CEBORA S.p.A.

PLASMA SOUND PC 6060/T

POWER SOURCE art. 355

SERVICE MANUAL

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CONTENTS

1 - GENERAL INFORMATION ....................................................................................................................3

1.1 - Introduction. ...........................................................................................................................................3
1.2 - General service policy. ............................................................................................................................3
1.3 - Safety information. .................................................................................................................................3
1.4 - Electromagnetic compatibility. ................................................................................................................3
2 - SYSTEM DESCRIPTION .........................................................................................................................4
2.1 - Introduction. ...........................................................................................................................................4
2.2 - Technical specifications. .........................................................................................................................4
2.3 - Description of power source art. 355. ......................................................................................................4
3 - MAINTENANCE......................................................................................................................................7
3.1 - Periodic inspection, cleaning. ..................................................................................................................7
3.2 - Operating sequence (fig. 3.2.1)................................................................................................................7
3.2.1 - Power source commands and signals.....................................................................................................7
3.2.2 - Power source operation.........................................................................................................................8
3.3 - Troubleshooting....................................................................................................................................10
3.3.1 - The power source does not start, led (V) off. .......................................................................................10
3.3.2 - Power source powered, led (V) lit, fan (21) stopped. ...........................................................................12
3.3.3 - Power source powered, the signals do not indicate correct values. .......................................................12
3.3.4 - The start button produces no effect. ....................................................................................................13
3.3.5 - No gas flows from the torch................................................................................................................14
3.3.6 - Gas flows from the torch, the pilot arc does not light (high frequency missing)....................................15
3.3.7 - Gas flows from the torch, the pilot arc does not light (contact tip voltage missing)...............................17
3.3.8 - In open circuit operation, the output voltage is not regular...................................................................18
3.3.9 - Irregular pilot arc starts, unstable pilot arc...........................................................................................20
3.3.10 - Transfer arc does not take place or is too weak for cutting...................................................................22
3.4 - Alarm signals........................................................................................................................................24
3.4.1 - Led (G) lit = temperature outside limits...............................................................................................24
3.4.2 - Led (L) lit = low gas pressure. ............................................................................................................24
3.4.3 - Led (S) steadily lit = power source blocked.........................................................................................25
3.4.4 - Led (S) flashing = short-circuit between electrode and nozzle, or electrode finished. ...........................26
4 - COMPONENTS LIST .............................................................................................................................27
4.1 - Power source art. 355 : see file ESP355.pdf enclosed at the end of the manual. ......................................27
4.2 - Table of components: see file ESP355.pdf enclosed at the end of the manual. ........................................27
4.3 - List of spare parts..................................................................................................................................27
5 - ELECTRICAL DIAGRAMS ...................................................................................................................28
5.1 - Power source art. 355 : see file SCHE355.pdf enclosed at the end of the manual. ...................................28
5.2 - Waveforms. ..........................................................................................................................................28
5.2.1 - Open-circuit output voltage, interrupted after approximately 300 msec. for missing pilot arc current (par.
3.3.6, 3.3.7, 3.3.9)..............................................................................................................................28
5.2.2 - Command signal for HF board (19), interrupted after approximately 300 msec. for missing pilot arc
current (par. 3.3.6). ............................................................................................................................28
5.2.3 - Open-circuit rectifier output voltage, interrupted after approximately 300 msec., for missing pilot arc
current (par. 3.3.8). ............................................................................................................................28
5.2.4 - Open-circuit inverter output voltage, interrupted after approximately 300 msec. for missing pilot arc
current (par. 3.3.8). ............................................................................................................................29
5.2.5 - Pilot arc current signal for its maximum time, approximately 2 sec., with the torch free in the air and
thus without transfer arc (par. 3.3.9). ..................................................................................................29
5.3 - Filter board (56) code 5.602.087/A........................................................................................................30
5.4 - Igbt board (69) code 5.602.085/A. .........................................................................................................31
5.5 - Secondary board (65) code 5.602.088/B. ...............................................................................................32
5.6 - Panel board (57) code 5.602.089............................................................................................................33
5.7 - Control board (26) code 5.602.086. .......................................................................................................34
5.8 - HF board (19) code 5.602.090/A. ..........................................................................................................35

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1 - GENERAL INFORMATION
1.1 - Introduction.
The purpose of this manual is to train personnel assigned to carry out maintenance on the
power source art. 355 for plasma cutting systems.

1.2 - General service policy.

It is the responsibility of the customer and/or operator to use the equipment appropriately, in
accordance with the instructions in the Instruction Manual, as well as to maintain the equipment
and related accessories in good working condition, in compliance with the instructions provided
in the Service Manual.
Any internal inspection or repairs must be carried out by qualified personnel who are
responsible for any intervention on the equipment.
It is forbidden to attempt to repair damaged electronic boards or modules; replace them with
original Cebora spare parts.

1.3 - Safety information.

The safety notes provided in this manual are an integral part of those given in the Instruction
Manual. Therefore, before working on the machine, please read the paragraph on safety
instructions in the aforementioned manual.
Always disconnect the power cord from the mains, and wait for the internal capacitors to
discharge (1 minute) before accessing the interior of the equipment.
Some internal parts, such as terminals and swirl rings, may be connected to mains or
otherwise hazardous potentials. It is therefore forbidden to work with the safety guards removed
from the machine unless strictly necessary. In this case, take special precautions such as wearing
insulating gloves and footwear, and working in a perfectly dry environment with dry clothing.

1.4 - Electromagnetic compatibility.

Please read and observe the instructions provided in the paragraph “Electromagnetic
compatibility” of the Instruction Manual.

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2 - SYSTEM DESCRIPTION
2.1 - Introduction.
The PLASMA SOUND PC 6060/T is a plasma arc system for cutting electrically conductive
materials.
It is made up of an electronic power source (art. 355), and a set of accessories for use in both
manual applications and automated systems (see list in Sales Catalogue).
The power source is controlled by microprocessor circuits, which manage the operative
functions of the cutting system and operator interface.

2.2 - Technical specifications.

To verify the technical specifications, see the machine plate, Instruction Manual, and Sales
Catalogue.

2.3 - Description of power source art. 355.

Art. 355 is a controlled current direct current power source, made up of a three-phase rectifier
bridge, a DC/AC converter (inverter) and an additional rectifier bridge.
It may be powered at either 230 or 400 Vac; the unit adapts automatically based on the
voltage applied to the power source input.
Referring to the electrical diagram in par. 5.1, drawing 4.1 and table 4.2, we can identify the
main blocks that make up the power source.
The main switch (53) powers the filter board (56), which contains the filter to reduce
conducted interference reflected in the mains, the pre-charge circuit for the inverter capacitors,
and the circuits to analyze and select the mains voltage.
The pre-charge circuit is made up of the varistors PTC1 and PTC2, and the relay RL3.
The microprocessor IC4 and the optocoupler IC1, IC2, and IC3 check for the presence of the
power supply 3 phases, and the relays RL1 and RL2 present on the filter board (56) (but
controlled by the control board (26) adapt the power source to the mains voltage.
The integrated circuit U1 generates the 13.8 Vdc service voltage to power the electronic
boards; the transformer TF2, together with the rectifier W2, generates the isolated supply voltage
for the torch start button circuit, on the panel board (57).
The relays RL5 and RL4 drive the solenoid valves EV1 (pilot arc) and EV2 (cutting),
respectively, based on the commands received from the control board (26).
The solenoid valves EV1 and EV2 (16), as well as the fan (21), are always powered at 230
Vac, whatever the power source supply voltage, due to the mains voltage adapter circuit carried
out by the relays RL1, RL2 and the primary winding of the transformer TF1.
The rectifier bridge (67) is connected to the output of the filter board (56), and rectifies the
mains voltage at the filter board (56) output, which may be approximately 230 or 400 Vac, into
direct current equivalent to respectively 320 and 560 Vdc, approximately. This voltage, applied
to the inverter, made up of the igbt board (69) and the igbt modules (68), is converted once again
into square-wave alternating voltage, suitable for powering the power transformer (27).
The power transformer (27) has a primary winding composed by two windings separated from
one another. By connecting them in series or parallel, the secondary circuit can receive the same
voltage, with the power source powered at either 230 or 400 Vac.
This switching is carried out by the relays RL1 and RL2 on the igbt board (69), controlled by
the control board (26), and takes place automatically based on the mains voltage; with the
voltage at 230 Vac, the two primary windings are parallel connected (RL1 = closed), while with
the voltage at 400 Vac the two primary windings are serial connected (RL2 = closed).

