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CUT40P
training manual
March.2011
Catalogue
• 1、Introduction of working principle
• 2、Introduction of main circuit（parts
different from MMA）
• 3、Introduction of control circuit
（parts different from MMA）
• 4、Introduction of panel circuit
• 5、Troubleshooting
• 6、Appendix
1、Introduction of
working principle
Rectifier
Inverter
Filter
DC
PFC
DC
Rectifier
AC
DC
50HZ
Hall
DC
Hall
Transformer
220-240VAC
DRIVE
Panel
MCU
Initialization
SG3525
Calculation
Comparison
Logic test
Working principle
OUT-
1
AC
+
AC
-
2
PFC
3
Q
4
T1
NPN
ZBYQ
ZBYQ
L1
OUT+
T2
-24V
HALL2
Current transformer
TRANS2
K1
GND
AC2
T3
AC1
OC1
OC2
AC110-230V-50/60HZ
L2
OUT-
INDUCTOR1
T4
GND
SOURCE&TIP
Pressure
Switch
GUN
IFOUT
1
2
DY1
IN
DY2
1
2
3
4
5
TIP test
WVOUT
QD
2
1
MAIN PCB
DYJC
POWER
3
2
1
I and D
4
3
2
1
IFIN
XFIF/IN/OUT
1
2
3
4
5
6
5
4
3
2
1
4
3
2
1
IFB1
IFB2
IFB3
IFB4
D_port
1
2
Transfer_IFB
1
2
3
GUN&TEST
1
2
3
4
PRESSURE
1
2
1
2
4
3
2
1
4
3
2
1
3
2
1
FAN
U_D
HF/QF
CONTROL PCB
DRIVE
1
2
WV
1
2
3
MB
OT
Drive1
Drive2
Drive3
Drive4
7 Drive5
6 Drive6
5 Drive7
WA
3
2
1
9
8
7
6
5
4
3
2
1
9
8
7
6
5
4
3
2
1
4
3
2
1
10
1
2
3
4
5
6
7
Heat
Relay
4420
Drive1
Drive2
Drive3
Drive4
Drive5
Drive6
Drive7
MB
10
PANEL PCB
GAS_ VALVE
Fan
IFB1
IFB2
IFB3
HALL
IFB4
System chart
Explosion drawing
Number
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
Serial number
Name
Quantity
8.253.020
8.301.620
5.496.110-R-7
7.425.631
5.496.604
7.411.010
8.713.638
8.425.641-B
8.425.640
8.425.639
5.496.803-E
8.069.620
7.557.031-A
7.458.033-C
7.667.001
7.155.140
8.123.632
6.271.639
7.321.104
7.421.541
7.231.275
7.425.634
8.124.620
7.253.009-B
7.232.637
7.624.270
8.124.640
7.253.400
8.124.622
7.445.319
8.055.620
7.401.070
8.425.646-B
8.425.642
6.185.639
7.720.010
8.831.001
8.462.116
8.068.620
7.232.730
7.154.402
Handle
Cover
CUT 30/40PFC Main Board
IGBT
Control Board
Rectifier
Control Board Insulation Film
Heat Sink(3)
Heat Sink(2)
Heat Sink(1)
40A CUT Panel Board
Front Panel
Water-proof Cover
Knob
Center Socket
Cable Fixed Clamp
Output Panel
Inductance
HALL
FRD
Thermostat
IGBT
Front Middle Plate
Solenoid Valves
Pressure Switch
T Joint
Valve Assembly Plate
Water And Oil Separator
Rear Middle Plate
Resistor
Bottom Plate
FRD
Heat Sink(5)
Heat Sink(4)
Main Transformer
FAN
Accessories Lid
Fast Socket
Rear Panel
Water-proof Switch
EU Standard Cable
1
1
1
6
1
2
2
1
1
1
1
1
1
1
1
1
1
1
1
2
2
1
1
1
1
1
1
1
1
2
1
2
1
1
1
1
1
1
1
1
1
2、Introduction of main
circuit（parts different
from MMA）
Part 2£ºPilot arc
2
1
ZYOUT
C126
OUT+1
R04
ZD4
R125
Part 1:Output rectifier
V13
WVOUT
3
2
1
R100
C100
R01
T10-1
T14-1
ZBYQ
GDN
GND
C101
R35
Test of
HL
+
OUT
R101
Part 4:
IN
IN
OUT
OUT
COUT1
T16-1
6
6
5
5
OUT+
cutting arc
COUT2
4
3
2
1
(different from
CUTSKILL 35)
