U20 U22 U24

U23U21U19U17U15U13U11U9U7U5U3U1

2006.02.08

PM-04-A3


36

1 111

R11

R9

R10

L1

CON3D8D7

CON1

D1R3

C2C1

R2

U9 U10 U11 U12 U1 U2 U3 U4 U5 U6 U7

U20U16 U24U17 U19U18U13 U23U22U21

U8

T3 T1

T2

T4

U14 U15

R4

C4C3

R1 R6

C6C5

R5 R8

C8C7

R7

R13

C12

R12 R17

C14C13

R16 R15

C10

C15

R14

R19

C17C16

R18

C11

D2

RV1

C9

AC/DC315/315P/TIG315 (T) 2005.09PD-13-B0

++

++

++

RT1

CON7

R1

R2 R5

R6

R4R3

C5

C6

C3

C4

C2

C1

CON8

CON1

RELY1

CON2

CON4

CON5

CP1

CP2

CP3

CON6

CON3

RT2

X4X3

X2

2005.09PZ-03-B0AC/DC.TIG(T)


37

D6

C8

C10

Q1

R5

R4

D5 VT1

R3

R6

CON4

D1

D2

D3

R2

R1

CP2

CP1

C1

C3

C2

C5

D4

C6

T1

CON1

C4

RELAY1

Z1

CON3

VT2

C9

CON2

C7

PZ-35-A0

2006.03.06

P1 P2

- +

-++-

+ -

- +

D18

D22

D1

D2

Z1

D24

D26

D25

D23Z5

D6

D11

D8

D16

D14D12

Z4

D9

Z3 D7

D5

D13

D10

D15

D20

D17

D21

D27

D4

D3

Z2

D19

D28

D30

D29

C18

R32

R45

R72

Q1

R15

C1

C17

C8

R1

C9

R4

CON5

Q3 Q4

R35

R37

R41

C29

R70 C26

C27

R6

R13

R18

R59

R62

R64

R65

R68

R58

R61

VR4

U7U6U5 U8

U3

CON6

CON10

CON9

CON7

CON11 CON12 LED1LED2

VR7

VR1

VR6VR8 VR9

VR2 VR3

VR5

U4

R12R9 R10

R2

R5

R19

R21 R22 R23 R24

R27 R29 R30

R33

R34

R38R39

R42

R25

R43 R44

R46 R47 R48

R50

R54

R51 R52

R56 R55

R57

R60

R69

R71

R73

R74

R76

CON13 CON15

D32D31 D34D33

C23

C22

U9

U2

R7

R11

CON8

L2L1

U1

C3

C5

L6L5

C2

R53

C15

C16

R63

R66

C21

C28

R67

C25

CON4

R8

CON3CON2CON1 R3

Q2

C10R17

R40

R36

R31

C4

L4

L3

C12

R20

R26

Q5 Q6

C24

C19

R14

R16

C6

C20

R75

L7

R28

C13

R49

C7

CON14

C14

C11

PK-31-A02006.02.08


38

+ +

+ +

+

CON12

CON3CON6

R2

R3

C9

R11

R12

R5

C1

C19R30

z1

R29

D7Z2

D1

D3

D4

D11 D12U6 Q2

CON1

C21

C14

CON10

C11

C5

CON15CON14

CON5

C3

CON13

R27R31

R23R26

C15

C22

R33

R22

R25

R4

U3 U5U4

U2

Q1

C28

C29

C24

R17

CON11

C2

CON2

C4

C6

R6R7

R9

CON4

LED1 R8

R32

U1U9

D6D5

CON9

C8

C18

L1

U7 C34C33

C26

C13

C27

C16

C25

C12

C20

U8

R19D8

D10

R10

R13

C31

CON7 CON8

R14

R20

R18R16

R15

R24R28

R35

R1

C32

C23

C17

R34

C10

C30

R21

PK-05-A4 2006.02.08

C13

D1

C12

C7

LED2

LED1

R4

P1

R14

R17

R29

R16

R31

R25

R21

R19 D5

R28

C8

R15

C15

Z2 Z3

R7R6

C4

R23

R32

D4

D3D2

Z1R12

R13

R9

R1

R2

R8

C6

C9

C5

C18 C1 C2

R30

U2

Q5

Q8Q7

Q4

C16

Q9

Q1

Q3

C14U3

C17

C10

C11

Q2

R24R22

R18

R3

R27

R5

R11R10

Q6

R26

C3

R20

U1

PK-03-A1 2006.02.08


39

+

+

+

C13

C12

C5

C17

C2

C8

CON3

CON2

R5

U1

C7

D1

C6

Q3

Q4

U4U5

C1

C4

R1

U3

U2Q2

Q1C3

C10 Q5

Q6

U8

U6

R10

U7

D5

C11

C9

C16

CON1

U10

U9

Q8

Q7 C14

D7

C15

U11

R13

CON5

CON4

R3

R7

R11

R15

D2

Z1

Z2Z3

Z4

D6

D3

D4

R14

R6

R2R4

R8

R12

R16

R9

2006.02.08PK-09-A3

C1

1

17

VT13 VT14 VT15 VT16 VT17 VT18 VT19 VT20 VT21 VT22 VT23 VT24

Z1

Z2

A2

A3

A1

Z4

Z3

12

7


R1 R12R11R10R9R8R7R6R5R4R3R2

16

2

5

4

3

_1

_2

_3

9

13

11

10

14

R24R13 R14 R15 R16 R17 R18 R19 R20 R21 R22 R23

8

15

6

PN-06-A1

2005.09

AC/DC250B.315(T)


