DTD 250 AC/DC Aristotig 250 acme Welding power source 0301 905110 Eaton 06896Service manual DTD 250 ACIDC DTD 250 AC/DC Introduction ‘This service mamulis intended to be used together with the operation manual where the spare part list can be found. epope u 2 B 4 15.18 7 w » 20.21, Page?Service mantal DTD 280 ACDC General Description Prinipal Diagram: ra) The newest generation of ESAB inverts are bad a fhe DC side on fast switching type IGBTs (insulated gate bipolar transistor). [At the converter for AC current, ow saturation voage type IGBTs ae installed ‘The prnzipte ofthe DC partis "Half bridge push pul flow converte”. ‘The nominal 400V three phases mains supply i rectified, filtered with Li and CS and then devided by two. ‘The AC-curent through the primary col of the transformer is controled with two IGBTs. (af beige one modal) ‘The output current is controlled by duration of the on sate of one IGBT.The contol {s 40kHz Only one IGBT ison atthe time. The minima ime gap between ow sates 3 us EKTRONIX 2252 leapiy ts gay [RIB aT PagesService manual DTD 250 ACDC General Description ‘The secondary middle taping of the transformer is the minus poe. ‘A choke in seis is smoothening the curent and sores estikng energy. ‘The bepiming andthe end ofthe traneformer is connecled to fart ecovery diodes where the cathodes are inked together at a heatsink which represents the plus pole. ‘The following shant delivers the actual current signal for control puspot. ‘The AC converter has four single module IGBTs. no contro signals apled all IGBTs are tured off -No output curent is posible! ‘Daring normal operation there ae citer control signals in straight polarity (wo IGBTs are ‘cnstwo are off Jr in reverse polarity. Just before changing the polarity the output current stvalue is decreased (or increased) 8 ‘certain value ftom which polarity is changed. ‘The change of polit is that fis thatthe arc Will not extinguish -even without using HIF- ‘anition. TeRTRONIK 2232 eres PFO] Ra = ch | : = ian we Ceerrr | | | 1 casa nd vag ring changing py ‘The final output curent contol (pulse width modulation) and protectin logic is done by hardware ‘The setvalue control and other logical funtion are realised with a micro-conrllr (B0C166) For very special applications this software may be adapted PageService manual DTD 280 AC/DC Component Description Sremedon IGBT 10041200 Pos or omaoleaty 421 nal tanner omit CB rman conta ‘meade EPROM end contol: Speed yew inv 2504 Saif AC Mok uber ARE feck rence cont int swich done for ORCconn gh equeey wie (ito masfomer OV/290V water ecler ly CD fr power euply “TEs; LED nomayon (ed at MST OKO 2a sO SIA«OV 100A; 12000 hatdge “2V Seeman 7OMA !!! DANGER !!! Mains voltage at PCB's and magnetic valve. PeesService manual DTD 250 AC/DC Description of the circuit boards MST Safety and current control (Puise width modulation) Bog tat aon) aa BET l PCB Tasks: Driving ofthe primary IGBTs “Control of Tl symetic “Corent and voltage measurement “Cutrnt contol “Start the aux-votage for HF-Start Supply Test volage (18..20V) for Lift Are “Supy of +/- 15 -Deiving the status and fault LED's Peyote down shut down Rost ote DC an ped efi) ‘asta modoltion on or high temp (60 ard); backto ie with 10 delay. ‘TAK; PCB for power supply ; fixed at PMST Input 42V AC ; PI trimmer for output setpiont ;The green LED is on, when OK. ‘Tasks: -Outpat (PWM) to HF transformer on main PCB for +/~ 15V soppy. Shut down ofthe supply in cate of overload. (agdfektve Integrated circuit) ISTW; PCB for output voltage and current treatment; fixed at PMST Sample snd bold circuits; measure eg attest PCB-Do not adjust! “Taske-Storage of current znd voltage after transitions wih 2OKE2 to reach smoother signals ‘for further processing, LETE; Power PCB at IGBT module ‘Contains the BRID (Start still voltage) circuit, primary curent sensor, symetrie monitor, ‘puch pull capacitors and connections forthe main transformer 1. ‘Tasle Interconnection between Mains estificr, CS Transformer TI, IGBT and PMST PCB, ASUP; Analog support ‘This PCB isan arrangement of analog circuits which carcterizes