1
2
3
4
0UT-
The output includes four parts:
Part 1: Output rectifier and snubber circuit
Part 2: Pilot arc
Part 3: Drive of pilot arc
Part 4: Test of cutting arc
XHIF
GDN
VCC
U6
1
OR1
2
3
4
C49
VCC
VCC
IN
OUT
NC
OUT
GND
GND
8
7
6
5
OR2
QD
2
1
C53
Part 3: Drive of pilot arc
C47
C44
2
Vin
Dnd
Part 1: Switch power that provides the power +24V to the fan
and gas valve, +24V,-24V,earth to control board.
Part 2: Test circuit of tip is to provide signal to control board
when tip of torch is absent.
U8
5
7
This page mainly includes two parts:
DC-DC
0V
R31
+0V
F1515S-1W
D19
1
OUT+1
C12
R34
Part 2:
Test of tip
OUTC52
Part 1: Switch power
FJ
1
2
DY1
D7
+24V1
D8
L1
C7
C9
C10
C8
1
2
R85
+01
D5
B3
3
2
1
D9
D15
L2
C11
C13
DY2
C14
R86
TVS1
D11
R88
C0
C6
D16
C46
C45
C15
D6
D13
R87
D17
-24V
R88-1
L3
D28
D27
C42
C25
C27
C28
R30
L5
R89
D18
2
6
R91
C43
1
F
X
S
C
5
R93
C40
C41
R92
U9
ZD8
L
D
U7A
4
D5-1
3
AC220V
R90
ZD9
1
2
3
4
5
View of main board
Photo of system power
3、Introduction of
control circuit（parts
different from MMA）
Part 1: Drive of pilot arc and test of cutting arc
D&T
drive
U301
R309
1
2
3
4
5
6
C302
This page includes forur parts:
R307
VCC
Part 1: Drive signal of pilot arc and test of cutting arc when the torch touches the
U302
C314
drive test
work piece during cutting.
R310
Part 2: Test circuit of input gas pressure
C305
R218
Part 3: Control circuit of gas valve
Part 4: Test circuit of over-current and over-temperature for protection.
24V
Part 2: Test of lower-pressure
R327
C310
24V
VCC
C311
R326
OT
+15V
D201
SP
U306
U305
PRESSURE
R322
1
2
C102
pressure
R312
1
2
3
R323
R248
C101
C104
VSS
GND2
VSS
R220
C304
VSS
VSS
GND2
C111
R242
24V
Part 3: Control of gas valve
QFS
D204
U203C
D200
SP
R243
10
8
9
R244
OC
R240
VCC
QFO
AirCtrl
C112
R314
1
2
R241
24V
4
U303
A
K
C
3
E
C109
GND2
C31
R315
Part 4: Test of over-current and over-temperature
T205
R316
C306
VSS
VSS
Circuit about test of tip or electrode.
Part 1: Test of Tip
OUT+1
When LED3 of panel board is blink, it may result from absent
1
Vin
Dnd
0V
you test that thevoltage between No pin 17 of MCU to ground
is "low" level, you can judge this trouble because of absent of
5
7
R31
of tip, electrode and cap or short citcuit of torch inside, and if
DC-DC
+0V
D19
F1515S-1W
2
+15V
tip or electrode.
U8
C12
C900
tip_test
R34
R901
Pin 17
R902
OUTDY2
C52
M ain board
1
2
3
4
5
CON5
VCC
MCU
5
4
3
2
1
SOURCE&TIP
ground
Circuit about test of torch cap.
24V
R325
C312
GUN&TEST
VCC
Pin 20
gun test
U307
R324
R311
C107
VSS
C303
MCU
4
3
2
1
GND2
R210
Part 2: Test of torch cap
When LED3 of panel board is blink, it may result from absent of tip, electrode and
cap or short citcuit of torch inside, and if voltage betw een No pin 20 of MCU to ground
is "low" level,you can judge this trouble because of absent of cap.