40

CON1 R13

3

6

C2

1

8


C1

Z3R14

D1

R15

Z1

Z2

A2

A3

A1

Z5

Z4

_8

_3

D2

C6

C3

VT13

C8

C7

C4


R1 R12R11R10R9R8R7R6R5R4R3R2

_12

_1

4

2

5

7

_5

_9

_7

_6

_4

_10

_11

_2

D3

R27R16 R17 R18 R19 R20 R21 R22 R23 R24 R25 R26

C5

X2

PN-05-A2

AC/DC250B.315(T)

2005.09

4.4 Troubleshooting of AC/DC315P/250P:

Trouble Analysis Solution 1. Turn on the machine, no display of the meter, the fan doesn’t work, no no-load voltage output in TIG/ARC mode.

a. The input voltage is abnormal. b. The power supply cable is not in good

connection with CP1/CP3 on bottom PCB PZ-03-B0, or the tie-in is damaged.

c. The power supply switch may be damaged or unclosed.



b. Check. c. Check and replace it if necessary. d. Check.


41

2. Turn on the machine, the meter displays, press the welding torch switch in TIG mode, there is gas out, no HF, turn to ARC mode, no no-load voltage output.

a. The connecting cable matching socket CON7/CON8 on bottom PCB PZ-03-B0 is in loose connection.

b. The prime relay RELAY1 on bottom PCB PZ-03-B0 doesn’t close well; the value of resistor RT1/RT2 increases.

c. The connecting cable matching socket CON2/CON4/CON5 on bottom PCB PZ-03-B0 with rectifying bridge is in loose connection.



damaged.



U1 on PK-03-A1 is damaged. Check if the 16th pin of U1 is 5V. If it’s not, replace the chip because U1 is damaged. Check if diode D2/D3/D4, audion Q2/Q3/Q4/Q5/ Q6/Q7/Q9, thyristor Q1, zener diode Z1/Z2/Z3, capacitor C17 or resistor R32 is damaged.


3. Turn on the machine, the meter displays, but the thermal resistor RT1/RT2 on bottom PCB PZ-03-B0 heats and smokes after a while.

a. The connecting cable (+24V) matching socket CON1 on bottom PCB PZ-03-B0 with socket CON14 on control PCB PK-05-A4 is in loose connection.

b. The relay RELAY1 on bottom PCB PZ-03-B0 is damaged.



resistor R35, MOSFET U1, audion Q2, chip U6 or capacitor C32 on control PCB PK-05-A4 is damaged.


42


a. The connecting cable matching socket CON2 on top PCB PM-04-A3 with socket CON1 on HF PCB PZ-35-A0 is in loose connection.

b. High voltage silicon granule D1/D2/D3/D4 or high voltage output capacitor C6/C7 on bottom PCB PZ-27-A0 is damaged.

c. CP1/CP2 is disconnected with the HF PCB.

d. The discharge nozzles P1/P2 on HF PCB have conglutination, excessive clearance or serious oxidation problem.

e. The ARC/TIG conversion switch on the panel or chip U7 on control panel PK-31-A0 is damaged.

f. The connecting cable matching socket CON8 on control PCB PK-31-A0 with socket CON4 on HF PCB PZ-35-A0 is in loose connection, or HF relay RELAY1, audion Q1, MOSFET VT1 or diode D5 on HF PCB is damaged.

a. Check. b. Check. c. Check. d. Adjust or replace it if necessary. e. Check and replace it if necessary. f. Check. Method: short-circuit the

socket CON4 on HF PCB PZ-35-A0, and turn on the machine, if no HF, the HF circuit on HF PCB goes wrong; if there is, the inductor L1/L2, chip U1/U3 or resistor R6 on control PCB PK-31-A0 is damaged.

5. Turn on the machine, and it appears normal, press the welding torch switch and there is gas out, the malfunction LED is on. Turn to ARC mode, the malfunction LED turns on.







c. Check. Turn off the machine, pull out the connecting cable matching the socket CON2 on top PCB PM-04-A3 with the socket CON1 on HF PCB PZ-35-B0, turn on the machine. If the malfunction LED is off, the transformer T1 on HF PCB is short-circuited or damaged. If it’s on, turn off the machine, pull out the connecting cable matching socket CON1 on top PCB PM-04-A3, turn on the machine. If the malfunction LED is on, MOSFET U1-U24 on top PCB or some part on drive module PK-08-A1 is damaged; if it’s off, transformer T1/T2/T3/T4 or rectifying diode U1/U24 on center PCB PD-13-B0 is damaged.


