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Transcript
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!!!