HT2000Troubleshooting

1、HT2000 的的故障診斷故障診斷 Copyright, 2000 Hypertherm, Inc. These materials cannot be reproduced in any formwithout the permission of Hypertherm, Inc. Copyright, 2001 Hypertherm, Inc. These materials cannot be reproduced in any formwithout the permission of Hypertherm, Inc.等離子弧需要的條件等離子弧需要的條件 電: 系統(tǒng)動(dòng)力和弧動(dòng)力 氣: 正

2、確的壓力和流量 啟動(dòng)條件: 高頻,引導(dǎo)弧, 切割弧. Copyright, 2001 Hypertherm, Inc. These materials cannot be reproduced in any formwithout the permission of Hypertherm, Inc.電路描述斬波器,開路電壓和切割電流控制板燈保持信號(hào)冷卻系統(tǒng)為了建立等離子弧必須有動(dòng)力運(yùn)轉(zhuǎn)設(shè)備并建立等離子弧為了建立等離子弧必須有動(dòng)力運(yùn)轉(zhuǎn)設(shè)備并建立等離子弧.CH130 Chopper #1CR1F5DC-PilotREC13DC+Control PCBI/O PCB+ Out- OutC1R4L1F

3、2125 ACS1Relay PCBREC3High Frequency ConsoleT2 Air CoreT1 High VoltageSpark GapsElectrode (-)Work (+)ShieldBLUBLKREDREC5HD2000 Torch CircuitChopper ControlMachine On - No Start Signal沒有啟動(dòng)信號(hào)+12 VDC(2) 1400 pFCapacitors(OPEN)JP9Nozzle+ OutCH130 Chopper #2- OutL2R1 (Shunt)R5R2 (Shunt)R3 (Total Shunt)F1

4、125 AR6A and 6BChopper ControlJP90 mV DC0 mV DCC2C1I/O PCB (RHF)REC 4Analog PCB3414151634+FUSE345678910781112C1BLKDC+22 mV DC(CLOSED)Electrode (-)電極R6A and 6B125 AControl PCB控制電路R3 (Total Shunt)+ OutR1 (Shunt)Nozzle噴嘴REDCS1I/O PCBREC 4Pilot Arc EstablishedWork (+)- OutCH130 Chopper #1C2(2) 1400 pFCa

5、pacitors電容Relay PCB中轉(zhuǎn)印刷電路JP9CH130 Chopper #2C1CR1125 AChopper Control斬波調(diào)壓REC3R2 (Shunt)- OutShield保護(hù)帽R4F5High Frequency Console高頻震蕩器I/O PCB (RHF)L2+12 VDCHD2000 Torch CircuitL1DC-22 mV DCT2 Air Core空心的Chopper Control斬波調(diào)壓JP9BLUF2PilotF1+ OutREC5T1 High Voltage高電壓R5REC13Analog PCB模擬印刷電路Spark Gaps火花缺口3

6、45678910141516+34FUSE34111278CH130 Chopper #1CR1F5DC-PilotREC13DC+Control PCBI/O PCB+ Out- OutC1R4L1F2125 ACS1Relay PCBREC3High Frequency ConsoleT2 Air CoreT1 High VoltageSpark GapsElectrode (-)Work (+)ShieldBLUBLKREDREC5HD2000 Torch CircuitChopper ControlArc Established - Cutting0 VDC(2) 1400 pFCap

7、acitors(OPEN)JP9Nozzle+ OutCH130 Chopper #2- OutL2R1 (Shunt)R5R2 (Shunt)R3 (Total Shunt)F1125 AR6A and 6BChopper ControlJP9100 mV DC100 mV DCC2C1I/O PCB (RHF)REC 4Analog PCB3414151634+FUSE345678910781112 Copyright, 2001 Hypertherm, Inc. These materials cannot be reproduced in any formwithout the per

8、mission of Hypertherm, Inc.主接觸器 (CON1)在電源的面板中間的右側(cè)打開蓋子檢查接觸器 Copyright, 2001 Hypertherm, Inc. These materials cannot be reproduced in any formwithout the permission of Hypertherm, Inc.接觸不好會(huì)引起相位丟失導(dǎo)致斬波器的損壞 Copyright, 2001 Hypertherm, Inc. These materials cannot be reproduced in any formwithout the permi

