Unitor UPC 1041 Instruction Manual Download Page 2 | Manualshive

Page: 2 / 46

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Revision date: 120813

Page 2 of 46

CONTENTS

1. TECHNICAL DATA

2. INSTALLATION

3. OPERATING INSTRUCTIONS

4. TORCH PARTS

5. MAINTENANCE

6. TROUBLE SHOOTING

7. SAFETY INSTRUCTIONS

8. SERVICE SECTION

UPC

‐

1041

Air

Plasma

Cutter

192

‐

404100

delivery

consist

of

:

Remarks

:

Plug

for

primary

cable

and

air

hose

is

not

supplied

as

this

will

depend

on

the

connections

available

onboard.

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Summary of Contents for UPC 1041

Page 1: ...Revision date 120813 Page 1 of 46 Instruction manual UPC 1041 Air Plasma Cutter...

Page 2: ...ATING INSTRUCTIONS 4 TORCH PARTS 5 MAINTENANCE 6 TROUBLE SHOOTING 7 SAFETY INSTRUCTIONS 8 SERVICE SECTION UPC 1041 Air Plasma Cutter 192 404100 delivery consist of Remarks Plug for primary cable and a...

Page 3: ...60 Hz 440 V The machine may be reset to 400 380 V as follows Disconnect the power source from 440V outlet Open the machine by removing the handle and cover Remove cable no 22 from 440V on the control...

Page 4: ...erage above 70 A Cutting Place the torch in position for cutting or gouging For most cutting operations the contact cutting shield should be used It is placed directly on the work piece at the edge wh...

Page 5: ...torch to a position where the distance from nozzle tip to work piece is 3 4mm 3 Tighten the allen screw on the inner ring 4 Tighten the allen screw on the outer ring with the wheels axis at 90 to the...

Page 6: ...en the machine is not in use or is only working at long intervals switch off the machine It contains mechanical components that should not be exposed to unnecessary wear It also protects against accid...

Page 7: ...5 Electrode for UPC 1041 w PTA 121 5 pcs 192 404005 6 Tool for electrode change 7 Swirl ring for UPC 1041 w PTA 121 2 pcs 192 404006 8 Nozzle 1 0mm 20 50 Amps for UPC 1041 w PTA 121 5 pcs 192 404007 8...

Page 8: ...e torch The moisture trap on the backside of the machine is self relieving by pressure drop this means that every time you start and stop a cutting cycle it will drain the moisture in the trap If clea...

Page 9: ...doesn t reactivate the torch during these 5min the fan switches off If the operator activates the torch within the 5min the Active fan control will reset the timing and when the operator stops the cut...

Page 10: ...during breaks Keep and cutting area and plasma machine components dry and clean and follow the maintenance recommendations strictly Working under elevated electrical endangerment This plasma cutting m...

Page 11: ...on The plasma arc produces intense ultraviolet and infrared radiation that can hurt the eyes and skin Therefore the following precautions have to be arranged Wearing of flame retardant welding clothes...

Page 12: ...EMC filter Make a visual inspection of the three varistors if any looks damaged then the machine has been connected to a voltage exceeding the approved 440VAC Check the incoming voltage and replace th...

Page 13: ...hine is disconnected from the main power supply Reconnect the incoming leads to the E5 EMC Filter Measure the three phases in the incoming socket with resistance measurement Correct value is approx 24...

Page 14: ...sure between W V and U on the incoming and outgoing side on the E5 EMC Filter with a summer measurement If no connection then replace the E5 EMC Filter Please note that the placement of V and W is shi...

Page 15: ...h Remove the fuse from the T1 Control transformer Measure between the cables 11 21 and 31 and the three phases on the incoming side on the main switch with a resistance or summer measurement Correct v...

Page 16: ...ve probe on cable 11 21 and 31 Correct value is approx 0 5V this can differ slightly between instruments If a short is measured then replace the D5 main rectifier Measure with instrument set to diode...

Page 17: ...e machine is used recently the values may differ Disconnect cable 73 and 74 from the D5 main rectifier Disconnect the pulse leads from the E2 PWM PCB connector A4 Measure between cables no 73 and 74 w...

Page 18: ...bit between different instruments but if very low or a short is measured on one pair then replace the E1 primary PCB Measure between pin 1 2 and 7 8 with the meter set to diode test and the negative...

