Cebora PLASMA PROF 164 HQC Service Manual
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Cebora PLASMA PROF 164 HQC Service Manual

Cebora PLASMA PROF 164 HQC Service Manual

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CEBORA S.p.A.
3.302.218
PLASMA PROF 164 HQC
POWER SOURCE art. 954 +
STARTER UNIT HV18 art. 472 +
GAS CONSOLE PGC1-2 art. 477 +
PVC VALVE CONSOLE art. 478 +
TORCH CP250G art. 1236
SERVICE MANUAL
1
9/8/2006

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Summary of Contents for Cebora PLASMA PROF 164 HQC

  • Page 1 CEBORA S.p.A. PLASMA PROF 164 HQC POWER SOURCE art. 954 + STARTER UNIT HV18 art. 472 + GAS CONSOLE PGC1-2 art. 477 + PVC VALVE CONSOLE art. 478 + TORCH CP250G art. 1236 SERVICE MANUAL 3.302.218 9/8/2006...

  • Page 2: Table Of Contents

    2.1.1 - Plasma PROF 164 HQC system........................ 5 - Technical specifications..........................5 - Description of Plasma PROF 164 HQC system................... 5 - Description of Power Source art. 954......................6 - Description of Starter Unit HV18 art. 472....................8 - Description of Gas Console PGC1-2 art.
  • Page 3 - Components table : see file ESP164.pdf enclosed at the end of the manual..........43 - ELECTRICAL DIAGRAMS ........................43 - Plasma PROF 164 HQC : see file SCHE164.pdf enclosed at the end of the manual......... 43 - Waveforms..............................43 5.2.1 - Reference signal for pilot arc current (par.

  • Page 4: General Information

    1.1 - Introduction. The purpose of the present manual is to train personnel assigned to carry out maintenance on the Plasma PROF 164 HQC system for automated plasma cutting systems. 1.2 - General service policy. It is the responsibility of the customer and/or operator to use the equipment appropriately, in...

  • Page 5: System Description

    2 - SYSTEM DESCRIPTION 2.1 - Introduction. The Plasma PROF 164 HQC is a system for cutting electrically conductive materials using a multigas plasma arc process, for mechanical systems. It consists of an electronic Power Source (art. 954), a Starter Unit HV18 (art. 472), a Gas Console PGC1-2 (art.

  • Page 6: Description Of Power Source Art. 954

    The version of the programs entered can be seen on the start-up screen of display (C) of the Power Source control panel. The updated MASTER and SLAVE programs are grouped together with the “Cebora Downloader” programming software into a single programming file, available along with instructions from the web site www.cebora.it..
  • Page 7 CEBORA S.p.A. The terminal J5 of the pilot arc board (58) also corresponds to the positive output (3) of the igbt module. This is connected to the nozzle resistor (17), which facilitates switching from pilot arc to transfer arc, and the nozzle potential output ready for connection to the Unit HV18. This connection, inside the pilot arc board (58), also leads to the Hall-effect current transducer, which sends the pilot arc current signal to the settings board (54).

  • Page 8: Description Of Starter Unit Hv18 Art. 472

    CEBORA S.p.A. The control board (38) also manages the user interface, which in this system is divided across two panels, one on the Power Source and the other on the Gas Console. The panel on the Power Source is managed directly by the panel board (38) on the Power Source; the one on the Gas Console is managed by the panel board (20) of the Gas Console, based on the information provided by the control board (38) via CAN bus line.

  • Page 9: Description Of Gas Console Pgc1-2 Art. 477

    CEBORA S.p.A. This system relies on the principle according to which the Power Source output voltage is greatest, approximately 260 Vdc, while with the pilot arc or transfer arc this voltage is determined by the cutting conditions (level of current, material to be cut, type of gas, etc.), thus significantly below 200 Vdc) (approximately 150 - 190 Vdc with pilot arc lit).

  • Page 10: Description Of Pvc Valve Console Art. 478

    CEBORA S.p.A. The PGC2 is essentially the replica of one of the 4 pneumatic circuits of the PGC1, with the difference that the devices used in this case are suitable for use in “high risk” environments since they work in contact with easily flammable gases.

