PROJECT 1300-1600-1650

Service Manual

CEA COSTRUZIONI ELETTROMECCANICHE ANNETTONI S.p.A

C.So E. Filiberto, 27 – 23900 LECCO – ITALY
Tel +39 0341 22322 – Fax +39 0341 422646
export@ceaweld.com
www.ceaweld.com

Rev. March 2011

 Index
• 1、Introduction of working principle
• 2、Introduction of main circuit
• 3、Introduction of control circuit
• 4、Introduction of panel circuit
• 5、Troubleshooting
• 6、Component test
1、Introduction of
working principle
 working principle
PROJECT 1300
Rectifier Filter Full bridge Inverter Rectifier DC
110V DC DC AC Hall

Transformer PC817

+
DRIVE 18V -
+

Arc Force
-
40mV
T
+ Hot start
PI G +
+

SG3525 Calculation Comparison Panel

 working principle
PROJECT 1650

Rectifier Filter Half bridge Inverter Rectifier DC

95V~ Hall
265V DC DC AC
PFC

Transformer PC817

DRIVE 18V

Arc Force
40mV T
Hot start
+
PI G +
+

L4981 SG3525 Calculation Comparison Panel

 working principle
PROJECT 1600

Rectifier Filter Half bridge Inverter Rectifier DC

220V DC DC AC Hall

Transformer PC817

+
DRIVE 18V -
+

Arc Force
-
40mV
T
+ Hot start
PI G +
+

SG3525 Calculation Comparison Panel

 PTC

IGBT OC1
DR1 DR3 IGBT OC2 OUT+

L?
OC
DR2 DR4 OUT-

-24V DR1
DR2
DR3
DR4 TRANS2
Pr1 DR5
FJ DR6
K1 AC115V/60HZ WVIN
DR7 DR5 IGBT DR7 IGBT
OC1 OC2 DR8

1 AC 2
+ DR6 DR8

3 AC - 4

LED1 LED2VR1

FAN
Pr2

System chart (PROJECT 1300)

 K1 AC110V-230V/50/60HZ

AC1 AC3 1 2
AC +

AC2 AC4 3 4
AC -

1 AC + 2 QD1 IGBT OC1 OUT+

OC2
3 AC - 4 L?
OC
QD2 OUT-

Pr1
IGBT DC/DC TRANS2

PFC QD3 IGBT

QD8
-24V OC1 OC2
IN

WVIN MBIN
FJ OT IFB IMOUT
LED1
Pr2

DYJC
VR1 K2

MB
FAN
LED2

Pr3

System chart (PROJECT 1650)

 K1 AC220-230/50/60HZ

AC1 AC3 1 2
AC +

AC2 AC4 3 4
AC -

QD1 IGBT OC1 OUT+

OC2

L?
OC
QD2 OUT-

Pr1
TRANS2

QD3 IGBT

QD8
-24V OC1 OC2
IN

WVIN MBIN
FJ OT IFB IMOUT
LED1
Pr2 VR1 K2

MB
FAN
LED2

Pr3

System chart (PROJECT 1600)

2、Introduction of main circuit

A--- main circuit of Full-bridge Inverter

B--- main circuit of Half-bridge Inverter
C--- PFC part Application introduction
 main circuit of Full-bridge Inverter
PROJECT 1300 R100
R102

C100
T11
T1 T4
J1 C17 C16 R42 QD1 R24 QD5 R28
D14
PTC C18
R32 R36 OC1 T12
OC2

ZD7 T17 R42-1 OC

ZBYQ
R40 R41
QD2 R105 R104 T15
C19
QD2 QD6 ZB2 L10
-24V + OUT
T7 QD2 T10 ZB2
QD3 R26 QD7 R30 C102 COUT1
T14

R34 R38
GDN
T13
Q1
AC3 1 AC + 2
QD8
AC4 QD8
3 AC - 4 R101
C101

R103
OUT
TR1
AC1 AC3
COUT2

AC2 R200
CU1 CU2 GDN
CY1

CU3 CU4GDN R200-1

D1

D10
AC4 QD1 L1
ZD8 15V
D4
R20 ZD3 R9-1 D7 C5 R6
R16 T13 C13
VCC C14 TVS1 C11
C1
15V
U3 QD2
R52
1 8 B1
VCC VCC C2 D11
IN D8 R7
2 7 QD7 R9-2 D2 C12 C6
1 IN OUT
2 D6 VCC B2
R50 3 6
3-24V NC OUT D5
L2
4 R21 ZD4 -24V
4 5 R17 T16
5 GND GND
6
7 OC1 R10
QD8 R9
8 OC2 D15 D9
VCC D12 R1 R2
QD5 C8
U4 C3