the control function of certain weldig modes (¢4, TIG , MMA welding ) ‘Fasis:-Adap the conyolsgnal ace. to welding mode. “Realization ofthe “ae force” for MMA welding Incase of power supply failure a the PMST please tae out his PCB and check again Ifthe faut disappears, exchange the ASUP . PageService manual DTD 250 AC/DC Description of the circuit boards PREW; Micro controller board (F202) Tasks: Control of all ogcal functions; exopeation mode Cento of al time netions, eguupslope time Creating the current set vals “Creating the frequency forthe ‘AC operation and control of the Le AC-block Ui ermlep -Start and stop ofthe HF generator i and magnetic valve 15 X51 Jumper norm. at X 8 (240A), X7 (400A), X6 (resistor load) ‘Test points at XS: GND: 13; WSVi12, HSVi14,-15VII5 ‘For testing the magnetic valve disconnect X9 and bridge 5 and 6 (mains vallage!!) For testing the HF init bridge | and 2 atthe cable plug side. KOMM; AC- management PCB; Tas: -Daiving ofthe four IGBTs -Contoling the speed ofthe fans. (dle and fast when tmp is higher than 60 grat GBT) Shut down at high temp. atthe IGBTs (more than 80 rd) Polarity change logic using the I sence signal. Atte left side of the PCB there ae the four channel controling the IGBT's ‘The ative ones are indicated by a green LED Either the inner or the outer ones ar on! Incase of over-volage or temperature a red LED is ighted up. Defective temperatur sensors can be detected by shortirnit atthe PCB. left mile connector) ‘The green LED on the *add on PCB" shouldbe on. Tho yellow LED indicates that the fan's ae at idle mode, HFZP; HE ignition unit ‘Task: “Generates at demand HE-pulses o ignite the are without touching the workpiece with the elekrode, ‘An azilary winding on the ansin transfornr (6O0V AC) supply this ait when matin is switched on. For testing you may bridge X 4, 1 & 2 to obtain HF ashe ouput ofthe HF choke, (upto TV) PogeService manual DTD 250 AC/DC Test beard “Bosed 4 Bovey a Reveal SEE I} ‘With the tetboard (0 301 005 111) the unit fimctions canbe checked without sing the sicrocontrollr PCB.(PREW) (Connect X1 and X2 othe PMST-PCB and X3 to KOMM-PCB, Switches: ‘TEST (Lif arc test volage ;18..20V) ‘ff at upside position. -MOD (modulation on ;60-80V) ‘off a upside position. [BRID (ausilary vohage for HF-start;80-100V) off at upside position. Polaritt(polaiy ) ‘mings at upside positon. LED information: New Tndicates—4/-15V OK! Beret indicates ready for operation MOD cin indicates modulation on; Volage at output! re indizates setpoint to high for more than two soconds ‘Temp _—indicatet_—_tomperature to high or open circuit ver indicates over or undervoliage (320_.470V) ‘SiirPMST indicates dnturbance at PMST-PCE Sie KOMM indicates disturbance at KOMM - PCB ALX4: Testpoins FROM-KOMM. platy signa ;5V oF OV REGAUS ‘uiput of analog controller before PWM modulation; 0..5V. ‘UINORM E1V=>1004; U: 1V-> 10V at output Sollwert Setpoint 0..5V => 0..500Amps.Service manual DTD 250 ACIDC Faultfinding WARNING! HIGH VOLTAGE ll PCB's ed ecuonie components possible when isis tamed on! Pee reer 'o grams [Symtom [Cause Renal No fncton | Detective mains cable Replace mans cae lg or socket jg or socket nai sich iain etch _ ower soppy st PMST PMsT Ro Tanaton; Mala fe | Short cei ti GBT mode [Replace DC-Bloek ows when machine ie ured on. _ _ [Overcmparatar LED on [Open cic or earth const ta | Check the PIC (70 100 Oem for no reason” | Pc resistor. ambien teperatre) replace | the fauity one. _ [Defective PMST_ Replace PMST No ps Hwa Magna valve dk Replace sas on [PREW defekt Adj ote Goat {Defective fon panel Replace panel are not recognized PREW Controle “ang up* Mains of /on [No reaction when torch [Defective Torch Replace baer pressed Remo socket PCB ‘ont ancl | PREW. a No HF Defecve DC Block [Revise PREW HE-Coll | 600 V Som main wafo missing _|Chec when mod is on. THF spares inside the machine [Check {Eg stcenral connecior | Ho start pout low adjisd | Test at mille positon No pues IGHT half” [Detsoive MST Reais bridge 4 ~ [No load valiage # DC |Delecive KOMIM RTGBT are |Checkrepaee ouput burnotat [off orloose