Elettro 471 Service Manual
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Elettro 471 Service Manual

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ELETTRO CF s.r.l.
1
PLASMA 56 COMPRESSOR INVERTER
POWER SOURCE art. 471 and art.471.48
SERVICE MANUAL
art.471 (Fig.1 3.2.1)
art.471.48 (Fig.2 3.2.1)
09/12/14

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Summary of Contents for Elettro 471

  • Page 1 ELETTRO CF s.r.l. PLASMA 56 COMPRESSOR INVERTER POWER SOURCE art. 471 and art.471.48 SERVICE MANUAL art.471 (Fig.1 3.2.1) art.471.48 (Fig.2 3.2.1) 09/12/14...

  • Page 2: Table Of Contents

    - SYSTEM DESCRIPTION ........................4 - Introduction ............................4 - Technical specifications........................4 - Description of power source art. 471 ....................4 - MAINTENANCE ..........................7 - Periodic inspection, cleaning ......................7 - Operating sequence (fig. 3.2.1) ......................7 3.2.1 - Power source commands and signals.

  • Page 3: General Information

    471 for plasma cutting systems. The power source exists in two variants: • art. 471 (3.2.1-Fig.1) • art. 471.48 (3.2.1-Fig.2) Art. 471 is equipped with a 4 m, ECF-71 torch with direct connection consisting of: power source start contact • negative potential (-) eyelet •...

  • Page 4: System Description

    The PLASMA 56 COMPRESSOR is a plasma arc system for cutting electrically conductive materials. It is made up of an electronic power source (art. 471 or art. 471.48) with three-phase compressor and a set of accessories for use in manual applications.
  • Page 5 The panel board (60), mounted on the front panel, acts both as a control panel for the power source, and as an input and conditioning interface for those signals especially affected by disturbances because they arrive from critical areas of the system. These signals include: − Start power source, − Torch type recognition (only art. 471.48) 09/12/14...
  • Page 6 ELETTRO CF s.r.l. The panel board (60) contains the following control elements: − Potentiometer to adjust the cutting current. − A set of leds to indicate the operating status. The signals processed by the electronic boards and present at their connectors are listed in the table in chapter five of this manual.

  • Page 7: Maintenance

    ELETTRO CF s.r.l. 3 - MAINTENANCE WARNINGS ANY INTERNAL INSPECTIONS OR REPAIRS MUST BE CARRIED OUT BY QUALIFIED PERSONNEL. BEFORE BEGINNING MAINTENANCE OPERATIONS, UNPLUG THE POWER SOURCE FROM THE MAINS AND WAIT FOR THE INTERNAL CAPACITORS TO DISCHARGE (1 MINUTE).

  • Page 8: Power Source Commands And Signals

    ELETTRO CF s.r.l. 3.2.1 - Power source commands and signals. Fig.1 (Art.471) Fig.2 (Art.471.48) 09/12/14...

  • Page 9: Power Source Operation

    ♦ The operations marked with this symbol refer to machine responses that must occur following an operator action. System shut off and unplugged from the mains.  Connect the torch to the power source (only art. 471.48)  Connect the cable of the positive pole of the power source to the workpiece. ...
  • Page 10 ELETTRO CF s.r.l. Correct? NO (see 3.3.9). Release the torch start button.  ♦ The arc shuts off immediately. The gas continues to flow for the post-gas time (approximately 100 seconds after the start button is released) to cool the torch.

  • Page 11: Troubleshooting

    ELETTRO CF s.r.l. 3.3 - Troubleshooting. WARNINGS ANY INTERNAL INSPECTIONS OR REPAIRS MUST BE CARRIED OUT BY QUALIFIED PERSONNEL. BEFORE REMOVING THE PROTECTIVE GUARDS AND ACCESSING INTERNAL PARTS, DISCONNECT THE POWER SOURCE FROM THE MAINS AND WAIT FOR THE INTERNAL CAPACITORS TO DISCHARGE (1 MINUTE).
  • Page 12 ELETTRO CF s.r.l. ♦ Check the integrity of the rectifier bridge (13), igbt (44) and the igbt board (46) and replace any defective components. ♦ Replace the filter board (10). SERVICES POWER SUPPLY TEST. Igbt board (46), connector J3, terminals 1 (+) - 5 (-) = +25 Vdc, approximately; terminals 4 ...