1 VCC VCC 8
R22 ZD5

1
D16 VCC R18 T15 U2
2 IN OUT 7 U1

M
R51 3 NC OUT 6 QD6 4
C
R/C11

S
S
S
S
4 5
GND GND R3
D13
2
3
7
8
D17 QD3 ZD1
C15

R19 R23 ZD6

T14
C7 ZD2
QD8
part6: switch power
Part1:Inorder to pass the AC1
TR1
AC3

EMI test we use an AC2 R200

EMC filter interpose

CU1 CU2

CY1

between the AC source.

(Only use in 130SE)
CU3 CU4GDN R200-1

AC4
Part1: EMC

J1
D14
Part2:soft starter PTC
Part2: Because of the big current
when Instant start the
Machine the soft starter has
ZD7 T17
+
R40 R41
be used to Reduce the current C19

impact .
-24V
 part3: full brige Inverter circuit
QD1 QD5

OC1
OC2

QD2

QD2 QD6 ZB2

ZB2

QD2
QD3 QD7

QD8
QD8

part4:PWM driver QD1

VCC
15V
QD2
1 VCC VCC 8
2 7 QD7
1 IN OUT VCC
2 3 6
3-24V NC OUT
4 4 5
5 GND GND
6
7 OC1
8 OC2 QD8
VCC
QD5

1 8
VCC VCC VCC
2 IN OUT 7
3 6
NC OUT QD6
4 GND GND 5

QD3

QD8

Full-bridge circuit and PWM driver

 part5:full wave rectifer

Part5: Through the transformer QD2

and full-wave rectifier ZB2

OUT+

Circuit Getting what we want

the current and voltage GDN

OUT-

GDN
 Switch power
L1 15V
D4
R9-1 D7 C5 R6
C14 TVS1 C11

B1
D8 R7
R9-2 D2 C12 C6

D5 L2 -24V

R9
D9
R1 R2
C8
5

U2
U1
Overvoltage
D

4
C
protection input
S
S
S
S

R3
2
3
7
8

ZD1
C15

C7 ZD2

part6: switch power

Part6:the switch power supply +15V and -24V power for the machine
 0

R100
R39-1 C100
D14 PTC
T13-1
Q1
1 2 DC+
AC +
R39 T1
ZD7 T17 R24 T14-1
3 4 QD1
AC - C20
R40 R41 C23 C19
C18 ZBYQ
R32
C22 ZBYQ
R38 T2 T15-1
-24V R25
C24 C17 C16
C21 ZBYQ

R33 T16-1
TR8
QD2
R38-1 COUT1
R200-1 R200
T17-1

T4 GDN
OC1 OC2
TR1 QD5 R28
AC1 T18-1
R36 R201
CIN2
AC2 R202
CIN1 T5 R101
R29 C101
CU3 CU4 CY1
R103
R37
GDN
QD6 COUT2

GDN

DC+

D1

D10 D4
QD1 C14 L1 15V
ZD8
R20 ZD3 ZD3-1 C5 R6
R16 T13 C13 D7
R9-1 TVS1 C11
C1
15V R52 15V B1
U3 QD2
D13
1 8
VCC VCC
IN C2 D8 R7
1-24V 2 IN 7 R9-2 D2 C12 C6
OUT B2
2
315V R50 3 NC OUT 6 D5
4 L2 -24V
4 5 R10
5 GND GND
6 D11
7 OC1
8 OC2 D9
D12 R1 R2
U4 C3 QD5 C8
15V R9
1 VCC VCC 8
R22 ZD5 ZD5-1