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The 4 resistors (29) connected to CN2 of igbt board (69) limit the current in the electrolytic
capacitors on the igbt board (69), which in turn level the direct current rectified by the bridge
(67). Their interruption makes these capacitors isolated and useless, while a short-circuit will
damage the capacitors.
The igbt board (69) contains the TA to detect the current at the primary circuit of the
transformer (27). Its signal is used by the control board (26) to adjust the pilot arc and cutting
current.
The secondary transformer circuit (27) is made up of 4 separate identical windings, connected
to a shared point on the terminal S2-S5 of the secondary board (65), to form a dual central socket
winding. The other ends of the 4 windings are connected to terminals S1 – S3 – S4 – S6 of the
secondary board (65), which lead to the diodes to rectify the alternating current generated by the
inverter (69). Inserted between the + output of the diodes (terminal L1 of secondary board (65))
and the + terminal of the secondary board (65) (terminal L2), the inductor (23) is connected to
level the power source output current.
In this way the direct current voltage at the output of the secondary board (65) and present at
its terminals (-) and (+) is available for the power source output.
The resistor (64) connected to CN2 of secondary board (65) helps balance the currents
between the secondary windings of the transformer (27). If interrupted, it may cause unstable
operation both in the pilot arc and while cutting, while a short-circuit will definitely damage the
secondary board (65).
The secondary board (65) includes the nozzle relays RL1 and RL3 to enable the nozzle
voltage, and the solenoid with reed bulb RL2 to detect the cutting current on the earth conductor
of the power source (workpiece potential).
When the two relays are in resting condition (thus with power source on or with pilot arc),
they provide on terminal F1, corresponding to the torch nozzle terminal, the same voltage
present on terminal L2 of the secondary board (65), corresponding to the + output of the power
source.
When the torch with pilot arc lit is moved close to the workpiece, the solenoid with reed bulb
detects the current passing through the earth conductor of the power source, and commands the
switch from pilot arc to transfer arc, by means of the nozzle relays RL1 and RL3, which cut off
voltage on the nozzle terminal F1. The reed RL2 simultaneously sends the same signal to the
control board (26), which starts the transfer arc working mode (cutting).
The secondary board (65) includes the Hall-effect current transducer to detect the cutting
current. Its signal is used by the control board (26) to limit the maximum output current of the
power source.
The cutting current is adjusted by the inverter, made up of the igbt board (69) and igbt
modules (68), appropriately controlled by the control board (26).
The control board (26) contains the main power source microprocessor, and supervises
management of the other boards. It adjusts the cutting current, generates the PWM signal to be
sent to the igbt (68) through the isolated drive circuits built into the same board, and also handles
diagnostics of the power source, managing the control panel consisting of the panel board (57).
Given the particular configuration of the inverter (control board (26) with built-in drive
circuits connected directly to the igbt (68)), quite these drive circuits suffer damage
following an igbt (68) fault. For this reason we recommend simultaneously replacing the
control board (26) along with the igbt (68). Otherwise, the new igbt controlled by defective
drive circuits would again be damaged. Similarly, should it be necessary to replace the
control board (26) following a fault in the igbt drive circuits, we recommend that you also
replace the igbt (68) at the same time.

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Between the (–) output terminal of the secondary board (65), corresponding to the shared
point of the secondary windings of transformer (27) (terminals S2-S5 on secondary board (65)),
and the power source negative output terminal (electrode potential), is connected the HF
transformer (52) which, appropriately driven by the HF board (19), generates the high voltage
and high frequency to engage the pilot arc.
The HF board (19) operation is subject to the presence of direct current voltage on the L2 and
(–) terminals of the secondary board (65) (equivalent to the power source output voltage), and is
controlled by the control board (26) through the filter board (56).
The power source power outputs, to which the torch is connected, are gathered into the central
adapter on the front panel. This is a multiple connector that incorporates a power socket for the
torch electrode, two contacts for the torch nozzle, two contacts for the start button, four contacts
for torch type recognition, and a pneumatic socket for the plasma gas. This central adapter is
fitted with a protective hood; a reed switch mounted on the panel board (57) detects its presence,
and prevents the power source from running if the hood is missing.
The panel board (57), 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, from torch button, (the start command, sent to the control board (26), is
isolated by means of the relay RL1 on panel board (57), and the corresponding circuit is
powered separately from the filter board (56)).
− Central adapter protection presence.
− Power source output voltage.
− Torch type recognition (see par. 3.3.4).
The panel board (57) contains the following control elements:
− Potentiometer to adjust the cutting current.
− Button to control Grid/Continuous operation.
− A set of leds to indicate the operating status.
On the rear panel is mounted the pressure regulator, complete with filter and pressure gauge
for the plasma gas. The regulator makes it possible to adapt the gas pressure to the type of torch
being used.
The signals processed by the electronic boards and present at their connectors are listed in the
table in chapter five of this manual.

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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).

3.1 - Periodic inspection, cleaning.

Periodically open the power source grids and check inside the aeration tunnel.
Remove any dirt or dust to ensure smooth air flow, and thus adequate cooling of the internal
parts of the power source.
Check the condition of the output terminals, output and power supply cables of the power
source; replace if damaged.
Check the condition of the internal power connections and connectors on the electronic
boards; if you find “loose” connections, tighten or replace the connectors.

3.2 - Operating sequence (fig. 3.2.1).

The following sequence represents correct functioning of the machine. It may be used as a
guiding procedure for troubleshooting.
It must be carried out after each repair without any errors.

3.2.1 - Power source commands and signals.

R P H M T U G S L V I F E B C A

0
SELF I
RESTART
PILOT
V
Plasma Cutter
Art. 355 Ø 35
40
45
1
2 0A/ 8 8 V- 6 0 /A1 0 4 V
30 50 ®

Ø X 35 % 60% 100% X 60% 100 % Via A.Costa, 24-Cadriano-Bologna

1,2 P.A.C.
I2 60A 50A 40A I2 60A 50A PC 6035/ T
25 55 TORCH TYPE
U2 104V 100V 96V U2 104V 100V Art.355
CEBORA
CP90
20 60 S
A U0 I 1max= 2 2 / 2 1 / 2 0 A I1max= 1 1 / 1 0 A N.

® 315V I 1eff = 1 3 / 1 2 / 1 7A I1eff = 9 / 8 A MADE IN ITALY

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3.2.2 - Power source operation.

NOTE
q Operations marked with this symbol refer to operator actions.
♦ The operations marked with this symbol refer to machine responses that must occur following
an operator action.

q System shut off and unplugged from the mains.

q Connect the gas intake to the fitting (B) on the rear panel.
q Connect the torch to the power source.
q Connect the cable of the positive pole of the power source to the workpiece.
q Connect the power source to the mains.
q Close the switch (C) on the power source.
♦ System powered, led (V) lit, fan running.
♦ On front panel, leds (G) and (L) off; led (S) lit for the first 5 seconds (mains
voltage analysis and selection), then off; led (U) lit or off depending on its status
before the last shutdown.

Correct? NO (see 3.3.1, 3.3.2, 3.3.3).

YES
q Turn the gas setting knob (E) to a pressure, as read on the pressure gauge (F), suited to the
type of torch in use (see Instruction Manual).
q Press several times the button (T) to make sure that the “SELF-RESTART PILOT” function
is selected. Finally, leave it in the “off ” position (led U off).
♦ Each time the button (T) is pressed, the led (U) goes on and off in sequence, to
indicate the status of the “SELF RESTART PILOT” function.

Correct? NO (see 3.3.3),

YES

WARNING
DURING THE FOLLOWING TESTS, DO NOT POINT THE TORCH AT PEOPLE OR
PARTS OF THE BODY, BUT ALWAYS TOWARDS AN OPEN SPACE OR THE
WORKPIECE.

q Briefly press the torch start button.

♦ Gas flows from the torch for approximately 5 seconds (maximum pre-gas time
without pilot arc).
The pressure reading on the pressure gauge (F) remains constant.

Correct? NO (see 3.3.4, 3.3.5).

YES
q Press the torch start button and hold it down for approximately 5 seconds to start the pilot arc.
♦ Pilot arc starts for the maximum pilot arc time (2 sec.). The gas continues to flow
for approximately another 100 sec. after the start button is released (post-gas
time).

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Correct? NO (see 3.3.6, 3.3.7,

3.3.8, 3.3.9).
YES
q With pilot arc lit, place the torch near the workpiece.
♦ Begin cutting. Adjust the knob (M) to the current level suited to the kind of
cutting.

Correct? NO (see 3.3.10).

YES
q 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.

Correct? NO (see 3.3.5),

YES
REGULAR OPERATION.

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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).

NOTE
Items in boldface describe problems that may occur on the machine (symptoms).
q Steps marked with this symbol refer to situations for which the operator must determine the
causes (causes).
♦ Operations preceded by this symbol refer to actions the operator must perform in order to
solve the problems (solutions).

3.3.1 - The power source does not start, led (V) off.

MAINS SUITABILITY TEST.

q No voltage at the power source input, because the mains surge protector is tripped.

NO Correct?