  • Page 11: Description Of Torch Cp250G Art. 1236

    CEBORA S.p.A. 2.8 - Description of Torch CP250G art. 1236. 2.8.1 - Layout of torch CP250G art. 1236 circuits. The torch CP250G is a multigas liquid-cooled torch for use on pantographs. Inside are a coolant circuit, a pneumatic circuit for the plasma gas, and a secondary pneumatic circuit for the cooling and outer nozzle protection gas.

  • Page 12: Maintenance

    CEBORA S.p.A. 3 - MAINTENANCE WARNING ANY INTERNAL INSPECTIONS OR REPAIRS MUST BE CARRIED OUT BY QUALIFIED PERSONNEL. BEFORE BEGINNING MAINTENANCE OPERATIONS, UNPLUG THE MACHINE FROM THE MAINS AND WAIT FOR THE INTERNAL CAPACITORS TO DISCHARGE (1 MINUTE). 3.1 - Periodic inspection, cleaning.

  • Page 13: Gas Console Commands And Signals

    Connect the Torch to the HV18 Unit. For more details on the connections, follow the instructions provided in the Instruction Manual of the Plasma PROF 164 HQC. Connect the Unit HV18 to the Power Source using the supplied extension art. 1179. This extension also incorporates the coolant liquid lines.
  • Page 14 CEBORA S.p.A. Connect the cable of the positive pole of the Power Source to the workpiece. Connect the Power Source to the mains. Close the switch (A) on the Power Source. ♦ System powered, on the Power Source panel led and display lit (lamp-test).
  • Page 15 CEBORA S.p.A. Use the key (A) to select the TEST function, led (A3) lit, to set the “gas circuit seal test”. Use the knob (C) to set the “ALL” function visible on display (D), to set the test for all gas circuits.

  • Page 16: Troubleshooting

    CEBORA S.p.A. 3.3 - Troubleshooting. WARNING ANY INTERNAL INSPECTIONS OR REPAIRS MUST BE CARRIED OUT BY QUALIFIED PERSONNEL. THE SWITCH (A) IS A FUNCTION SWITCH, NOT A MAIN POWER SWITCH. THIS IS WHY THERE IS HAZARDOUS VOLTAGE PRESENT INSIDE THE POWER SOURCE EVEN WHEN THE SWITCH IS SET TO “0”.
  • Page 17 CEBORA S.p.A. ♦ Check power cable and plug and replace if necessary. ♦ Check the mains voltage conditions. SERVICE TRANSFORMER (50) POWER SUPPLY TEST. Fuse board (50), connector J6, terminals 0 - 230 = 230 Vac; connector J6 – 0 and connector J7 –...
  • Page 18 CEBORA S.p.A. ♦ Make sure there is 27 Vac voltage on terminals TP2 - 27V of fuse board (50); if missing, check the wiring between the service transformer and fuse board (50), and if necessary replace the service transformer (50).

  • Page 19: Power Source Powered, Operator Panels On Power Source And Gas Console On, Fan (20) Stopped

    CEBORA S.p.A. ♦ Make sure the panel board (38) is properly mounted on control board (38) on the Power Source. ♦ Replace the control (38) and/or panel (20) boards. 3.3.2 - Power source powered, operator panels on Power Source and Gas Console on, fan (20) stopped.
  • Page 20 CEBORA S.p.A. ♦ Shut off the Power Source, wait for the capacitors to discharge (1 minute), temporarily disconnect connector J4 from pre-charge board (45) and check the resistance between terminals 1 and 2 of J1 of pilot arc board (58). Correct value = diode junction in one direction and >Mohm with the instrument probes reversed.

  • Page 21: Power Source Powered, Display And Signals Does Not Indicate The Correct Values

    When turned on, after the start-up phase, the keys on the operator panels of the Power Source and Gas Console allow all of the steps involved in selecting the “Job” and “Mode” as described in par. 3.2.3, and in the Instruction Manual of the Plasma PROF 164 HQC. Correct? ♦...

  • Page 22: The Start Command Produces No Effect

    CEBORA S.p.A. 3.3.4 - The start command produces no effect. ERROR CODE TEST. When turned on, after the start-up phase, displays (B) and (C) on the Power Source and displays (F) and (M) on the Gas Console indicate an alarm situation.