1
D15 R18 T15 U2
2 IN OUT 7 U1

M
3 6 R11 4
R51 NC OUT QD6 C

S
S
S
S
4 5 D16
GND GND R3

2
3
7
8
ZD1
C15

C7 ZD2

main circuit of Half -bridge Inverter

 AC2 C144 AC4 ZD10-1 D10
CY1 CU4 RX QD1
AC1
CU1 CU2
GDN
C1

1
2
CU3 IN
R16 R20 ZD3 ZD3-1
1-24V T13
AC3 2
3 15V R52 C2
R200 R200-1
4 U3 QD2
5
D14 J1 6 1 8 D1-1
7 OC1 VCC VCC B2
8 OC2 2 7
IN OUT
3
3 6 3
NC OUT
R50
4 5 D1-2 R10 4
ZD2 T6 ZD10 GND GND 1 4
16 6

R184 R185 C3
C143 5
5 D12
8
8 QD5
-24V U4 D2-1
7
R102-1
1 8 2 7
VCC VCC 29 9
R18 R22 ZD5 ZD5-1
2 7 T15
IN OUT R102
3 6 R11 10
10
NC OUT D2-2 QD6
ZD11 R51
4 5
JC ZD02 GND GND
U1-2 R08 R05 R01 R00
1 R100
2 C100
C18 R09
R010

R04 R03 R02 R39 R40 R41 R42 R43 R44 R45 R46 R47 R48 R49 R71 R53 R54 R55
R105
C17 C23 C25 T18-1
DC+
T1 2
R24 C R106 T14-1
C125 QD1 1
C20 B

E
QD6
R32 GM1600CEL 6(3.2x3.6):3(5.2x3.5)
ZBYQ
T15-1

3
U1 R187 T2
1 2 R25 ZBYQ 3
AC V+ 3
V7-1 C21 ZBYQ 1
3 4 1
AC V- C102 T19-1
R33 4
4
TR8 OUT
L4 C19 C22 C24 QD2 2
2
U2 V7 T16-1 COUT1-1 COUT1
AC3 1 2 D+ DC+ 5
AC V+ 5
C141 GDN
AC4 3 4 T4 OC1 OC2
AC V- R150 R28 T17-1
QD5
C00 R167
R36
F1515S
R56 R57 R58 R59 R60 R61 R62 R63 R64 R65 R66 R67 R68 R69 R70 T5
+UB 7 +0V Dnd 2 R29
R151 C106 F1515S-1W
5 0V Vin 1 15V
R157 C105-3 R168
R170 R37
C142
QD6 COUT2
QD6 R101 C101
R152
R169 D+ GDN

R156
C103 +UB R172 R171 D5
R103
R183
+UB C124
R23 C109 R173 R103-1

QD6 D7
R154

19
13

14

L1
7

QD6 R104 15V

IAC

VCC

VFEED
VA-OUT
VRMS

15 3 QD6 D8 C13 C9 R6
PUVLO VP TVS1
C0 C6 C11
4981 20
GDRV R158
CAOUT

16 C107
ISENSE

SYNC
MULT

SGND

PGND

D5-1 C104
VREF
COSZ

ROSZ

LFF
IPK

QD6 B3 3
SS

CX R88 3
R153

R155 D15 C14 R7

D6 1 14 4 C12 C10
2

18

17

12

11

10

QD6
D16 L2
R178

5 -24V
C110 5
QD6 2
6
R89 26
C108 R179-1
7 D17
R186-1

V9 V9-1 7
R179 R90 R91
C121 C8

R175
5

1
C122 U6
R89-1 U5 4 1
R186

M
R177 V8-1 4 3 2
C
S
S
S
S
QD6 R176 R180
R182

R3
C120
2
3
7
8

C123 ZD8
V8 C15

V12 R174
C7 ZD9

R1 QD6
R181
QD6

main circuit of PFC and Half –bridge Inverter

PROJECT 1650
 PFC chip and theory
• L4981(see the PDF document)
• Power input : 94V～265VAC
• PFC output: 360(working)～385(open circuit)
VDC
（Test position: See the next page）
Test position: Test the voltage of main capacitor.
 PFC theory: Boost
1 Inductance
Diode
AC input 4 2
Main DC
IGBT
capacitor output
Rectifier
3

