Kaliburn SR-45i, User Manual

Page: 47 / 71

Maintenance and Troubleshooting SR-45i User’s Manual
CON2 or associated wiring may be bad. If
CON2 pulls in, the auxiliary switch or
associated wiring may be bad.
7. Red D.C. Power light or associated wiring may
be bad.
8. Pilot Arc lead has a leak or loose fittings.
Contactor making noise 1. Contactor has accumulated dust inside. Take
contactor apart and blow out with compressed
air.
2. Check 24VAC supply for low voltage. 24VAC
can be measured between TB2-7 and TB2-8.
The arc will not transfer to the
workpiece
1. Loose work ground connection.
2. Pierce height too high.
3. Incorrect, damaged, or worn consumables.
No spark between the spark gap
electrodes
1. Improper spark gap. Set the spark gap to .015”
(.38 mm).
2. Worn spark gap electrodes. Clean electrodes
with fine sandpaper and set the gap to .015”
(.38 mm). Replace electrodes that have a
rounded face.
3. Verify that all LED’s illuminate in the proper
order.
4. In mode 0 or 2, if all LED’s illuminate, but the
HF LED does not, replace the logic-regulator
p.c. board.
5. Visually check all terminal connections around
the high frequency transformer and spark gap
assembly.
6. Disconnect the high frequency transformer
TR4 and check for 120 VAC across the supply
leads after a start signal has been received and
the HF LED has illuminated. If 120 VAC is
present, go to step 6. If 120 VAC is not
present, check the continuity in the lines from
P3-18 to TB2-6, from P3-17 to TR4, and from
TR4 to TB2-1. If all lines are good, give the
system a start signal, wait for the HF LED to
illuminate, and check for 120 VAC between
P3-18 on the logic-regulator p.c. board and
TB2-1, then between P3-17 and TB2-1. If P3-
18 reads 120 VAC but P3-17 does not, replace
the logic-regulator p.c. board. Note that P3
must be plugged in to the logic-regulator p.c.
board to obtain the correct readings.
7. Check the high frequency transformer TR4
primary and secondary windings. Replace TR4
if either winding is open.
8. Remove the wire from the high frequency
capacitor C9 and check the capacitor for a
short circuit. Replace if necessary.
9. Check the primary and secondary windings of
the high frequency coupling transformer TR5.
Replace TR5 if either winding is open.
5-9