9、ssion of Hypertherm, Inc.The CH130 Chopper (P/N 029922)For systems with Green Interlock LEDsTri Colored LED Copyright, 2001 Hypertherm, Inc. These materials cannot be reproduced in any formwithout the permission of Hypertherm, Inc.The CH130 Chopper (P/N 129118)For systems with Amber Interlock LEDsTr

10、i Colored LED Copyright, 2001 Hypertherm, Inc. These materials cannot be reproduced in any formwithout the permission of Hypertherm, Inc.Tri-Color LED (LED3):沒有電源LED 是白色.有電源但沒有啟動(dòng)LED 是紅色有弧轉(zhuǎn)移且輸出電流為100 Amps,LED是黃色.或紅綠色?如果斬波器失控時(shí),LED是綠色.紅色紅色 (LED1):LED 是亮紅色的,如果通過JP6有120VAC加在斬波器上的話. Copyright, 2001 Hypert

11、herm, Inc. These materials cannot be reproduced in any formwithout the permission of Hypertherm, Inc.CH130 斬波器功能斬波器功能:輸入整流橋通過鋁電解帽轉(zhuǎn)換 AC為DC.IGBT 作為一個(gè)高頻(15KHz)開關(guān)調(diào)整電流輸出模擬板和控制板共同來監(jiān)控和控制斬波器的輸出. Copyright, 2001 Hypertherm, Inc. These materials cannot be reproduced in any formwithout the permission of Hypert

12、herm, Inc.檢查檢查 OCV: 開路電壓是斬波器沒有負(fù)載輸出,沒有轉(zhuǎn)移弧.時(shí)測(cè)量的.移開所有從電源來的電源斷開在高頻控制箱內(nèi)高頻變壓器上的120VAC插頭.Separate this connector Copyright, 2001 Hypertherm, Inc. These materials cannot be reproduced in any formwithout the permission of Hypertherm, Inc.檢查檢查 OCV:移開并檢查斬波器上的兩個(gè)保險(xiǎn) (F1 and F2)在給出HT2000一個(gè)啟動(dòng)信號(hào)后檢查輸入整流橋的輸出端為 280VDC.

13、檢查 280VDC 在斬波器的底部 + WORK 和 TORCH兩個(gè)連接端.如果沒有這個(gè)電壓,請(qǐng)按照HT2000的維修手冊(cè)里的維護(hù)章節(jié)做斬波器測(cè)試. Copyright, 2001 Hypertherm, Inc. These materials cannot be reproduced in any formwithout the permission of Hypertherm, Inc.兩個(gè)斬波器輸出電流是并行的兩個(gè)斬波器輸出電流是并行的. 每個(gè)斬波器輸出總設(shè)定電流的一半每個(gè)斬波器輸出總設(shè)定電流的一半. 可以在旁路上做快速檢查可以在旁路上做快速檢查.R2 is for theLeft C

14、hopperR1 is for theRight ChopperR3 is for both ChoppersFor R1 and R2 1mVDC = 1A OutFor R3 1mVDC = 2A Out Copyright, 2001 Hypertherm, Inc. These materials cannot be reproduced in any formwithout the permission of Hypertherm, Inc.D3 - 5VDCD8 錯(cuò)誤代碼錯(cuò)誤代碼D9 - 12VDCD4 弧轉(zhuǎn)移弧轉(zhuǎn)移D5 起動(dòng)信號(hào)起動(dòng)信號(hào)(老型號(hào)老型號(hào))D14 - 起動(dòng)信號(hào)起動(dòng)信號(hào)

15、(新產(chǎn)品型號(hào)新產(chǎn)品型號(hào))D6 互鎖互鎖OK Copyright, 2001 Hypertherm, Inc. These materials cannot be reproduced in any formwithout the permission of Hypertherm, Inc.一些錯(cuò)誤是可以通過控制板上D8燈閃爍來表明閃爍的次數(shù)表示相對(duì)應(yīng)的一個(gè)錯(cuò)誤閃爍: ON .5 秒和 OFF .5 秒在OFF 2秒中間的反復(fù). 計(jì)算連續(xù)亮的次數(shù).如果D8常亮表示控制板內(nèi)部錯(cuò)誤其它的LED表示其它的問題 Copyright, 2001 Hypertherm, Inc. These materia

