MMA WELDING PRODUCT

REPAIR PROCESS OF GYSMI 160P

Auteur : Alexis Gillet 1/16

Date : 30/06/2016
www.gys.fr
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 MMA WELDING PRODUCT

REPAIR PROCESS OF GYSMI 160P

Summary
1) Prior analysis and advice ................................................................. 3
1.1) Safety reminder ...................................................................................................................... 3
1.2) General advice in organizational intervention (Internet home page) .................................... 3
1.3) Useful tips for following diagnosis .......................................................................................... 3
1.4) Equipment required ................................................................................................................ 3

2) Structural diagram .......................................................................... 4

3) Pre Diagnostic ................................................................................. 5
4) Symptoms and failures.................................................................... 5
4.1) The unit trips the mains breaker switch: .................................................................................... 5
4.1.a) Control isolation SMI to earth ....................................................................................................... 5
4.1.b) Diode bridge control ..................................................................................................................... 6
4.2) The unit starts but not welding .................................................................................................. 6
4.3) Repair algorithm : ....................................................................................................................... 7
4.3.a) Main algorithm .............................................................................................................................. 7
4.3.b) Secondary algorithm ..................................................................................................................... 8
4.4) Test and control the circuit board : ............................................................................................ 9
4.4.a) Overvoltage protection repair....................................................................................................... 9
4.4.b) Power supply repair .................................................................................................................... 10
4.4.c) Check and repair of the control circuit ........................................................................................ 10
4.4.d) Check and repair of the thermal protection ............................................................................... 13

5) Product setting procedure ............................................................. 13

6) Detailed structural diagram........................................................... 15
7) Annexe(s) ..................................................................................... 16

Auteur : Alexis Gillet 2/16

Date : 30/06/2016
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200307
 MMA WELDING PRODUCT

REPAIR PROCESS OF GYSMI 160P

1) Prior analysis and advice

1.1) Safety reminder

The repairs must be performed by qualified person(s).

Before any intervention in the internal generator, make sure that the set is unplugged.

1.2) General advice in organizational intervention (Internet home page)

Read the Overview of Inverters GYSMI.

Read the disclaimers GYSMI Guarantee on all models - see the homepage on the Internet.
Perform a visual inspection to detect any obvious faults (hot spots, badly crimped terminal, browned
diode, burnt transformer, mechanical failure, power module (component(s ) destroyed, burnished zone)).

1.3) Useful tips for following diagnosis

The CMS components can become short or open circuit.

Verification of resistance with a multimeter in the « ohm » position.
Verification of diodes with a multimeter in the « diode » position.
For all connections on the board, solder probes on the points of contact indicated.
The circuit board is varnished, pay attention to the risk of poor contact due to the isolation created by the
varnish, use probes with a sharp tip in order to break the layer of varnish.
Check the section with the most common symptoms and failures.
Check the procedure step-by-step and make repairs if necessary.

1.4) Equipment required

A Multimeter.
An oscilloscope and a x10 probe.
A 60V power supply isolated from the earth, current limited to 2 amps.
Connection cables with crocodile clips.

Auteur : Alexis Gillet 3/16

Date : 30/06/2016
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 MMA WELDING PRODUCT

REPAIR PROCESS OF GYSMI 160P

2) Structural diagram

* The values presented are indicative only and may vary from tens
of millivolts at the SMI.

Auteur : Alexis Gillet 4/16

Date : 30/06/2016
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 MMA WELDING PRODUCT

PROCESS REPAIR OF GYSMI 160P

3) Pre Diagnostic

Faults Causes Remedies

The orange light is on, the
device does not deliver any
current.
Only the green LED is on but
the device does not weld.
There are small amounts of
static shock when you touch
the body of the machine.
Thermal protection  Check the connections
circuit was triggered. 3 min max. (Orange light off)
Poor connection of the
earth clamp or electrode  Check the connections.
holder.
 Multimeter in the « ohms » position.
 Check the continuity between earth and
the mains cable.
 You should read low resistance (court-
circuit)
 If OK
 Check your electric installation by a
Not earth continuity. professionnal.

 Check the polarity (+/-) advised on the

The unit welds poorly. Wrong polarity (+/-).
electrode box.

4) Symptoms and failures

4.1) The unit trips the mains breaker switch:

4.1.a) Control isolation SMI to earth

 Disconnect the plug from the product.

