Castolin Castotig 2002 ( mw2000?)

[Jan-DIY]

Hey.
May for spares.
What problem he has?
May he made a thread here?
I generally not source parts from CN if there’s no other way of getting them.
They counterfeit everything.

Power Transistor better source from mouser or Digikey if they got

 

[Macfun]

Don't know exactly ...
Not sure that he speaks english.
He had the usual burnt resistances on top board, but this was not the only problem.
He burnt 4x IXFN at start on DC- (why did he select this, I don't know ...).
He also replaced IGBT by chinese copy of Fronius 41.0003.0145 IGBT.
And he replaced some components on BPS20 board, which is not same version as mine, layout is slightly different.
Maybe he made it more messy (should I write messier ?) than before ...

I am not sur you will make a bargain with it ...

 

[Jan-DIY]

Not interested of bargain in this.
What he changed and why?
Primary stage working?
Secondary diodes also?
Fault messages like 117 or anything else?

 

[Jan-DIY]

To get primary Mosfet broken it is not a matter of polarity on secondary side.

 

[Jan-DIY]

Did he get a scope on gate signals?

 

[Macfun]

Well I don't know what he exactly did and measure.
I tried to help him by sending boards and components pictures, but they were different ...
He changed the 3 resistors on top board, some resistors and other components on the primary board (the side where the gas vale is), the IXFN units, and 2 IGBT on secondary side (as on your picture).
But still trouble and IXFN burnt.
He gave away and probably would sell it as is ...
Maybe I can ask him if he speaks english ...
If yes, I'll PM you.

 

[Jan-DIY]

Welcome.
But a little busy

 

[Macfun]

Bad news, he speaks only french.
And his welder is older than my 2002, but still a 2002, with the Fronius rectangular connector for the command, and the standard DINSE connector.
Forget about it ...
Picture with the twins condensers :

 

[Jan-DIY]

Seems first generation.
Never seen before.
Gate driver section without dedicated driver.
Seems standard push pull stage.
To be honest I’m not interested to buy but maybe can help to fixing it.
Is it primary short?
Already checked Zener and Schottky diodes?
You can test this circuit without transistors to check proper gate signals.

 

[Macfun]

Hello Jan.
I think it is not interesting to go further with this one.
Sometimes it is better to stop trying remotely repairing it.
If it's free, maybe for spare parts as some are compatible.

 

[Macfun]

They are OKW knobs if memory serves correctly, the caps are not expensive.

Good memory, Hugh, indeed !
I checked the OKW website, and found almost everything, except ... the thick small red arrow.
OKW only make red color for THIS one, on request.
So ... here are what I finally got (with OKW references), worth to know it's cheap and available.
Of course it's better to change all covers at once for a better look ... and keep old ones to rebuild another front panel (especially for Jan-DIY !).

 

[EdVonSchleck]

Hello Guys,

i have a problem with my Castotic 2002:

Somehow it suddenly sopped working.
Voltage is shown but when i want to start welding, there is no starting arc.
However, if i touch the metal with the electrode, welding starts - but this not not how it is supposed to be :-)

I checked the three resistors on the top PCB, and confirmed they are O.K.

Regards from Germany

 

[Macfun]

Hello.

1. TIG or MMA (stick) welding ?
2. MMA position shows approximately 45-48 Volts on display ?
3. All LEDs ON on top PCB (check picture on middle of page 4 of this thread) ?

 

[EdVonSchleck]

Hello.

1. TIG or MMA (stick) welding ?
2. MMA position shows approximately 45-48 Volts on display ?
3. All LEDs ON on top PCB (check picture on middle of page 4 of this thread) ?

TIG welding.
I will check 2 and 3

 

[Macfun]

Are you on the right HF start position with the toggle switch, not lift arc position ?

 

[EdVonSchleck]

pictures

 

[EdVonSchleck]

Here is a video of the problem.

I tried toggle switch 1 and 2. I also tried AC welding, its the same Problem. I tried 200 Amps, still no change.

 

[Macfun]

I don't hear gas flow ...
And when powering the 2002, you shouldn't have 45V displayed in TIG mode, only MMA (I just checked mine).
Also, the left green LED (front display, starting amp step) must be OFF. Does it stay ON all the time ?

 

[brockenhammer]

Can you measure 230V on the in side of the HF unit (the grey box, labelled EGT SIG..., mounted downside up) when pressing the trigger.
These units sometimes fail. You can get these from EGT Industrieelektronik for about 120,-€ new.

 

[EdVonSchleck]

I don't hear gas flow ...
And when powering the 2002, you shouldn't have 45V displayed in TIG mode, only MMA (I just checked mine).
Also, the left green LED (front display, starting amp step) must be OFF. Does it stay ON all the time ?

i activated the switch on the handle for the Picture. when i Release the switch 0v is shown an the green led is off.

also i closed the gas on the argon bottle for this test