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PLASMA 100 Operating Manual

Troubleshooting Guide

Fault Cause

Remedy

1. The AC power indicator

light is not lit and cutting
arc can not be
established.

1. No power input or main power

switches damage.

2. Primary fuse is blown.
3. Indicator

damage.

4. Indicator light is open circuit.

1. Check input power or replace

main power switch.

2.  Replace primary fuse.
3.  Replace indicator light.
4.  Replace indicator light.

2. The AC power indicator

light on and cutting arc
can not be established.

1. Input voltage unstable.

2. Diode

damage.

3. Pilot Arc PCB damage.

1. Connect stabilizer or reset power

switch.

2. Replace

diode.

3. Replace pilot Arc PCB.

3. The warning indicator

light on.

1. Over

load.

2. IGBT

damage.

1. Reduce current or wait moment.
2. Replace

IGBT.

a. No gas flow

no spark.

1. Cutting torch switch leads are

disconnected.

2. Cutting torch switch damage.
3. Gas pressure too slow.

1. Reconnect.

2. Replace cutting torch switch.
3. Set the gas pressure correctly.

b. Gas

flow

continues
no spark.

1. HF starter dirty or spark gaps not

enough.

2. HF starter damage.

1. Clean the starter and adjust the

spark gap between 0.3~0.8mm.

2. Replace

starter.

c. No gas flow

have spark.

1.  Cutting torch damage.
2.  Gas hose is cut.
3.  Solenoid value damage.

1.  Replace cutting torch.
2.  Replace gas hose.
3.  Replace solenoid value.

4. PCM

mode
no
pilot
Arc
starts.

d. Gas

flow

continues
have spark.

1.  Cutting torch damage.
2.  Poor Electrode or Tip.
3.  Pilot Arc PCB damage.

1.  Replace cutting torch.
2.  Replace Electrode or Tip.
3.  Replace pilot Arc PCB.

5. PCM mode unstable Arc.

1. Electrode or tip damage.
2. Cutting torch bad contact or

damage.

3. Gas flow is improper.
4. Cutting torch gas hose is cut.
5. Cutting torch wrong position

(negative for cutting torch).

6. Control PCB damage.
7. The cutting current setting too low.

1.  Replace electrode or tip.
2.  Replace cutting torch.

3.  Check all the consumable parts.
4.  Replace cutting torch.
5. Reconnect.

6.  Replace control PCB.
7. Increase.

6. PCM mode incorrect

output.

1. Cutting torch bad contact.
2. Wrong

setting.

3. Control PCB damage.
4.

Potentiometer damage or
disconnected.

1. Replace.
2. Reset.
3. Replace control PCB.
4. Replace or reconnect.

7.The cutter has no output.

1. The select switch set incorrectly.
2. Bridge diode damage.
3. IGBT

damage.

1. Correctly set the select switch.
2. Replace.
3. Replace.

8. The cut result is bad.

1.  The electrode damages.
2.  The cutting tip damages.
3.  Gas pressure is improper.
4.  The cutting speed too quick or too

slow.

1. Replace.
2. Replace.
3. Set the gas pressure correctly.
4. Set the cutting speed correctly.

Table 6

Содержание PLASMA 100

Страница 1: ...MODEL PLASMA 100 Operating Manual Owner s Manual IMPORTANT Read these instructions before installing operating or servicing this system First Edition Manual No K0901 ...

Страница 2: ...TION 7 2 01 Electrical Input Connections 8 2 02 Specifications 10 2 03 Duty cycle 10 3 0 OPERATOR CONTROLS 11 3 01 PLASMA 100 controls 11 3 02 Cut parameter description 13 4 0 SET UP FOR PCM 14 5 0 POWER SUPPLY CONTROLS INDICATORS AND REATURES 15 6 0 MAINTENANCE 16 7 0 BASIC TROUBLESHOOTING 16 7 01 Check the item and excrescent phenomenon exclusion method 16 7 02 Power source problems 18 8 0 REMAR...

Страница 3: ... Seconds Remote outputs control Panel Remote Percent Remote Function DC Direct Current Arc Control SMAW AC Alternating Current t2 Gas Post Flow Time 2T GTAW t1 Gas Pre Flow Time 4T GTAW VRD Voltage Reduction Device Circuit Repeat Function GTAW Negative Spot Function GTAW Positive High Frequency Starting GTAW Gas Input Lift Start GTAW Gas Output ...

Страница 4: ...negligence strict tort or under any warranty or otherwise shall not except as expressly provided herein exceed the price of the goods upon which such liability is based No employee agent or representative of KENZO is authorized to change this warranty in any way or grant any other warranty PURCHASER S RIGHTS UNDER THIS WARRANTY ARE VOID IF REPLACEMENT PARTS OR ACCESSORIES ARE USED WHICH IN KENZO S...

Страница 5: ... be dangerous and hazardous to your health z Keep all fumes and gases from the breathing area Keep your head out of the welding fume plume z Use an air supplied respirator if ventilation is not adequate to remove all fumes and gases z The kinds of fumes and gases from the arc welding cutting depend on the kind of metal being used coatings on the metal and the different processes You must be very c...

Страница 6: ...e formed and trapped under aluminum workpieces when they are cut underwater or while using a water table Do not cut aluminum alloys underwater or on a water table unless the hydrogen gas can be eliminated or dissipated Trapped hydrogen gas that is ignited will cause an explosion NOISE Noise can cause permanent hearing loss Arc welding cutting processes can cause noise levels to exceed safe limits ...