Page 19: ...74 and the Out on the E1 primary pcb with the meter set to diode test and positive probe on cable 74 Correct value is approx 0 35 This value may differ a bit between different instruments but if very...

Page 20: ...primary pcb with the meter set to diode test and negative probe on cable 73 Correct value is approx 0 35 This value may differ a bit between different instruments but if very low or a short is measure...

Page 21: ...0VAC depending on the supply voltage If one phase is missing check the mains fuses Switch on the machine Check the voltage on the D5 main rectifier between cable no 73 and 74 positive probe on cable 7...

Page 22: ...ow or not existing check the fuse on the control transformer If fuse is undamaged replace the control transformer If fuse is broken replace the fuse and try again If the fuse breaks again then disconn...

Page 23: ...es on the T1 control transformer between 0 and 24V Correct value approx 24VAC If low replace the control transformer Check the secondary voltages on the T1 control transformer between 0 and 13 5V Corr...

Page 24: ...Revision date 120813 Page 24 of 46 Measure the voltage between TS1_A and TS1_B on the secondary PCB Correct value is 10VDC if low or missing replace the PCB and TS1 Switch off the machine...

Page 25: ...66 on the K1 pressure switch with resistance or summer measurement at approx 3 5 bar the K1 pressure switch should switch on Correct value is 0 ohm If the pressure switch doesn t switch on replace the...

Page 26: ...Disconnect the pulse leads from the E2 PWM PCB connector A4 Check the Fuse on the E2 PWM PCB with summer or resistance measurement If the fuse is broken try replacing it with a new and switch on the...

Page 27: ...27 of 46 Switch on the machine and press the torch trigger after about 1 sec the LED D11 should light up and stay lit for about 3 sec If D11 doesn t light up replace the E2 PWM PCB Reconnect the puls...

Page 28: ...the main transformer leads and one of the choke leads Measure between D3A and D3B with diode test and the red probe on D3B Correct value is approx 0 35 If a low value or a short is measured replace t...

Page 29: ...ansistor module TS1 Measure between TS1_B and TS1_C with diode test and the red probe on TS1_C Correct value is OL or unlimited If a low value or a short is measured replace the transistor module TS1...

Page 30: ...itch on the machine Measure the relay inside the copper winding between point J1 and J2 Correct value is 18VDC If no voltage then replace the E4 Secondary PCB Switch off the machine Reconnect the lead...

Page 31: ...voltage Remove jumper J1 from the E3 ignition control pcb Measure between P and minus on the E4 secondary PCB with a DC voltage measurement Correct value is approx 240VDC If this value is incorrect re...

Page 32: ...ne off the leds are lit Pre flow Press torch trigger D17 lights up indicating post flow Pilot arc After about 1sec D16 lights up indicating that the PWM PCB should start to send out pulses to the prim...

Page 33: ...rial has been detected and the Control ignition pcb is activating the cutting flow switching off pilot transistor and increasing current from pilot current to cutting current Post flow After finished...

Page 34: ...up After approx 5min the fan should switch off and D23 and D28 should go out Press the torch trigger D23 and D29 lights up indicating that the cutting signal controls the AFC To test the thermal contr...

Page 35: ...nnect the machine from main power supply Remove handle and cover Disconnect the trigger leads Disconnect the pilot lead by removing the M6 nut from the pilot lead connector Disconnect the Current air...

Page 36: ...torch leads Insert the leads on the new torch through the cable restraint Connect the nut on the Current air lead to the current connector Take care not to over tighten Connect the pilot lead to the...

Page 37: ...3 Page 37 of 46 Connect the trigger leads to the trigger connector Polarity is not important Tighten the cable restraints locking nut Take care not to over tighten since this may hinder airflow Replac...

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Page 42: ...Revision date 120813 Page 42 of 46...

Page 43: ...Revision date 120813 Page 43 of 46 Notes...

Page 44: ...Revision date 120813 Page 44 of 46 Notes...

Page 45: ...Revision date 120813 Page 45 of 46...

Page 46: ...ing Assens Bagenkop Bogense Copenhagen Ebeltoft Enstedvaerket Havn Esbjerg Fakse Ladeplads Havn Fredericia Frederiksund Frederiksvaerk Fredrikshavn Faaborg Gedser Great Belt Grenaa Graasten Gulfhavn H...

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