  • Page 23: No Gas Flows From The Torch

    CEBORA S.p.A. 3.3.5 - No gas flows from the torch. NOTE To check the efficiency of the pneumatic circuits, we recommend performing the “Gas seal” test, (see Instruction Manual). During the test the pneumatic circuits are individually charged and discharged with gas. The gas discharge takes place through the torch nozzles.
  • Page 24 CEBORA S.p.A. ♦ With Power Source off, temporarily disconnect the connectors J4, J5, J6 and J7 from solenoid valve board (2) and check the resistance on the terminals of the solenoid valve coils. Correct value = approximately 12 ohm (27 ohm for V10 on Console FPGC-2).

  • Page 25: Gas Flows From The Torch, The Pilot Arc Does Not Light (Nozzle Voltage Missing)

    CEBORA S.p.A. 3.3.6 - Gas flows from the torch, the pilot arc does not light (nozzle voltage missing). POWER SOURCE OUTPUT VOLTAGE TEST. Pilot arc board (58), terminals TP3(+) – TP7(-) = approximately +280 Vdc, for a duration of 1 second (maximum pilot arc time) after pressing the start command.

  • Page 26: Gas Flows From The Torch, The Pilot Arc Does Not Light (High Frequency Missing)

    CEBORA S.p.A. 3.3.7 - Gas flows from the torch, the pilot arc does not light (high frequency missing). NOZZLE VOLTAGE TEST. Pilot arc board (58), terminals J5(+) – TP7(-) = approximately +280 Vdc, for a duration of 1 second (maximum pilot arc time) after pressing the start command.

  • Page 27: In Open Circuit Operation, The Output Voltage Is Not Regular

    CEBORA S.p.A. ♦ Check the wiring between the terminal of the HF transformer (7) secondary circuit, TP3 on control box board (5), and the torch electrode terminal. If you find loose connections, tighten and replace any damaged components. ♦ Make sure that there is no short-circuit between connectors CN1 and CN4 on HF board (2) or in the wiring of the HF transformer (7) primary circuit.
  • Page 28 CEBORA S.p.A. Correct? ♦ Check the wiring between J3 settings board (54) and J7 of control board (38). ♦ With Power Source off, temporarily disconnect J7 from control board (38) and check the resistance on terminals 3 and 7 of settings board (54). Correct value = >Mohm.

  • Page 29: Irregular Pilot Arc Starts, Unstable Pilot Arc

    CEBORA S.p.A. 3.3.9 - Irregular pilot arc starts, unstable pilot arc. PLASMA GAS PRESSURE TEST. Gas pressure in the plasma chamber of the correct torch. Correct? ♦ Check operation of the Gas Console and gas circuits, performing if necessary the tests in par.

  • Page 30: Transfer Arc Does Not Take Place Or Is Too Weak For Cutting

    CEBORA S.p.A. ♦ With Power Source off, temporarily disconnect the cables of the extension art. 1179 from the Power Source terminals (53) and J5 of torch board (42), and check the isolation between the disconnected cables and towards earth. This makes it possible to test the isolation of extension art.
  • Page 31 CEBORA S.p.A. CURRENT MEASUREMENT SIGNALS TEST. Control board (38), connector J7, terminals 5(+) and 1(-) = approximately +0.7 Vdc (“Power Source output current measurement” signal); terminals 2(+) and 1(-) = approximately +2 Vdc (“nozzle current measurement” signal) with pilot arc lit.

  • Page 32: Cooling Unit Does Not Work Correctly

    CEBORA S.p.A. 3.3.11 - Cooling unit does not work correctly. COOLING UNIT ENABLE TEST. Control board (38), connector J20, terminals 2 - 4 = 0 Vac, contact closed, unit connected (27 Vac, contact open, unit not connected) with Power Source powered (this signal is actually disabled by means of a jumper in the flow meter wiring).
  • Page 33 CEBORA S.p.A. ♦ Check fuse on the rear panel of the Power Source. If interrupted, replace and check the resistance on the terminals of pump (13). Correct value = approximately 9 ohm. If incorrect, replace pump (13). ♦ Check the wiring between J3 pre-charge board (45) and J13 control board (38).

  • Page 34: Error Codes And Alarm Signals

    CEBORA S.p.A. 3.4 - Error codes and alarm signals. 3.4.1 - 02 - Hardware lockup. Power source lockup due to software error. Replace the control board (38). 3.4.2 - 06 - Communication error on CAN bus. Communication error between control board (38) and panel board (20) on Gas Console, detected by Master control on control board (38).