connection mine Ye _| Machine ras hist —|IGBT a AC Boek hort cet om KOMM before rest (+o _ -15V) ire docs not wock — [Beteoive PST epace PaesService manual DD 250 AC/DC Faulfinding Possible faults: ‘Some Logi funktons not work or unexpactedoperaton Setinge atthe Wort pana re not ecognsod Nemodulaion Logic none do net work Curent sting - nt corect Nemodutson. Fro funeion. (Gesvahe mani, Curent seting alway at minimum. Fron pane LEDs ar of immed ofickaig Unusual a noe: Liar doesnot wor; Dan not funning at a Medulation does nt sar. Temp faut on for ‘no reaeor Front paral LED's are of cinmed ortckenng Main use bows when the machine's swéched on HF oice crbut no spare at xc porno HF Nona lea vttage when mediation sen ‘Temp LED romaine on ns not unning but app. 150V of 230V AC are at the AC fan's rot ning tal niy ne platy or na weling is possbe. Moduiston doesnot tat Noo oa votage at trina, but at DC Block ote (iy one olay or no welding s possible Stor-droutor AC block No water crculaton; Row switch does nct operate; Fuse Blown Mocdaon doas nt start Page 10‘Service manual DTD 250 ACDC Faultfinding =pTD250 = 010s 132 oxo 01005 199 CC ‘01005 134 OKC we ‘Troubleshouting yrange DC mange AC hock lock 301 005 138 ‘301 005 139 t Tana t foorietaane Ifthe mains fuse blows when the machine is switched on , itis adviced to change the whole DC - Block Page 11Service manual DID 250 ACDC Faulfinding if modulation starts at mma postion, But netffom torch tigger trace signals acc. to diagram. 301_005 080 a x9 PT gs2|2 18 Renote Socket arpa panel (Central connectors are Sand; JOKC connectors are A and B numbered. [GND signal at X4 pin 1. Tf remote corirol does not workor the current setvalue fs ahvays at minimum, trace signals acc. to diagram. 01 005 031 20t_006 080 Bae ys £ sees ad aw else Is sl | — | Renoie Soke grey ar ‘Measuring poins ..see next page ! Page 12Service manual DTD 250 ACIDC Faulfinding If control from the Font panel doss not work, check ace 10 diagram the SV supply.The shown circuit from current int ie simular to al feedback signals! Control panel PRE % ae + a v4 Frecueney vs08——_Ramate sets aod Current? Yee Upsiope Bown-siope Vies — Sotstaey cure Vets Gas prev pout tow" Vico inom Vise Sart/end Soment yao Unorm Vat2 Banco! ‘Signal wth wo informations are switched over fo the microcontroller 36 heya Page 13.Service manual DTD 280 ACIDC Faulfinding Mains distribution ofa DTD 250 AC/DC Ifa fanis not running or the magnetic valve is not opesing.please check supply vollage ace-diagrm. ! Danger! 230V AC to Ground ..- do ot touch ! ‘Tost with Mains off Resitance of Manctic vale app.: 110. Ohm ‘DC block fan_app.: 150 Ohm ‘AC block fan_spp.: 630 Ohm (both 315 Ohm) ry 2 rere | 424)" a AC~Block @) Fa X21 wiz xa To uater cooler PagelService manual DTD 250 ACIDC Fauktinging Signals between machine side and control PCB (PST X1) ‘The lift ae teat voltage (US- and US app. 18V) is stated from the controller at PREW via V226.The current is led to max 20mA st shortcut condition. Measuring points... nest pagel IE Fic a3 Peto Signals between IGBT"s and control PCB (PMS X 8 & 6) “The circuits for diving the IGBT"s are galvanic separated to the electronics but they se at MAINS POTENTIAL! “Test wih Mains off: Disconncced X8 and X6Moasure with an Obrmmeter atthe geen plug If the resistance isles than 9K, the IGBT is defektve.Service manual DTD 250 ACIDC Faulfinding ‘Signals between PCB's ,PMST, LETE and machine side. {fhe Temp LED stays on dsconneced X12 - the PTC resistor should have 60.100 Ohm tambien temperate and no contact fo ground. All other channel at that pg should be ‘bridged. (0 Ohm) BRIO Syretrie control ux. Uoltge on varz usa vant o13 “The I sence transformer can be checked by measuring the resistance at the disconnected pag 1XSItshoold have app. 3 Ohm. ‘With a seope set 19 AC at V412 anode to GND the primary curent of T1 canbe soz, ‘Au wolage i used t support the HF-igntion and sated from the controler atthe PREW ‘will BRID signal ‘The symetie control can only be checked at extreme welding conditions. rust Ta oa] Po oe] po] Bee] une var co O vas 3d an ™ ——e