  • Page 13: Power Source Powered, Led (A) Lit, Fan (9) Stopped

    ELETTRO CF s.r.l. 3.3.2 - Power source powered, led (A) lit, fan (9) stopped. FAN (9) TEST. Fan (9) fast-on terminals = 230 Vac, approximately, with mains at 230 Vac, after closing  switch (58). Correct? ♦ Make sure that there are no mechanical impediments blocking the fan (9).

  • Page 14: The Start Button Produces No Effect

    ♦ Check the wiring between connector CN2, terminals 2, 4 of panel board (60) and terminals 7, 8 of the central adapter on power source (art. 471.48). ♦ For art. 471 make sure that the torch recognition jumper is present on pin 2,4 of connector CN2 panel board (60).

  • Page 15: No Gas Flows From The Torch

    ELETTRO CF s.r.l. 3.3.5 - No gas flows from the torch. COMPRESSOR TEST. Terminals of remote control switch coil (6) = 230 Vac, approximately, with torch button  pressed. The time o f t h e o p e r a t i o n c o n t r o l o f t h e c o m p r e s s o r d e p e n ds on the pre-gas and post-gas times and on the testing conditions.

  • Page 16: Gas Flows From The Torch, The Pilot Arc Does Not Light (Contact Tip Voltage Missing)

    (art. 471.48). ♦ Check the conditions of the torch cables and their correct connection on the secondary boards (70) and on the panel board (60) (art.471). ♦ Check the condition of the fixed adapter (48), torch cable and torch, especially make sure there are no short-circuits or isolation leaks between the conductors or between the contacts of the fixed adapter (48).

  • Page 17: In Open Circuit Operation, The Output Voltage Is Not Regular

    ELETTRO CF s.r.l. 3.3.7 - In open circuit operation, the output voltage is not regular. WARNING FOR THE FOLLOWING TESTS UNSCREW THE NOZZLE HOLDER (26) FROM THE TORCH, REMOVE THE ELECTRODE (23), THE DIFFUSOR (24), THE NOZZLE (25) AND AT LAST REASSEMBLE THE NOZZLE HOLDER (26).
  • Page 18 ELETTRO CF s.r.l. ♦ Check the wiring and integrity of the resistor (72) with connector CN2 on secondary board (70). Correct value of the resistor (72) = 10 Kohm. ♦ Check conditions of the transformer (53). Replace if damaged or showing signs of burns.

  • Page 19: Irregular Pilot Arc Starts, Unstable Pilot Arc

    ELETTRO CF s.r.l. 3.3.8 - Irregular pilot arc starts, unstable pilot arc. PLASMA GAS PRESSURE TEST. Gas pressure correct in the plasma chamber of the torch.  Correct? ♦ Check obstructions and/or presence of gas in the gas hose coming out of the compressor (4).
  • Page 20 (4). ♦ For art. 471.48: check the integrity and the continuity of wiring of the terminals 4 and 5 of the fixed connection for torch (E-fig.2) and terminal F1 on secondary board (70). Check the conditions of fixed connection and torch cable;...

  • Page 21: Transfer Arc Does Not Take Place Or Is Too Weak For Cutting

    Correct? ♦ Check connections between torch, earth cable and boards of the power source. ♦ For item 471.48: check continuity of central terminal of fixed connection for torch and terminal “-” on secondary board (70), (electrode potential); between output (G) of the power source and terminal (+) on secondary board (70) (earth potential).
  • Page 22 If you find loose connections, tighten and replace any damaged components. ♦ For item 471: Check the condition of the torch body and of the torch; especially make sure there are no short-circuits or isolation leaks between the conductors. Replace any worn or damaged components.

  • Page 23: Alarm Signals

    ELETTRO CF s.r.l. 3.4 - Alarm signals. 3.4.1 - Led (C) lit = temperature outside limits. This alarm indicates that the temperature of the igbt (44) has risen beyond the allowed limits. In this situation we recommend that you not shut off the power source, to keep the fan (9) running and thus allow rapid cooling.

  • Page 24: Led (B) Steadily Lit = Power Source Blocked

    ELETTRO CF s.r.l. 3.4.3 - Led (B) steadily lit = power source blocked. This indicator indicates that the power source is in a check process, in the first 5 seconds after closing the switch (58), or, thereafter, is blocked due to a hazardous condition.

  • Page 25: Components List

    ELETTRO CF s.r.l. 4 - COMPONENTS LIST 4.1 - Power source art. 471 and 471.48 4.2 - Table of components 4.3 - List of spare parts. Essential spare parts. Ref. Description Qty. control board filter board panel board secondary board igbt board Recommended spare parts.