43




CON3 on HF PCB PZ-35-A0 with socket CON7 on control panel PK-31-A0 is in loose connection.

d. Some part in the magnet valve control circuit on HF PCB PZ-35-A0 or on control panel PK-31-A0 is damaged.


argon is impure.

a. Clear. b. Replace. c. Check. d. Check with a multi-meter if

MOSFET VT2, diode D6, zener diode Z1 on HF PCB or audion Q1 on control PCB PK-31-A0 is damaged or if the magnet valve control cable matching the socket CON2 is disconnected.







d. Loose connection exists inside the machine, e.g. the connecting cable matching socket CON4 on control panel with the remote control.




a. The rectifying bridge matching the socket CON2/CON4/CON5 on bottom PCB PZ-03-B0 is damaged.



9. When in TIG mode, adjust the value of the decay potentiometer to the maximum and release the welding torch switch, the gas valve shuts off, and no current output.




44






a. The space between discharge nozzles P1 and P2 on HF PCB PZ-34-A0 is too big or small, or their surface is badly oxidized.

b. The high-voltage capacitor C3/C4 on HF PCB is damaged, or the capacitance becomes smaller.



electricity leakage problem exists in arc-starting coil matching CP1/CP2 on HF PCB.





b. Loose contact exists in MOSFET VT1-VT24 on top PCB PM-04-A3 or rectifying diode U1/U24 on center PCB PD-13-B0.






CON8 on control panel PK-31-A0 with socket CON4 on bottom PCB PZ-35-A0 is in loose connection, or chip U1 on control panel PK-31-A0 is damaged.

a. Check with a multi-meter if chip U8 or diode D14/D18 on control panel PK-31-A0 is damaged. Disconnect the connecting cable matching the socket CON9, short-circuit both terminal of socket CON9 and check if the manual switch board PH-10-A1 is short-circuited.

b. Check.


45


a. The relay RELAY1, audion Q1, diode D5, MOSFET VT1 on HF PCB PZ-35-A0 or chip U1 on control panel PK-31-A0 is damaged.

b. The connecting cable matching socket CON13 on control panel PK-31-A0 with socket CON5 on control PCB PK-05-A4 is in loose connection.




a. Adjust. Methods: 1. Turn to ARC mode, adjust the value of variable resistor R9 on control PCB PK-05-A4 to make the show value of the meter be the value of the corresponding machine type. 2. Turn to TIG mode, do not press the manual switch, adjust the value of variable resistor VR1 on preset PCB PH-10-A0 to make the show value of the meter be the value of the corresponding machine type.

16. No pulse when in pulse mode.

a. The panel pulse conversion switch is damaged.

b. The connecting cable matching socket CON2/CON3 on control panel PK-31-A0 with the pulse conversion switch is short-circuited, or chip U4, capacitor C4/C11, potentiometer VR2/VR3 or diode D24 is damaged.











46





a. Check. b. Check if the diode D9/D2/D1, chip

U6, audion Q2 or potentiometer VR4 on control panel PK-31-A0 is damaged.




b. The MOSFET VT13, rectifying diode D1/D3, resistor R14/R13 or zener diode Z3 on inverter PCB PN-05-A2 is damaged.







22. When the pulse conversion switch is at no-pulse state, in ARC/TIG mode, the welding current is invariable, and there is only maximum current.

a. The diode D24 on control panel PK-31-A0 is damaged.








the value of resistor R44. 24. The tungsten is badly burned out in AC mode.

a. The value of AC clean width on the panel is adjusted too big.

a. Adjust the clean width smaller.


a. The connecting cable matching socket CON4 on control panel PK-31-A0 is in loose connection.


a. Check. b. Check if diode D23, zener diode

Z5, resistor R32/R35/R46 or inductor L3/L4 on control panel PK-31-A0 is damaged.


47

5. WSE250/315 5.1 The structure drawing of WSE250/315 5.1.1 The structure drawing of WSE250




48

5.1.2 The structure drawing of WSE315



5.2 The general connection diagram of WSE250/315:

CONTROL MODULE

ELECTRIC DIAGRAM

Top Board

DRIVE MODULE

PK-03-A1

DC24V

WSE250/315

VH

-03

VH-02

VH-02

THERMAL SWITCH


VH-03

14V

14V

0 0

AC380V

AC220V

(VH-04)*2

DRIVE LINE

XH

-02

XH

-03

VH-02XH-03

DC12V

VH-02

XH-04 XH-03VH-03 XH-04

CON11

CON6CON1


CON2

CON4

CON9CON14

CON15 CON12 CON13

METER

PK-08-A1

PM-04-A3

CON

3

CON

1Port

Port

CP3

CP2

INPUT AC380V

CON

6 2

CO

N4

CO

N5

CON

8/C

ON

7

DC532V

CON6CON3

CON2

AC220V

CON

5PH-20-A1

CON

4CO

N6A

C22

0V

FA

N *

2

PZ-03-B0

BOTTOM BOARD

CON3

VH-04

CON

1

CENTER BOARD

PD-13-B0

VH

-09(

8)