com AO = PagetService manual DTD 250 ACIDC Foultfinding Signals between PCB's ,KOMM,PREW and machice side. If he AC function i disturbed or only one polarity welding is possible, check ac.to digram. Meas pont se page 13 . F257 BPEL RB + [= | 5 Isence] a z lo RRS TL cow 2x 2208 re TIS 4] x3] & ‘The MOS ‘Transsior V301 is controling app.400V DC at C9, Voltage pocks at the + /- ban fom the AC-bock exceeding that level are cutoff by diode VS. Peeks below that level are needed for resriking the arc after polarity change ‘The signal fom I sence i a picture ofthe main curent othe workpiece and wsed to detect the 20 crossing at polarity change. GND at X3.1 ie ooo “ Py x4) I) FETS OMIM, ‘The diving circuits forthe IGBT's are simula tothe DC- block ones. (page 15) 22) Signal lew: + or- 131015. fag a Ci™,,, 8 =. 10 Pagel?Service manual DTD 280 ACIDC Faulding Time sequence at “Pilot function mode a & 2, Bae carentvovar sein 0 3SA Bie care! 1 then $0% of caren 1 4. Uplope tin aut Sot panel 010 10s. 5 Main current (came 1) jus at font panel; $10 250, 6. Current 2 :adjust at front pane! ;10 to 90% of current 1. 7. Downslope time, adjust at front panel ;0 to 10sec. 8 End coment; adj R11; Oto SSA; preset 5A, 9. Ga posto at font panel 0030s PCB RI2 RIO RI Front panel PagelService manual DID 250 ACIDC Faulfinding [Restart after major repair at DC -Bock ;No need after exchange ! ‘Disconnect the plug X1 ofthe ignition unt. Connect the testboard 0301 00S 111 to the PMST ‘and KOMM PCBS. Switches at off postion. ‘Supply power side from aga. sep. adjustable transformer (iil et to 2e0) and electronic ‘wih nominal vole. ‘Check the contol voltage at both transistor inate. (-15V) Sitch MOD to on and sein more than ro. Check the contol ollage a both transistor inputs. Compare with picture on page 3. Sitch MOD off [Look at KOMM PCB. Change the polarity switch and watch that to LED's are changing. Tncrease slowly the voliage from 0 to 400'V atthe power side and watch the input current. (hort cient?) ‘The overfunder vollage LED should tam off after approx. 20 se. (Connect an instrument parallel with 4K7, SW to the out terminal, ‘Control 15-17 V when TEST switch is tuned on Switch off again. ‘Control 60-65 V when MOD switch i ted on. ‘Control 85-50 V wien BRID is ational swiched on Switch both off sgaintDiscoanect instrument, ‘Disconnect adjustable transformer and reconnect the maschine to normal conition'(400V fom smains supply) ‘Switch MOD on snd adjust setpoint i IV => 100 A Toit MMA welding, Disconnect Test PCB and hock on PREW PCB. (While machin is off) ‘Reconnect Ignition unit At XI cableoutet ontop! ‘Test all fnctions. Basle tests: “lf the Temp-LED is remaining on you may shortcrcuit the faulty sensor for tet. “In case a power IGBT i faulty, normally all contacts are shortcut which can easily be checked by ohmmeter. When "no load voltage” is obtained atthe DC-part but nota the out terminals check the AC ‘Block IGBTs. (two IGBTs have to be on) “IE fit on the powersde occurs please check al diodss ofthe mains rectifier and the fonction ofthe mains switch! “Check the voliage with a scope at KOMM XI, 5 and 8 when the modulation i on should not exced 450V! Pagel9Service manual DTD 250 AC/DC ‘Exchange parts: 'G Paustrcs Cee 005 090, Faulfinding How to eschange parts; Positions see next paget ‘Mark 3Sqmm cables when disconnected! la top handle pos 2 alse) anew op cove Paews a ford] 2 oral fom art es tht ory agape Now dconect ten eis fom adj pun se. Tike eu ¢ sows oni r Top apap (dws) semove tp cove aews af fea et boreal chine eu the oe oni ped "Now diacrmec lees fom FCB and emore pon ap Ra Ce pS aH 3 bora om mane aide td he ote os au peel Tap lane pox en) rapove ep cove @ daews at Fe) on -cabe om mosis ae und he oer ows at panel ‘Now. disconnect awies fen FOB and noe ee poston, jater cooler 1301 005 140 Topline pos (sions) emove tp cove Gales a Sah Erbor-ate fom macine ade td he oer fos aj peel op anal pos eva) reve pene Gao a a) et bor eae mcs sie andthe other om aj pared 9-1, i, [band Askewsin he omer etcangeServise manual DTD 280 ACIDC Housing overview Page?Page 43 7