YES
♦ Eliminate any short-circuits in the connections between the power cable, switch
(53) and filter board (56).
♦ Make sure that the terminals U1, V1 and W1 on filter board (56) are not short-
circuited between themselves or towards earth. If short-circuited, disconnect the
wires from terminals U2, V2 and W2 of filter board (56) from the terminals of the
rectifier bridge (67) and repeat the tests. If the short-circuit is still present, replace
the filter board (56). If the short-circuit has been removed, make sure the rectifier
bridge (67), igbt (68) and igbt board (69) are intact, and replace any defective
components.
♦ Mains not suited to power the power source (ex.: insufficient installed power).

MAINS CONNECTION TEST.

q Rectifier bridge (67) input terminals (wires from terminals U2, V2 and W2 of filter board
(56)) = approximately 3 x 230 or 3 x 400 Vac, according to mains voltage, with switch (53)
closed.

YES Correct?

NO
♦ Check power cable and plug and replace if necessary.
♦ Check the switch (53) and replace if defective.
♦ Check the mains voltage conditions, and especially that none of the power supply
three phases is missing.

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♦ Check the integrity of the rectifier bridge (67), igbt (68) and the igbt board (69)
and replace any defective components.
♦ Check the integrity of the varistors PTC1 and PTC2 on filter board (56) and/or
wait for them to cool if you made repeated attempts to start.
♦ Replace the control board (56).

SERVICES POWER SUPPLY TEST.

q Filter board (56), connector CN1, terminals 1 (+) - 5 (-) = +25 Vdc, approximately; terminals
4 (+) - 5 (-) = +13.8 Vdc, approximately.

YES Correct?

NO
♦ Check the wiring between CN1 filter board (56) and CN9 control board (26).
♦ With the power source off, temporarily disconnect the connector CN1 on
secondary board (65), and repeat the test of the voltages on the connector CN1 of
filter board (56). If the values are correct, replace the secondary board (65). If
incorrect, with the power source off, also disconnect CN9 on control board (26)
and repeat the test of the voltages on the connector CN1 of filter board (56). If the
values are correct, replace the control board (26). If incorrect replace the filter
board (56).

PANEL BOARD (57) POWER SUPPLY TEST.

q Panel board (57), connector CN1, terminals 1 (+) - 10 (-) = +5 Vdc.

YES Correct?

NO
♦ Check the wiring between CN1 panel board (57) and CN2 control board (26).
♦ With the power source off, temporarily disconnect the connector CN1 on panel
board (57) and make sure that the voltage on connector CN2, control board (26),
terminals 1 (+) - 10 (-) = +5 Vdc. If the result is correct replace the panel board
(57); if incorrect replace the control board (26).
♦ Replace the control (26) and/or panel boards (57).
♦ Check the wiring between CN1 panel board (57) and CN2 control board (26).
♦ Replace the control (26) and/or panel boards (57).

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3.3.2 - Power source powered, led (V) lit, fan (21) stopped.

FAN (21) TEST.

q Fan (21) fast-on terminals = 230 Vac, approximately, with mains at 230 or 400 Vac, after
closing switch (53).

NO Correct?

YES
♦ Make sure that there are no mechanical impediments blocking the fan (21).
♦ Replace the fan (21).
♦ Check the wiring between fan (21) and connector CN2, terminals 2 and 6 on filter board (56).
♦ Check the presence of the power supply three phases on terminals U1, V1 and W1 on filter
board (56), with a voltage value equivalent to the supply voltage of the power source. If
incorrect, check the cable, power plug and switch (53) and replace if defective.
♦ Replace the filter board (56).

3.3.3 - Power source powered, the signals do not indicate correct values.

MAINS VOLTAGE SELECTION AND SELF-RESTART-PILOT TEST.

q Upon start-up, green led (V) lit, leds (G) and (L) off, led (S) lit for the first 5 seconds (mains
voltage analysis and selection), then off; led (U) lit or off depending on its status before the
last shutdown.
q With power source powered, 5 seconds after closing the switch (53) (mains voltage selection),
pressing the button (T) will turn the led (U) on and off in sequence, indicating that the “Self-
restart-pilot” function is activated/deactivated.

YES Correct?

NO
♦ See Alarm signals, par. 3.4.
♦ Carry out the SERVICES POWER SUPPLY TEST and PANEL BOARD (57)
POWER SUPPLY TEST in par. 3.3.1.
♦ Replace the control (26) and/or panel boards (57).
♦ Correct operation.

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3.3.4 - The start button produces no effect.

WARNING
FOR THE FOLLOWING TESTS DISCONNECT THE CONNECTOR CN1 ON HF BOARD
(19) TO PREVENT HIGH FREQUENCY FROM BEING GENERATED.

START BUTTON TEST.

q Panel board (57), terminals CN4 (+) and CN3 (-) = +35 Vdc (button contact open) and RL1
on panel board (57) resting, with start button on torch released; 0 Vdc (contact closed) and
RL1 powered, with button pressed.

YES Correct?

NO
♦ Check the wiring between terminals CN3 and CN4 of panel board (57), terminals
1 and 9 central adapter on power source, torch button and contact of the nozzle
protection on the torch.
♦ Check the wiring between connector CN2, terminals 2, 3, 4 and 5, of panel board
(57), and, respectively, terminals 2, 3, 4 and 7 of the central adapter on the power
source, and make sure that the torch recognition jumper is present on the torch
patch connector (suitable torches must have the jumper between terminals 2 and 4
of the central adapter, e.g.: Cebora CP90).
♦ Make sure that the nozzle guard is correctly mounted on the torch and in good
working order. If defective or showing signs of wear, replace.
♦ Check torch button. If defective, replace.
♦ Make sure that connector CN8, on panel board (57), terminals 1 (+) and 2 (-) =
+35 Vdc, approximately, with power source powered. If correct, replace the panel
board (57). If incorrect, with power source off temporarily disconnect the
connector CN8 from panel board (57) and make sure that the voltage on connector
CN4 of filter board (56), terminals 1 (+) and 2 (-) = +35 Vdc approximately. If
correct check the wiring between CN8 panel board (57) and CN4 filter board (56),
or replace the panel board (57). If incorrect check the power supply conditions of
the power source (see par. 3.3.1) and/or replace the filter board (56).
♦ In case of damage to the panel board (57), make sure that conductors of the start
button, the electrode and torch nozzle are perfectly insulated. If insulation is
reduced, replace the complete torch. An isolation leak between the torch cable
conductors may damage the panel board (57).

START COMMAND TEST.

q Control board (26), connector CN2, terminals 11 (+) and 12 (-) = +13.8 Vdc, (RL1 contact
open) with torch start button released; 0 Vdc (contact closed) with button pressed.

YES Correct?

NO
♦ Check the wiring between CN1 panel board (57) and CN2 control board (26).
♦ Temporarily disconnect, with power source off, connector CN1 from panel board
(57) and check the resistance between terminals 11 and 12 of CN2 control board
(26) = approximately 25 Kohm. If incorrect, replace control board (26). If correct
replace relay RL1 on panel board (57) or panel board (57).
♦ Replace control board (26).

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3.3.5 - No gas flows from the torch.

WARNING
FOR THE FOLLOWING TESTS DISCONNECT THE CONNECTOR CN1 ON HF BOARD
(19) TO PREVENT HIGH FREQUENCY FROM BEING GENERATED.

PILOT ARC SOLENOID VALVE TEST.

q Solenoid valve EV1 (16) terminals, (the one with flow reductor and connected with blue wires
to terminals 3 and 7 of CN2 on filter board (56)) = 230 Vac, approximately, with torch button
pressed (with mains at both 230 and 400 Vac). The time the solenoid valve remains open
depends on the pre-gas and post-gas times and on the testing conditions.

YES Correct?

NO
♦ Check the wiring between solenoid valve EV1 (16) and CN2 filter board (56).
♦ Check the wiring between CN1 filter board (56) and CN9 control board (26).
♦ Make sure that the supply voltage to the fan (21) is correct, see par. 3.3.2. (this
voltage is the same that powers the solenoid valves EV1 and EV2 (16).
♦ With power source off, check the resistance between the solenoid valve EV1 (16)
terminals = 2500 ohm, approximately. If 0 ohm (short-circuit), replace solenoid
valve EV1 (16) and filter board (56).
♦ Replace the control (26) and/or filter boards (56).
♦ With power source off, check the resistance between the solenoid valve EV1 (16) terminals =
2500 ohm, approximately. If > Mohm (winding broken), replace solenoid valve EV1 (16).
♦ Check the presence of the gas at the inlet fitting (B) and that the pressure and flow rate in the
intake conduit meet the specification values (see Instruction Manual).
♦ Make sure that the threaded part of the air fitting (B) inserted in the pressure regulator (E) is
no more than 6 - 8 mm (1/4” - 5/16”) long, to avoid any possible malfunction of the regulator
(E).
♦ Check the working order of the pressure regulator (E) and pressure gauge (F); replace if
defective.
♦ Make sure there are no occlusions in the gas hoses of the power source or in the flow
regulator inserted in the solenoid valve fitting.
♦ Replace the solenoid valve EV1 (16).