CON3

+

-

+-

OU

T1

OU

T2

INVERTER BOARD

PN-0

5-A

2PN

-06-

A1

CON

1V

H-0

5V

H-0

4

50W

450R

*4

CON1 CON5

PK-09-A3

DRIVE BOARD

CON

3AC2

0V*4

0

AC380V

AC220V

T

T

CON

2

OR

C

ON

4

XH-03(2)


Gun switch

CONTROL HF

PH-10-A01

CON15 DC12VPK-05-A4

PK-10-A1CON12

CP1

Port

DC+24V

HF BOARD

PZ-34-A0

CON

2

HF

CON3

CO

N4

CON1

+24V

CON2

+24V CONTROL GAS

REMOTE RESISTANCE

CON

10

CON8 OR CON9CON12

PROTECT LED

CON

6

CON11

THERMAL SWITCH

CONTROL BOARD

PK-10-A1

CON

3

CON

4

CON7

CON

5

AC/DC

CON1

CONTROL GAS

CON2

REMOTE SWITCH

CONTROL METER

ARC FORCE

PK-10-A1 CON8/9

GAS


49

5.3 The diagram of WSE250/315’s HF PCB PZ-34-A0 and control panel PK-10-A1:

+

VT1

R2

VT2

Z2Z3

C11

R3

C5

RELAY1

CON3

C6

T1

BR1

CON1

Z1

C10

C8

C7

C9

C1

CON2

C2

R4

CON4

D2

D1

D3D4

R5

C4

C3

R1

CP1CP2

2006.03.06

PZ-

34-A0

5W1K

1mH

R6C12

L1

R7

P2P1P1

- CON12

R11

D25

C23

C24

R23C18

C1

C5

C16

D18

R10

U4

D13

D10

D8

R14

D23D22

D12

D11

CON2CON1

D14

R19

R17

C6

C8

C15

C10

C13

R22

C4

Q1 Q2

C22

R5

R1

R3

R25

R7

R4

R13

R12

C9

C2

D9

D1

C14

C20

C11

R31

R2

R32

R35

R28

R6

R16

Q4

Q3

R18

R15

R20

C3

C19

C21

C7

R29

D15

D3

D19

U3

R24

R34

R26

CON7 CON8CON5CON4 CON6 CON11

VR4

VR5

VR2VR1 VR3

LED2LED1

CON3 CON9 CON10

D20

D16

D21

D17

C12

D5

D4

R8

D2

R27R30

R33

R21

D24

R9

C17

D6

U1

U2

D7

PK-10-A1 2006.02.09


50

5.4 Troubleshooting of WSE250/315: Trouble Analysis Solution

1. Turn on the machine, no display of the meter, the fan doesn’t work, no no-load voltage output in ARC/TIG mode.

a. The input voltage is abnormal. b. The input cable is not in good connection

with CP3/CP2/CP1 on bottom PCB PZ-03-B0, or the tie-in is damaged.

c. The power supply switch may be damaged or not closed.



b. Check. c. Check and replace the power

supply switch if it’s damaged. d. Check.


a. The connecting cable matching socket CON7/CON8 on bottom PCB PZ-03-B0 is in loose connection.

b. The prime relay RELAY1 on bottom PCB PZ-03-B0 doesn’t close well; the value of resistor RT1/RT2 increases.

c. The connecting cable matching socket CON2/CON4/CON5 on bottom PCB PZ-03-B0 with rectifying bridge is in loose connection.



damaged.



U1 on PK-03-A1 is damaged. Check if the 16th pin of U1 is 5V. If it’s not, replace the chip because U1 is damaged. Check if diode D2/D3/D4, audion Q2/Q3/Q4/Q5/ Q6/Q7/Q9, thyristor Q1, zener diode Z1/Z2/Z3, capacitor C17 or resistor R32 is damaged.


3. Turn on the machine, the meter displays, but the thermal resistor RT1/RT2 on bottom PCB PZ-03-B0 heats and smokes after a while.

a. The connecting cable (+24V) matching socket CON1 on bottom PCB PZ-03-B0 with socket CON14 on control PCB PK-05-A4 is in loose connection.

b. The relay RELAY1 on bottom PCB PZ-03-B0 is damaged.



resistor R35, MOSFET U1, audion Q2, chip U6 or capacitor C32 on control PCB PK-05-A4 is damaged.


51


a. The connecting cable matching socket CON2 on top PCB PM-04-A3 with socket CON3 on HF PCB PZ-34-A0 is in loose connection.

b. High voltage silicon granule D1/D2/D3/D4 or high voltage output capacitor C6/C7 on HF PCB PZ-34-A0 is damaged.

c. CP1/CP2 is disconnected with the HF PCB.

d. The discharge nozzles P1/P2 on HF PCB have conglutination, excessive clearance or serious oxidation problem.

e. The ARC/TIG conversion switch on the panel is damaged.

f. The connecting cable matching both output terminal with socket CON4 on HF PCB PZ-34-A0 is in loose connection, or HF relay RELAY1, zener diode Z2/Z3, MOSFET VT1 or resistor R4/R6 on HF PCB is damaged.

a. Check. b. Check. c. Check. d. Adjust or replace it if necessary. e. Check and replace it if necessary. f. Check.

