SMALL INVERTERS MMA 85A

CEMONT S1000

Loc. Casalmenini - 37010 Rivoli Veronese - Verona -Italy

Tel. (+39). 45.6208901 - Fax (+39). 45.6200041 - Txl 481294 CEM I

1104
 REPAIR SCORES

SERIES: 1104 Small Inverters (S)MMA 85A Fixed Points 20

Repair code Repair scores

01 Control board 9
11 Switch 2
14 Electric fan 4
28 Detached wire repair 4

Pag. 2 1104
 SMALL INVERTERS MMA 85A GB

1.0 REPAIR INSTRUCTIONS 2. Check on all the harnesses the insulation of

the cables and the state at the connection
points.
1.1 GENERAL CLEANING
Remove the machine shell and clean carefully 1.3 CHECK OF THE MAIN COMPONENTS WITH
with compressed air. TESTER (OHMMETER) ON THE CIRCUIT
REF. 1
1. Check for the presence of short circuits on the
1.2 MACHINE: VISUAL INSPECTION rectifier bridge and the correct value of the
1. Check the general conditions of the electronic power resistance (fig. 3)
circuit ref. 1, particularly:
• the varistor (fig. 1) if it presents bursting
marks
• the state of the levelling condensers C29 and
C30, check if there are swellings or breaks
on the container

FIG. 3 REF. 1

2. IGBT of the primary circuit and diodes of

recycle: test points G-C, G-E, C-E of compo-
FIG. 1 REF. 1
nents 1 and 2; points A-K of components 3 and
4 (fig. 4)

1
4

FIG. 2 REF. 1
2
FIG. 4 REF. 1

• check for the presence of cracks or breaks

on the welds of the following components: 3. Diodes of the secondary circuit: check points
• transformer T1 A-B of diode 1 and points A-C of diode 2 (fig.
5).
• impedance L2
• the presence of burn tracks or electric If there are short circuits or faults during these
discharge marks on the printed circuit tests, replace the electronic circuit.
In case of faults, replace the electronic circuit ref. 1

1104 Pag. 3
GB SMALL INVERTERS MMA 85A

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Pag. 4 1104
 SMALL INVERTERS MMA 85A GB

B
C A

FIG. 5 REF. 1

FIG. 8 REF. 1
1.4 CHECK OF GENERATOR OPERATION
WITH OSCILLOSCOPE AND VOLTMETER 2. Disconnect the feeder; set the oscilloscope
1. Connect a feeder on the zener VZ2 with GND with a range of 1V/Div and connect the probe
on the anode and supply with approx. 15Vdc; X100 between points M and P (fig. 9); connect
set the oscilloscope on a time base of 5 uS the machine to the power supply, switch it on:
and a range of 0.5 V/Div with probe x10 and
verify:
• the presence between points: E (GND) - A
(probe) and F (GND) - B (probe) (fig. 7) of
the waveform shown in fig. 8: if the waveform P
differs from the one in the figure or it is not
present, the electronic circuit is broken.
Solution: board replacement ref. 1.

A E
M
FIG. 9 REF. 1

• the motor fan starts up, and after approx. 2

seconds a wave will appear as in fig. 10.

B F

FIG. 7 REF. 1

FIG. 10 REF.1

1104 Pag. 5
GB SMALL INVERTERS MMA 85A

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Pag. 6 1104
 SMALL INVERTERS MMA 85A GB

• check with a voltmeter that the output vol- 9. Disconnect the machine from the resistive load
tage is approx. 55Vdc (see test specification and wait until the machine starts to work again
point 2). (the thermostatic protection led turns off).
• If the wave form does not appear or the 10.Carry out MMA welding tests at maximum cur-
output voltage is not correct, replace the rent (one electrode)
electronic circuit ref. 1
Carry out the final test after the repair.

