Elettro C.F. PLASMA 36 User manual

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PLASMA 36 COMPRESSOR
INVERTER
POWER SOURCE art. 481
SERVICE MANUAL

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CONTENTS
1 – GENERAL INFORMATION .........................................................................................................................3
1.1 – Introduction...........................................................................................................................................3
1.2 – General assistance ................................................................................................................................3
1.3 – Safety information. ...............................................................................................................................3
1.4 – Electromagnetic compatibility..............................................................................................................3
2 – SYSTEM DESCRIPTION..............................................................................................................................4
2.1 – Introduction...........................................................................................................................................4
2.2 – Technical specifications........................................................................................................................4
2.3 – Description power source item 481.......................................................................................................4
3 - MAINTENANCE ............................................................................................................................................5
3.1 – Periodic inspection, cleaning ...............................................................................................................5
3.2 – Operations sequence (pict. 3.2.1)..........................................................................................................5
3.2.1 – Power source commands and signals...............................................................................................5
3.2.2 – Power source operation....................................................................................................................6
3.3 - Troubleshooting.....................................................................................................................................7
3.3.1 – Power source does not start, LED A off ..........................................................................................7
3.3.2 – Power source powered, LED A lit , fan (9) stopped........................................................................8
3.3.3 - Power source powered, the signals do not indicate correct values...................................................8
3.3.4 – Start button produces no effect. .......................................................................................................9
3.3.5 –No gas flows from the torch..............................................................................................................9
3.3.6 – Gas flows from the torch, the pilot arc does not light....................................................................10
3.3.7 – Transfer arc does not take place or is too weak for cutting ...........................................................10
4 – LIST OF SPARE PARTS..............................................................................................................................11
4.1 - Power source item 481.........................................................................................................................11
4.2 - Components table ................................................................................................................................11
4.3 - Spare parts list......................................................................................................................................11
5 – ELECTRICAL DIAGRAMS........................................................................................................................12
5.1 – Power board ........................................................................................................................................12

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1 - GENERAL INFORMATION
1.1 - Introduction.
The purpose of this manual is to train personnel assigned to carry out maintenance on
the power source art. 481 for plasma cuttingsystems.
1.2 - General service policy.
It is the responsibility of the customer and/or operator to use the equipment appropriately,
in accordance with the instructions in the Instruction Manual, as well as to maintain the
equipment and related accessories in good working condition, in compliance with the
instructions provided in the Service Manual.
Any internal inspection or repairs must be carried out by qualified personnel who are
responsible for any intervention on theequipment.
It is forbidden to attempt to repair damaged electronic boards or modules; replace them
with original ELETTRO CF s.r.l. spareparts.
1.3 - Safety information.
The safety notes provided in this manual are an integral part of those given in the
Instruction Manual. Therefore, before working on the machine, please read the paragraph on
safety instructions in the aforementionedmanual.
Always disconnect the power cord from the mains, and wait for the internal capacitors
to discharge (1 minute) before accessing the interior of theequipment.
Some internal parts, such as terminals and swirl rings, may be connected to mains or
otherwise hazardous potentials. It is therefore forbidden to work with the safety guards
removed from the machine unless strictly necessary. In this case, take special precautions
such as wearing insulating gloves and footwear, and working in a perfectly dry environment
with dryclothing.
1.4 - Electromagnetic compatibility.
Please read and observe the instructions provided in the paragraph “Electromagnetic
compatibility” of the InstructionManual.