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CEBORA S.p.A. 15

3.3.6 - Gas flows from the torch, the pilot arc does not light (high frequency missing).

NOTE
Some of the following tests may be checked only in the second after pressing the torch start
button, due to failure by the pilot arc to strike.

HF OSCILLATOR TEST.
q HF board (19), discharger SCI1 discharges at regular intervals, for approximately one second,
with start button pressed.

NO Correct?

YES
♦ Check connections between torch and boards of the power source; more
specifically, between terminals 5 and 6 of the fixed torch fitting and CN6 – CN7
on panel board (57) (nozzle potential); between central terminal of the fixed torch
fitting, HF transformer (52) secondary winding, terminal “A” panel board (57)
and terminal “-” on secondary board (65), (electrode potential). If you find loose
connections, tighten and replace any damaged components.
♦ Check the connection between terminals CN6 – CN7 and CN5 on panel board
(57).
♦ Make sure that there is no short-circuit between the connectors CN2 and CN3 of
HF board (19) or in the connection of the HF transformer (52) primary winding.
♦ Make sure the fixed torch fitting does not have an isolation leak, thus that it is not
crossed by high-voltage surface discharge. If necessary, replace with a new one.
♦ Check cable, central adapter and torch grip; if worn or damaged or with insulation
leak, replace.
♦ Check the torch electrode and nozzle; replace if worn or damaged.
♦ Make sure that the gas pressure in the torch plasma chamber is not too high. If
necessary, check the operation of the pressure regulator (E) and pressure gauge
(F), and observe the technical specifications (see Instruction Manual).
♦ Go to par. 3.3.7.
♦ Make sure that the connection between the connectors CN2 and CN3 of HF board (19) with
the primary circuit of the HF transformer (52) is not interrupted. If necessary reset the
connection or replace the HF transformer (52) and/or HF board (19).
♦ Check the distance between the tips of the discharger SCI1 (correct value = 0.9 mm.).

WARNING
FOR THE FOLLOWING TESTS DISCONNECT THE CONNECTOR CN4 ON HF BOARD
(19) TO PREVENT HIGH FREQUENCY FROM BEING GENERATED.

HF BOARD (19) POWER SUPPLY TEST.

q HF board (19), connector CN1, terminals 1 - 4 (gnd) = fig. 5.2.1, with start button pressed
(open-circuit output voltage, interrupted after approximately 300 msec., for missing pilot arc
current).

YES Correct?

NO

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CEBORA S.p.A. 16

♦ Check the wiring between CN1 HF board (19) and terminals L2 and “-” on
secondary board (65).
♦ With power source off, temporarily disconnect the connector CN1 on HF board
(19) and check the resistance between the terminals 1 and 4 of CN1 on HF board
(19). If 0 ohm (short-circuit), replace the HF board (19) and secondary board (65).
♦ Go to par. 3.3.8.

WARNING
FOR THE FOLLOWING TESTS RE-CONNECT THE CONNECTOR CN4 AND
DISCONNECT THE CONNECTOR CN1 ON THE HF BOARD (19) TO KEEP THE HIGH-
FREQUENCY DISABLED.

HF COMMAND TEST.
q HF board (19), connector CN4, terminals 2 - 1 (gnd) = fig. 5.2.2, with start button pressed
(command signal for HF board (19), interrupted after approximately 300 msec. for missing
pilot arc current).

NO Correct?

YES
♦ Replace the HF transformer (52).
♦ Replace the HF board (19).
♦ Check the wiring between CN4 HF board (19) and CN3 filter board (56).
♦ Check the wiring between CN1 filter board (56) and CN9 control board (26).
♦ With power source off, temporarily disconnect connector CN3 from filter board (56) and
check the resistance between the terminals 1 and 2 of CN4 on HF board (19) = 1200 ohm
approximately. If > Mohm (circuit broken) replace relay RL1 on HF board (19) or HF board
(19). If 0 ohm (short-circuit) replace the HF board (19), and check the continuity of the
connection between terminals 9 of CN1 and terminal 1 of CN3 on filter board (56). If
interrupted reset the connection between these two terminals; if intact, also replace control
board (26).
♦ Replace the control board (26).

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CEBORA S.p.A. 17

3.3.7 - Gas flows from the torch, the pilot arc does not light (contact tip voltage missing).

NOTE
Some of the following tests may be checked only in the second after pressing the torch start
button, due to failure by the pilot arc to strike.

WARNING
FOR THE FOLLOWING TESTS DISCONNECT THE CONNECTOR CN4 ON HF BOARD
(19) TO PREVENT HIGH FREQUENCY FROM BEING GENERATED.

POWER SOURCE OUTPUT VOLTAGE TEST.

q Panel board (57), terminal “C”, and central terminal of the fixed torch fitting (gnd) = fig.
5.2.1, with start button pressed (open-circuit output voltage, interrupted after approximately
300 msec., for missing pilot arc current).

YES Correct?

NO
♦ Go to par. 3.3.8.

NOZZLE VOLTAGE TEST.

q Panel board (57), terminals CN7 and “A” (gnd) = fig. 5.2.1, with start button pressed (open-
circuit output voltage, interrupted after approximately 300 msec., for missing pilot arc
current).

NO Correct?

YES
♦ Check connections between torch and boards of the power source; more
specifically, between terminals 5 and 6 of the fixed torch fitting and CN6 – CN7
on panel board (57) (nozzle potential); between central terminal of the fixed torch
fitting, HF transformer (52) secondary winding, terminal “A” panel board (57)
and terminal “-” on secondary circuit board (65), (electrode potential). If you find
loose connections, tighten and replace any damaged components.
♦ Check the condition of the central adapter, torch cable and torch, especially make
sure there are no short-circuits or isolation leaks between the conductors or
between the contacts of the central adapter. Replace any worn or damaged
components.
♦ Go to par. 3.3.6.
♦ Check the wiring between terminals CN5 of panel board (57) and terminal F1 secondary
board (29).
♦ With the power source off, temporarily disconnect terminal F1 from secondary board (65) and
check the resistance between the terminals F1 and L2 on secondary board (57). Correct value
= 0 ohm (N.C. contacts of the relays RL1 and RL3, serial connected). If > Mohm (circuit
broken), replace RL1 and/or RL3 on secondary board (65) or replace the secondary board
(65).
♦ Check the continuity of the connection between terminals CN5 and CN6 – CN7 on panel
board (57); if interrupted reset the connection between these three terminals.
♦ Replace the panel board (57).

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CEBORA S.p.A. 18

3.3.8 - In open circuit operation, the output voltage is not regular.

WARNING
FOR THE FOLLOWING TESTS DISCONNECT THE CONNECTOR CN4 ON HF BOARD
(19) TO PREVENT HIGH FREQUENCY FROM BEING GENERATED.

SECONDARY CIRCUIT RECTIFIER OUTPUT VOLTAGE TEST.

q Secondary board (65), terminals L1 and S2-S5 (gnd) = fig. 5.2.3, with start button pressed
(open-circuit rectifier output voltage, interrupted after approximately 300 msec., for missing
pilot arc current).

NO Correct?

YES
♦ Check the connection of the choke (23) with the terminals L1 and L2 on
secondary board (65).
♦ Make sure the reed bulb RL2 is properly mounted between the L2 and (+)
terminals on secondary board (65).
♦ Check the continuity between the terminals S2-S5 and (-) and that the Hall-effect
current transducer (SH1) is properly mounted on secondary board (65).
♦ Check the wiring between terminals “C” and “A” of panel board (57) and
terminals (-) and (+) of the secondary board (65).
♦ Make sure the secondary HF transformer (52) circuit is connected to the central
terminal of the fixed torch fitting and terminal “A” on panel board (57).
♦ Replace the secondary board (65).

INVERTER OUTPUT VOLTAGE TEST.

q Secondary board (65), terminals S1 and S2-S5 (gnd) = fig. 5.2.4, with start button pressed
(open-circuit inverter output voltage, interrupted after approximately 300 msec., for missing
pilot arc current).
q Repeat the measurement with terminals S3, S4, and S6 in place of S1 = same waveform.

NO Correct?

YES
♦ Make sure the connections of the secondary windings of the transformer (27) are
correct and intact on terminals S2-S5, S1, S3, S4, and S6 of secondary board (65).
If you find loose connections, tighten and replace any components with damaged
terminals.
♦ Replace the secondary board(65).
♦ Check the wiring between CN1 igbt board (69) and CN8 control board (26).
♦ With the power source off, temporarily disconnect the secondary windings of the transformer
(27) from terminals S1, S3, S4 and S6 of secondary board (65), and check the integrity of the
secondary rectifier, testing the resistance between each of the terminals S1, S3, S4 and S6 of
secondary board (65) and terminal L1 (“+” rectifier potential) and terminal 1 of CN2 on
secondary board (65) (“-” rectifier potential). For each measurement point, the correct value =
diode joint in one direction and > Mohm with the instrument probes reversed. If short-
circuited or low-resistance replace the defective diodes or replace the secondary board (65).

