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Some common troubles of plasma cutting machine and Countermeasures

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Some common troubles of plasma cutting machine and Countermeasures

Classification:
FAQ
Author:
Source:
Release time:
2019/12/06 10:22
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Serial number Failure phenomenon cause of issue Method of exclusion
1 After turning on the "power switch" of the host, the power indicator is off 1. "Power indicator" light is broken replace
2, 2A fuse is broken replace
3.No input three-phase 380V voltage Overhaul
4. The input 380V three-phase voltage is out of phase. "Missing phase indicator" light is on The multi-phase voltage measurement with a multimeter should meet the requirements
5, power on, etc. replace
6, control board or host is broken Overhaul
2 After turning on the input three-phase power, the fan does not rotate, but the "power indication" light is on 1.Input three-phase power lacks phase Building material method is the same as this table 1.4
2.Fan leaves are stuck by foreign objects Remove foreign body
3.The fan power plug is loose Reinsert
4.The fan lead is broken Overhaul
5.Fan is damaged Replace or overhaul
3 After the three-phase input power is connected, the power indicator is on and the fan rotates normally, but there is no airflow in the torch nozzle after turning on the "test gas" switch 1.No input compressed air Maintenance of gas source and gas supply pipeline
2. The "air filter regulator" on the back of the host is out of adjustment, and the pressure gauge indicates zero. "Insufficient air pressure" indicator lights up red Readjust the pressure. The method is: turn the "air filter pressure reducer" handwheel clockwise to increase, otherwise decrease.
3, "test gas" turned on badly replace
4.The electromagnetic valve in the host is broken Overhaul or replacement
5. Leakage or short circuit in the gas supply pipeline Overhaul
4 After turning on the "test gas" switch, there is airflow in the nozzle. When the "cut" light is turned on and the torch switch is closed, there is no airflow or host program action 1.The torch switch is broken or the switch is disconnected. Replace or overhaul
2. The "cutting" switch is broken replace
3.The host control circuit board is damaged Overhaul
4, the host control transformer or related lines or components are damaged Overhaul
5.The host is in a protective shutdown state due to insufficient air pressure and high temperature After the air pressure returns to normal or the host temperature returns to normal, it will return to normal by itself.
6. The water cooling system equipped with the water-cooled cutting torch is not working properly, or the water tank is short of water, which causes insufficient air pressure and puts the host in a protective state Check and resolve, if the water supply pressure is insufficient, increase the water supply pressure
5 Turn on the torch switch, there is air flow in the nozzle, but neither "high-grade" nor "stop" can cut 1.Input three-phase power lacks phase Overhaul
2.Air pressure is less than 0.45Mpa Adjust to normal as described in Table 3.2
3.The input air flow is too small Increase input air flow 300L / min
4. Poor electrical conduction between the "cut ground wire" chuck and the workpiece or the "cut ground wire" wire breaks Re-clamp or service the wire
5, nozzle electrode or other parts in the torch are damaged Replace with new parts
6.The cutting method is incorrect The torch nozzle should be placed at the starting point of workpiece cutting before turning on the torch switch
7, cutting torch cable is open Use multimeter R * 10 to measure the path between the conductive part of the “output interface” of the host and the torch electrode, otherwise the surface cable will be broken
8, the host "FD" spark gap is too large or short circuit Readjust the tungsten rod gap to about 0.5mm-0.8mm. If it is a triple tungsten rod structure, the two gaps add up to 0.5mm-0.8mm
9, the relevant parts of the main circuit or components are damaged, such as pressure controllers, etc. Overhaul
10.The control circuit board in the host is out of order or damaged Overhaul or replacement
11.The torch is damaged Use a multimeter R * 10K to measure the resistance value of the torch electrode holder and the external thread M32 or M35. The resistance value should be close to several hundred K. If the resistance value is too small (such as several K to several Ω), it indicates that the damage or moisture is serious. Measure after washing and drying, and replace it after confirming damage
6 The contact type can cut, but the non-contact type can not cut. The experimental non-transfer arc non-sparking spray nozzle 1, 15A fuse fuse open circuit replace
2. The indicated value on the “Air Filter Regulator” is too high Adjust as shown in Table 3.2
3.The electrode nozzle or other parts in the cutting torch are damaged replace
4. The cutting torch is wet, and the moisture content of the compressed air is too large. Dry the cutting torch and dry the compressed air before passing it into the machine