2.0 FINAL TEST U

1. Carry out the safety test according to our ope-

T
rative instruction N. SLL12, before proceeding,
act as follows:
• on the electronic board (ref. 1) short-circuit
points U, T and a rheophore of the primary
circuit of the transformer (fig. 12)switch on PRIMARY CIRCUIT OF
• switch on THE TRANSFORMER

• short-circuit the feeder plug FIG. 11 REF. 1

• short-circuit the output dinse..

After the test remove all the short circuits and switch
off.
2. Connect the generator to the power supply
(230 Vac), switch it on and check if the voltage
of the outputs is 55 Vdc (+/- 5%): switch off the
generator.
3. Connect the generator to the resistive load: the
load must be regulated so that the voltage on
the load, with maximum current, is between
20V and 24V. Apply oscilloscope probe as in
fig. 8
4. Set the regulation knob to the centre of the
dial, switch on the generator, turn the knob to FIG. 12 REF. 1
the maximum welding current and read with
the amperometer the maximum current indica-
ted on the technical table with +/- 5% tole-
rance. You will see on the oscilloscope a
waveform as in fig. 12. T
5. If the current readings differ, use the trimmer T
(fig. 13) to obtain the correct current value.
6. Short-circuit the load and verify that after 1,5
sec. the current descends to approx. 35A.
7. Regulate the resistive load to measure the
minimum current (8A - 20V), set the minimum
current on the frontal panel and check with the
amperometer that there is a value lower than
the one indicated on the technical table.
8. Disconnect the probe, switch off the generator
FIG. 13 REF. 1
and with the load to the maximum current, let
the machine work at the greatest capacity till
the thermostatic protection intervenes (the
thermostatic protection led turns on).

1104 Pag. 7
GB SMALL INVERTERS MMA 85A

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Pag. 8 1104
 LISTA PEZZI DI RICAMBIO - SPARE PARTS LIST - PIÈCES DÉTACHÉES - ERSATZTEILLISTE - LISTA DE LAS PIEZAS DE RECAMBIO

06

11 09 72 01

56

12

S 1000
08 14 10

1104 TAV. 1A
 LISTA PEZZI DI RICAMBIO - SPARE PARTS LIST - PIÈCES DÉTACHÉES - ERSATZTEILLISTE - LISTA DE LAS PIEZAS DE RECAMBIO

LISTA RICAMBI S 1000 230V

RE
CODE DESCRIZIONE DESCRIPTION DESCRIPTION BESCHREIBUNG DESCRIPCIÓN
F.

ELEKTRONISCHE CIRCUITO
01 800022451 CIRCUITO ELETTRONICO CIRCUIT BOARD CIRCUIT ÉLECTRONIQUE
SCHALTUNG ELECTRÓNICO

ANNEAU D’ACC. DE LA SAN-

06 800018138 AGGANCIO CINGHIA FITTING BELT KUPPLUNG ENGANCHE
GLE

08 800043592 CAVO DI ALIMENTAZIONE POWER CABLE CABLE D’ALIMENTATION NETZKABEL CABLE DE ALIM.

09 800018908 PRESSA CAVO CABLE CLAMP SERRE-CABLE KABELSCHELLE PRENSACABLE

10 800005503 BLOCCHETTO DI BLOCK FIXING GUIDE CARTE BEFESTIGUNGS- BLOQUE DE

FISSAGGIO LAGER FIJACIÓN
10.1 090020135 INSERTO INSERT INSERT EINSATZ INSERTO

11 035038041 INTERRUTTORE SWITCH INTERRUPTEUR SCHALTER INTERRUPTOR

12 800019348 RACCORDO DINSE DINSE COUPLING EQUERRE SUPPORT DINSE VERSCHRAUBUNG EMPALME DINSE

VENTILADOR
14 073010037 MOTOVENTILATORE ELECTRIC FAN MOTOVENTILATEUR MOTORLÜFTER
ELÉC.