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2 - SYSTEM DESCRIPTION
2.1 - Introduction.
The PLASMA 26 COMPRESSOR INVERTER is a plasma arc system for cutting
electrically conductive materials.
It consists of an electronic power source (item 481) and a series of accessories which allow
its adaptation to several kinds of uses.
The power source is controlled by microprocessor boards, which manage the cutting
system’s operational functions and the operator interface.
2.2 - Technical specifications.
To verify the technical specifications, see the machine plate and Instruction Manual.
2.3 - Description of power source item 481.
Item 481 is a controlled current inverter power source, consisting of a single-phase rectifier
bridge, a PFC module and an IGBT DC/DC converter.
Referring to the wiring diagram, you can identify the main blocks that make the power
source.
The main switch (24) powers the fan (9) and the power board (8) that contains the filter to
reduce conducted interference reflected in the mains, the pre-charge circuit and the PFC
circuit.
The pre-charge resistance limits the amount of current absorbed from the mains, only
during the starting of the machine.
When the group of electrolytic capacitors reaches a certain voltage threshold, the pre-
charge relay short-circuits the pre-charge resistance and only the green LED A remains lit on
the front panel.
The power board (8) is the real cutting current generator, which converts the alternating
voltage at switch (24) input into continuous voltage adjusted according to cutting
requirements.
The adjustment of the cutting current is made by the power board (8) and depends on
signals and parameters set by the power board itself.
The signalling LEDs and the potentiometer for setting working parameters are positioned
in the power board (8).

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3 - MAINTENANCE
WARNINGS
ANY INTERNAL INSPECTIONS OR REPAIRS MUST BE CARRIED OUT BY
QUALIFIED PERSONNEL.
BEFORE BEGINNING MAINTENANCE OPERATIONS, UNPLUG THE POWER
SOURCE FROM THE MAINS AND WAIT FOR THE INTERNAL CAPACITORS TO
DISCHARGE(1 MINUTE).
3.1 - Periodic inspection, cleaning.
Periodically open the power source grids and check inside the aeration tunnel.
Remove any dirt or dust to ensure smooth air flow, and thus adequate cooling of the
internal parts of the power source.
Check the condition of the output terminals, output and power supply cables of the
power source; replace if damaged.
Check the condition of the internal power connections and connectors on the electronic
boards; if you find “loose” connections, tighten or replace theconnectors.
3.2 - Operating sequence (pict. 3.2.1).
The following sequence represents correct functioning of the machine. It may be used
as a guiding procedure fortroubleshooting.
It must be carried out after each repair without anyerrors.
3.2.1 - Power source commands and signals.

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3.2.2 - Power source operation.
NOTE
Operations marked with this symbol refer to operatoractions.
The operations marked with this symbol refer to machine responses that must occur
following an operator action.
System shut off and unplugged from themains.
Connect the cable of the positive pole of the power source to theworkpiece.
 Connectthepowersourcetothemains.
Close the switch (H) on the power source.
System powered, led (A) lit, fan running.
On front panel, leds (C) and (D) off; led (B) lit for the first 5 seconds
(analysis phase), then off
Correct? NO (see 3.3.1, 3.3.2, 3.3.3).
YES
DURING THE FOLLOWING TESTS, DO NOT POINT THE TORCH AT PEOPLEOR
PARTS OF THE BODY, BUT ALWAYS TOWARDS AN OPEN SPACE OR THE
WORKPIECE.
 Press thetorchstartbutton and hold it down.
Gas flows from the torch and the pilot arc starts for the maximum pilot arc
time (2 sec.). The gas continues to flow for approximately another 100 sec.
after the start button is released (post-gas time).
Correct? NO (see 3.3.4, 3.3.5, 3.3.6).
YES
With pilot arc lit, place the torch close to the workpiece.
Begin cutting.
Correct? NO (see 3.3.7).
YES
 Releasethetorchstartbutton.
The arc shuts off immediately. The gas continues to flow for the post-gas time
(approximately 100 seconds after the start button is released) to cool thetorch.
Correct? NO (see 3.3.5).
YES
REGULAR OPERATION.