 Multimeter in « ohms » position.

 Check the value between the screws of the
primary and earth.
 You should read infinite resistance.

 Otherwise, the SMI is probably down.

 Change the power block, réf.97820.
 See procedure to change SMI (annexe).

Auteur : Alexis Gillet 5/16

Date : 30/06/2016
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PROCESS REPAIR OF GYSMI 160P

4.1.b) Diode bridge control

 Multimeter in « diode » position.

 Check the value with multimeter.
 The value should be around 540mV between each
diode

 Otherwise (diode is short-circuited), the SMI is

probably down.
 Change the power block, réf.97820.
 See procedure to change SMI (annexe).

4.2) The unit starts but not welding

 Check the output voltage of the unit.

 Connect the unit to the mains.

 Multimeter in « volt » position.
 Measure the voltage across the Texas connectors.
 The value must be : 60V +/-5%

 Otherwise, check the following items.

 Check the screws on the Texas connectors (circled in

red)

 If the PCB is burnt.

 Remove any burn marks/corrosion (Blue arrow).
 Change the screw réf.41288.

 In some circumstances (faulty circuit) :

 Cut the card and the degraded areas.
 Place a cable (10 mm²) between the screw and the
Texas connectors as shown below.
 The must be tightened to 3 N.m.
 Check the mechanical strength of bolts.

 Loosen the screws.

 Test with a rod.
 Do not push strongly.
 Check whether one of the bolts (shown on the right)
moves.
 If the bolt moves, the SMI is down.
 Change the power block, réf.97820.
 See procedure to change SMI (annexe).
 When the test is complete, tighten the screws.
 These must be tightened to 2.5 N.m.

Auteur : Alexis Gillet 6/16

Date : 30/06/2016
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PROCESS REPAIR OF GYSMI 160P

4.3) Repair algorithm :

4.3.a) Main algorithm

Auteur : Alexis Gillet 7/16

Date : 30/06/2016
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4.3.b) Secondary algorithm

Auteur : Alexis Gillet 8/16

Date : 30/06/2016
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PROCESS REPAIR OF GYSMI 160P

4.4) Test and control the circuit board :

For the following test, measurements are performed under restricted Low Voltage 60V 2A.

 Turn on the 60V supply.

 Power the card directly to the electrical terminals,

as shown.
 Pay attention to the polarity.
 Both relays must switch.
Consumption Avec SMI Sans SMI
Product off 0.045A 0.050A
Product on 0.10A 0.053A

4.4.a) Overvoltage protection repair

 Power on diodes bridge.

 Change the following components :

Transistors : Q41P01 : STD2N ref.64069
Q41P02 : MMBTA ref.64070

Diodes : D41P09 : ZENER 12V ref.64304

D41P11, D41P10 : GS1M ref.64030

Resistor : R41P12 : 0Ω ref.64109

Varistance : V41P01 : 470Ω ref.64100

Auteur : Alexis Gillet 9/16

Date : 30/06/2016
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PROCESS REPAIR OF GYSMI 160P

4.4.b) Power supply repair

 Change the following components :
Transformers : TR51X01 ref.64140

Transistors : Q51P01 : MMBTA06LT1 ref.64070

Q51P10 : ST01NK802T4 ref.64438

Diodes : D52P02 : 1N4148W ref.64014

D51P02 : ZENER 15V ref.64311
Resistors :
R51P25 : 47Ω ref.64018
R51P33 : 221Ω ref.64384
R51P31, R51P32 : 1,3Ω ref.64389
R51P21, R51P22, R51P23 : 330kΩ ref.64024

Chip : U51P01 : FAN6862R ref.64546

4.4.c) Check and repair of the control circuit

 For the following measures, taking –HF as the

reference on the screws of the diodes bridge as
shown.

Output signal of the 3845:

 Capture the control signal at the output pin 6 of

the UC3845.
 Using an oscilloscope probe (see below)

 Other result is a niche 100KHz 17V signal (see

below cons).