  • Page 35: 39 - Nozzle Current Transducer Reading Error

    CEBORA S.p.A. 3.4.5 - 39 - Nozzle current transducer reading error. NOZZLE CURRENT TRANSDUCER TEST. Settings board (54), connector J1, terminals 1(+) – 3(-) = approximately 0 Vdc, with Power Source powered without delivering current. Correct? ♦ Check the wiring between J1 settings board (54) and J2 pilot arc board (58).

  • Page 36: 49 - Nozzle Current During Cutting

    CEBORA S.p.A. TORCH BOARD (42) POWER SUPPLY TEST. Torch board (42), connector J11, terminals 1 and 2 = 8 Vac. Correct? ♦ Check the wiring between J11 torch board (42) and J3 fuse board (50). ♦ Check fuse F5 fuse board (50); if broken, replace and make sure that terminals 1 - 2 of J11 on torch board (42) are not short-circuited.

  • Page 37: 51 - Torch Not Recognized

    CEBORA S.p.A. TORCH ADAPTER PROTECTION SIGNAL TEST. Control board (38), connector J2, terminals 11(+) and 12(-) = 0 Vdc with protection engaged (RL2 contact on torch board (42) closed, DIP1-D closed); +5 Vdc with protection disengaged (RL2 contact on torch board (42) open, DIP1-D open).

  • Page 38: 53 - "Trg" On Display (B) Of The Power Source And (F) Of The Gas Console. Start Button Pressed While Resetting The Operating Mode

    CEBORA S.p.A. 3.4.11 - 53 - “trG” on display (B) of the Power Source and (F) of the Gas Console. Start button pressed while resetting the operating mode. Some alarms, such as “low gas pressure” or “high temperature,” stop the Power Source when the corresponding indicator is lit, but are not saved and are automatically reset when the conditions return to within the allowed limits.

  • Page 39: 74 - "Th""1" On Displays (B) (C) Of The Power Source And (F) (M) Of The Gas Console. High

    CEBORA S.p.A. 3.4.13 - 74 - “TH”“1” on displays (B) (C) of the Power Source and (F) (M) of the Gas Console. High temperature of the igbt group on pilot arc board (58) or of the transformer (27). With this alarm we recommend not shutting off the Power Source, to keep the fan running and thus allow rapid cooling.

  • Page 40: 80 - "Opn" On Display (B) Of The Power Source And Display (F) Of The Gas Console. Guard On Power Source Or Hv18 Module Open

    CEBORA S.p.A. The alarm circuit is indicated on the Gas Console by the flashing corresponding display, while the displays (F) and (M) of the Gas Console read “GAS” “LO” or “err” “79”. NOTE Since operation of the 5 gas pressure detection circuits is checked during the “Gas Seal” test, this test may be used in troubleshooting these alarms.

  • Page 41: 81 - Gas Console Not Connected

    CEBORA S.p.A. ♦ Check the wiring between J3 torch board (42), terminal board to connect the torch to the Power Source, switch (46) on the Power Source safety guard, extension art. 1179, connector J2 on control box board (5) of the module HV18 and switch (11) on the safety guard of the module HV18.

  • Page 42: 83 - Nozzle Protection Or Torch Disconnected

    CEBORA S.p.A. ♦ With Power Source off, temporarily disconnect J12 from panel board (20), and check, after restarting the Power Source, on terminals 2(+) and 1(-) of J12 on panel board (20), voltage = +5 Vdc. If incorrect, replace panel board (20).

  • Page 43: Components List

    CEBORA S.p.A. 4 - COMPONENTS LIST 4.1 - Plasma PROF 164 HQC : see file ESP164.pdf enclosed at the end of the manual. 4.2 - Components table : see file ESP164.pdf enclosed at the end of the manual. 5 - ELECTRICAL DIAGRAMS 5.1 - Plasma PROF 164 HQC : see file SCHE164.pdf enclosed at the end of the manual.

  • Page 44: Fuse Board (50), Code 5.602.257

    CEBORA S.p.A. 5.3 - Fuse board (50), code 5.602.257. 5.3.1 - Topographical drawing. 5.3.2 - Connector and fuse table. Conn. Terminals Fuse Value Function 1 - 2 1.25 A 20 Vac output for pilot arc board (58) power supply. A - B 1.25 A...