5. Turn on the machine, and it appears normal, press the welding torch switch and there is gas out, the malfunction LED is on. Turn to ARC mode, the malfunction LED turns on.







c. Check. Turn to TIG mode, turn off the machine, pull out the connecting cable matching the socket CON2 on top PCB PM-04-A3 with the socket CON3 on HF PCB PZ-34-A0, turn on the machine. If the malfunction LED is off, the transformer T1 on HF PCB is short-circuited or damaged. If it’s on, turn off the machine, pull out the connecting cable matching socket CON1 on top PCB PM-04-A3, turn on the machine. If the malfunction LED is on, MOSFET U1-U24 on top PCB or some part on drive module PK-08-A1 is damaged; if it’s off, transformer T1/T2/T3/T4 or rectifying diode U1/U24 on center PCB PD-13-B0 is damaged.


52




CON2 on HF PCB PZ-34-A0 with socket CON8/CON9 on control panel PK-10-A1 is in loose connection.

d. Some part in the magnet valve control circuit on HF PCB PZ-34-A0 or on control panel PK-10-A1 is damaged.


argon is impure.


MOSFET VT2, zener diode Z1 on HF PCB, audion Q3 or resistor R31/R33 on control PCB PK-10-A1 is damaged or if the magnet valve control cable matching the socket CON1 is disconnected.








e. The panel remote control conversion switch is damaged.


the cable. d. Check. e. Check.


a. The rectifying bridge matching the socket CON2/CON4/CON5 on bottom PCB PZ-03-B0 is damaged.



9. When in TIG mode, adjust the value of the decay potentiometer to the maximum and release the welding torch switch, the gas valve shuts off, and no current output.

a. The audion Q5, resistor R64/R65/R68 or chip U6 on control panel PK-31-A0 is damaged.



53






a. The space between discharge nozzles P1 and P2 on HF PCB PZ-35-A0 is too big or small, or their surface is badly oxidized.

b. The high-voltage capacitor C6/C7 on HF PCB is damaged, or the capacitance becomes smaller.



electricity leakage problem exists in arc-starting coil matching CP1/CP2 on HF PCB.





b. Loose contact exists in MOSFET VT1-VT24 on top PCB PM-04-A3 or rectifying diode U1/U24 on center PCB PD-13-B0.






CON3 on control panel PK-10-A1 with socket CON3 on AC drive PCB PK-09-A3 is in loose connection, or chip U1/U4 or diode D11/D12/D14/D15 on control panel PK-10-A1 is damaged.


a. Check with a multi-meter if chip U3, diode D18/D22 or audion Q4 on control panel PK-10-A1 is damaged. Disconnect the connecting cable matching the socket CON5/4, and check if the manual switch board PH-10-A1 is short-circuited.

b. Check. c. Check.


54


a. The relay RELAY1 or MOSFET VT1 on HF PCB PZ-34-A0 is damaged, or the value of variable resistor R6 varies.

b. Some part on inverter PCB PN-05-A2 is

damaged.

a. Check and replace it if necessary; adjust the value of resistor R6 smaller to make sure that there is no HF when welding.

b. Check if rectifying diode D1/D3, zener diode Z3, MOSFET VT13 or resistor R14 is damaged.



a. Adjust. Methods: 1. Turn to ARC mode, adjust the value of variable resistor R9 on control PCB PK-05-A4 to make the show value of the meter be the value of the corresponding machine type. 2. Turn to TIG mode, do not press the manual switch, adjust the value of variable resistor VR1 on preset PCB PH-10-A01 to make the show value of the meter be the value of the corresponding machine type.








a. Check. b. Check if the diode D23/D24, chip

U4 or potentiometer VR2 on control panel PK-10-A1 is damaged.




b. The MOSFET VT13, rectifying diode D1/D3, resistor R14/R13 or zener diode Z3 on inverter PCB PN-05-A2 is damaged.



55






20. The welding current is variable, and the maximum current is too big.

a. The audion Q1/Q2 on control panel PK-10-A1 is damaged.









a. The value of AC clean width on the panel is adjusted too big.

a. Adjust the clean width smaller.


a. The connecting cable matching socket CON1 on control panel PK-10-A1 is in loose connection, or the panel remote control matching socket CON2 is damaged.

b. The potentiometer inside the pedal control or the toggle switch is damaged.

a. Check. b. Check.