16、ls cannot be reproduced in any formwithout the permission of Hypertherm, Inc.(1) 等離子啟動(dòng)后, I.H.S. 完成,在30秒后沒有返回 (2) 互鎖錯(cuò)誤(3) 保持信號(hào)在預(yù)流后30秒內(nèi)沒有釋放(4)沒有弧轉(zhuǎn)移(O2: 300ms ; N2: 2 SECS)(5) 轉(zhuǎn)移的弧電流在ramp up前丟失(6) Chopper #1電流丟失(7) Chopper #2電流丟失(8)轉(zhuǎn)移的弧電流在ramp down 前丟失(9) 軟件錯(cuò)誤(10) 輸入電壓超出 -15% 的變化 Copyright, 2001 Hypert

17、herm, Inc. These materials cannot be reproduced in any formwithout the permission of Hypertherm, Inc.什么是保持電路什么是保持電路?如果是兩把割槍在同一個(gè)機(jī)架上為了切割同樣的零件必須同時(shí)起弧除去外部的起弧時(shí)間控制, 即使兩個(gè)電源同時(shí)受到啟動(dòng)信號(hào),但是提升裝置的速度也有不同.所以保持信號(hào)就是; 保持“快的” 機(jī)器,等待慢的機(jī)器完成初始定位 (HIS).這就可以讓兩臺(tái)電源能夠同時(shí)開始起弧. Copyright, 2001 Hypertherm, Inc. These materials cannot

18、 be reproduced in any formwithout the permission of Hypertherm, Inc.How does it work?+12V+12VTB3TB3ONLY ifthis signalis HIGHallowSTART toProceedONLY ifthis signalis HIGHallowSTART toProceedClose this relay if theMachine has recieved aSTART but HAS NOTrecieved an IHSCOMPLETEClose this relay if theMac

19、hine has recieved aSTART but HAS NOTrecieved an IHSCOMPLETEHT2000 #1HT2000 #2MicroProcessor LogicMicroProcessor LogicHOLD CableD21D21R5610KR5610K1234567891011121314151612345678910111213141516Y1Y1 Copyright, 2001 Hypertherm, Inc. These materials cannot be reproduced in any formwithout the permission

20、of Hypertherm, Inc.常見問題常見問題?如果兩把割槍不能同時(shí)起弧可能是保持電纜有問題.如果機(jī)器不能產(chǎn)生高頻,同時(shí)錯(cuò)誤號(hào)3在控制板上,這表明控制板有問題或者保持電纜短路. 移開 D21的一個(gè)腳在控制板上.保持電纜帶電, 電源干擾可能產(chǎn)生上述問題. Copyright, 2001 Hypertherm, Inc. These materials cannot be reproduced in any formwithout the permission of Hypertherm, Inc. Copyright, 2001 Hypertherm, Inc. These materi

21、als cannot be reproduced in any formwithout the permission of Hypertherm, Inc.如果有冷卻問題如果有冷卻問題:流量開關(guān)有問題 (Coolant Flow Interlock)如果消耗品壽命太短割槍或者消耗品過熱.WARNING:Turn off power at the machine AND at the disconnect switch before removing any covers from the power supply. There is 240 VAC in the power supply ev

22、en when it is OFF. Copyright, 2001 Hypertherm, Inc. These materials cannot be reproduced in any formwithout the permission of Hypertherm, Inc.冷卻系統(tǒng)問題解決冷卻系統(tǒng)問題解決1.確定水是滿的2.檢查每分鐘為 3/4 gallon回流 Copyright, 2001 Hypertherm, Inc. These materials cannot be reproduced in any formwithout the permission of Hyper

23、therm, Inc.測(cè)量回流測(cè)量回流3.按住 ON 開關(guān),強(qiáng)制泵運(yùn)行Return Hose Copyright, 2001 Hypertherm, Inc. These materials cannot be reproduced in any formwithout the permission of Hypertherm, Inc.如果沒有水流如果沒有水流6.檢查馬達(dá)和閥V1 有240VAC.7.如果有但不工作就更換NOTE:在電源分配板上的 240VAC 繼電器 (CR3) 在前面 5個(gè)互鎖信號(hào)沒有得到滿足時(shí)是不會(huì)吸合的.MotorPumpSolenoid Valve Copyrigh