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CEBORA S.p.A. 19

NOTE
To replace the diodes of the secondary rectifier, we recommend that you follow the instructions
in the order in which they appear below.
1. Unscrew the screws fastening the secondary circuit board (65) to the dissipater.
2. Unscrew the diode holding screws, thereby freeing the secondary circuit board (65) and diodes from
the dissipater.
3. Cut the leads of the diodes and free the solder pads of the printed circuit from the residue of leads and
tin, so that the holes of the solder pads are open.
4. Clean the surface of the dissipater thoroughly to remove any residue of thermal paste.
5. Position the new diodes, with the leads bent upward, on the dissipater using the screws provided, but
without tightening them, after first inserting a new thin layer of thermal paste between the diodes
and dissipater.
6. Position the secondary circuit board (65) on the dissipater, centering each bent lead of the diodes in
the corresponding free hole of the printed circuit solder pad.
7. Fasten the secondary circuit board (65) to the dissipater, tightening the holding screws.
8. Tighten the screws fastening the diodes to the dissipater, making sure that the diodes do not move
from their position aligned with the holes of the printed circuit solder pads.
9. Weld the leads of the diodes in the printed circuit solder pads.

♦ Check the wiring and integrity of the resistor (64) with connector CN2 on secondary board
(65). Correct value of the resistor (64) = 10 Kohm.
♦ Check conditions of the transformer (27). Replace if damaged or showing signs of burns.
♦ Make sure the connections are correct and intact in the primary windings of the transformer
(27) on terminals P1, P2, P3 and P4 on igbt board (69). If you find loose connections, tighten
and replace any components with damaged terminals.
♦ With the power source off, temporarily disconnect the terminals of the primary windings of
the transformer (27) from terminals P1, P2, P3 and P4 on igbt board (69), and check the
resistance between the terminals P1, P2, P3 and P4 on igbt board (69). Correct value =
>Mohm in all measurements. If you find a short-circuit or low resistance, replace the relays
RL1 and/or RL2 on igbt board (69), or the igbt board (69).
♦ Check the integrity of the igbt modules (68), checking the resistance between each of the
terminals P1 and P4 of igbt board (69) with the (+) and (-) terminals of igbt board (69). For
each measurement point, the correct value = diode joint in one direction and > Mohm with the
instrument probes reversed. If short-circuited or low-resistance replace the defective igbt
module (68) and/or replace the igbt board (69).
♦ Check the wiring between drive terminals of the igbt modules (68) and connectors CN3, CN4,
CN5 and CN6 on control board (26), taking care to observe the polarity of these connections.
WARNING
In the case of a fault of an igbt module (68) or a drive section of the control board (26),
we recommend that you also replace both the igbt module (68) and the control board (26)
at the same time. An igbt fault quite frequently damages the drive section to which it is
connected. Similarly, a drive section fault quite frequently damages the igbt to which it is
connected.

♦ Check the wiring and integrity of the resistors (29) with connector CN2 on igbt board (69).
Correct value of the resistors (29) = 6 ohm.
♦ Check the presence of the power supply three phases on terminals U1, V1 and W1 of filter
board (56).
♦ Check the presence of approximately 320 or 560 Vdc, (according to the power source supply
voltage) on the (+) and (-) terminals on igbt board (69). If incorrect, carry out the MAINS
CONNECTION TEST, par. 3.3.1.
♦ Replace the filter (56) and/or igbt (69) and/or control (26) and/or secondary board (65).

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CEBORA S.p.A. 20

3.3.9 - Irregular pilot arc starts, unstable pilot arc.

PLASMA GAS PRESSURE TEST.

q Gas pressure correct in the plasma chamber of the torch.

YES Correct?

NO
♦ Check the presence of the gas at the intake fitting (B) and that the pressure and
flow rate in the intake line meet specifications (see Instruction Manual).
♦ Make sure that the pressure regulator (E) and pressure gauge (F) are working
properly; replace if defective.
♦ Make sure that the threaded part of the air fitting (B) inserted in the pressure
regulator (E) is no more than 6 - 8 mm (1/4” - 5/16”) long, to avoid any possible
malfunction of the regulator (E).
♦ Make sure there are no occlusions in the gas hoses of the power source.
♦ Make sure that solenoid valve EV1 (16), for pilot arc (the one with the flow
reductor and connected by blue wires to terminals 3 and 7 of CN2 on filter board
(56)) = open; solenoid valve EV2 (16), for transfer arc (the one connected by
purple wires to terminals 1 and 8 of CN2 filter board (56)) = closed. If incorrect,
check the wiring and operation of the solenoid valves, or replace the filter board
(56) (also see PILOT ARC SOLENOID VALVE TEST, par.3.3.5 and
TRANSFER ARC SOLENOID VALVE TEST, par. 3.3.10).
♦ Check presence of the flow regulator on the solenoid valve EV1 (16).

WARNING
FOR THE FOLLOWING TEST DISCONNECT THE CONNECTOR CN4 ON HF BOARD
(19) TO PREVENT HIGH FREQUENCY FROM BEING GENERATED.

PILOT ARC VOLTAGE TEST.

q Panel board (57), terminal CN7, and central terminal of the fixed torch fitting (gnd) = fig.
5.2.1, with start button pressed (open-circuit output voltage, interrupted after approximately
300 msec., for missing pilot arc current).

YES Correct?

NO
♦ Check the presence of the power supply three phases on terminals U1, V1 and W1
of filter board (56).
♦ Go to par. 3.3.7.

WARNING
FOR THE FOLLOWING TESTS RE-CONNECT THE CONNECTOR CN4 ON HF BOARD
(19) TO ENABLE GENERATING HIGH FREQUENCY.

WARNING
Due to lighting the pilot arc and the HF pulses, some instruments may not be suitable for
measuring signals in the following tests. Given the sensitivity of the measuring points, we urge
you to use the utmost care and precision, scrupulously following the instructions provided in the
present manual and using only instruments certified compatible with these phenomena.

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CEBORA S.p.A. 21

PILOT ARC CURRENT TEST.

q Control board (26), connector CN10, terminals 2 – 3 (gnd) = fig. 5.2.5, with pilot arc lit (pilot
arc current signal for its maximum time, approximately 2 sec., with the torch free in the air
and thus without the transfer arc).

YES Correct?

NO
♦ Check the wiring between CN10 control board (26) and CN1 secondary board
(65).
♦ Make sure the current transducer SH1 is properly mounted on secondary board
(65).
♦ Check the supply voltage of current transducer SH1 on secondary board (65),
connector CN1, terminals 1 (+) and 3 (-) = +13.8 Vdc, approximately. If incorrect,
with power source off, temporarily disconnect connector CN10 from control
board (26) and check the resistance between the terminals 1 and 3 of CN1
secondary board (65) = approximately 2.7 Kohm. If 0 ohm (short-circuit) replace
the secondary (65) and control (26) boards. If >Mohm (circuit broken) replace the
secondary board (65).
♦ With power source off, temporarily disconnect CN1 from secondary board (65)
and check the resistance between terminals 2 and 3 of CN10 on control board
(26). Correct value = two diodes junction in one direction and >Mohm with the
instrument probes reversed. If incorrect, replace control board (26).
♦ Make sure the TA SH1 is properly mounted on igbt board (69), and check its
wiring with terminals FS3 and FS4 on control board (26).
♦ With the power source off, temporarily disconnect the wires from terminals FS3
and FS4 on control board (26) and check the resistance between the terminals FS3
and FS4 on control board (26). Correct value = two diodes junction in both
directions. If incorrect, replace control board (26).
♦ Make sure that the power source regularly delivers open-circuit output voltage,
performing if necessary the tests in par. 3.3.8.
♦ Replace the control (26) and/or igbt (69) and/or secondary board (65).
♦ Check the wiring between terminals 5 and 6 of the fixed torch fitting and CN6-CN7 on panel
board (57).
♦ Check the central adapter and torch cable; replace if aged or cracked.
♦ Check the electrode, swirl ring and torch nozzle; replace if worn or damaged.
♦ Make sure the internal parts of the torch are properly insulated, including cables; if in doubt,
replace the entire torch.
♦ Replace the control (26) and/or igbt (69) and/or secondary board (65).

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CEBORA S.p.A. 22

3.3.10 - Transfer arc does not take place or is too weak for cutting.

WARNING
Due to lighting the pilot arc and the HF pulses, some instruments may not be suitable for
measuring signals in the following tests. Given the sensitivity of the measuring points, we urge
you to use the utmost care and precision, scrupulously following the instructions provided in the
present manual and using only instruments certified compatible with these phenomena.

OPERATING TEST IN PILOT ARC.

q Pilot arc lights normally, pilot arc stable.

YES Correct?

NO
♦ Go to par.3.3.9.