  • Page 45: Pre-Charge Board (45), Code 5.602.242

    CEBORA S.p.A. 5.4 - Pre-charge board (45), code 5.602.242. 5.4.1 - Topographical drawing. 5.4.2 - Connector and fuse table. Conn. Terminals Function 1 - 4 180 Vac input for DC-capacitors pre-charge on pilot arc board (58). 1 - 2 “DC-capacitors pre-charge complete” signal output.

  • Page 46: Control Board (38), Code 5.602.239

    CEBORA S.p.A. 5.5 - Control board (38), code 5.602.239. 5.5.1 - Topographical drawing. 3.302.218 9/8/2006...
  • Page 47 CEBORA S.p.A. 5.5.2 - Connector table. Conn. Terminals Function 1 - 2 “transfer arc” output signal. 3(+) - 4(-) current external digital reference input. 5 - 6 “operating permission” (interlock) signal input, from system. 7 - 8 “emergency stop” signal input, from system.

  • Page 48: Settings Board (54), Code 5.602.237

    CEBORA S.p.A. 5.6 - Settings board (54), code 5.602.237. 5.6.1 - Topographical drawing. 5.6.2 - Connector table. Conn. Terminals Function “nozzle current” signal input. 2(+) - 3(-) +15 Vdc output to nozzle current transducer power supply. 4(+) - 3(-) -15 Vdc output to nozzle current transducer power supply.

  • Page 49: Pilot Arc Board (58), Code 5.602.255

    CEBORA S.p.A. 5.7 - Pilot arc board (58), code 5.602.255. 5.7.1 - Topographical drawing. 5.7.2 - Connector table. Conn. Terminals Function 1(+) - 2(-) +250 Vdc input for DC-capacitors pre-charging, on pilot arc board (58). “nozzle current” signal output. 2(+) - 3(-) +15 Vdc input for nozzle current transducer power supply.

  • Page 50: Torch Board (42), Code 5.602.266

    CEBORA S.p.A. 5.8 - Torch board (42), code 5.602.266. 5.8.1 - Topographical drawing. 5.8.2 - Connector table. Conn. Terminals Function NU (torch recognition). A - B “guard open” signal input, on Power Source and module HV18. output voltage output, nozzle potential.

  • Page 51: Panel Board (38), Code 5.602.240

    CEBORA S.p.A. 5.9 - Panel board (38), code 5.602.240. 5.9.1 - Topographical drawing. 5.9.2 - Connector table. Conn. Terminals Function signals bus with control board (38). 1-3-5-7-9 +8 Vdc power supply input, for Power Source panel board. 2-4-6-8-10 0 Vdc power supply input, for Power Source panel board.

  • Page 52: Remote Board (59), Code 5.602.252

    CEBORA S.p.A. 5.11 - Remote board (59), code 5.602.252. 5.11.1 - Topographical drawing. 5.11.2 - Connector table. Conn. Terminals Function GND. 1 - 9 “start” signal input. 2 - 10 “emergency stop” signal input, from system. 3 - 11 “operating permission” (interlock) signal input, from system.

  • Page 53: Control Box Board (5), Code 5.602.033 (On Module Hv18)

    CEBORA S.p.A. 5.12 - Control box board (5), code 5.602.033 (on module HV18). 5.12.1 - Topographical drawing. 5.12.2 - Connector tables. Conn. Terminals Function A - B NU. (start input from torch button). A - B “guard open” signal output, on module HV18.

  • Page 54: Solenoid Valve Board (2), Code 5.602.245 (On Gas Console)

    CEBORA S.p.A. 5.14 - Solenoid valve board (2), code 5.602.245 (on Gas Console). 5.14.1 - Topographical drawing. 5.14.2 - Connector table. Conn. Terminals Function 1(+) - 3(-) +18 Vdc output, for panel board (20) power supply. 4(+) - 3(-) +8 Vdc output, for panel board (20) power supply.

  • Page 55: Panel Board (20), Code 5.602.244 (On Gas Console)

    CEBORA S.p.A. 5.15 - Panel board (20), code 5.602.244 (on Gas Console). 5.15.1 - Topographical drawing. 5.15.2 - Connector table. Conn. Terminals Function 1(+) - 4(-) +18 Vdc flow gauge PT1 power supply output. gas flow signal input, in the “Plasma PreFlow” circuit.

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