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Summary of Contents for Wilhelmsen UPC-85ML
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Page 1: Trouble Shooting
Trouble Shooting Manual UPC-85ML... - Page 2 CAUTION! Turn OFF and disconnect input power before working on the machine Wait discharge of capacitors (minimum 2 minutes) and be sure voltage is near zero before touching any parts. PROBLEM CASE SOLUTION The Machine does not switch on. Power supply off. Step 1 -Check the incoming power supply are correct.
- Page 3 (PICTURE 6) Input bridge rectifier (PICTURE Boost system (PICTURE 11) . They are faulty and to be replace. Step 2 Input cable damaged. -Check the input cable and plug (PICTURE 1). The pilot arc doesn’t start. -Red led (reset) on. Step 1 -Press the reset button to be ready to cut (see instructions...
- Page 4 The inductive value of the Step 5 reading is >1 ohm. -The Power transformer must be replace if reading are > 1ohm. (PICTURE 10) Cutting performance deteriorating. -Consumable (tip and Step 1 electrode) wears out. Check the consumables, try to substitute with new ones (PICTURE 18).
- Page 5 Thermal protection LED blinking -Exceed duty cycle. Step 1 Indicates over temperature -Let the machine cool down. PC8 inverter Module NTC1 or After 4 minutes the message NTC2. disappears and it is possible to start cutting again. HT1 or HT3 message -Exceed duty cycle.
- Page 6 -Boost power board (PCB5) for NTC 3 and 4. - The sensor under the secondary inverter board for NTC 5. During cutting, the Circuit Breaker trip. Make sure the cutting current Check the fuse size. does not require input power 230V 1Ph: 25A greater than what supplied by 400V 3Ph: 16A...
- Page 7 Error messages Indicates mains supply Switch off the generator and problem. check the power supply. • Verify that the power cord is plugged into the receptacle. • Verify that the line voltage is not PF0 permanent message too low (more than 10% below the rated voltage 230V).
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Page 8: Right Side
RIGHT SIDE Boost power board Flyback board Driver inverter LEM sensor PCB5 PCB11 board PCB9 board PCB13 Driver boost board PCB6 Boost logic control board PCB4 Primary Inverter Secondary Inverter Power rectifier FAN3 board PCB8 board PCB12 board PCB2 LEFT SIDE FAN2 FAN1... - Page 9 Line filter boost board Bus DC board PCB7 Logic board PCB10 PCB1 Pilot arc power switch K1 FRONT REAR Power transformer T1 Output inductance XL1 Boost inductance PCB3...
- Page 10 EXPLANATION Check the power supply cable and the ON/OFF switch. Disconnect the machine to the power supply and switch on the main switch. Check the continuity, with a diode tester, between points A1-I1, A2-I2 and A3-I3. If there is no continuity, you have to check the single parts step by step.
- Page 11 3-phase Input bridge rectifier (PCB3) To check the Input bridge rectifier (all three bridges PD1,PD2 and PD3), carry out the following measurements with a diode tester: Probe Probe Measu Black ‘OL’ Black >.42 Black >.42 Black ‘OL’...
- Page 12 For testing the IGBT module is necessary remove the two Driver inverter board (PCB9). Primary inverter IGBT (PCB1) To check the Primary inverter IGBT, carry out the following measurements with a diode tester: Red Probe Black probe Measure ‘OL’ >0.9 / OL ‘OL’...
- Page 13 Remove FAN3 support before operate on the Secondary inverter PCB. Secondary inverter DIODE (PCB12). To check the Secondary Inverter Diode, carry out the following measurements with a diode tester: Red Probe Black probe Measure >.35 >1.7 /‘OL’ If the diodes are faulty, remove the pcb board and replace the isotop diodes.
- Page 14 -Check the value of NTC sensor IGBT Module (PCB8) with the ohm-meter tester. Normally reading should be 10KΩ @25°C. NTC1 NTC2 NTC value -Check the value of NTC sensor Boost module (PCB5) with the ohm-meter tester. Normally reading should be 10KΩ @25°C. NTC3 NTC4 NTC value...
- Page 15 -Check value sensor Secondary diode with the ohm-meter tester. Normally reading should be 10KΩ @25°C. NTC value Power transformer. Locate the connections between power transformer and Primary inverter board (PCB8). Disconnect and measure between: -Conn1 Pin 1-2 and Pin 3-4= > 0,4 ohm. -Conn2 Pin 1-2 and Pin 3-4= >...
- Page 16 Step 1. Check the correct indication of the LEDs on the Logic contrl boost PCB4: -DL1 illuminates. -DL4 illuminates. -DL5 Illuminates. -DL6 blinks slowly. -DL7 off. 24Vdc Step 2. Check the 24Vdc logic power supply voltage Step 3. Vbus. Check the 730Vdc power supply voltage. Step 3.
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Page 17: Set Pressure
N.B. Always replace the Driver boost board together with the faulty Power boost. SET PRESSURE Make sure that the air pressure regulator is setting at 4,8 bar. - Page 18 Check the motor fan: -FAN1= pin1(+), pin2(-) = 24Vdc max -FAN2= pin3(+), pin4(-) = 24Vdc max Note: Fan on demand! Pilot arc power switch (K1). Remove the plastic cover protection. Visual inspection to check the power contacts. Turn ON the machine and verify: -during the pilot arc contacts are close;...
- Page 19 Check the solenoid valve: V= 15Vdc Check the continuity of the cable, with a diode tester, between the main switch and the control board PCB 1. Check the continuity of the cable, with a diode tester, between the Flyback board PCB 11 (J2) and the front logic board PCB 10 (J1) and are properly connected.
- Page 20 Photos comparison of new and worn consumables. E) 4pin connector: -pin1/pin2= switch torch (white/green cable) -pin3/pin4= safety (black/orange cable) F) 1pin connector= Pilot (red cable) G) 9/16” coupling= compressed air.
- Page 21 Torch Shield cup Start Cartridge Electrode head Body max. life Shield cup Digital multiplemeters. For diode test refer to below pic for correct setting. ‘OL’ means Open Loop. Check the auxiliary voltage generated by the flyback board (PCB11) as follows: -between Pin1 and Pin6 of J2 = 24Vdc -between Pin1 and Pin2 of J3 = 24Vdc...
- Page 22 Check the pressure switch: -With pressurized air circuit greater than 3 bar closed contact.
- Page 23 PCB13 PCB12 PCB7 PCB8 PCB9 PCB10 PCB11 PCB6 PCB5 FAN1 FAN3 PCB4 FAN2 PCB2 PCB3 PCB14 PCB1...
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