1
+15V
Imin
VCC
R5
Part 2: D/A convert of PWM signal
-15V
2
R206
Part 3: Current comparison
and PI adjust
11
R4
3
R351
2
U203A
ZD203
U201C
1
D350
gun
3
9
8
C204
gun test
R205
C207
R249
10
R6
C315
2
4
D351
R350
R331
11
+15V
1
R208
13
3
14
12
Imax
D401
-15V
U201D
R207
IF
C205
U201A
2
PPG
R200
R201
1
U201B
R204
R203
R209
R330
6
3
7
5
R202
C200
4
R217
R211
C202
+15V
R216
+15V
15
+15V
R214
C208
comparison of pre-set value and
5
R213
feedback, PI adjust, SG3525 PWM
R215
7
8
VREF
Sy nc
OSC
Tr
Rd
SSt
Vc
OUTA
OUTB
Sd
V+
Tc
GND
convert of PWM signal from MCU,
16
3
4
6
VCC
U200
This page mainly includes D/A
VCOMP
CON7
13
11
14
10 SP
2
OC
C210
1
C401
C211
1
2
3
4
5
6
7
9
C400
12
chip.
R212
C209
Part 1: SG3525-Output drive signal
to inverter IGBT
View of control board
Photo of control board
DRIVE
WA
SOURCE&
TIP
WV
SWITCH
MB
D&T
HF/QF
GUN&T
EST
PRESSURE
OT
• DRIVE--Connected with main board to provide drive
signal for discrete IGBT.
• SOURCE&TIP--Connected with main board to
provide control board with power source and test
signal of tip.
• MB--Connected with panel board to communicate.
• HF/QF--Connected with main board to provide
power source for the gas valve and the outside
photo coupler circuits.
• GUN&TEST--Connected with the torch to provide
signal of gun and torch cap.
• PRESSURE--Connected with the pressure switch to
test the input gas pressure.
• OT--Connected with the temperature relay to
provide over-temperature signal for MCU.
• D&T--Connected with main board to provide
drive signal for pilot IGBT and sample signal
of cutting arc.
• WV--Connected with the output to sample
voltage signal.
• WA--Connected with HALL sensor to sample
current signal.
• SWITCH--To select test or normal status.
1-up 2-up 3-up
1-down 2-down 3-up
Test status
Normal status
Wvf: by adjusting it to make the voltage of Pin 25 of
MCU is 1.0V when the output voltage is 100V.
Imax: by adjusting it to make the pre-setting
maximum current accord with the actual current.
Imin: by adjusting it to make the pre-setting
minimum current accord with the actual current.
4、Introduction of panel
circuit
J1
VCC
I_Welding
VCC
R106
C103
pressureI
SP_D
gas test
HF/LIFT
3
2
1
I_Welding
2
gas test
workI
C105
1
3
VCC
R101
C102
C101
CURRENT
VCC
R105
LED1
LED3
C109
LED4
LED2
pressureI
SP_D
C110
1
2
3
4
5
6
7
8
9
10
workI
C108
C111
Electrical drawing of panel board
View of panel board
Photo of panel board
5、Troubleshooting
Series A: Troubles about panel display
Series B: Troubles about power system
Series C: Troubles about cutting
Presentation of panel
LED1:
power
display
LED2:Over-temprature or
Over-current alarm
LED4:
work
display
LED3:Lower-pressure,tip
or short-circuit alarm
Varistor-To set the
cutting current
Select switch-To set RUN
(normal work) or SET
(gas test) status


