1. CUT40P training manual
March.2011

2. 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

3. 1、Introduction of working principle

4. Working principle

5. System chart

6. Explosion drawing

8. 2、Introduction of main circuit（parts different from MMA）

11. View of main board

12. Photo of system power

13. 3、Introduction of control circuit（parts different from MMA）

15. Circuit about test of tip or electrode.

16. Circuit about test of torch cap.

18. View of control board

19. Photo of control board

20. GUN&TEST
SOURCE&TIP MB
HF/QF
DRIVE
PRESSURE OT WA WV
D&T
SWITCH

21. 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.

22. 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.

23. SWITCH--To select test or normal status.
1-up 2-up 3-up
Test status
1-down 2-down 3-up
Normal status

24. Wvf: by adjusting it to make the voltage of Pin 25 of MCU is 1
Wvf: by adjusting it to make the voltage of Pin 25 of MCU is 1.0V when the output voltage is 100V.

25. Imax: by adjusting it to make the pre-setting maximum current accord with the actual current.

26. Imin: by adjusting it to make the pre-setting minimum current accord with the actual current.

27. 4、Introduction of panel circuit

28. Electrical drawing of panel board

29. View of panel board

30. Photo of panel board

31. 5、Troubleshooting Series A: Troubles about panel display
Series B: Troubles about power system
Series C: Troubles about cutting

32. Presentation of panel LED1: power display LED4: work display
LED2:Over-temprature or Over-current alarm
LED3:Lower-pressure,tip or short-circuit alarm

33. Varistor-To set the cutting current
Select switch-To set RUN (normal work) or SET (gas test) status

34. Trouble: 1、The input pressure is too low.
A-1: LED3 is always on.
Trouble: 1、The input pressure is too low.
2、Something abnormal with pressure switch.

35. Test position 1: Check the voltage of No 3 pin of U305（Photo coupler） to ground. (Refer to test table)

36. Solution 1: 1、Regulate the input pressure to 75PSI/5.2Bar.
2、Clear the dust of gas tube inside the machine.

37. Test position 2: To test the pressure switch, as follows:
Normal pressure
Lower pressure
Solution 2: Change the pressure switch.

38. A-2: Put this switch on the position of “SET” or press the torch, but no gas output.
Trouble: Gas valve or power source.

39. Test position: Check the voltage of these two white wires, and about +24V is OK.

40. 1、Check the cable connected to the gas valve.
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.

41. 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.

42. Test position 1: Checking the voltage of No 17 pin of MCU to ground
Test position 1: Checking the voltage of No 17 pin of MCU to ground. (Refer to test table)

43. Solution 1: Install the tip and electrode properly.

44. Test position 2: Checking the status of these wires
Test position 2: Checking the status of these wires. (Refer to test table)

45. Solution 2: Install the cap properly.

46. Solution 3: Remove the cap, tip and electrode and clean the inside of torch, then reassembly them properly.

47. A-4: LED2 is on.
Trouble: Over-current or over-temperature.

48. Test position 1: Checking the voltage of No 3 pin of U306 to ground
Test position 1: Checking the voltage of No 3 pin of U306 to ground. (Refer to test table)

49. 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.

50. Test position 2: Checking the voltage of No 8 pin of U203 to ground
Test position 2: Checking the voltage of No 8 pin of U203 to ground. (Refer to test table)

51. 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.

52. A-5: No arc output but no alarm display when press the torch.
Resolution:
1、 Put this switch on the position of “RUN”.

53. 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.

54. A-6: LED1 is not on when switch on the machine:
Trouble: Power source or wrong connection

55. Solution:
1、Connect the main input cord properly.
2、Verify that the range of input voltage is about VAC.
3、Turn the power switch to “ON” position.

56. 4、 Check the cable between the control board and the panel board.

57. 5、 Check No32 pin of MCU on control board, and test if there is +5V, if not, check the part of switch power.

58. 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
Over-temperature
“Low” level(<=5V)
“High” level(>=10V)
No 3 pin of chip U306 to ground
Refer to A-4
Over-current
No 8 pin of chip U203 to ground
Lower-Pressure
No 3 pin of chip U305 to ground
Refer to A-1

59. 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.

60. 2、 Put the red switch on the following position,1-down,2-down,3-up(on),which means normal status.

61. 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.

62. B-2: There is pilot arc output but can not be transferred to cutting arc when press the torch and contact the work piece.
Resolution:
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.

65. B-3: The output is too low or unstable or inadequate. 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、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.

66. B-4: The pilot arc is hard to ignite and easy to go out. Resolution:
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.

67. 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.

68. 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.

69. 6、Appendix PFC chip--4981 PWM chip--SG3525 PWM chip--SG3524
Switch chip--TOP246

70. Q & A

71. Thanks for your
attention!!!