Auteur : Alexis Gillet 10/16

Date : 30/06/2016
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PROCESS REPAIR OF GYSMI 160P

 If the output signal is absent, check the input

signal :
 The supply voltage of 3845.
 Pin 7, measured voltage 15V
 The presence and variation of the set of the 3845.
 Pin 1, Voltage Min : 2.36V
Voltage Max : 4.16V

 If the set is not present :

 Change the following components :

Transistors : Q22P01 BSR16 ref.64001

Q22P02 2N7002 ref.64269
Q22P03 BSS84P ref.64612

Chip : U21P01 3845 ref.64507

Auteur : Alexis Gillet 11/16

Date : 30/06/2016
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Output signal of the L6386:

 Keeping the mass on the – HT :

 See higher square wave PWM signal on the screw

near power capacitors (below)

 Signal shown on right

 Keeping the mass on the –HT :

 See lower square wave PWM signals on the screw

near the transformer (below)

 Signal shown on right

 If the signals are not present :

 Change the following components :

Resistor : R21P10 : 4,7Ω ref.64017

Diodes : D21P01 D21P04 : Zener 16V ref.64023

D21P02 D21P03 : BAT42W ref.64026

Chips : U21P01 : UC3848B ref.64507

U21P02 : L6386 ref.64079

Auteur : Alexis Gillet 12/16

Date : 30/06/2016
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PROCESS REPAIR OF GYSMI 160P

4.4.d) Check and repair of the thermal protection

 Thermal protection is triggered by a short

circuit using a small flat screwdriver
between pins 5 and 6 of the SMI connector.

 When the thermal protection is triggered,

the orange Led lights on.

 If the thermal protection does not work or

is constantly lit :

 Change the following components :

Resistor : R13P12 : 10Ω ref.64012

Diode : D13P01 : ZENER 18V ref.64012
Chips : U13P01 U13P02 : TL331 ref.64508
Transistors : Q13P01 Q13P03 : BSR14 ref.64002

5) Product setting procedure

This operation is to do each change SMI and change microcontroller. To adjust the product, one can proceed
in 2 ways :
a. By attaching the product via load bank ref.060418.
b. By welding with the device.
For the welding set, you require two operators for the adjustment operation. An operator welds while the
other rotates the potentiometer on the product.

Preparation :
 Connect the product to 230V.
 Use amperemeter.
 Amperemeter in position continuous current
(A-DC).

1) Setting by load bench.

 Measure the DC current produced by the
product.

2) Setting by welding.
 Prepare many electrodes Ø4 to weld 2 or 3
minutes.

Auteur : Alexis Gillet 13/16

Date : 30/06/2016
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PROCESS REPAIR OF GYSMI 160P

Product setting :

As soon as the green LED

lights, weld using an Weld using an electrode
Turn the potentiometer electrode with a diameter with a diameter of 4mm
Connect the device
and place it directly in of 4mm or to pull a current until the unit is in thermal
to the mains with
min position, the fan via a load bank. protection, LED lights
the potentiometer
should rotate, green LED Gradually turn the orange.
set to « off ».
off. After one second, the potentiometer until there Once that is on, the
green LED should light. is a current of 160A on the setting is stored.
clamp and wait for the fan
to cut out.
If the setting did not work, reset the machine(as shown below) and refer back to this operation

Product reset :

 Turn off the product.

 Wait 15 seconds.
 Apply short circuit (weld wire) between pin A and B.
 Turn on the 60V supply.
 Wait green light is on (average 10 seconds).
 Turn off the product.
 Remove the wire between the pin A and B.

 The machine is reset and the product setting can be

apply. (cf. paragraph 5)

Auteur : Alexis Gillet 14/16

Date : 30/06/2016
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 6) Detailed structural diagram

Auteur : Alexis Gillet 15/16

Date : 30/06/2016
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 7) Annexe(s)

 Unscrew the PCB from the power block.

 Add tin to facilitate the operation.

 With a big solder and ferrule soldering

adapted.
 Heat the tin on the connector.

 Wait the tin is completely warm.

 Remove the circuit.

 Clean up the circuit connector pads.

 To make this operation you could use

desoldering wick or desoldering pump.

 Clean up the power block connector of

tin; if you want use it again.

 To make this operation you could use

desoldering wick or desoldering pump.

 Screw before weld the connector when you

remove the power block.
 These must be tightened to 2.5 N.m.

 Be careful short-circuit between the

differents pins of connector.

Auteur : Alexis Gillet 16/16

Date : 30/06/2016
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