After Sales Procedure

Transcription

1 After Sales Procedure I N V E S T I N T H E F U T U R E 1/20

2 Table of contents : I. OVERVIEW OF FEATURES OF THE MACHINE II. CIRCUIT PRESENTION a) Main board b) Primary card c) Secondary card d) Microcontroller board e) Power supply unit f) Circuit board g) Display board and keyboard III. ELEMENT INTERCONNECTION a) Circuit diagram b) Wiring IV. DIAGNOSTIC TROUBLESHOOTING a) Machine does not start b) Machine starts but there is no current c) Machine starts but no adjustment or change of mode is possible d) The thermal protection LED stays on e) No HF f) No gas g) No current in AC mode I N V E S T I N T H E F U T U R E 2/20

3 INVERTER Technology, GYSMI 207 HF AC/DC is controlled by micro-processor with digital control panel. TIG Start-up: I. OVERVIEW OF FEATURES OF MACHINE - 2 possibilities: HF contactless or contact LIFT - Adjust Ideal Position: The system helps you to position the electrode before the current rises. A very low intensity is issued, acting as a beam. (Available in 4T and 4Tlog) 3 functions of Torch trigger: - 2 Times - 4 Times - 4 Times "LOG : The operator chooses between two welding currents (hot current and cold current) at any time by a short pulse on the trigger 3 processes AC/DC : - TIG...Common settings AC and DC: pre-gas / current rise / welding current (1 or 2 possible mode intensities 4Tlog)/post-gas/ current decrease. Specific adjustments AC: Balance (20 to 60 %) cleaning / penetration Frequency to focus the arc precisely (20 to 200 Hz) Manual or automatic (AC Easy function) - TIG Pulse...Mode sets the hot/cold current and frequency. Mode Easy Pulse: operator determines the average welding current. The machine automatically determines the frequency, the hot/cold current. - TIG Spot This function allows spot-welding of work piece to fix it in place before completing the full weld in TIG mode 5 Memory Settings: To save and recall selected TIG parameters. MMA Welds all steels, stainless steel, cast iron, rutile or basic electrodes easily. In addition to the Anti-Sticking, this product offers: Adjustable Hot Start: Assists the start of TIG welding for different metals (Hot START low: for thin sheets - Hot START high for difficult metals to weld : dirty or oxidized) Adjustable Arc Force: for better penetration and to prevent sticking. PROFESSIONAL DEVICE Ventilation Tunnel to protect the internal electronics from dust. INTEGRATED ) PFC (Power Factor Correction) The PFC regulates and uses the power supply more effectively. With this technology, Gysmi 207 works on a simple 16A- 230V plug, even during heavy use, a against 32A-230V for an equivalent machine without PFC. Ideal for working on long extension leads or generators. I N V E S T I N T H E F U T U R E 3/20

4 II. CIRCUIT PRESENTATION a) Main board (ref GYS.97151C) PFC Device HF Card Power supply unit Microprocessor The main board serves as a base for the device, and is attached to the top of the primary and secondary cards. The card also holds the HF card, the Power Supply Unit and the Microprocessor. The PFC (Power Factor Corrector), the transformer and Hall Effect sensors used to measure current, are all located on the main board. I N V E S T I N T H E F U T U R E 4/20

5 b) Primary Card (ref GYS.97152C) D22S02 Thermal protection of the primary card D21S02 Thermal protection of PFC D41P01 D41P02 PWM signal Indicator D11P02 Voltage Indicator D51P01 Energized +HTMMA D32P12 Indicator: 16V D43P04 PFC operation Indicator Normal operation of the device: => connect the device to the mains, open hood. THE UNIT IS POWERED, ELECTRIC HAZARD D11P0: voltage indicator => always on when connected to the mains power. D51P01: voltage indicator +HT => always on once the machine has started. D32P12: 16 volts DC on => always on once the machine has started. D41P01 & D41P02: PWM signal Indicator => always on MMA, TIG and when the trigger is activated D43P04: PFC operation => flashes when the PFC is operating. D21S02: thermal protection PFC => shows the thermal protection of PFC, orange LED lights up front when on. D22S02: thermal protection of the primary card => indicates the thermal protection of the primary card, orange LED lights up front when on. I N V E S T I N T H E F U T U R E 5/20