6. AC/DC160 6.1 The structure drawing of AC/DC160:


56

No. Description No. Description No. Description

1 Cover 9 Pilot-socket (2 pins) 17 Inverter PCB 2 2 Handle 10 Pilot-socket (3 pins) 18 AC Driver PCB 3 Button 11 Rubber foot 19 Fan 4 Function switch 12 Coupling socket 20 Inductance 5 EMC PCB 13 Bottom PCB 21 Heat sink 6 Main switch 14 Center PCB 22 Input cable 7 Front panel 15 Top PCB 23 Digital meter 8 Fast-socket 16 Inverter PCB 1

6.2 The general connection diagram of AC/DC160:

ELECTRIC DIAGRAM

Top Board

DRIVE MODULE

AC/DC160

REMOTE RESISTANCE

PK-07-B0

PM-21-A0

CON

9

CON

5

Port

Port

CP3

CP4

INPUT AC220V

CON

5 C

ON

9

CON

1

DC308V

CON3 CON8

AC220V

PZ-36-A0

BOTTOM BOARD

CON

1

CO

N10

CON7

CO

N2

CENTER BOARD

PD-22-A2VH

-07(

6)

AC220V FAN *2

CON1

+

-

+-

OU

T1

OU

T2

INVERTER BOARD

PN-0

2-A

2PN

-01-

A1

CON8

PROTECT LEDCURRENT R

CON9

CON11

THERMAL SWITCH

CONTROL BOARD

PK-32-A2

CON

1V

H-0

5V

H-0

4

50W

160R

CON1 CON5

PK-09-A3

DRIVE BOARD

CO

N12

CON

3AC2

0V*4

0

AC

380V

AC

220V

T

CO

N2

O

R

C

ON

4

XH-03(2)


Gun switch

CON

5

CON7

AC/DC

CONTROL HF

CON1

CON6

CO

N7HF

CONTROL MODULE

PK-02-A1

+24V

CON

2

FEED BACK

CONTROL GAS TIME

CON4

CON4 CON10CON8

THERMAL SWITCH

CON3

CON3

METER

CON6

CON10

CO

NT

RO

L L

INE

CONTROL HF

PK-32-A0 CON4

CON2

TIG/ARC

CON

6 2T/4T


57

6.3 The diagram of AC/DC160’s top PCB PM-21-A0, control module PK-02-A1, center PCB PD-22-A1, bottom PCB PZ-36-A0, AC drive PCB PK-09-A3, inverter PCB PN-01-A1/PN-02-A2 and control panel PK-32-A0:

+

+

++

+

R11

CON3

CON6

R14

R12

C2

U2

U3

R29

LED2

CON8C18

R23

R24

C19

CON10

R26

LED1

C15

R19R18 CON4

R16

Q1

R15

C9

Z3

Z2

C6

Z1

R7

R33R32R31

R34

R1 R4R3R2

C17 C16

C11

D5

D4

C12U4

P1

C10

T1

C23C22 CON9

VT9 VT10 VT11 VT12

VT4VT3VT2VT1

R9C7

R10C8

R28 C24R27C21

P2

D3

D2

CON2CON1

C13

VT7

VT8

VT6

VT5

R25

C20

C3

C26 C27

C5

R30

C25

P3

R21R22

R13Z4

D8D9

D7D6

R20C14

D1

R5R6R8

C1

U1

T2CON5

R17

C4

CON7

X2

PM-21-A0

2006.02.08

++

R19 R20

R25

C10

R22

R27

C15

Q2

U2

C9

C7

D4

R29

Q4

Q1

R16

R18

C3

R24

Q3

Q8

Q9

Q6U1

C13

LED1

LED2

D1 D2

R8

Z4

R28

C5

C6

C2

C8

C14

Z2

R23

C1

C11

D3

Z1

C16

R9

R17

R3

R10

R13

R2R12

R14

R11

R4R5 R6

R15

R26

R30

Q7

Q5

R7

Z3

C4

C12

R1

R21

2006.02.08PK-02-A1


58

R1

C4

C3

RV1

D9 D10

D1D4

T1T2

D7 D8

C5

C1

D3D2

R5

R2

C6R6

L3

L2

C2R3

CON1

D5 D6

Cu

R4

Cu

L1

2005.12.20PD-22-A2

P1 P2

+ +

+

+ +

C6

D7

CON3

R8

R6

VT1

R7

R9

CON6

RV1

RELAY2

R11

C10

VT2

CON1

C4C3

RV2 RV3

RV4RT1

CP3

CP4RELAY3

VT3

U1

CON4

R10

CON9

CON5

RV5

CON8

C11C12

D11

D12

R5

R4

D10

C2

CON10

Z2Z1

Z3

CON7

C1

C7 C8

RELAY1

T1

D6

C5

C3

C4

C2

CP1

CP2

R1

R3

D5

D2

D1

C9

C1

CON2

R2

2

1

Q1

AC/DC160(D) 2005.09PZ-36-A0

1R1 L1

+

+

+

C13

C12

C5

C17

C2

C8

CON3

CON2

R5

U1

C7

D1

C6Q3

Q4

U4U5

C1

C4

R1

U3

U2Q2

Q1C3

C10 Q5

Q6

U8

U6

R10

U7

D5

C11

C9

C16

CON1

U10

U9

Q8

Q7 C14

D7

C15

U11

R13

CON5

CON4

R3

R7

R11

R15

D2

Z1

Z2

Z3

Z4

D6

D3

D4

R14

R6

R2R4

R8

R12

R16

R9

2006.02.08PK-09-A3


59

C1

Z4

Z3

Z2

Z1 R3 R4

R12R11R10R9

R5 R6

R7 R8

R2R1

VT1 VT2 VT3 VT6

VT7 VT9 VT10 VT11

35

32

34

37

VT5

VT12

VT4

VT8

AC/DC200(D)

