CUTMASTER 102
SERVICE
Manual 0-4998
5-10
2. Bring the torch to the work piece and transfer to cutting
arc.
• OK-TO-MOVE signal is present. (Meter shows
continuity)
3. Remove jumper from the CNC connector.
• OK-TO-MOVE signal OFF (Meter shows no continu
-
ity)
• Gas continues to flow
• DC LED goes OFF
After 20 second Post flow time
• Gas solenoid closes
• Gas flow stops
If the unit has the Basic CNC Interface harness the test is
complete. If the unit does not function as stated above,
then note the symptom and proceed to Section "5.10 CNC
Interface Problems". If the unit has the Automation Inter-
face PCB installed, continue with this section.
4. There are three (3) ARC VOLTAGE signals available
from the J1 connector.
a) J1-9 (+) to J2-7 (-)
b) 2-5 (+) to J2-6 (-) (Auto Interface PCB 4 connector
P1 with no jumper installed) = ARC VOLTS divided
by 16.67.
c) J2-5 (+) to J2-6 (-) (Auto Interface PCB 4 connec
-
tor P1 with jumper installed between pins 1 and 2)
= ARC VOLTS divided by 30
d) J2-5 (+) to J2-6 (-) (Auto Interface PCB 4 connec
-
tor P1 with jumper installed between pins 2 and 3)
= ARC VOLTS divided by 50
Measure the voltage between these points while piloting
(Open Circuit Voltage) and while cutting. The voltages
should approximate those listed below
Open Circuit Voltage
Cutting Voltage
a) 300 VDC
100 VDC
b) 18 VDC
6 VDC
c) 10 VDC
3.3 VDC
d) 6 VDC
2 VDC
This completes the CNC Interface Test. If the above are all
correct then the unit is functioning correctly. If the unit does
not function as stated, then note the symptom and proceed to
Section "5.10. CNC Interface Problems".
5.07 Main Input and Internal Power
Problems
A. Primary input line fuse blows as soon as
primary disconnect is closed.
1. Primary input cable installed incorrectly.
a) Check wiring of primary power cable to the contac
-
tor. See illustration below.
2. W1 jumpers installed incorrectly
a) Check jumper installation for correct phase being
used.
Art # A-08493
Input Power Cable Connections
Three-Phase (3ø)
Store copper jumpers on base plate
Single-Phase (1ø) and Jumper Settings
GND
L1
L2
L3
L4
GND
L1
L2
L3
L4
Single and Three Phase Input Power Wiring
3. W1 contactor points are stuck closed
a) Check per section 5.11-A.
4. Primary plug not wired correctly.
a) Check manufacturer's plug installation instructions.
5. Primary input cable is defective.
a) Check cable for shorts.
B. Primary line fuses blow immediately after ON/
OFF SWITCH (SW1) is turned to ON position.
1. Shorted Input Diode Module
a) Check per section 5.11-B and 5.11-C.
2. Shorted Input Capacitor PCB 2
a) Check per section 5.11-D.
C. Gas flows with ON/OFF SWITCH in OFF
position
1. Foreign debris has lodged in gas solenoid.
a) Replace gas solenoid. This is a problem caused by
improperly filtered air supply. Customer needs to
add filtration to air supply prior to unit inlet.
Summary of Contents for CUTMASTER 102
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