Страница 7: ...cal parts Disconnect input power conductors from de energized supply line before moving the cutting power source WARNING FALLING EQUIPMENT can cause serious personal injury and equipment damage z Lift unit with handle on top of case z Use handcart or similar device of adequate capacity z If using a fork lift vehicle place and secure unit on a proper skid before transporting ...

Страница 8: ...ectrically conductive parts in the near vicinity of the operator which can cause increased hazard have been insulated Installation Location Be sure to locate the cutter according to the following guidelines z In areas free from moisture and dust z In areas not subjected to abnormal vibration or shock z In areas free from oil steam and corrosive gases z Place at a distance of 304 79mm or more from ...

Страница 9: ...t match one of the electrical input voltages shown on the input data label on the unit nameplate Contact the local electric utility for information about the type of electrical service available how proper connections should be made and inspection required The line disconnect switch provides a safe and convenient means to completely remove all electrical power from the cutting power supply wheneve...

Страница 10: ...e Interference may be transmitted by a high frequency initiated or stabilized arc cutting machine in the following ways Direct Radiation Radiation from the machine can occur if the case is metal and is not properly grounded It can occur through apertures such as open access panels The shielding of the high frequency unit in the Power Source will prevent direct radiation if the equipment is properl...

Страница 11: ...ecrease the duty cycle increases If the cutting amperes are increased beyond the rated output the duty cycle will decrease WARNING Exceeding the duty cycle ratings will cause the thermal overload protection circuit to become energized and shut down the output until has cooled to normal operating temperature Continually exceeding the duty cycle ratings can cause damage to the cutting power source N...

Страница 12: ...ork cable 3 Pilot Arc Terminal 4 14 Pin Receptacle 5 Output Gas Fitting 6 Negative Terminal for plasma cutting torch 7 Amperage Control 8 Post Flow Gas Optional 9 Gas Check Switch 10 2T 4T Switch Optional 11 Digital Meter Amp 12 DC Power Indicator 13 Water Pressure Indicator 14 Gas Indicator 15 Warning Indicator 16 AC Power Indicator ...

Страница 13: ...crew 19 Input Power Cable Port 20 Fuse Figure 3 Pin Function A Cutting torch switch B Cutting torch switch Table 4 WARNING When the cutter is connected to the primary supply voltage the internal electrical components maybe at primary potential with respect to earth ...

Страница 14: ... Manual 3 02 Cut parameters description Figure 4 PLASMA 100 front panel with parameter description Parameter Description Cutting Current This parameter sets the cutting current Table 5 Cut parameter description for PLASMA 100 ...

Страница 15: ...e arc is dependent on the cutting arc voltage and as cutting voltage varies between different classes of electrodes cutting current at any one setting would vary according to the type of electrode in use The operator should use the cutting current range values as a guide and then finally adjust the current setting to suit the application Figure 5 Set up for PLASMA 100 WARNING Before connecting the...

Страница 16: ...TORS AND REATURES Figure 6 PLASMA 100 front panel 1 Main Power Switch 2 Amperage Control 3 Post Flow Gas 4 Gas Check Switch 5 2T 4T Switch 6 Digital Meter Amp 7 DC Power Indicator 8 Water Pressure Indicator 9 Gas Indicator 10 Warning Indicator 11 AC Power Indicator ...

Страница 17: ... machine to insure that they are tight and the wires are not frayed or overheated Inspect internal wiring of machine for loose or frayed connections tighten or repair as necessary It would also be advisable to check connections to wire feeders fixtures etc at this time Any damaged cable or hoses should be replaced DANGER HIGH VOLTAGE is present internally even with the control power switch in the ...

Страница 18: ...tting torch damage 2 Gas hose is cut 3 Solenoid value damage 1 Replace cutting torch 2 Replace gas hose 3 Replace solenoid value 4 PCM mode no pilot Arc starts d Gas flow continues have spark 1 Cutting torch damage 2 Poor Electrode or Tip 3 Pilot Arc PCB damage 1 Replace cutting torch 2 Replace Electrode or Tip 3 Replace pilot Arc PCB 5 PCM mode unstable Arc 1 Electrode or tip damage 2 Cutting tor...

Страница 19: ...pply voltage Defective control circuit Have an accredited KENZO service agent inspect then repair the cutter 3 Cutting current reduces when cutting Poor work lead connection to the work piece Ensure that the work lead has a positive electrical connection to the work piece 4 No gas flow when the torch trigger switch is depressed A Gas hose is cut B Gas passage contains impurities C Gas regulator tu...

Страница 20: ...outputting and giving the red candle demonstration warning 8 3 Ambient temperatures high when big electric current long time continuous working the cutting machine has stopped because of the heat outputting gets down until the temperature drop only then restores 8 4 When cutting machines do not use temporarily its depository should maintain dryly cleanly The environment relative humidity is not bi...

Страница 21: ... 02 1 4XP1 1 4XP2 1 4XP3 1 4XP4 1 4XP5 D3 D4 1 2 3 4 7CN8 1211 4 1 9CN1 1 9CN2 1 9CN3 1 9CN4 L1 P FP7 827 006 FP7 828 013B FP7 826 003A FP7 820 041B FP7 820 040B FP7 820 020C PILOT ARC Diode PCB PILOT ARC PCB HF PCB FP7 820 026A R7 1R 200W 1 2 A B Torch trigger switch 1 2 3 4 5 6CN1 2001 5 1 2 3 4 5 6 7 6CN3 2001 7 1 6CN6 1 6CN5 1 2 6CN4 1211 2 JP1b 24V JP2b 0V FP7 820 006D filter PCB 1 2 3 4 5 7C...

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