  • Page 26: Electrical Diagrams

    ELETTRO CF s.r.l. 5 - ELECTRICAL DIAGRAMS 5.1 - Power source art. 471 and 471.48 5.2 - Waveforms. 5.2.1 - Open-circuit output voltage, interrupted after approximately 300 msec. for missing pilot arc current (par. 3.3.6, 3.3.8). 5.2.2 - Open-circuit rectifier output voltage, interrupted after approximately 300 msec., for missing pilot arc current (par.

  • Page 27: Open-Circuit Inverter Output Voltage, Interrupted After Approximately 300 Msec. For Missing Pilot Arc Current (Par. 3.3.7)

    ELETTRO CF s.r.l. 5.2.3 - Open-circuit inverter output voltage, interrupted after approximately 300 msec. for missing pilot arc current (par. 3.3.7). 5.2.4 - Pilot arc current signal for its maximum time, approximately 2 sec., with the torch free in the air and thus without transfer arc (par. 3.3.8).

  • Page 28: Filter Board (10)

    ELETTRO CF s.r.l. 5.3 - Filter board (10) 5.3.1 - Topographical drawing. 5.3.2 - Connector table. Conn. Terminals Function three-phase mains voltage input. R-S-T U-V-W three-phase mains voltage output. 09/12/14...

  • Page 29: Igbt Board (46)

    ELETTRO CF s.r.l. 5.4 - Igbt board (46) 5.4.1 - Topographical drawing. 5.4.2 - Connector table. Connector Terminals Function Q1 - Q2 output for transformer (53) primary winding. “+” - “-” direct current input 560 Vdc, approximately for inverter power supply 2 - 6 output for fan (9).

  • Page 30: Secondary Board (70)

    ELETTRO CF s.r.l. 5.5 - Secondary board (70) 5.5.1 - Topographical drawing. 5.5.2 - Connector table. Connector Terminals Function 1(+) - 3(-) 13.8 Vdc power supply input for power source output current transducer. power source output current signal output. 4(+) - 5(-) 25 Vdc power supply input for pilot arc/transfer arc switching relay.

  • Page 31: Panel Board (60)

    ELETTRO CF s.r.l. - Panel board (60) 5.6.1 - Topographical drawing. 5.6.2 - Connector table. Connector Terminals Function 1(+) - 10(-) 5 Vdc panel board (60) power supply input. 2(+) - 4(-) cutting current potentiometer power supply input. “cutting current reference” signal output from potentiometer cursor.

  • Page 32: Control Board (63)

    ELETTRO CF s.r.l. 5.7 - Control board (63) 5.7.1 - Topographical drawing. 5.7.2 - Connector table. Conn. Terminals Function 1 - 2 input compressor thermostat 3 - 4 CN2 1(+) - 10(-) 5 Vdc panel board (60) power supply output.
  • Page 33 Art./Item 471 01/21...
  • Page 34 Art./Item 471.48 01/21...
  • Page 35 POS. DESCRIZIONE DESCRIPTION STÜCKLISTE DESIGNATION DENOMINACIÓN DESCRIÇÃO SUPPORTO HANDLE GRIFF HALTER SUPPORT MANCHE SOPORTE MANIJA SUPORTE PEGA MANICO HOLDER MANICO HANDLE GRIFF MANCHE MANGO PEGA TETTUCCIO TOP PANEL OBERE PLATTE PANNEAU SUPERIEUR PANEL SUPERIOR PAINEL SUPERIOR COMPRESSORE COMPRESSOR KOMPRESSOR COMPRESSEUR COMPRESOR COMPRESSOR RACCORDO...
  • Page 36 CIRCUITO IGBT GHIERA RING NUT GEWINDERING COLLIER ABRAZADERA VIROLA PRESSACAVO STRAIN RELIEF ZUGENLASTUNG SERRE-CABLE PRENSA - CABLE FIXADOR DO CABO art.471 ADATTATORE FIXED ADAPTER ZENTRALANSCHLUSS ADAPTATEUR FIXE ADAPTADOR FIJO ADAPTADOR FIXO FISSO art.471.48 BLOCCACAVO CABEL LOCK KABELSCHLOSS SERRURE DE CABLE...
  • Page 37 Farben-Codierung Codification Codificación Codificação cores Codifica colori Wiring diagram elektrische couleurs schéma colores cableado conjunto eléctrico cablaggio elettrico colour code Schaltplan électrique eléctrico de cabos Nero Black Schwarz Noir Negro Negro Rosso Rouge Rojo Vermelho Grigio Grey Grau Gris Gris Cinzento Bianco White...

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471.48

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