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3.3 - Troubleshooting.
WARNINGS
ANY INTERNAL INSPECTION OR REPAIR MUST BE PERFORMED BY QUALIFIED
PERSONNEL.
BEFORE REMOVING THE PROTECTION COVERS AND ACCESSING INTERNAL PARTS,
DISCONNECT THE MACHINE FROM THE MAINS AND AND WAIT FOR THE INTERNAL
CAPACITORS TO DISCHARGE (1 MINUTE).
NOTE
Items in boldface describe problems that may occur on the machine(symptoms).
Steps marked with this symbol refer to situations for which the operator must determine the
causes (causes).
Operations preceded by this symbol refer to actions the operator must perform in order to
solve the problems (solutions).
3.3.1 - The power source does not start, led (A) off.
MAINS SUITABILITY TEST.
No voltage at the power source input, because the mains surge protector istripped.
NO
Correct?
YES
Eliminate any short-circuits in the connections between the power cable, switch
(24) and power board (8).
Mains not suited to power the power source (ex.: insufficient installed power).
MAINS CONNECTION TEST.
Input terminals J2 – J3 on power board (8) = 230 Vac approx., with switch (24) closed.
YES Correct?
NO
Check power cable and plug and replace if necessary.
Check the switch (24) and replace if defective.
Check the mains voltage conditions.
Check the integrity of the rectifier bridge DS1 on power board (8).
POWER BOARD PRE-CHARGE TEST (8).
Power board (8), pre-charge relay K1 closes when the machine is switched-on.
YES Correct?
NO
Check working conditions of relay K1
Check working conditions of pre-charge resistance PT1
Replace the power board (8)
Replace the power board (8).

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3.3.2 - Power source powered, led (A) lit, fan (9) stopped.
FAN (9) TEST.
Fan (9) fast-on terminals = 230 Vac, approximately, after closing switch (24).
NO
Correct?
YES
Make sure that there are no mechanical impediments blocking the fan (9).
Replace the fan (9).
Check the wiring between fan (9) and connector J2 and J3 on power board(8).
Check the presence of 230V approx. on switch (24).
Check the switch (24) and replace if defective.
3.3.3 – Power source powered, the signals do not indicate correct values.
LED (D) steady lit, insufficient air.
-Carry out the compressor test, see par. 3.3.5.
LED (C) steady lit, thermal protection.
-Check the working conditions of thermostat and replace if defective.
-Replace the power board (8).
LED (B) steady lit, power source blocked.
This indicator indicates that the power source is in an analysis phase, in the first 5 seconds
after closing the switch (24), or, thereafter, is blocked due to a hazardous condition. Check
the value of supply voltage.
If previous steps have not solved the problem, replace the power board (8).

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3.3.4 – Pressing start button produces no effect.
START COMMAND TEST.
Press the torch button and check the electrical continuity between torch button contacts on terminals
1-2 of connector J16 on power board (8).
YES Correct?
NO
Check wiring between terminals 1 – 2 of J16 and the torch (16).
Check that the nozzle protection is properly mounted on the torch and in good
working conditions. If defective or showing signs of wear, replace.
Check the torch button. If defective, replace it.
Replace the power board (8).
Replace the power board (8).
3.3.5 – No air flows from the torch.
COMPRESSOR (10) TEST.
Compressor terminals (10) = 230 Vac approx. with the torch button pressed and for the post-gas
time.
YES Correct?
NO
Check the wiring between the compressor (10) and J4 of power board (8).
Replace the power board (8).
Replace the compressor (10).

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3.3.6 –Gas flows from the torch, but the pilot arc does not light.
Pressing the torch button, the pilot arc lights
YES Correct?
NO
Check the conditions of torch consumables. If showing signs of wear, replace.
Check wiring between terminals 3 of J16 and torch (16).
Check the working conditions of pilot arc relay K2 on the power board (8).
Replace power board (8).
Regular operation
3.3.7 – Transfer arc does not take place or is too weak for cutting.
TRANSFER ARC SWITCHING TEST
Make sure that with the torch close to the workpiece and the pilot arc lit, the reed relay contact L3
on power board (8) closes.
NO Correct?
YES
Check the working conditions of relay K3 on power board (8).
Make sure that the earth cable (27) is connected to the workpiece.
Check the wiring between the earth cable (27) and the connector J17 on power
board (8).
Check the wiring between the torch (16) and the connector J18 on power board
(8).
Replace the power board (8).
Replace the power board (8)