6 c) Secondary card (ref GYS.97051C) D21S01 D15SO2 Com 1 D16S02 Com 3 D17S02 Com 4 D18S02 Com 2 D35S02 Indicator VCC down D35S03 Indicator VCC top 2 D35S04 Presence VCC top 1 D35S02: Indicator VCC down D35S03: Indicator VCC top 2 D35S04: Indicator VCC top 1 D13S2 et D13S03 Indicate the directionof current flow =>Always on. => Always on. => Always on. D21S01: position always on MMA D21S01: MMA position, only lights D13S03. MMA DC (trigger activated) TIG AC (trigger activated) D15S02 : com when alternating - D16S02 : com when alternating + D17S02 : com when alternating - D18S02 : com when alternating + 1 = LED lights ; 0 = LED off I N V E S T I N T H E F U T U R E 6/20

7 d) Microprocessor card (ref GYS.97154C) This card receives the majority of device information and controls functions and signals for other boards in the machine. D12S01 à D12S07 Unused D42S01 PFC Control D43S01 Voltage control relay D44S01 Control Power Relay D46S03 Control valve D42S01: PFC Control D43S01: Voltage control relay D44S01: Power control relay => always on => always on => always on D46S0: Control valve => only lights up when the gun trigger is activated D12S01 à D12S07: unused. I N V E S T I N T H E F U T U R E 7/20

8 e) Power supply unit (ref GYS.97155C) This card receives the mains voltage and delivers the necessary voltages to other boards of the unit. It creates voltages of -15V, +15V, +24V. This card also supplies the voltage used by the microprocessor. There is a second power supply on the primary card. D11P02 16V Primary Indicator 13S02-15V Secondary Indicator D14S01 +15V Secondary Indicator D14S02 24V Secondary Indicator D11P02:16V primary Indicator D13S02: -15V secondary Indicator D14S01:+15 V secondary Indicator D14S02: 24 V secondary Indicator => always on, whatever the mode used => always on, whatever the mode used => always on, whatever the mode used => always on, whatever the mode used I N V E S T I N T H E F U T U R E 8/20

9 f) Circuit board (ref GYS.97159C) This card supports multiple functions of the device; it receives information from the microprocessor. It provides control of the solenoid and fan, and generates the RF signal that is then amplified by the transformer. D14P05 HF Control D44S01 Fan Power Indicator D31S02 Valve Control Status of LEDs for the different modes of the device: MMA Tig lift Tig HF trigger off trigger on trigger off trigger on D14P D44S D31S = LED lights ; 0 = LED off I N V E S T I N T H E F U T U R E 9/20

10 g) Display board (ref GYS.97061C) and keyboard Keyboard of the 207 AC/DC réf GYS The 207 display board is connected to the keyboard and exchanges information with the microprocessor; it serves as an interface between the user and the machine. I N V E S T I N T H E F U T U R E 10/20

11 III. ELEMENT INTERCONNECTION a) Circuit diagram : I N V E S T I N T H E F U T U R E 11/20

12 Wiring Secondary PCB 5 4 Actions Parts tools Additional Information Connect The ribbon cable on the 1 microprocessor board Clip Connect screw Pass fix the DIN connector the fan on the HF board Sheathed cable of the choke(self) Cable pass Texas cable (+) Secondary cable to the PCB with spacer and screws Pawl tip 17 Screwdriver tip Align the lug Follow order: terminal / brass washer / spring washer / screw I N V E S T I N T H E F U T U R E 12/20

13 Turn the post to make the connection to the other side nd connecter Primary PCB I N V E S T I N T H E F U T U R E 13/20

14 Clip the terminal 90 of the line on the primary board and the other terminal on the main board. (Marking ~ on the pcb) Clip the terminal 90 of the line on the primary board and the other terminal on the main board (Marking ~ on the pcb) Clip the terminal 90 of the line on the primary board and the other terminal on the main board (Marking ~ on the pcb) Clip the terminal 90 of the line on the primary board and the other terminal on the main board (Marking ~ on the pcb) Fix the cable/wire of the self on the primary adapter Fix the cable/wire of the HF HT (95 281) on the circuit board Connect microprocessor board ribbon cable: pay attention to the orientation Link layer/ribbon cable with a clamp cables 8 9 Screw the ring of the self HF HT on the Texas (-) (washer on the terminal) using a ratchet with 17 - bit (2 son) Clip the terminal 90 of the line on the primary card and the other terminal on the earth rivet. I N V E S T I N T H E F U T U R E 14/20