PFC chip control

 PFC
U1
Inductance R187
1 2
AC V+
V7-1
3 4

UFRD
AC V-

L4
U2 V7
AC3 1
AC V+
2 D+ DC+
C141
AC4 3
AC 4
V- R150
C00 R167

F1515S
+UB 7 2
+0V Dnd
R151 C106 F1515S-1W
5 1 15V
R157 0V Vin R168
C105-3

Test of AC current
R170
C142

QD6
Voltage PI
R152
R169 adjust
Feed_forward voltage
R156
C103 R172
+UB R171

+UB
R23
R183
C109
C124
R173
Test of output
QD6 voltage
R154

19
13

14
7
4
QD6

Under voltage protection

IAC

VCC

VFEED
VA-OUT
VRMS
15 3 QD6
PUVLO VP

input
4981 GDRV
20
R158 Overvoltage
CAOUT
16 C107

ISENSE
SYNC MULT

SGND
PGND
VREF
COSZ
ROSZ
protection output

LFF
IPK

SS
CX
R153

R155
2
8
5
9
18
17
12
11
6
10
1
QD6
R178

Soft start
QD6 C110

Current PI adjust C108

R179-1

R186-1
V9 V9-1
C121 R179

Overcurrent protection C122

R175

input R177
R186
V8-1

QD6 R176 R180

R182

C120
C123
V8

V12
R174
IGBT
The sense resistor R1 QD6
R181
QD6
Photo of PFC part
 Test of 110V or 230V input (Analog control)
JC U1-2 ZD02
1 R08 R05 R01 R00 DC+
2
C18 R09
R010

R04 R03 R02 DC-

Included in main circuit -15 VCC

R33 R16 R63
C23
CU1 VCC
GD1 GD2 PI1 PI2
JC U3A
R26

1 GD2 3 4
R23

R18
C10
GD R40 PI
2 2
1

GD1 D28
13
R36
11

CU2 14
12
-15 U3D
C9 R54 R58

IF R59 R25 To SG3525 Pin2

R20 R19

Included in control circuit

 Test of 110V or 230V input
D5
R200 R201 R202
DYJC
2
C0 C6 1
R206
AC input Rectifier C50
D5-1 R203 R204 R2085

Included in main circuit

VCC U309 ZD300
4 1 R401 U_D
C A
Pin 30 U_detect 3 2 C807 2
E K 1
R407
MCU
C808 R408

Included in control circuit

3、Introduction of
control circuit
 Introduction of control circuit -1
PROJECT 1300
R13 R8 +15V +15V
Uweld 1 4
+15V +15V
WVIN 2 3 CU3 CU1
Uist-Iso
1 R11 C8 C7
U2
5V 24V
2 C5
U< CU4 GND CU2
R5 LD1
GND GND
-15V -15V
+15V

14
U3B U5A U5B
5 R95 R94
Uist-Iso +
7 U-OK 1 2 StickTimer 3 4
6 U>7V NoStick U3D
R38 -
+15V
D15
C99 D14 C101 12
R82

7
1,3V GND +
14 +15V

+
R39 GND
GND GND
GND 4V -> 2mA ->200A 13
-
C9
U3C RegSum R26
10
GND + 8 M8
ArcForce R19 R20 PI
D27 D28 9
- Iist-In
+14V 19V U<7V
R14 R21 C10
Uist-Iso R18 R58
-14V 18V +15V
R10 R80 If U< add 20A -0,5V .. +3,6V
U5D U3A R25

4
-15V
D12 UVS
C11 D25 R29 GND
3 +
GND 9 8 /BlockingAF AF+ IsAF 1
+15V 2 - R6 R59
R97
U7A Imin=3A
R100

11
BlockingAF
R61 R42 1
IsHo 2
Isoll
-15V -15V GND
R32 U4C
Iist-In
10
+ R35 U5C Ca. 240ms
13
IsU<
8 HSTimer 5 6

12
9 HotStart
40mV - +
D19 DX R2 U7C C4
R101 IsEL 3 410 11IsSum
C27
U7B
5 ZD3
GND
GND EL2
U7D
I>2A
+15V R62 DX1 R60 R102 -Isoll
D7 EL IsTi 8 9

IFB R30 R3
C3 U5E
6

1 +15V
2 -15V D6 R4 +15V
3 Iist-In R15 11 10 TIG
4 GND U5F
GND
D9
I>0 U<7V 13 12UTOK TIGWelding
LD2