2005.09

PN-01-A1

R8

R7

Z5

Z4

Z2

Z1

R3 R4

R15R14R13R12

R5 R6

R10 R11

R2R1

VT1 VT2 VT3 VT6

VT8 VT9 VT10 VT12

VT5

VT13

VT4

VT11

C5

CON1

C6

Z3R9

D1

VT7

D1

C3

C1

C4

C2

AC/DC200(D)

PN-02-A2

2005.09


60

PK-32-A0 2006.02.08

+-

-+

D33

D1

Z1

D10D9 D11 D12D8

D16

D17

D27

D25

D23

D21

D18D20

D24

D22

D19

Z3

D7D6

D5

D3

D2

D28

Z2

D34

D35

D15

D13

D26

D4

D14

R64

R59

C26U10

VR5

U1

C17

C21

R12

R10

R25

CON2

L2 L1

C4

R2

R3

R5

CON1

R31

R21

C6

R19R15R14 R16 R17 R18

C13

R50

R63

R60R61

R53R52

R62

R65

R54

Q5Q4

C22

C2

C3

Q1

C7C9

C8

R36

Q3Q2

R35

CON3

U5

R33

R38

R40

R43

R46

U9

C16

C12

U7

CON6

CON7

CON10 CON11

CON9CON8

CON12

CON4

U8

R51

R58

R37

R39

R55

R9

R66

R6

R7

R27

R30

R34

R44

R47

R57

R20

R24

R26

R28

R45R48R49

R1

R42

LED2

LED1

VR2

VR9

VR7

VR1

U4

CON5

C10

U3\U6

R11

R13

C1

R41

U2

C15

Q6

C20

C24

C23

C25R68

L4

L5

D31

D32

D29

D30

C11

C19R32

C18

R23R22

C5

R29

C14

R67

R56

L7

R8

R4

L3

L6

6.4 Troubleshooting of AC/DC160:

Trouble Analysis Solution 1. Turn on the machine, no display of the meter, the fan doesn’t work, no no-load voltage output.

a. The input voltage is abnormal. b. The input cable is not in good connection

with CP3/CP4 on bottom PCB PZ-36-A0, or the tie-in is damaged.

c. The power supply switch may be damaged or not closed.

d. The connecting cable matching socket CON6/CON7/CON8 on bottom PCB PZ-36-A0 is in loose connection.


b. Check. c. Check and replace the power

supply switch if it’s damaged. d. Check.


61



b. The prime relay RELAY3 on bottom PCB PZ-36-A0 doesn’t close well; the value of resistor RT1/RT2/RT3/RT4 increases.

c. The connecting cable matching socket CON5/CON9 on bottom PCB PZ-36-A0 with rectifying bridge is in loose connection.


e. Some part on top PCB PM-21-A0 is

damaged.



U1 on PK-02-A1 is damaged. Check if the 16th pin of U1 is 5V. If it’s not, replace the chip because U1 is damaged. Check if diode D1/D2/D3, audion Q1/Q2/Q3/Q5/ Q6/Q7/Q8/Q9 or zener diode Z1/Z2/Z3/Z4 is damaged.

e. Check if MOSFET VT5-VT8, pin P3 or manostat U2 is damaged.

3. Turn on the machine, the meter displays, but the thermal resistor RT1/RT2/VT3/VT4 on bottom PCB PZ-36-A0 heats and smokes after a while.

a. The connecting cable (+24V) matching socket CON10 on bottom PCB PZ-36-A0 with socket CON1 on top PCB PM-21-A0 is in loose connection.


c. The auxiliary power supply part on top PCB PM-21-A0 is damaged.


resistor R17, diode D4/D5, chip U3 or OC U4 on top PCB PM-21-A0 is damaged.


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4. Turn on the machine and it appears normal, press the welding torch and there is gas out, the malfunction LED is not on, no HF, but there is no-load voltage output.

a. The connecting cable matching socket CON7 on top PCB PM-21-A0 with socket CON2 on bottom PCB PZ-36-A0 is in loose connection.

b. High voltage silicon granule D1/D2/D5/D6 or high voltage output capacitor C7/C8/C9 on bottom PCB PZ-36-A0 is damaged.

c. CP1/CP2 is disconnected with the bottom PCB.

d. The discharge nozzles P1/P2 on bottom PCB have conglutination, excessive clearance or serious oxidation problem.

e. The connecting cable matching socket CON 4 on control panel PK-32-A0 with socket CON3 on bottom PCB PZ-36-A0 is in loose connection, or HF relay RELAY1, MOSFET VT1, audion Q1, diode D7, resistor R6-R9, rectifying bridge D1 or resistor R1/R3 on bottom PCB is damaged.

a. Check. b. Check. c. Check. d. Adjust or replace it if necessary. e. Check.