15 IV. DIAGNOSTIC TROUBLESHOOTING All these checks should be done while the machine is turned OFF. To power the electronic cards you must connect an external power supply 60V DC directly to the power cable and disconnect the fan. Consumption of the device at a 60V Ialim 0.12A to 0.14A Power off Ialim 0.25 TIG DC or AC Mode Ialim 0.27A to 0.30A MMA mode a) The machine does not start If your device does not switch on when you press the button on the keyboard, you must: - Check that the mains supply voltage is correct. U Check voltage : U = 60V DC If the voltage is zero, remove the power cable from the machine (ref 21480) - Check the overall condition of the various electronic circuits (identify if there are damaged components, disconnected cables/wires etc...) - Check power supply to the power supply card : I N V E S T I N T H E F U T U R E 15/20

16 Check for damaged components on the card. During normal operation of this card, the 4 LEDs are lit. If is not the case, you must replace this card ref.97058c. - Check that the keyboard is connected to the display board Make sure the cloth keyboard is connected to the microprocessor board. b) No power output - Control of output voltage Connect the machine to the mains supply and select MMA mode, the fan will start. Measure (with a multimeter with a voltage of 60V) at output of the Texas connector. If the test is ok, check condition of the machine accessories. - Control of the power block columns of the primary adapter. I N V E S T I N T H E F U T U R E 16/20

17 Start by removing the cables, connectors and ribbon cables that are on the board in order to remove it. Remove the 11 screws with a torx 25 screwdriver and be careful not to damage the connectors that link the two SMI boards. Check the stability of the primary block columns. Change the block if one or more columns are broken. - Control of the power block columns of the secondary card I N V E S T I N T H E F U T U R E 17/20

18 Same stage as the primary card, start by disconnecting everything connected to the card to be able to remove. Remove the screws with a torx 25 screwdriver to take out the card. Check the stability of the secondary block columns. Change the block if one or more columns are broken. - Control of PWM signals Plug in the machine, put in MMA mode and observe the primary card. Check that the voltage reaches the primary card and the diode bridge has not shortcircuited. Observe the presence of the output signals of Tip, if the signals are absent, replace the microprocessor board. I N V E S T I N T H E F U T U R E 18/20

19 c) The machine starts but no adjustment or change of mode is possible This issue indicates that there is a problem with the communication between the keyboard device and the microprocessor, which manages various functions. Firstly ensure proper connection of the ribbon cable to the keyboard display board, and then the ribbon cable between display board and the microprocessor board. If all connections are good, replace the display card (ref 97061C) and microprocessor (ref 97154C). This problem may also due to mechanical failure of the power supply; it creates a bad representation of the output voltage on the microprocessor blocking functions. Check that the columns of the power units are not broken (same approach in the previous paragraph). d) The orange LED lights Make sure the machine has finished its cooling cycle, wait at least 3 minutes before further testing. On the primary card, check that the two LEDs indicating a thermal fault are extinguished. Otherwise replace the primary card (ref 97590). If both LEDs are off, the defect must come from the microprocessor board that must replace (ref 97154C). e) No HF First connect the machine, Select HF Tig mode, and connect the torch to the machine. Press and hold the trigger for at least 3 seconds; check that the card is receiving the HF information to generate the HF. For this, the LED should light up when activating the trigger. Check the relay RL13X01. If the LED is lit and that the machine does not generate HF, replace the HF card (ref 91159C). If the LED does not light up, the microprocessor fails to control the HF and should therefore be replaced (ref 97154C) I N V E S T I N T H E F U T U R E 19/20

20 f) No gas To check whether your machine sends the gas, put in Tig mode (lift or HF) and pull the trigger of the torch. Observe HF card, the LED Indicator for the solenoid valve will be activated when the trigger is pressed. If the LED does not light, replace the microprocessor board (ref 97154C) because it no longer controls the output of gas. If the LED lights up, but there is still no gas, check the voltage reaches the solenoid. If there is 24V output in the cables, replace the valve (ref 71542), otherwise replace the HF card (ref 97159C). g) No current in AC mode If your device works correctly in MMA, TIG DC mode but it does not supply Tig AC current, this means that there is a problem on the secondary card. Replace the card and its power block (ref 97051C). I N V E S T I N T H E F U T U R E 20/20