5.

7 Troublesh ootin g GU IDE

A. Power Light (PL1) does not co e on. 1. Visually inspect the machine for any damage. 2 . Check if the cooling fan is running. If not, then check the following : a. Check if the machine power cord is plugged to the input power receptacle. b. Measure the input power at the receptacle. If not present, then check the wall disconnect switch and it s fuses. c. Check !use "!1#. If fuse is ok, then check the input circuit breaker "C$1# for proper operation. %eplace if defecti&e. ' . If abo&e items check () , the problem is internal. *end unit to an +uthori,ed %epair *tation for repair. a. If the cooling fan is running, then measure &oltage between pins -2.11 and -2.1/ of the control board "should be 110 V+C#. If there is no &oltage, then replace transformer 12. b. If the &oltage is present, then the pilot light may be burnt out. !. "o Air #low 1. Check air inlet supply. 2nit re3uires '24 C!5 at 60 psig. 2 . Check air hose and connections. 1ighten if leaking. ' . 7oes air flow when 8air test9 switch is in test position: a. If not, check torch consumables, replace if necessary. b. If abo&e items check () , the problem is internal. 1ake unit to an +uthori,ed %epair *tation for repair. $. The Power light is on% but nothing h&''ens when the torch switch is de'ressed. #&ult light does not &cti(&te. NOTE: Unplug high frequency connection before attempting to work on this problem. 1. Check the -ilot +rc fuse "!2# located on the rear panel. +n open fuse will indicate a short in the torch. If the fuse is all right, then check the following: a. ;ith the machine power on, depress the torch switch. (n the control board the <=7 1 should be lit as long as the switch is depressed. If not then check: i. 1urn power off to the machine. 2nplug Control board. -ut an ohmmeter across -0.1 and -0.2 to take resistance reading. 7epress torch switch. Meter should read a short. If not, then one of the following is not working properly: ii. 1orch switch or the leads. 2nplug the torch switch leads at the machine. -ut a meter across the two plug pins. *hould read a short when the torch switch is depressed. If not, then either broken switch leads or malfunctioning switch. b. Check 12 transformer secondary &oltages at the plugs -1 and -2. %efer to system schematic. %eplace the transformer if the correct secondary &oltages are not present. c. If e&erything abo&e checks out all right, then the -C$1 Control $oard should be replaced. '0 D. #&ult light &cti(&tes when torch switch is closed. 1he !ault circuit is used to monitor conditions necessary for the safe operation of the -CM.>?0. 1he fault light will glow amber under the following conditions and operations will come to a complete stop: 1. )igh*Low line (olt&ge. 1he !ault <ight will r&'idl+ blin, on &nd o-- "0 times per second#. 1his indicates that the input &oltage is outside the 8@9 or 8.9 10A safe operating range rating. 2. #low -&ult . 1he fault light will be ostl+ on but will blink off for 1B14th of a second e&ery second. 1his indicates that the air flow is low. a. Check the air pressure at the machine regulator. It should be adCusted to 60 psig. If no air pressure, check the air at the supply point. +lso, check for any obstructions in the air hose.

