Thermal Dynamics CUTMASTER 60i Service Manual page 63

b. Low or sagging line. Low can be measured, should be at least 185 VAC. A line sagging under load is
difficult to detect as it only sags during the load and as soon as the fault appears the load gets removed.
Best to insure the circuit supplying the AC outlet is rated for the full Imax capacity from the input wiring
specifications in the operators manual.
c. Missing phase, measure all 3 phases, L1 to L2, L2 to L3, L3 to L1. If missing look for blown fuse in the
AC supply.
d. E002 at idle due to Low bulk capacitor voltage.
The PFC board boosts the capacitor voltage to about 750V. Note when the E002 occurs. The PFC has 2 sec-
tions, one section operating can boost the voltage OK at idle and piloting and even transfer at low current
but if one section is not working the increased load of transfer at higher current, above 40A, will cause the
voltage to droop resulting in the E002 code at that time.
i. Measure DC voltage from GND PRI (-) to J305-3(+). Normally the voltage should be about 750VDC.
Without the PFC boost this voltage will be about 1.4 times the incoming AC voltage. For example for
230 VAC the DC would be about 320VDC. If that is the case it means the PFC board is not working.
Continue to determine the cause.
ii. Incorrect routing of the PFC inductor leads where they attach at studs labeled IND1_OUT and
IND2_OUT can be critical. If the leads are not routed as shown but are closer to the T800 and T801
current sense transformer it can cause the one or both halves of the PFC to not work. Usually this
would not be a problem unless the board has just been replaced. Loosen and move the leads so they
look like the pictures.
iii. First confirm the board is enabled. Measure J800-7(+) to GND_PRI, normally about 8V, if low the PFC
is being disabled. Remove J610 from the Inverter board. You will get E001 fault but the PFC should
still run and boost the capacitor voltage to about 750V. If not replace the PFC board.
!
iv. The Control & Display board determines when to disable the PFC by activating a circuit on the In-
verter board. Reinstall J610 and remove J800 from the PFC. Measure resistance from J800-7 to J800-8.
It should be open, if low, from zero to a few hundred ohms, replace the Inverter board. Otherwise
Replace the Control & Display board.
Manual 0-5475
CAUTION
Single phase and 3 phase PFC boards are different, have different
catalog numbers! Using the wrong one may cause it to fail
SERVICE
CUTMASTER 60i
Art # A-13304
.
5-29