24、t, 2001 Hypertherm, Inc. These materials cannot be reproduced in any formwithout the permission of Hypertherm, Inc.如果有如果有 至少至少3/4 加侖加侖/每分鐘的每分鐘的 回流回流:移開過濾重新接好.打開電源,如果 COOLANT FLOW LED 還是表明有問題,須更換流量開關(guān).反之則更換過濾芯.如果有少于如果有少于3/4 加侖加侖/每分鐘的每分鐘的 回流回流移開割槍上易損件放上保護(hù)帽檢查是否有1加侖/每分鐘在割槍上如果少說明要檢查泵,馬達(dá), 電磁 閥, 管路. Copyrig

25、ht, 2001 Hypertherm, Inc. These materials cannot be reproduced in any formwithout the permission of Hypertherm, Inc.割槍割槍6.如果割槍上有 1加侖每分鐘,說明到割槍的流量是好的. 7.更換割槍重新做流量測(cè)試.如果沒有3/4到1加侖 /每分鐘就檢查泵,馬達(dá), 電磁閥和管路.檢查泵和管路檢查泵和管路如果馬達(dá),泵和閥正常工作就要更換管路如果流量還是沒有好就更換整個(gè)泵單元. Copyright, 2001 Hypertherm, Inc. These materials cannot

26、be reproduced in any formwithout the permission of Hypertherm, Inc.引導(dǎo)弧浪涌回路手動(dòng)起弧弧轉(zhuǎn)移為了建立一個(gè)等離子弧必須有一個(gè)機(jī)械裝置或相應(yīng)的過為了建立一個(gè)等離子弧必須有一個(gè)機(jī)械裝置或相應(yīng)的過程來啟動(dòng)建立電弧程來啟動(dòng)建立電弧. Copyright, 2001 Hypertherm, Inc. These materials cannot be reproduced in any formwithout the permission of Hypertherm, Inc.引導(dǎo)弧故障引導(dǎo)弧故障:檢查引導(dǎo)弧繼電器工作正常(CR1).檢

27、查主接觸器的觸點(diǎn) (CON1).檢查引導(dǎo)弧電纜.檢查割槍電纜.檢查浪涌電路如果割槍沒有亮如果割槍沒有亮,并且在高頻箱中有高頻的話并且在高頻箱中有高頻的話, 那說明問題一定那說明問題一定出現(xiàn)在引導(dǎo)弧的回路上出現(xiàn)在引導(dǎo)弧的回路上 Copyright, 2001 Hypertherm, Inc. These materials cannot be reproduced in any formwithout the permission of Hypertherm, Inc.檢查氣路.檢查割槍電纜.做氣體泄漏測(cè)試.做斬波器測(cè)試.High Frequency Arc EstablishedC1Work

28、(+)L1The output of the choppers is a seriesof pulsesChopper OutputThe result is that there is enough current soon enough toestablish the pilot arcPower SupplyOutputElectrode (-)NozzleThe surge injection capacitor (C1) discharges as soon as the circuit is established asthe high frequency breaks over

29、between the electrode and the nozzleSurge InjectionOutputShieldHT2000 Surge Injection CircuitAfter the inductors (L1 & L2) are charged their output is a seriesof pulses exactly out of phase with the choppersInductor OutputCR1+ OutCH130 Chopper #2- Out- Out+ OutCH130 Chopper #1L2R4R5R6 A & B+

30、在引導(dǎo)弧狀態(tài)下的電流輸出在引導(dǎo)弧狀態(tài)下的電流輸出TimeCurrentOutput CurrentsSurge Injection CapacitorChopper Total Circuit Copyright, 2001 Hypertherm, Inc. These materials cannot be reproduced in any formwithout the permission of Hypertherm, Inc.浪涌電路問題浪涌電路問題:檢查電阻 R4, R5, 和R6A/B的值 (see manual for values).檢查浪涌電容的工作. Copyright,

31、 2001 Hypertherm, Inc. These materials cannot be reproduced in any formwithout the permission of Hypertherm, Inc.手動(dòng)點(diǎn)火手動(dòng)點(diǎn)火:找得TB3.在#159 和 #160上接一個(gè)按紐開關(guān).等HT2000上電后, 用這開關(guān)控制割槍的點(diǎn)火.在HT2000上電前,開關(guān)要處于 OFF位置.131618REC5PCB2 Copyright, 2001 Hypertherm, Inc. These materials cannot be reproduced in any formwithout