5. The wire between the "arcing arc interface" and the torch is broken Use the multimeter R * 10 to measure the path between the "arcing interface" terminal and the torch metal pressure cap
6, cutting torch damage The inspection method is the same as this table 5.11
7 "Cut Thickness Select" switch can cut in one position, but not in the other position 1.Cut thickness selection switch or wire is broken replace
2. One of the AC contactors CJ1 or CJ2 in the host is broken Replace or repair
3. The rectifier main transformer B1 is broken or the related wires are open. service
8 Arc instability during operation 1.The air pressure is too low or too high Re-adjustment, refer to Table 3.2
2.The torch nozzle or electrode is burned replace
3.The input AC voltage is too low Adjust the input AC voltage
4. Poor electrical conduction between "cutting ground wire" and work Well connected
5.The cutting movement speed is too slow Adjust movement speed
6.The spark generator cannot automatically cut off the arc When normal, turn on the torch switch and the spark generator discharge time should be 0.5-1S, and then automatically stop, otherwise, it indicates that the control circuit board is out of control; the control circuit or component is faulty and should be repaired
7. The related components in the host are not working properly Overhaul
9 The cutting thickness cannot reach the rated index 1.The input three-phase voltage cannot reach 380V Adjust the input voltage
2.The input power capacity is too small. Should increase input capacity
3.The input compressed air pressure is too low or too high Adjust to 0.4Mpa, please refer to Table 3.2
4. The input compressed air flow is too small, and the pressure gauge display value drops from normal to about 0.3Mpa during work. When the work is stopped and the power switch is turned off, the pressure returns to normal immediately. Add to the input compressed air flow to 300L / min; if the internal hole of the pipeline is too small, you should change the pipeline larger than φ8mm
5. The gear selected by the "thickness selection" switch is not suitable Switch to "upscale"
6.The cutting speed is too fast Slow down the cutting speed
7.The working material does not match Table 2. Adjustment parameters
8.The nozzle hole is burned Adjust the new nozzle
9.The electrode has been burned out replace
10.Wrong nozzle model Adjust the correct nozzle
11. The gas path system or cutting torch cable is damaged and leaks air, and the air flow in the hole in the nozzle is significantly reduced. Repair or replacement
10 Notched material 1.The nozzle electrode is damaged replace
2. Nozzle electrode installation position is different axis Reinstall correctly
3.The cutting speed is too fast Moderately slow
4.The nozzle axis is not perpendicular to the plane of the workpiece Adjust to solve
11 The incision is too wide and the incision quality is not good 1.The cutting speed is too slow Adjust speed
2.The nozzle and electrode have been burned Update
3. The working material and thickness do not match the position of the "Cut Thickness Selection" switch. Adjustment
4, the nozzle model is incorrect, the inner hole is too large Swap the correct nozzle
12 Burning torch 1.The metal pressure cap is not tight After replacing the electrode nozzle, it should be pressed in time.
2. The conductive connection of the torch is loose, the cable air pipe is broken, and the water-cooled torch interface is leaking Check and solve in time
3. Poor insulation at the torch joint Ensure that the joints are well insulated
4. The ceramic protective sleeve on the cutting torch is damaged, but it is not replaced in time. Should be replaced in time
5, too much water in the compressed air Drain the accumulated water in the "Air Filter Decompressor" in time, if the moisture content in the compressed air
6. The cutting torch is wrong when starting cutting Water-cooled cutting torch should be selected when cutting by parallel machine. The current carrying capacity of air-cooled cutting torch is too small to use.
7.The electrode was not replaced in time after the electrode was burned The electrode should be updated in time after burnout
8. When the water cooling torch works, the water system is abnormal or the ambient temperature is too low, and the interface leaks water. Check and solve, and can not work in freezing temperature environment
13 Rectifier diodes D1-D6 often burn out 1.The reverse voltage of the newly replaced diode is too low Should choose a diode with reverse withstand voltage> 1200V
2, C101-C103; C104; C106 or R101; one or more of R102 is damaged replace
3. The rectifier transformer B1 is damaged Replace or repair
4.The cutting torch is damaged Remove the cutting torch from the host, use a multimeter R * 10K gear to measure the electrode and the external thread of the cutting torch M32 or M35, the resistance value should be close to ∽, if it is below tens of K, it is damaged
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