19 800041050 CINGHIA BELT SANGLE GÜRTEL CORREA

56 090015031 MANOPOLA KNOB VOLANT POIGNÉE DREHKNOPF VOLANTE PERILLA

72 023065206 SUPPORTO SUPPORT SUPPORT AUFHÄNGUNG SUPORTE

LISTA RICAMBI S 1000 115V

Ref. Code DESCRIZIONE DESCRIPTION DESCRIPTION BESCHREIBUNG DESCRIPCIÓN

ELEKTRONISCHE
01 800022531 CIRCUITO ELETTRONICO CIRCUIT BOARD CIRCUIT ÉLECTRONIQUE CIRCUITO ELECT.
SCHALTUNG

ANNEAU D’ACC. DE LA
06 800018138 AGGANCIO CINGHIA FITTING BELT KUPPLUNG ENGANCHE
SANGLE

08 800044035 CAVO DI ALIMENTAZIONE POWER CABLE CABLE D’ALIMENTATION NETZKABEL CABLE DE ALIM.

09 800018908 PRESSA CAVO CABLE CLAMP SERRE-CABLE KABELSCHELLE PRENSACABLE

10 800005503 BLOCCHETTO DI BLOCK FIXING GUIDE CARTE BEFESTIGUNGS- BLOQUEO DE

FISSAGGIO LAGER FIJACIÓN
10.1 090020135 INSERTO INSERT INSERT EINSATZ INSERTO

11 035038041 INTERRUTTORE SWITCH INTERRUPTEUR SCHALTER INTERRUPTOR

12 800019348 RACCORDO USCITA COUPLING RACCORD VERSCHRAUBUNG EMPALME

VENTILADOR
14 073010037 MOTOVENTILATORE ELECTRIC FAN MOTOVENTILATEUR MOTORLÜFTER
ELÉC.

19 800041050 CINGHIA BELT SANGLE GÜRTEL CORREA

56 090015031 MANOPOLA KNOB VOLANT POIGNÉE DREHKNOPF VOLANTE PERILLA

72 023065206 SUPPORTO SCHEDE SUPPORT SUPPORT AUFHÄNGUNG SUPORTE

1104 TAV. 1B
 LISTA PEZZI DI RICAMBIO - SPARE PARTS LIST - PIÈCES DÉTACHÉES - ERSATZTEILLISTE - LISTA DE LAS PIEZAS DE RECAMBIO

06

11 09 01

56

12

14 72 S 1000 REV.1
08

1104 TAV. 2A
 LISTA PEZZI DI RICAMBIO - SPARE PARTS LIST - PIÈCES DÉTACHÉES - ERSATZTEILLISTE - LISTA DE LAS PIEZAS DE RECAMBIO

LISTA RICAMBI S 1000 230V

Ref. Code DESCRIZIONE DESCRIPTION DESCRIPTION BESCHREIBUNG DESCRIPCIÓN

ELEKTRONISCHE CIRCUITO
01 800022451 CIRCUITO ELETTRONICO CIRCUIT BOARD CIRCUIT ÉLECTRONIQUE
SCHALTUNG ELECTRÓNICO
ANNEAU D’ACC. DE
06 800018138 AGGANCIO CINGHIA FITTING BELT KUPPLUNG ENGANCHE
LA SANGLE

08 800043592 CAVO DI ALIMENTAZIONE POWER CABLE CABLE D’ALIMENTATION NETZKABEL CABLE DE ALIM.

09 800018908 PRESSA CAVO CABLE CLAMP SERRE-CABLE KABELKLEMME PRENSACABLE

11 035038041 INTERRUTTORE SWITCH INTERRUPTEUR SCHALTER INTERRUPTOR

12 800019348 RACCORDO DINSE DINSE COUPLING EQUERRE SUPPORT DINSE VERSCHRAUBUNG EMPALME DINSE

VENTILADOR
14 073010037 MOTOVENTILATORE ELECTRIC FAN MOTOVENTILATEUR MOTORLÜFTER
ELÉC.