R7 D10
GND I>0
 Introduction of control circuit -2
PROJECT 1300
+15V
M9 +15V C17 + C24
IP
VCC +15V
R56 GND
R44
D16 D3 R81 C18

1
IMOUT D1 if ( IP>20V ) OC=1 C21
1
IPrA + C19
IPrB
2

Gnd
R70 R71 IP2 12 U4D D22 2 3
3 +
14 OC -24V In Out -15V
4 OutA SP VD3
+7.5V 13
5 OutB -
6 +15V
C80
7
D2 D4 C15 R45
GND
8 -24V C103 +15V R27
C16 C52 GND Vc OutA
D11
GND
R31

15
U6
PWM
MBIN MPGND M1 Vref 16 VREF Vc
13 LD3

VCC
R1 3 11
1 GND 4 Sync OUTA 14
2 EL SP-Out SP M2 Tr 6 OSC OUTB OutB
3 +15V Tr 10
4 Isoll-In
R28 Tc 5
Sd
2
5 +15V Isoll M3 Tc V+ UVS
-15V
ZD1 R12 V-
1 R40
R22 Rd7 Comp Sd

GND
M4 SSt8 Rd 9
SP
Uist-Iso SSt COMP
R57
+ C100
D8 M5 C12 C13

12
* Ipr -Begr. * Iist-In C14 GND
R17 R23 IP-Bas M6
IP Isoll
3

/Pullsoll
+ R24 JP1
C2 1 Q2 M7
1 UVS
2
GND M10
2

No Ipr-Begr. -24V
+15V
NTC-GND
4

+10V U4A
3
+
D24
OT R33 R36 1Ubte2
-20Degree 2 SP
NTC-GND +15V -
R37
11

R41
ZD2 -15V
NTC-IN R43
R46 FB-NTC

GND U4B
OT NTC-GND 5 D13
1 OT
+
7Ubte1
2 R47
NTC-IN 6
3 NTC -
R48 C82 R49

GND R50 ME1 ME2 ME3 ME4

Adjust
 U3D

GND 12 + 14 +15V
13
Part 1: current comparison and C9
RegSum
-
R26
PI adjust. R19 R20 PI
Iist-In
+15V U3A C10

4
R18 R58
GND 3 + 1 -0,5V .. +3,6V
IsSum 2 R25
-
UVS

11
C4 -15V R6 R59

ZD3 Imin=3A
R102
-15V GND

C103 +15V R27

GND Vc OutA

15
U6

Vref 16 VREF Vc 13

VCC
3 Sync OUTA 11
4 OSC OUTB 14 OutB
Tr 6
Tr 10
Tc 5 Sd
Tc V+ 2 UVS
R22

R12 V- 1 R40
Rd7 Comp Sd
SSt8 Rd GND 9
SP
Part 2:SG3525 PWM output +
SSt COMP
C100
R57
C12 C13
12

C14 GND
 part 4:OC test M9 +15V
IP
Part 4: OC test R44 R56
When the current IMOUT IPrA
D16 D3 R81
D1 if ( IP>20V ) OC=1
1 IPrB
exceeds the maximum 2
3
R70 R71 IP2 12 +
U4D D22
Current we set ，the OC 4
5
OutA
OutB +7.5V 13 -
14 OC
SP
C80
Signal will turn high level 6
7
+15V
GND
D2 D4 C15 R45
8 -24V
And the PWM Signal will C16 C52
GND
be blocked until we switch
Off the machine and
switch on again. +15V
NTC-GND

4
+10V U4A
3 D24
+
OT R33 R36 1Ubte2
SP
-20Degree2
+15V -
NTC-GND
Part 5: OT Test R37

11
There are two ZD2
R41
-15V
over-temperature NTC-IN
R46 FB-NTC
R43
detection means
GND U4B
(Thermal Test and NTC OT NTC-GND D13
5
1 OT + 7Ubte1
2 R47
Test). 3 NTC-IN NTC 6 -
In this machine we use R48 C82 R49
Thermal Test . GND R50
Adjust
part 5:OT Test