5. Turn on the machine, and it appears normal, press the welding torch switch and there is gas out, the malfunction LED is on.







c. Check. Turn off the machine, pull out the connecting cable matching the socket CON7 on top PCB PM-21-A0 with the socket CON2 on bottom PCB PZ-36-A0, turn on the machine. If the malfunction LED is off, the transformer T1 on bottom PCB is short-circuited or damaged. If it’s on, turn off the machine, pull out the connecting cable matching socket CON5 on top PCB PM-21-A0, turn on the machine. If the malfunction LED is on, MOSFET VT1-4/VT9-12 on top PCB or some part on drive module PK-07-B0 is damaged; if it’s off, transformer T1/T2 or rectifying diode D1-4/D7-10 on center PCB PD-22-A1 is damaged.


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6. Turn on the machine and it appears normal, it can start arc, but the welding point appears black.



CON10 on bottom PCB PZ-36-A0 with socket CON3 on control panel PK-32-A0 is in loose connection.

d. Some part in the magnet valve control circuit on bottom PCB PZ-36-A0 or on control panel PK-32-A1 is damaged.


argon is impure.


MOSFET VT2, diode D10/D11, zener diode Z1, relay RELAY2 on bottom PCB or audion Q1 on control PCB PK-32-A0 is damaged or if the magnet valve control cable matching the socket CON4 is disconnected.





b. The capacitor C1/C2/C3/C4/ on bottom PCB PZ-36-A0 leaks or is damaged.






a. The rectifying bridge matching the socket CON5/CON9 on bottom PCB PZ-36-A0 is damaged.



9. Adjust the value of the decay potentiometer to the maximum and release the welding torch switch, the gas valve shuts off, and no current output.

a. The audion Q4, resistor R54/R59 or diode D27 on control panel PK-32-A0 is damaged.





c. Check and replace it if necessary. d. Check and replace it if necessary.


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11. The arc starting is bad. a. The space between discharge nozzles P1 and P2 on bottom PCB PZ-36-A0 is too big or small, or their surface is badly oxidized.

b. The high-voltage capacitor C7/C8/C9 on bottom PCB is damaged, or the capacitance becomes smaller.







a. The connecting cable matching socket CON2 on top PCB PM-21-A0 with socket CON1 on center PCB PD-22-A2 is in loose connection.

b. Loose contact exists in MOSFET VT1-4/VT9-12 on top PCB PM-21-A0 or rectifying diode U1-4/U7-10 on center PCB PD-22-A2.






CON12 on control panel PK-32-A0 with socket CON3 on AC drive PCB PK-09-A3 is in loose connection, or chip U5 or diode D16/D17/D20/D24/D26 on control panel PK-32-A0 is damaged.


a. Check with a multi-meter if chip U1, diode D1/D2 on control panel PK-10-A1 is damaged. Disconnect the connecting cable matching the socket CON5, short-circuit CON5, and check if the manual switch board PH-10-A1 is short-circuited.

b. Check. c. Check with a multi-meter one by

one. 14. Incessant HF exists when welding is carried out.

a. The relay RELAY1, audion Q1 or MOSFET VT1 on bottom PCB PZ-36-A0 is damaged.

b. Some part on inverter PCB PN-02-A2 is damaged.

a. Check and replace it if necessary. b. Check if rectifying diode D1, zener

diode Z3, MOSFET VT7 or resistor matching socket CON1 is damaged.


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15. Press the manual switch, when no load, it appears normal in DC mode, but there is abnormal sound in AC mode.







a. Check. b. Check if the diode D19, chip U9,

potentiometer VR5 or audion Q6 on control panel PK-32-A0 is damaged.




b. The MOSFET VT7, rectifying diode D1, or zener diode Z3 on inverter PCB PN-02-A2 is damaged.


18. Press the welding torch switch, there is gas out, there is only small current, and the pre-flow time is variable.












a. The value of clean width potentiometer VR5 on control panel PK-32-A0 is adjusted too big.

a. Adjust the clean width smaller, or parallel connect a resistor of 200K with resistor R18 on control panel PK-32-A1.


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a. The conversion switch on the panel is damaged.

b. The toggle switch inside the pedal control is damaged.

c. The potentiometer inside the pedal control is damaged.

d. The connecting cable matching socket CON1 on control panel PK-32-A0 is in loose connection.

a. Check. b. Check. c. Check. d. Check.


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Documents

REPAIR MANUAL - · PDF file1.3 The diagram of AC/DC200P’s top PCB PM-03-A2, center PCB PD-08-B0, bottom PCB PZ-06-B4, control panel PK-31-A0, low-voltage control PCB