TRANSFER ARC SWITCHING TEST.

q Control board (26), connector CN10, terminals 6 (+) and 5 (-) = 0 Vdc, (reed contact RL2 on
secondary board (65) closed) with torch close to the workpiece and transfer arc lit (thus while
cutting), (approximately +25 Vdc, reed contact RL2 open, with power source powered or with
pilot arc lit).

YES Correct?

NO
♦ Check connections between torch, earth cable and boards of the power source,
more specifically, between central terminal fixed torch fitting, HF transformer
(52) secondary winding, terminal “A” panel board (57) and terminal “-” on
secondary board (65), (electrode potential); between output (H) of the power
source, terminal “C” on panel board (57), and terminal (+) on secondary board
(65) (earth potential). If you find loose connections, tighten and replace any
damaged components.
♦ Make sure the reed bulb RL2 is properly mounted in the solenoid provided on
secondary board (65).
♦ Make sure that, with power source off, the switch in the reed bulb RL2 works
properly: move a magnet near the bulb and check the resistance between the
terminals 6 and 5 of CN10 on control board (26) = 0 ohm (reed contact closed).
Move the magnet away from the bulb, resistance = >1 Kohm (reed contact open).
If incorrect replace the reed bulb and solenoid, or the complete secondary board
(65).
♦ Check the presence of the power supply three phases on terminals U1, V1 and W1
of filter board (56).
♦ Check the wiring between CN10 control board (26) and CN1 secondary board
(65).
♦ With power source off, temporarily disconnect connector CN1 from secondary
board (65) and turn the power source back on. Make sure that voltage on control
board (26), connector CN10 terminals 6 (+) and 5 (-) = approximately +25 Vdc. If
correct, replace the secondary board (65). If incorrect check the wiring between
terminals 1, 5 and 10 of CN9 control board (26), with terminals 1, 5 and 10 of
CN1 filter board (56).

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CEBORA S.p.A. 23

♦ Replace the control (26) and/or secondary (65) and/or filter boards (56).

TRANSFER ARC SOLENOID VALVE TEST.

q Solenoid valve EV2 (16) terminals (the one connected by purple wires to terminals 1 and 8 of
CN2 filter board (56)) = approximately 230 Vac, (with mains at both 230 and 400 Vac), with
torch close to the workpiece and transfer arc lit (thus while cutting).

YES Correct?

NO
♦ Check the wiring between solenoid valve EV2 (16) and CN2 filter board (56).
♦ Check the wiring between CN1 filter board (56) and CN9 control board (26).
♦ Make sure that the supply voltage to the fan (21) is correct, see par. 3.3.2. (this
voltage is the same that powers the solenoid valves EV1 and EV2 (16)).
♦ With power source off, check the resistance between the solenoid valve terminals
EV2 (16) = approximately 2500 ohm. If 0 ohm (short-circuit), replace solenoid
valve EV2 (16) and filter board (56).
♦ Replace the control (26) and/or filter boards (56).
♦ With power source off, check the resistance between the solenoid valve terminals EV2 (16) =
approximately 2500 ohm. If >Mohm (winding broken), replace solenoid valve EV2 (16).
♦ Check connections between torch, earth cable and boards of the power source; more
specifically, between central terminal fixed torch fitting, HF transformer (52) secondary
winding, terminal “A” panel board (57) and terminal “-” on secondary board (65), (electrode
potential); between output (H) of the power source, terminal “C” on panel board (57), and
terminal (+) on secondary board (65) (earth potential). If you find loose connections, tighten
and replace any damaged components.
♦ Check the condition of the central adapter, torch cable and torch; especially make sure there
are no short-circuits or isolation leaks between the conductors or between the contacts of the
central adapter. Replace any worn or damaged components.
♦ Check the condition of the electrode, nozzle, nozzle holder and swirl ring of the torch.
Replace if they show signs of wear.
♦ Check the presence of the power supply three phases on terminals U1, V1 and W1 of filter
board (56).
♦ Check the presence of the gas at the inlet fitting (B) and that the pressure and flow rate in the
intake conduit meet the specification values (see Instruction Manual).
♦ Make sure the pressure regulator (E) and pressure gauge (F) are working properly; replace if
defective.
♦ Make sure that the threaded part of the air fitting (B) inserted in the pressure regulator (E) is
no more than 6 - 8 mm (1/4” - 5/16”) long, to avoid any possible malfunction of the regulator
(E).
♦ Make sure that there are no occlusions in the gas hoses of the power source, especially in the
section involving the solenoid valve EV2 (16).
♦ Replace the solenoid valve EV2 (16).
♦ Replace the control (26) and/or panel (57) and/or secondary board (65).

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CEBORA S.p.A. 24

3.4 - Alarm signals.

3.4.1 - Led (G) lit = temperature outside limits.

This alarm indicates that the temperature of the igbt (68) has risen beyond the allowed limits.
In this situation we recommend that you not shut off the power source, to keep the fan (21)
running and thus allow rapid cooling.
This is reset automatically when the temperature returns within the allowed limits.
THERMOSTAT TEST.
q Control board (26), terminals FIS2 (+) and FIS1 (-) = 0 Vdc, contact closed, appropriate
temperature (approximately +7 Vdc, contact open, temperature outside limits).

YES Correct?

NO
♦ Check the wiring between FIS1 and FIS2 on control board (26) and the thermostat
located on the igbt dissipater (68).
♦ Replace thermostat or control board (26).
♦ Make sure the fan (21) is working properly (see par. 3.3.2).
♦ Make sure that air flows smoothly, and there is no dust or other impediments to cooling in the
aeration tunnels.
♦ Make sure that the working conditions comply with the specified values, especially observing
the “duty cycle”.
♦ Replace the control board (26).

3.4.2 - Led (L) lit = low gas pressure.

This alarm indicates that the gas pressure at the power source intake (B) has fallen below the
allowed limits (approximately 3.5 bar).
This is automatically reset when the pressure returns within the allowed limits.
PRESSURE SWITCH (11) TEST.
q Control board (26), connector CN1, terminals 3 (+) - 4 (-) = 0 Vdc, contact closed, pressure
OK (+7 Vdc, contact open, pressure low).

YES Correct?

NO
♦ Check the wiring between CN1 control board (26) and pressure switch (11).
♦ Make sure that gas is present at the intake fitting (B), and that the pressure and
flow rates in the intake conduit meet the values specified (see Instruction
Manual).
♦ Make sure that the pressure regulator (E) and pressure gauge (F) are working
properly.
♦ Make sure that the threaded part of the air fitting (B) inserted in the pressure
regulator (E) is no more than 6 - 8 mm (1/4” - 5/16”) long, to avoid any possible
malfunction of the regulator (E).
♦ Make sure there are no occlusions in the gas hoses of the power source.
♦ Replace the pressure switch (11) and/or control board (26).
♦ Replace control board (26).

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CEBORA S.p.A. 25

3.4.3 - Led (S) steadily lit = power source blocked.

This indicator indicates that the power source is in the process of selecting the mains voltage,
in the first 5 seconds after closing the switch (53), or, thereafter, is blocked due to a hazardous
condition.
To identify the cause seek out the possible error conditions among those described in the
following chapters.

- Power source supply voltage incorrect.

The start-up moment is decisive in selecting the operating range. This is selected by the relays
RL1 and RL2 on filter board (56): RL2 selects the range between 230 and 400 Vac; RL1 selects
the +/- 10% applied to the range selected by RL2.
This provides the following operating ranges.

mains voltage RL1 RL2 power source led S

>440 off off running off
440 – 350 on off
350 – 290 off off blocked on
290 – 230 off on running off
230 – 190 on on
<190 off off blocked off*
* with voltage <190 Vac the power source is blocked even if the led (S) remains off.

Once set, thus after the first 5 seconds have elapsed after closing the switch (53), the range of
operation does not change until the next start-up.
If the supply voltage of the power source upon start-up is between approximately 290 and 350
Vac, the control blocks the unit with the red led (S) lit.
This is reset automatically when the voltage returns within the allowed limits.
If the supply voltage of the power source upon start-up is less than approximately 190 Vac,
the control blocks the unit with the red led (S) off. When the voltage returns within the allowed
limits, the power source remains blocked, and the red led (S) lights when the threshold of 190
Vac is exceeded.
To reset, you must shut off and restart the power source with the correct voltage.

- Incorrect supply voltage of the electronic boards (13.8 Vdc).

If an unexpected value of the electronic boards power supply (13.8 Vdc) is detected, this
control blocks the power source, with the red led (S) lit.
This voltage generated by U1 of filter board (56) may be measured on CN1, terminals 4 (+)
and 5 (-).
Its rated value is 13.8 Vdc, and the alarm thresholds are: <12 Vdc, >17 Vdc
Proper operation is automatically restored when the voltage returns within the allowed limits
for at least 3 seconds.
To test this alarm, perform the SERVICES POWER SUPPLY TEST, par. 3.3.1.