Uweld 1 4 +15V
R13 R8 2 3
WVIN Uist-Iso
Part 6: voltage test 1 R11 C8 C7
U2 C5
2
part 6:votage test
GND
 part 7:
U3C
GND 10 R80ArcForce R29 D12
+ 8 AF+
D27 D28 9 -
Arc force R14 R21
+14V 19V

Uist-Iso -14V 18V

R10

4
-15V
3 U3A
GND + 1 Ig
2 -
+15V part 8:
R100

11
C4
IsSum
R32 U4C
10 R35 U5C D21 ZD3
Iist-In + 8 HSTimer 5 6
Hot start

5
40mV 9 -
+
D19 R? R102
R101 4 3
C27 RES2
U7C
HCF4066BM1.
GND D20
R25
GND
Isoll

+15V

14
U3B U5A U5B
5 R95 R94
Uist-Iso + 7 U-OK
U>7V 1 2 StickTimer 3 4 NoStick
R38 6
-
D15
Protect of +15V
C99 D14 R82 C101
7

1,3V

+
R39 GND GND
short circuit GND GND

part 10:
 MBIN
1 GND R1
2 EL SP
3 SP-Out
4
Isoll-In
R28
5 +15V Isoll
ZD1

Part 11:
Part 11: limit of power D8
when we short JP1 the * Ipr -Begr. *
No Ipr-Begr.
R17 R23
function will disappear. IP
IP-Bas

3
/Pullsoll
+ R24 JP1
C2 1 Q2
1
2
GND

2
View of control board
PROJECT 1300
 Photo of control board(95S)

FJ OT IFB DRIVER

MBIN

WVIN
• FJ ---- Connected with the FAN of the machine. 1_-24V，2_ GND
• OT ---- Connected with the temperature sensor to provide over-temperature
signal. 1_NTC-GND，2_OT，3_NTC.
• IF ---- Connected with HALL sensor to sample current signal.
1_+15V，2_-15V，3_Iist-In，4_GND.
• DRIVER ---- Connected with main board to provide PWM signal and
control board power. 1_IPrA， 2_IPrB，3_GND,4_out-A，5_out-B，
6_+15V，7_GND，8_-24V.
• WVIN----Connected with the output to sample voltage signal.1_+，2_-.
• MBIN---- Connected with panel board . 1_GND，2_EL，3_SP-Out,
4_Isoll-In，5_+15V.
 Introduction of control circuit
PROJECT 1650 T/M FN C103 VCC R27
VCC

13
-15

5
R33 R16 R63

15
C4 C23 U6
SC1 CU1 VCC
1 2 4 3 VCC VREF 16 13
GD1 GD2 PI1 PI2 VREF Vc

VCC
ZD3 R26 R22 3 11
U3A Sync OUTA
R23 4 14

4
U7A U7C OSC OUTB IMOUT
DX C10 6
Tr 1
MET1 10 SP
U7D 3 R18 C12 Sd 2
R2 1 GD R40 PI 5
Tc V+
2
C100 3
VCC D01 DX1 W1 2 R12 4
1
MBIN 8 9 D28 7 V- 5

GND
1 8
Rd
9
6
2 MET U3B 13 SSt COMP 7
U5C R36

11
3 SP 6 CU2 14 VCC C14 D16 8
4 D6 7 12 D02 C13 R81
R1 R97
6

T/M5 T/M-1 U3D D2

12
5 6 5 -15 C9
6 C3 R54 R58
R3 C1 D3
VCC C16
IF R59 R25 WV
R4 D9 U5F D4
12 13 IN1 R20 R19
D1
OC C15 R28 R28-1
D10 WV
10 11 ZD01
U5E C28 D11 D12 R80
VCC R01 R02
WVIN R13 R8 U2 R9 SC1 VCC R100 R101