19 800041050 CINGHIA BELT SANGLE GÜRTEL CORREA

56 090015031 MANOPOLA KNOB VOLANT POIGNÉE DREHKNOPF VOLANTE PERILLA

72 800019504 SUPPORTO SUPPORT SUPPORT AUFHÄNGUNG SUPORTE

LISTA RICAMBI S 1000 115V

Ref. Code DESCRIZIONE DESCRIPTION DESCRIPTION BESCHREIBUNG DESCRIPCIÓN

ELEKTRONISCHE CIRCUITO
01 800022531 CIRCUITO ELETTRONICO CIRCUIT BOARD CIRCUIT ÉLECTRONIQUE
SCHALTUNG ELECTRÓNICO

ANNEAU D’ACC. DE LA
06 800018138 AGGANCIO CINGHIA FITTING BELT KUPPLUNG ENGANCHE
SANGLE

08 800044035 CAVO DI ALIMENTAZIONE POWER CABLE CABLE D’ALIMENTATION NETZKABEL CABLE DE ALIM.

09 800018908 PRESSA CAVO CABLE CLAMP SERRE-CABLE KABELKLEMME PRENSACABLE

11 035038041 INTERRUTTORE SWITCH INTERRUPTEUR SCHALTER INTERRUPTOR

12 800019348 RACCORDO USCITA COUPLING RACCORD VERSCHRAUBUNG EMPALME

VENTILADOR
14 073010037 MOTOVENTILATORE ELECTRIC FAN MOTOVENTILATEUR MOTORLÜFTER
ELÉC.

19 800041050 CINGHIA BELT SANGLE GÜRTEL CORREA

56 090015031 MANOPOLA KNOB VOLANT POIGNÉE DREHKNOPF VOLANTE PERILLA

72 800019504 SUPPORTO SCHEDE SUPPORT SUPPORT AUFHÄNGUNG SUPORTE

1104 TAV. 2B
 SCHEMA ELETTRICO - WIRING DIAGRAM - SCHÉMA ÉLECTRIQUE - STROMLAUFPLAN - ESQUEMA ELÉCTRICO

1104 TAV. 3
CIRCUITO ELETTRONICO - ELECTRONIC CIRCUIT - CIRCUIT ÉLECTRONIQUE - ELEKTRONIKSCHALTUNG - CIRCUITO ELECTRÓNICO
RIF. 1 - HF 322 - COD. 800022451

1104 TAV. 4 A
CIRCUITO ELETTRONICO - ELECTRONIC CIRCUIT - CIRCUIT ÉLECTRONIQUE - ELEKTRONIKSCHALTUNG - CIRCUITO ELECTRÓNICO
RIF. 1 - HF 322 - COD. 800022451

1104 TAV. 4 B
CIRCUITO ELETTRONICO - ELECTRONIC CIRCUIT - CIRCUIT ÉLECTRONIQUE - ELEKTRONIKSCHALTUNG - CIRCUITO ELECTRÓNICO
RIF. 1 - HF 322 - COD. 800022451

1104 TAV. 4 C
CIRCUITO ELETTRONICO - ELECTRONIC CIRCUIT - CIRCUIT ÉLECTRONIQUE - ELEKTRONIKSCHALTUNG - CIRCUITO ELECTRÓNICO
RIF. 1 - HF 322 - COD. 800022451 - REV. 1

HACER UNA SOLDADURA EN LOS DIODOS

MANTENER ADHERENTE PLATAFORMA Y
CONDENSADORES, ANTES DE SOLDAR
APLICAR SILICONE EN LA BASE DE LOS

V33 Y V41

1104 TAV. 4 D
CIRCUITO ELETTRONICO - ELECTRONIC CIRCUIT - CIRCUIT ÉLECTRONIQUE - ELEKTRONIKSCHALTUNG - CIRCUITO ELECTRÓNICO
RIF. 1 - HF 322 - COD. 800022451 - REV. 1

1104 TAV. 4 E
CIRCUITO ELETTRONICO - ELECTRONIC CIRCUIT - CIRCUIT ÉLECTRONIQUE - ELEKTRONIKSCHALTUNG - CIRCUITO ELECTRÓNICO
RIF. 1 - HF 322 - COD. 800022451 - REV. 1

1104 TAV. 4 F