- Phase missing in the power supply line of the power source.

If the power source is mistakenly powered with only two phases, or with two phases +
neutral, this control blocks the power source, with the red led (S) lit.
To restore proper operation, shut off and restart the power source with the correct mains
connections.

3.302.098-A 25/06/03
CEBORA S.p.A. 26

NOTE
In special conditions, a missing phase will not stop the power source (with led (S) lit), but
only cause operating problems such as an unstable pilot arc or failing to cut. In these cases, make
sure the three phases of the power mains are properly connected, and check their voltage.

- Start button pressed during power source start-up.

See par. 3.3.4.

- Central adapter protection (R ) not engaged.

When the central adapter protection is missing, this stops the power source with red led (S) lit.
This is reset automatically when the protection is correctly positioned in its slot.
CENTRAL ADAPTER PROTECTION TEST.
q Control board (26), connector CN2, terminals 9 (+) and 10 (-) = 0 Vdc with protection
engaged, +7 Vdc with protection disengaged.

YES Correct?

NO
♦ Check the wiring between the reed switch of the central adapter protection and the
(SENS) terminals on panel board (57), and between CN1 panel board (57) and
CN2 control board (26).
♦ Make sure the central adapter protection is properly mounted, and especially that
the magnet in the protection hood is close to the reed on the panel board (57),
when the hood is inserted.
♦ Replace the panel board (57) and/or control board (26).
♦ Replace control board (26).

- Contact of the reed bulb RL2 on secondary circuit board (65) closed upon power source start-up.
- Gas flows from the torch as soon as the power source is powered.
If the reed contact RL2 on secondary board (65) is found closed upon start-up, the power
source remains blocked, without delivering current and with the led (S) on.
The solenoid valve EV2 (16) is directly connected to the reed RL2, thus when it is closed it
causes the solenoid valve EV2 to open and gas to flow from the torch (also see TRANSFER
ARC SOLENOID VALVE TEST par. 3.3.10).
To analyze the problem, carry out the TRANSFER ARC SWITCHING TEST, par. 3.3.10.

3.4.4 - Led (S) flashing = short-circuit between electrode and nozzle, or electrode finished.
A short-circuit or heavy isolation leak between the electrode terminals and torch nozzle may
interfere with striking the pilot arc.
When the electrode finds conditions insufficient to ensure proper operation of the power
source, it may be difficult to achieve good quality cutting.
These situations block the power source with led (S) flashing.
To solve the problems we recommend:
− Check electrode and torch nozzle; replace if worn or damaged.
− Make sure the internal parts of the torch, including cables, are properly insulated; if in
doubt, replace the entire torch.
− Check the center adapter; replace if aged or cracked.
Also, since the circuits to detect the nozzle voltage are contained in the panel board (57), and
those for analysis in the control board (26), check the wiring between these two boards and
replace if necessary.

3.302.098-A 25/06/03
CEBORA S.p.A. 27

4 - COMPONENTS LIST
4.1 - Power source art. 355 : see file ESP355.pdf enclosed at the end of the manual.

4.2 - Table of components: see file ESP355.pdf enclosed at the end of the manual.

4.3 - List of spare parts.

Essential spare parts.

Ref. Code Description Qty.

19 5602090 HF board 1
26 5602086 control board 1
56 5602087 filter board 1
57 5602089 panel board 1
65 5602088 secondary board 1
69 5602085 igbt board 1

Recommended spare parts.

Ref. Code Description Qty.

21 3165075 fan 1
23 5605458 inductance 1
27 5600546 power transformer 1

3.302.098-A 25/06/03
CEBORA S.p.A. 28

5 - ELECTRICAL DIAGRAMS
5.1 - Power source art. 355 : see file SCHE355.pdf enclosed at the end of the manual.
5.2 - Waveforms.

5.2.1 - Open-circuit output voltage, interrupted after approximately 300 msec. for missing
pilot arc current (par. 3.3.6, 3.3.7, 3.3.9).

5.2.2 - Command signal for HF board (19), interrupted after approximately 300 msec. for
missing pilot arc current (par. 3.3.6).

5.2.3 - Open-circuit rectifier output voltage, interrupted after approximately 300 msec.,
for missing pilot arc current (par. 3.3.8).

3.302.098-A 25/06/03
CEBORA S.p.A. 29

5.2.4 - Open-circuit inverter output voltage, interrupted after approximately 300 msec.
for missing pilot arc current (par. 3.3.8).

5.2.5 - Pilot arc current signal for its maximum time, approximately 2 sec., with the torch
free in the air and thus without transfer arc (par. 3.3.9).

3.302.098-A 25/06/03
CEBORA S.p.A. 30

5.3 - Filter board (56) code 5.602.087/A.

5.3.1 - Topographical drawing.

5.3.2 - Connector table.

Conn. Terminals Function
- U1-V1-W1 three-phase mains voltage input.
- U2-V2-W2 three-phase mains voltage output for rectifier (67).
CN1 1 +25 Vdc on boards relay power supply output.
CN1 2 230/400 Vac supply voltage selector relay command input.
CN1 3 pre-charge relay command input.
CN1 4 +13.8 Vdc boards power supply output.
CN1 5 0 Vdc boards power supply output.
CN1 6 “enable” signal output.
CN1 7 +/– 10% supply voltage selector relay command input.
CN1 8 pilot arc solenoid valve EV1 (16) command input.
CN1 9 HF relay command input.
CN1 10 transfer arc (cutting) solenoid valve EV2 (16) command input.
CN2 1-8 output for solenoid valve EV2 (16).
CN2 2-6 output for fan (21).
CN2 3-7 output for solenoid valve EV1 (16).
CN2 4-5 NU
CN3 1-2 HF relay command output.
CN4 1(+) - 2(-) 35 Vdc start button circuit power supply output on panel board (57).

3.302.098-A 25/06/03
CEBORA S.p.A. 31

5.4 - Igbt board (69) code 5.602.085/A.

5.4.1 - Topographical drawing.

5.4.2 - Connector table.

Connector Terminals Function

CN1 1-4 RL2 relay command input to connect the primary windings for 400 Vac mains.
CN1 2-3 RL1 relay command input to connect the primary windings for 230 Vac mains.
CN2 1-2 connection to current limiting resistors for the DC capacitors.
- P1 - P2 output for a transformer (27) primary winding.
- P3 - P4 output for a transformer (27) primary winding.
- “+” - “-” direct current input (320/560 Vdc, approximately) for inverter power supply.

3.302.098-A 25/06/03
CEBORA S.p.A. 32

5.5 - Secondary board (65) code 5.602.088/B.

5.5.1 - Topographical drawing.

5.5.2 - Connector table.

Connector Terminals Function

CN1 1(+) - 3(-) 13.8 Vdc power supply input for power source output current transducer.
CN1 2 power source output current signal output.
CN1 4(+) - 5(-) 25 Vdc power supply input for pilot arc/transfer arc switching relay.
CN1 6 pilot arc/transfer arc signal output from reed RL2.
CN2 1-2 connection to secondary circuit rectifier load resistors.
- L1 - L2 output current leveling choke (23) connection.
- S2 - S1 transformer (27) secondary winding 1 connection.
- S2 - S3 transformer (27) secondary winding 2 connection.
- S5 - S4 transformer (27) secondary winding 3 connection.
- S5 - S6 transformer (27) secondary winding 4 connection.
- “-” output – secondary board (65) (electrode potential).
- “+” output + secondary board (65) (potential of the workpiece, earth).
- F1 output + secondary board (65) (nozzle potential).

3.302.098-A 25/06/03
CEBORA S.p.A. 33

5.6 - Panel board (57) code 5.602.089.

5.6.1 - Topographical drawing.

5.6.2 - Connector table.

Connector Terminals Function

CN1 1(+) - 10(-) 5 Vdc panel board (57) power supply input.
CN1 2(+) - 4(-) cutting current potentiometer power supply input.
CN1 3 “cutting current reference” signal output from potentiometer cursor.
CN1 5 “pressure low” signal input.
CN1 6 “temperature high” signal input.
CN1 7 “grid/continuous” signal input and output from self-restart pilot button.
CN1 8 “power source blocked” signal input.
CN1 9 “central adapter protection presence” signal output.
CN1 11 - 12 “start” command output for control board (26).
CN2 1-3-5-6 NU
CN2 2-4 “torch recognition” signal input.
- CN3 - CN4 “start” signal input from torch button.
- CN5 nozzle potential input from secondary board (65).
- CN6-CN7 outputs for torch nozzle.
CN8 1(+) - 2(-) 35 Vdc power supply input for start button circuit on panel board (57).
- A electrode potential output (to the HF transformer (52)).
- C + output (H) of the power source (potential of the workpiece, earth).

3.302.098-A 25/06/03
CEBORA S.p.A. 34

5.7 - Control board (26) code 5.602.086.

5.7.1 - Topographical drawing.