3
1 U1B
2 6
R03
C8 W4 R14 C20 1 Q01
7 R5
C7 5 U1D
VCC D7 12
R11 C5 R10 R24 R60 IFJC R32

2
14 VCC
-15 13 IF
C30 C17
4

U1A R21
3 D14 R82
CX1
R7-1 R7 WVIN1 1 U1C 9 C24

1
R6 R6-1 VCC 2 U5A U5B 8 C19
IN1 10 C21 C18

GND
R38 1 2 R94 3 4 FN FJ
11

D5 D13 3 2 2
WVIN1 U4C
5

R37 -15V Vin 1

-15 C101 9
DC-DC1
R51 D15 R95 D25 8 VD3
0V

+0V

T/M-1 C99 -15 VCC

F1515S-1W

U5D 10
R42 R34
12

R39 D18
R47 8 9 R78
Vin

Dnd

SC1 MET D24 OT

10 11 1
C32 C27 R35 SP 2
C82
1

U7B VCC 3
T9
D26 U3C 10 IFJC
R15 GD R48 8 C81 R50
4
9 D27 U4A
VCC T/M-1 R49 D30
VRD 3 R43 JC
1
2 GD2 1
CX2 PI1 2
IFB VCC C52 R56 GD1
11

VCC T8 R31
1 R44 U4D
2 -15 R46
OC 12 D22 -15
3 IF VCC R57 SP D29 U4B
4 14
-15 13 5 R41 D23
CU3 CU4 C80 7 R29 PI2
C11 6
R45 R30
 Function of VRD

VCC
WVIN U2
1 R13 R8
2
C8
C7
R11

Part12:VRD R7 D5

R7-1

R6-1 DC-DC1
7 2
+0V Dnd
R6 5 F1515S-1W 1
R15
0V Vin

VCC
Part12:
View of control board
PROJECT 1650
 Photo of control board
PROJECT 1650)
VRD FJ OT IFB DRIVER

JC W1 W4 WVIN MBIN
• VRD --- selection of VRD.
• JC --- Connected with main board sample input
voltage .
• W1 --- Adjust of max_current
• W4 --- Adjust of arc_force_point. (when the output
voltage below 18V adjust voltage of U1pin5 to 0 V.
 Introduction of control circuit
PROJECT 1600
T/M FN C103
VCC VCC R27
13

15
C4 U6
SC1 CU1 VCC
1 2 4 3 VCC VREF 16 13
R16 R63 VREF Vc

VCC
R26 3 11
ZD3 U3A R22 4 Sync OUTA 14

4
U7A U7C OSC OUTB IMOUT
DX 6
Tr 1
R2 R18 C10 10 SP
U7D 3 PI C12 5 Sd 2 2
1 -15 Tc V+ 3
VCC DX1 W1 2
C100 4
MBIN 8 9 R20 R19 V-
1
5
7

GND
1 Rd 6
MET U3B 8 9
2 U5C CU2 C9 13 R12 SSt COMP 7

11
3 SP 6 IF 14 C13 C14 D16 8
4
R1 D6 7 12 R81
R97
6

U3D D2

12
5 T/M 5 6 5 -15
C3 R54 R58
R3 D3
C1 VCC C16
R59 R25 WV D1
R4 D9 U5F D4
12 13 IN1
D23
R61 OC C15 R28 R28-1

D10
10 11

U5E D11 D12

VCC
WVIN R80 SC1 VCC R100 VCC
R13 R8 U2 R9 U1B R101 C17
1
2 W4 6 R14
C8 7 R5
C7 5 U1D C24

1
R11 VCC
R10 R24 D7 R60 12
R32
C5 14 C21 C18
13 IF

GND
-15 C19
C30
4

IFB U1A R21 FJ

3 D14 CX1 3 -15V Vin 2 2
1 VCC WVIN1 1 U5A R82 U5B U1C 9
1
2 -15 VCC 2 8 VD3
3 IF IN1 10 -15
VCC
4 R94
R38 1 2 3 4 FN
11

D13 R78
R62 WVIN1 U4C
C101 R37 9 D24 OT
-15
VCC D15 R95 8 SP
1
2
C99 U5D R34 10 C82
12

R39 D18 3
8 9
VCC R42 10 11 MET R31
-15
CU3 CU4 SC1 R35 VCC
U7B
C32 C27 C11 R30
C83 R46
U4B

4
6 ZD5 ZD6 U4A
7 3
5 1 SC1
2 R29
VCC C52
R56

11
R44 U4D
OC 12 R57 D22
14 SP -15
13
C80
R45
View of control board
PROJECT 1600
Photo of control board
PROJECT 1600
FJ OT IFB DRIVER