A-1: LED3 is always on.
Trouble: 1、The input pressure is too low.
2、Something abnormal with
pressure switch.
Test position 1: Check the voltage of No 3 pin
of U305（Photo coupler） to ground. (Refer to test
table)

Solution 1:
1、Regulate the
input pressure to
75PSI/5.2Bar.
2、Clear the dust
of gas tube inside
the machine.
Test position 2:
To test the pressure switch,
as follows:
Normal pressure
Lower pressure
Solution 2: Change the pressure switch.

A-2:

Trouble: Gas valve or power source.
Put this switch on the position of “SET”
or press the torch, but no gas output.
Test position: Check the voltage of these
two white wires, and about +24V is OK.

Solution:
1、Check the cable connected to the gas valve.
2、After test the voltage of gas valve. If not,
check the part of switch power. If yes, change
the gas valve.

A-3: LED3 will blink and no arc output when
press the torch.

Trouble: Absent of cap, tip or electrode or
short circuit inside the torch.
Test position 1:
Checking the voltage of No 17
pin of MCU to ground. (Refer to test table)
Solution 1: Install the tip and electrode properly.
Test position 2:
Checking the status of these
wires. (Refer to test table)
Solution 2: Install the cap properly.
Solution 3:
Remove the cap, tip and electrode
and clean the inside of torch, then reassembly
them properly.


A-4: LED2 is on.
Trouble: Over-current or over-temperature.
Test position 1: Checking the voltage of No 3 pin
of U306 to ground. (Refer to test table)

Solution 1:
1、Check the inside of machine and keep air flow
well.
2、Check for blocked fan and correct condition.
3、Cool the machine for several minutes and
assure that the machine is used within the rated
duty cycle.
Test position 2: Checking the voltage of No 8 pin
of U203 to ground. (Refer to test table)

Solution 2: If the voltage of No 8 pin of U203
to ground is high level, which means the machine
inside is in over-current condition, and need to
check the parts of output diodes, main
transformer and inverter discrete IGBT in the
main board.

A-5:
No arc output but no alarm display when press
the torch.

Resolution:
1、 Put this switch on the position of “RUN”.
2、Use the correct type torch which is suitable for
the machine
3、Check the torch inside and change these parts
if necessary.
4、Air pressure is too high.
5、Make sure that the machine is in on the status
of normal mode, but not test mode.
6、Check the control board and main board.

A-6: LED1 is not on when switch on the
machine:

Trouble: Power source or wrong connection
Solution:
1、Connect the main input cord properly.
2、Verify that the range of input voltage is
about 95-270VAC.
3、Turn the power switch to “ON” position.
4、 Check the cable between the control board
and the panel board.
5、 Check No32 pin of MCU on control board, and test if
there is +5V, if not, check the part of switch power.
Test table
Normal
status
Trouble
status
Test position
Remarks
Tip or electrode
“High”
level(>
=3.5V)
“Low”
level(<
=1V)
No 17 pin of MCU to
ground
Refer to
A-3
Torch cap
Closed
Open
Orange and black wires
of “GUN&TEST”
socket
Refer to
A-3
Over-temperature “Low”
level(<
=5V)
“High”
level(>
=10V)
No 3 pin of chip U306 to
ground
Refer to
A-4
Over-current
“Low”
level(<
=5V)
“High”
level(>
=10V)
No 8 pin of chip U203 to
ground
Refer to
A-4
Lower-Pressure
“High”
level(>
=3.5V)
“Low”
level(<
=1V)
No 3 pin of chip U305 to
ground
Refer to
A-1

B-1: There is no-load voltage but no arc output
when press the torch.

Resolution:
1、 Check the drive cable between control board
and main board.
2、 Put the red switch on the following position,1down,2-down,3-up(on),which means normal status.
3、 Unstable or improper connection between the
torch and power system.
4、 Test whether the IGBT of pilot arc is good.
5、 Check the part of main board.

B-2:

Resolution:
There is pilot arc output but can not be
transferred to cutting arc when press the torch and
contact the work piece.
1、 Unstable connection between the earth cable and
work piece.
2、 Check the test cable between control board and
main board.
3、 Keep proper distance between the torch and
work piece.

B-3:

Resolution:
The output is too low or unstable or
inadequate.
1、Check all input and output connection cables.
2、 Make sure that work cable has a proper
connection to a clean and dry area of work piece.
3、Make sure the correct input voltage according
to the nameplate.
4、Keep proper distance between the torch and
work piece.
5、Check the part of main board.

B-4: The pilot arc is hard to ignite and easy to go

Resolution:
out.
1、 Change the tip, electrode or torch cap which
may be worn.
2、The air pressure is too high and adjust it to
75PSI/5.2BAR.
3、Check the main board and control board.

B-5: Output is restricted and can not be
controlled.

Resolution:
1、 Check all input and output connection cables.
2、 Make sure that work cable has a proper
connection to a clean and dry area of work piece.
3、Check the part of main board.


C-1: The quality of cutting is not so good.
Resolution:
1、 Adjust the proper cutting current according
to the thickness and material of work piece.
2、The speed of cutting is too quick.
3、Clean the surface of work piece.
4、Change the tip, electrode and cap.
5、Keep proper distance between the torch and
work piece.
6、Appendix




PFC chip--4981
PWM chip--SG3525
PWM chip--SG3524
Switch chip--TOP246
Q&A
Thanks for your
attention!!!