5.7.2 - Connector table.

Conn. Terminals Function
CN1 1-2 input from pressure switch (11).
CN1 3-4 NU.
CN2 1(+) - 10(-) 5 Vdc panel board (57) power supply output.
CN2 2(+) - 4(-) cutting current potentiometer power supply output.
CN2 3 “cutting current reference” signal input from potentiometer cursor.
CN2 5 “pressure low” signal output.
CN2 6 “temperature high” signal output.
CN2 7 “grid/continuous” signal output and input from self-restart pilot button.
CN2 8 “power source blocked” signal output.
CN2 9 “central adapter protection presence” signal input.
CN2 11 - 12 “start” command input.
CN3 1(G) - 2(E) command output for gate igbt3.
CN4 1(G) - 2(E) command output for gate igbt1
CN5 1(G) - 2(E) command output for gate igbt2
CN6 1(G) - 2(E) command output for gate igbt4.
CN8 1-4 RL2 relay command output to connect the primary windings for 400 Vac mains.
CN8 2-3 RL1 relay command output to connect the primary windings for 230 Vac mains.
CN9 1 +25 Vdc on boards relay power supply input.
CN9 2 230/400 Vac supply voltage selector relay command output.
CN9 3 pre-charge relay command output.
CN9 4 +13.8 Vdc boards power supply input.
CN9 5 0 Vdc boards power supply input.
CN9 6 “enable” signal input.
CN9 7 +/– 10% supply voltage selector relay command output.
CN9 8 pilot arc solenoid valve EV1 (16) command output.
CN9 9 HF relay command output.
CN9 10 transfer arc (cutting) solenoid valve EV2 (16) command output.
CN10 1(+) - 3(-) 13.8 Vdc power supply output for power source output current transducer.
CN10 2 power source output current signal input.
CN10 4(+) - 5(-) 25 Vdc power supply output for pilot arc/transfer arc switching relay.
CN10 6 pilot arc/transfer arc signal input from reed RL2.
- FIS1 - FIS2 input from thermostat on igbt (68) dissipater.
- FIS3 - FIS4 transformer (27) primary winding current signal input, from TA SH1 on igbt board (69).

3.302.098-A 25/06/03
CEBORA S.p.A. 35

5.8 - HF board (19) code 5.602.090/A.

5.8.1 - Topographical drawing.

5.8.2 - Connector table.

Conn. Terminals Function

CN1 1-4 power supply input for HF board (19) power.
- CN2 - CN3 output for HF transformer (52).
CN4 1(-) - 2(+) HF relay command input.

3.302.098-A 25/06/03
59
pos DESCRIZIONE DESCRIPTION pos DESCRIZIONE DESCRIPTION
01 SUPPORTO MANICO HANDLE SUPPORT 36 ANELLO O.R. O.RING
02 MANICO HANDLE 37 DIFFUSORE DIFFUSER
03 COPERCHIO COVER 38 CORPO TORCIA (TESTINA) TORCH BODY (HEAD)
04 CORNICE FRAME. 39 ELETTRODO (CONF. DA 5 PZ.) ELECTRODE (PACK. 5 PCS.)
05 PANNELLO PANEL 40 DIFFUSORE ISOLANTE SWIRL RING (PACK 2 PCS.)
(CONF. DA 2 PZ.)
06 PANNELLO POSTERIORE BACK PANEL
41 UGELLO (CONF. DA 10 PZ.) NOZZLE ( PACK. 10 PCS.)
07 PRESSACAVO STRAIN RELIEF
42 PORTAUGELLO NOZZLE HOLDER
08 CAVO RETE POWER CORD
43 TORCIA COMPLETA COMPLETE TORCHE
09 MANOMETRO GAUGE
44 PROTEZIONE PROTECTION
10 RIDUTTORE REGULATOR
45 PANNELLO ANTERIORE FRONT PANEL
11 PRESSOSTATO PRESSURE SWITCH
46 MANOPOLA KNOB
12 RACCORDO FITTING
47 PRESA SOCKET
13 RACCORDO FITTING
48 ADATTATORE FISSO FIXED ADAPTOR
14 RACCORDO FITTING
49 RACCORDO FITTING
15 RACCORDO FITTING
50 RACCORDO FITTING
16 ELETTROVALVOLA SOLENOID VALVE
51 RACCORDO A 3 VIE T-FITTING
17 SUPPORTO SUPPORT
52 TRAS. ALTA TENSIONE HIGH-VOLTAGE TRANS.
18 LATERALE SIDE PANEL
53 INTERRUTTORE SWITCH
19 CORCUITO ALTA FREQUENZA HIGH-FREQ. CIRCUIT
54 PROTEZIONE PROTECTION
20 DISSIPATORE RADIATOR
55 SUPPORTO RIDUTTORE REGULATOR SUPPORT
21 MOTORE CON VENTOLA MOTOR WITH FAN
56 CIRCUITO FILTRO FILTER CIRCUIT
22 SUPPORTO SECONDARIO SECONDARY SUPPORT
57 CIRCUITO PANNELLO PANEL CIRCUIT
23 IMPEDENZA CHOKE
58 PIANO INTERMEDIO INSIDE BAFFLE
24 SUPPORTO PRIMARIO PRIMARY SUPPORT
59 SUPPORTO IMPEDENZA IMPEDANCE SUPPORT
25 DISSIPATORE RADIATOR
60 RACCORDO FITTING
26 CIRCUITO DI CONTROLLO CONTROL CIRCUIT
61 PROTEZIONE PROTECTION
27 TRASFORMAT. DI POTENZA POWER TRANSFORMER
62 CONTATTO CONTACT
28 SUPPORTO SUPPORT
63 DIODO DIODE
29 RESISTENZA RESISTANCE
64 RESISTENZA RESISTANCE
30 PIEDE FOOT
65 CIRCUITO SECONDARIO SECONDARY CIRCUIT
31 FONDO BOTTOM
66 TERMOSTATO THERMOSTAT
32 CAVO MASSA EARTH CABLE
67 RADDRIZZATORE RECTIFIER
33 ADATTATORE MOBILE MOVABLE ADAPTOR
68 I.G.B.T. I.G.B.T.
34 CAVO TORCIA TORCH CABLE
69 GRUPPO I.G.B.T. I.G.B.T. UNIT
35 IMPUGNATURA CON HANDGRIP WITH PUSHBUT
PULSANTE TON

La richiesta di pezzi di ricambio deve indicare sempre: numero di arti- When ordering spare parts please always state the machine item and
colo, matricola e data di acquisto della macchina, posizione e quantità serial number and its purchase data, the spare part position and the
del ricambio. quantity.

58
 QUESTA PARTE È DESTINATA ESCLUSIVAMENTE AL PERSONALE QUALIFICATO.
THIS PART IS INTENDED SOLELY FOR QUALIFIED PERSONNEL.
DIESER TEIL IST AUSSCHLIEßLICH FÜR DAS FACHPERSONAL BESTIMMT.
CETTE PARTIE EST DESTINEE EXCLUSIVEMENT AU PERSONNEL QUALIFIE.
ESTA PARTE ESTÁ DESTINADA EXCLUSIVAMENTE AL PERSONAL CUALIFICADO.
ESTA PARTE È DEDICADA EXCLUSIVAMENTE AO PESSOAL QUALIFICADO.
TÄMÄ OSA ON TARKOITETTU AINOASTAAN AMMATTITAITOISELLE HENKILÖKUNNALLE.
DETTE AFSNIT HENVENDER SIG UDELUKKENDE TIL KVALIFICERET PERSONALE.
DIT DEEL IS UITSLUITEND BESTEMD VOOR BEVOEGD PERSONEEL.
DENNA DEL ÄR ENDAST AVSEDD FÖR KVALIFICERAD PERSONAL.
AUTOV TO TMHVMA PROORIVZETAI APOKLEISTIKAV GIA TO EIDIKEUMEVNO PROSWPIKO.V

CODIFICA COLORI WIRING DIAGRAM CODIFICA COLORI WIRING DIAGRAM

CABLAGGIO ELETTRICO COLOUR CODE CABLAGGIO ELETTRICO COLOUR CODE
A NERO BLACK L ROSA-NERO PINK-BLACK
B ROSSO RED M GRIGIO-VIOLA GREY-PURPLE
C GRIGIO GREY N BIANCO-VIOLA WHITE-PURPLE
D BIANCO WHITE O BIANCO-NERO WHITE-BLACK
E VERDE GREEN P GRIGIO-BLU GREY-BLUE
F VIOLA PURPLE Q BIANCO-ROSSO WHITE-RED
G GIALLO YELLOW R GRIGIO-ROSSO GREY-RED
H BLU BLUE S BIANCO-BLU WHITE-BLUE
K MARRONE BROWN T NERO-BLU BLACK-BLUE
J ARANCIO ORANGE U GIALLO-VERDE YELLOW-GREEN
I ROSA PINK V AZZURRO BLUE

56