32、the permission of Hypertherm, Inc. Copyright, 2001 Hypertherm, Inc. These materials cannot be reproduced in any formwithout the permission of Hypertherm, Inc.弧轉(zhuǎn)移問題弧轉(zhuǎn)移問題:找到 pins 14, 15, and 16 on REC5 在主控板(PCB2).電流傳感器接到這三個(gè)腳:RED = +12VDC, BLUE = Signal, BLACK = Ground平時(shí)有12VDC在 Signal 和 Ground. 當(dāng)工作電纜上電

33、流被檢測(cè)到電壓就變?yōu)?0VDC.檢查有12VDC在pins 14和15. Copyright, 2001 Hypertherm, Inc. These materials cannot be reproduced in any formwithout the permission of Hypertherm, Inc.弧轉(zhuǎn)移問題弧轉(zhuǎn)移問題:短接 pins 15 和 16 等割槍點(diǎn)火后.注意如果在主控制板上 D4 亮就短接兩個(gè)腳.如果D4亮和割槍繼續(xù)工作說明 電流傳感器有問題電流傳感器有問題.如果 D4亮和弧滅了說明工作電纜或者連接有問題.如果D4 不亮,問題是在主控制板. Copyright,

34、 2001 Hypertherm, Inc. These materials cannot be reproduced in any formwithout the permission of Hypertherm, Inc.氣系統(tǒng)割槍高度控制系統(tǒng)In order to establish a Plasma Arc there must be an GAS available for ionization and to control the shape of the arc. Copyright, 2001 Hypertherm, Inc. These materials cannot be

35、 reproduced in any formwithout the permission of Hypertherm, Inc.Plasma Gas SupplyHT2000 Gas ConsoleOff ValveAssembly 4X2 CablePlasma Gas LineMotor Valve ConsoleSecondary Pressure Gauge Copyright, 2001 Hypertherm, Inc. These materials cannot be reproduced in any formwithout the permission of Hyperth

36、erm, Inc.OnStartTransferSV1ASV1BSV2SV3SV4ASV5SV6StopSimplified Version of the O2 Plasma Process Gas System Timing ChartSV4BSV7 Copyright, 2001 Hypertherm, Inc. These materials cannot be reproduced in any formwithout the permission of Hypertherm, Inc.O2 INSHIELD INN2 INO2 Plasma SelectedMachine in ON

37、 StateHT2000 Gas SystemRefer to the appropriate process timing chart.FL1PS1PG1FM1MV2SV2SV3MV3SV1BSV1AFM2PS2FL2PG2PG3MV4MV1SV4ASV4BFL3SV6CO1PS3SV7SV5Cap SenseShield GasCut-flowPre-flowGas ConsoleRHF ConsoleValve Console“OFF Valve”M Copyright, 2001 Hypertherm, Inc. These materials cannot be reproduced

38、 in any formwithout the permission of Hypertherm, Inc.O2 INSHIELD INN2 INO2 Plasma SelectedMachine in START State(Pre-Flow)HT2000 Gas SystemRefer to the appropriate process timing chartM.FL1PS1PG1FM1MV2SV2SV3MV3SV1BSV1AFM2PS2FL2PG2PG3MV4MV1SV4ASV4BFL3SV6CO1PS3SV7SV5Cap SenseShield GasCut-flowPre-flo

39、wGas ConsoleRHF ConsoleValve Console“OFF Valve” Copyright, 2001 Hypertherm, Inc. These materials cannot be reproduced in any formwithout the permission of Hypertherm, Inc.O2 INSHIELD INN2 INO2 Plasma SelectedMachine in TRANSFER State(Cut-Flow)HT2000 Gas SystemRefer to the appropriate process timing chartM.FL1PS1PG1FM1MV2SV2SV3MV3SV1BSV1AFM2PS2FL2PG2PG3MV4MV1SV4ASV4BFL3SV6CO1PS3SV7SV5Cap SenseShield GasCut-flowPre-flowGas ConsoleRHF ConsoleValve Console“OFF Valve” Copyright, 2001 Hypertherm, Inc. These