b. +ir flow may be blocked at the torch tip. Check the torch consumables. +lso check for any obstructions in the torch leads. NOTE: If above items check OK , the problem is internal. send unit to an Authorized epair !tation for repair. c.. -ut the D+ir Check switch to (n position. +ir should flow through torch. If not, then the flow switch may be stuck due to oil in the air. Clean air flow switch per supplier s instructions or replace switch. 1o check if the flow switch is open, put &oltmeter leads between -1.12 and -1.1. It should read about 12 V7C. ;hen the flow switch closes, the &oltage will drop to ,ero &olts. d. +ir Check switch may also be malfunctioning if the air is flowing continuously or putting in the (n position does not turn air on. '. . (er Te 'er&ture. 1he fault light will be ostl+ o-- but will blink on for 1B14 of a second, e&ery second. 1his generally indicates that the duty cycle has been eEceeded. +llow the power source to cool before returning to operate. a. 1hermal switch may be open. It will open if the temperature at the IF$1 base reaches G/ oC. ;ith the machine power off, check the continuity between -1.1 and -1.2 of the control board. If the switch is (), then the ohmmeter should read a direct short. If not then it should read open. b. If the switch is malfunctioning, replace it. Clean the surface of the heat sink before installing the switch. /. .(er $urrent. 1he fault light will be on continuousl+. 1his indicates that the input current to the main transformer has eEceeded preset limits. a. 1o check if the output is shorted, measure the resistance by putting the ohmmeter leads "make sure to disconnect 5I !re3uency leads#:9@9 of the meter to 1orch 8@9 output terminal and ;ork 8.9 lead of the meter to the 8.9 output terminal. %eading should be about 2 ) (hms. %e&erse the &oltmeter leads, the resistance reading should be less than 1.0 ) (hms. b. If the resistance reading is different than abo&e, check the torch, the output bridge and !ilter $oard "-C$.0#. E. A ir is .n but nothing h&''ens when torch switch is o'er&ted. 1. Check the torch. Make sure that the heat shield is &ery tight. 2. Check to assure high fre3uency is present at the torch. If not, then listen for high fre3uency at the high fre3uency generator. It is located on the bottomBright side of the unit. 1he high fre3uency gap is set to 4.4/49. Disconnect )I #/E0UE"$1 le&ds. Check for 110 &olt supply to the high fre3uency unit between -2.12 H -2.1' of the control board with torch switch closed. '. ;ith 5I !%=I2=JCK leads disconnected, measure open circuit &oltage. It should be 2?0 V7C between 8;ork9 and 81orch9 terminals. If it is not present then any one of the following may not be working properly: a. Check the operation of the 1hermal *witch. *ee 7.'.a. abo&e. b. Check +ir Check switch operation. It might be stuck in (n position. -ilot arc will not initiate if this switch is in the (J position. "safety reasons#

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'6

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c. Check air flow switch. 1here may be internal short. *ee 7.2.c abo&e. d. Measure &oltage across C1 or C2 capacitor. It should be as follows: approE. '20 V7C for the 24>B2'4 &olt unit. approE. 2>4 V7C to '20 V7C for the /44 or /64 &olt unit approE. /14 V7C for the 0?0 &olt unit If not, one of following could be malfunctioning: 1#. Check the capacitors C1 and C2 for any damage. 2 .# Check input bridgeB*C% Module "I$%# 1his can be checked without taking it out of the circuit using an &oltBohmeter. %eplace it if found malfunctioning. !ollow bridge installation instructions. ' .# Check Inrush current resistor, %14 and *C%1. $oth are located on the input bridge heat sink. %eplace it if malfunctioning. e. IF$1s "2 on 2'4 V, and 1 on the /44 V H /64 V units# may be blown. *ee IF$1 installation procedure. $efore replacing IF$1s, make sure to check the ,ener diodes and pico fuses on the IF$1 dri&er boards. #. )igh #re2uenc+ &nd Pilot Arc &re on but 3&in Arc does not tr&ns-er. 1. Make sure work clamp is connected to work material. 2 . Check the torch. %eplace consumables if necessary. ' . Make sure the current setting potentiometer is set abo&e 14 amps. If it is, set below 14 amps, then 5I !%=I2=JCK will go on and off at 0 sec inter&als. G. Poor $utting Per-or &nce. 1. Check air supply regulator . It should be adCusted to 60.?0 psig. 2 . 1he air supplied to the torch should be free of oil and water. ' . Make sure the consumables in the torch are acceptable. /. Check open circuit &oltage. *ee =./ abo&e. 0. Check the output. 2se a calibrated current probe capable of measuring 144 amps in the presence of high fre3uency.

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'? ). A ir does not shut o--. 1. Check air test, the gas solenoid &al&e is energi,ed when the switch is in the 8on9 position. 2 . 7oes air flow stop when the torch switch is unplugged: If yes, check and repair the torch. If not, send unit to an +uthori,ed %epair *tation for repair. a. Check &oltage to solenoid coil, if present when torch switch is unplugged, replace -C$1. If &oltage is 849, replace solenoid &al&e. I. 3&in &rc is di--icult to st&rt. 1. 1he most common reason is worn or missing consumables. Check and replace if necessary. 2 . Input air must be clean and dry. ' . Input air pressure must be between 60 . ?0 psig. /. 1orch connections must be tight. 0. ;ork cable and clamp must be in good condition and must make a good electrical connection to the material to be cut. 6. If abo&e items check () , the problem is internal. send unit to an +uthori,ed %epair *tation for repair. a. Missing or weak pilot arc. Check pilot arc fuse, open circuit &oltage, pilot arc resistors and pilot arc wiring. b. Inoperati&e starter board "-C$.0#.

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J(1=: *chematics and ;iring 7iagrams on