MBIN

WVIN

W1 W4
4、Introduction of panel circuit
PROJECT 1300-1600-1650
Electrical drawing of panel circuit

VCC
RM1 VCC
VR1
RM2
MB
1 LED1
2
3
4
5 K1 LED2
panel PCB
Photo of panel board
5、Troubleshooting
 LED1: power display

Welding
Current

Process selector LED2:Working Indicator

 Common troubles Solutions

Open the shell and check the welding connector

1.When starting the power source, the fan of the front panel and control panel or replace it.
works, but the power light is not on.
(1) Something unusual is blocked in the blade.
Clear it out.
(2) The fan is damaged. Replace the fan with
2 When starting the power source, the power the same type.
light is on, but the fan doesn’t work. (3) The connector of fan not connect to the
machine.

3 When starting the power source, the fan and Over-voltage input. Check the input voltage.
the power light work normally at the beginning The voltage should be kept between AC90 and
but stop working later. 135V.
4. When starting the machine, the power light (1) Check whether there are some Component
keeps flickering. damaged on control board .
(2) Check whether there are IGBT damaged.
(refer to IGBT test) .
(3) Replace the transformer of the B1 switch
power supply on the main board and the U1
TOP244Y Integrated Circuit.
 The current adjustment potentiometer is damaged.
5. The current can’t be adjusted. Replace the potentiometer with the same type.

HALL is damaged. Replace the HALL with the

6. The current is infinite. same type.

7. When starting the machine, the chief

switch of input power source trips Replace the 5010 rectifying bridge.
instantaneously.

(1) Check the output of the No. 11 pin and No.

14 pin of IC 3525 on the control board (refer
to IC 3525 test) ,if the control board works
well. Otherwise, please replace it.
8. When starting the machine, the fan and the (2) If the voltage of control board is right, the
power light work normally, but there’s no problem may arise in the main board. Then,
voltage and circuit output. use the multimeter to check the IGBT (refer
to IGBT test of wave ) If the circuit occurs or
an obvious evidence of explosion appears.
We must switch off machine and check
whether there are IGBT (refer to IGBT test)
or FRD (refer to FRD test) damaged.
Component test

1、 SG 3525 Test
2、IGBT Test
3、FRD Test
SG3525 Testing

We can use the

oscilloscope test pin
11 and pin 14 if the
wave as good as the
following figure, then
the control board
works well .
Wave of SG3525 pin 11 or pin 14
Wave of IGBT pin 1and pin 3
The location of IGBT

1 23 12 3 12 3

321
 Preparation of test IGBT
 1、We must Switch off the machine
 2、After 5 minutes we can test .
 3、Turn the rotary switch to test diode.
 4、keep 3 seconds when we test every step.
 5、If the result we test as similar as the following
picture .we can say the IGBT is good. Otherwise
there are some IGBT damaged.
IGBT Test(A-1) IGBT Test(A-2)
IGBT Test(A-3) IGBT Test(A-4)
IGBT Test(A-5) IGBT Test(A-6)
Solutions when the IGBT is damaged.
 1、 Check the circuit of IGBT driver may be there
are some components damaged.
 2、Remove IGBT one by one and test as following
page.
 3、After we Remove the damaged IGBT. Check the
IGBT drive wave (between the G、E) as same as the
below.
 4、If not ,we must Replace Components of driver
circuit .
 5、Replace IC TC 4420.
 6、 If the wave is ok .Replace the damaged IGBT.
IGBT Test(B-1) IGBT Test(B-2)
IGBT Test(B-3) IGBT Test(B-4)
The location of FRD
 Preparation of test FRD
 1、We must Switch off the machine
 2、After 5 minutes we can test .
 3、Turn the rotary switch to test diode.
 4、keep 3 seconds when we test every step.
 5、If the result we test as similar as the following
picture .we can say the FRD is good. Otherwise
maybe some MUR are damaged.
FRD Test(A-1) FRD Test(A-2)
FRD Test(A-3) FRD Test(A-4)
 Solutions when the FRD is damaged

 1、 Remove FRD one by one and test as following page.

 2、 Replace the damaged FRD.

FRD Test(B-1) FRD Test(B-2)
FRD Test(B-3) FRD Test(B-4)
Thanks for your
attention!!!