Cebora POWER SPOT 5500

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Summary

1 GENERAL INFORMATION

1.1 - Introduction.

Purpose of the manual to train personnel for maintenance on the power source art. 2153.

1.2 - General service policy.

Customer responsibility for equipment use, maintenance, and qualified personnel for repairs.

1.3 - Safety information.

Safety notes are integral; disconnect power, wait for capacitor discharge, measure voltage.

1.4 - Electromagnetic compatibility.

Instructions for electromagnetic compatibility to be followed as per Instruction Manual.

2 - SYSTEM DESCRIPTION

2.1 - Introduction.

POWER SPOT 5500 system for welding ferrous/non-ferrous studs/rivets, made of electronic power source and accessories.

2.2 - Technical specifications.

Refer to machine plate, Instruction Manual, and Sales Catalogue for technical specifications.

2.3 - Description of power source art. 2153.

Capacitor discharge power source with transformer, rectifier, capacitors, and static switch.

3 - MAINTENANCE

3.1 - Periodic inspection, cleaning.

Remove dust from vents, check output terminals/cables, and internal connections/connectors for damage or looseness.

3.2 - Sequence of operations (fig. 3.2.1).

Represents correct machine functioning and can be used for troubleshooting after repairs.

3.2.1 - Power source commands and signals.

Diagram showing front panel controls and connections for the power source.

3.2.2 - Starting the power source.

Step-by-step procedure for powering on the system, connecting accessories, and initial checks.

3.3 - Troubleshooting.

3.3.1 - The power source does not start, led (C) on control panel unlit.

Troubleshooting steps for no power and unlit control panel LED, including mains suitability and connection tests.

3.3.2 - Power source powered, fan (34) stopped.

Troubleshooting steps for a stopped fan, including fan test, wiring checks, and power board replacement.

3.3.3 - Power source powered, the start button produces no effect.

Troubleshooting steps for the start button not working, including command test, wiring, and component checks.

3.3.4 - In open circuit operation, the voltage at the DC-capacitors (24) is not regular.

Troubleshooting for irregular open circuit voltage on DC-capacitors, involving voltage adjustment test and component checks.

3.3.5 - In resistive load operation, the output voltage is not regular.

Troubleshooting for irregular output voltage during resistive load test, including load test, wiring, and component checks.

3.3.6 - In actual working conditions (thus with high currents), the welding quality is not satisfactory.

Troubleshooting for poor welding quality under high currents, checking accessories, sheet metal, and DC-capacitors efficiency.

3.4 - Error codes.

3.4.1 - E1 - Transformer (31) temperature above limits.

Error E1: Transformer overtemperature. System blocks, fan runs. Reset automatically when cooled.

3.4.2 - E2 - Scr (3) short-circuited.

Error E2: SCR short-circuited. No voltage on output terminals, hazardous for positioning.

3.4.3 - E3 - Dc voltage on the DC-capacitors (24) irregular.

Error E3: Irregular DC voltage on capacitors. Triac defect or short-circuit. Blocks power circuit.

3.4.4 - E4 - DC-capacitor (24) irregular charge.

Error E4: Irregular or slow capacitor charging. Voltage regulator inefficient. Blocks welding.

3.4.5 - E5 - DC-capacitors (24) irregular discharge.

Error E5: Irregular capacitor discharge. Discharge resistor faulty or interrupted. Blocks system.

4 - COMPONENTS LIST

4.1 - Power source art. 2153: see file ESP2153.pdf enclosed at the end of the manual.

Reference to a separate PDF file for the power source component list.

4.2 - Components table: see file ESP2153.pdf enclosed at the end of the manual.

Reference to a separate PDF file for the components table.

4.3 - List of spare parts.

Lists essential and recommended spare parts for the power source unit.

5 - ELECTRICAL DIAGRAMS

5.1 - Power source art. 2153: see file SCHE2153.pdf enclosed at the end of the manual.

Reference to a separate PDF file containing the electrical diagrams for the power source.

5.2 - Waveforms.

Displays waveforms related to the power source operation, specifically output voltage.

5.2.1 - Output voltage upon scr (3) engagement (par. 3.3.5).

Illustrates the output voltage waveform when the SCR engages, as described in troubleshooting section.

5.3 - Power board (12) code 5.602.169.

5.3.1 - Topographical drawing.

Diagram showing the physical layout and component placement on the power board.

5.3.2 - Connector table.

Details connectors on the power board, their terminals, and functions.

5.4 - Control board (2) code 5.602.168.

5.4.1 - Topographical drawing.

Diagram showing the physical layout and component placement on the control board.

5.4.2 - Connector table.

Details connectors on the control board, their terminals, and functions.