How To Repair A PLASMA CUTTER!
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- Опубліковано 14 сер 2016
- A UA-cam viewer gave me a Lotos Plasma cutter(ltp5000d) with a faulty pilot arc to see if I could repair the unit. In this video I'll show you the unit(in and out), and how I tested various components to discover why the unit was no longer cutting(along with no power to the cooling fan). You'll also learn which components are most likely to fail in plasma cutters. Enjoy!
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I've been electronics for over 30 years and still in business I'm going to tell you did one heck of a job in presentation, totally awesome!!!!!!! Thank YOU
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Thanks for the video. Not only did I replace a 5 legged transistor and solder a jumper wire to a burned up Hypertherm Powermax 30 plasma cutter PCB with amazing results but I also replaced a burst capacitor inside a brand new SIMADRE CUT 50 Chinese "plasma cutter" very much like yours sadly with no luck. It does have a dead black digital panel so I will look inside it again to hopefully get it going. It was received DOA by my friend that gave it to me. The Hypertherm was a $100 gamble and with the short cut testing I have conducted thus far it works fine.
Love your videos! Very well explained and it is really handy how you show how to test the components and also name what they exactly are. thank you so much for these.
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Thanks for covering a majority of the possible issues and test procedures. Even though it turned out to be a resistor and a relay only, It helps to know the other points to check.
You're welcome Doug! Be sure to check out my video playlists, rate thumbs up, and share my channel with others.
This was such an enjoyable video to watch. I love how meticulously you explain everything. Thumbs up and a subscription from me!
Really clear and detailed instructions for trouble shooting. Like the fix for the relay, no waste of good parts.
Very clear, concise video. I have the same cutter and this gives me a much clearer understanding of it's operation. Thank you
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This was one of the best videos I have seen for trouble shooting something I've seen in a long time keep up the good work.
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Great video with plenty of clear explanations. It seems that there are quite a few people out there with dead Lotos equipment
I have learned a lot from your videos. Very clear and concise! Thanks.
Great video! Love your detailed, yet concise explanation and narration.
Attempting second repair of a 520D plasma/TIG/stick combo machine. First time it failed with a very loud pop when I turned it on. A 1" or so length of thick solder tracing below Relay 1 ( occupied by the exact model of Songle relay that you replaced ) had blown completely off. Replaced the relay (which may have been ok), and it worked again. This last time it broke I was cutting steel which had a lot of holes in it, causing the plasma arc to repeatedly go out and back on. At one point the machine suddenly shut off, and has not come back on since. Not sure what the problem is this time, but my large caps are slightly bulging.
Always replace bulging caps.
Excellent video! I am so glad you were able to fix it. I hope you get a lot of use out of it.
I could not have made this video without you giving me the plasma cutter. Thanks Steve!
Excellent!! Very clearly spoken and explained diagnostic video. I was, however, expecting you to show a dissected view of the faulty relay. Very nice work. I like the way you repurpose the relays from other sources. I do that as much as possible, saves $$ outlay on repairs, plus the fact some parts may be obsolete or out of stock that these can work as well or better. Thanks for posting. 😏
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Friend, you are a gift that keeps giving !!
Glad you enjoy the videos Paul! Please be sure to share my channel with many others so I can continue to create helpful and interesting videos well into the future. Thank you!
Very nice instructional video... easy to understand and a great source for checking a faulty plasma unit. Thank you for taking the time and sharing your knowledge! Great job and congratulations to you owning a hopefully long living plasma cutter. ;)
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Very comprehensive! I have a Lotos 3 way machine LTPDC2000D that has that same issue of not turning on. I'm thinking the power boards may be similar. The other day I used the plasma cutting function to cut a 1/4" X 4' bar, turned it off and that was the last time I used it. It now won't turn on. I'm hoping the relay issue you've discovered is it. But I do realize the rest of the board needs looking at as well.
Hope you figure it out. Thanks for watching!
Excellent video, clear and precise working through the machine in a clear logical manner. Fixed my CUT 50 badged as an LTSUK. The spark gap was too wide! simple intermittent fault which had been with the machine since I bought it. Thank You :-)
@@nathanielwyeth3778 No, just wouldn't start.
@@dianasmith8890 how wide did you set your start up gap? Thanks.
Thank you very much, great video. I just now fixed mine. I had one bad power supply board relay, and both diode bridge rectifiers! I replaced both relays since they came 3 in a pack. Works like a champ now!
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What where the signs of your bad relay
@@anthonylester3247 well, I wasn't getting an arc across the electrodes inside...looking at the relay it had discoloration to its plastic cover. Email me, I'll send some photos I found. Campbell donald at hot mail
Extremely good walk thru of troubleshooting! Kudos and thanks!
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Great grab on this Doug. A little work and you have a fine tool. Really good fix it tips as usual.
Carl
Thanks Carl!
Absolutely amazing video! Very well done!
Such an excellent tutorial. Thanks very much, I've learned quite a lot.
Great to hear. :-)
Great video, I always make a point of checking the resistance of mosfet to heat sink if thermal transfer insulation pads are used, Had a few faults due to badly aligned insulation pads in production.
Big Thumbs Up.
Thanks for watching Mike!
Great video , good camera work . Everyone should make videos this good .
Glad you enjoyed the video Rick! I have a lot of excellent videos on my channel that cover many different subjects, so be sure to check out my extensive video playlists for other videos of interest to you, rate thumbs up, and share my channel with others. Thank You
Great video thanks for posting info on these machines.
I have the same machine with no air flow. Valve not getting voltage. Everything else working fine. Any suggestions would be helpful.
Once again thanks for such a great video.
Amazing job sir! We need more like you.
Nice n precise explanation- It has increased my confidence to repair Plasma cutters....
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I watch with care n attention- your videos increase my knowledge-
Excellent troubleshooting and explanations!
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That was a nice repair I have that same model cutter. pretty handy machines hope it stays working well for you
It should! :-)
Excellent video wish I had someone to check my plasma cutter in or around NYC! Willing to take it apart
Thank you for the great video I have the exact same plasma cutter, you inspired me to take it apart and try to repair it, I removed one of the boards you did and what I found are 6 of the 9 pins on the transformer with broken solders.
Thanks friend for your prompt response, which tells me to calibrate the spark and try it, and it did not work
Plasma cutter does not arc!
Hi. Excellent video.., well done!
Wish I had your knowledge... and I'm hoping you might see my post and reply!
I have Jasic ct312dc Arc, Tig and Plasma... imported from China in 2009 and replaced a capacitor and the on/off switch. In general very happy with the machine, though!
I have not used the plasma function for almost a year and my welder stood unused for the whole of last winter in my workshop. This summer I have used the arc weld function without problems.
This morning I hooked the cutting torch up and could not get it to arc.
After opening up and cleaning with compressed air, I managed to get an arch and do a cut.
Glad that I seemed to have solved the problem, I replaced the cover and again no spark!
I found the wires in the torch head shorted due to wear. Soldered, insulated and continuance test positive from the trigger button, to the connection point.
Spark gap set at 1mm (0.04") and sparking. No visible damage to any parts, fan operates and compressed air flow set at 0.4Mpa.
Earth functioning perfectly when tested with stick welding.
Water trap in-line and always worked.
I adjusted the spark gap from 1.2mm down to .8mm, with 10mm intervals.
Still no spark... any ideas ?
thanksdt
Could be MANY things. Inspect all wiring connections as well as the relays.
Cool video. I'm looking at getting one of these for a small cnc plasma table. I want to use a proma thc that requires ark ref voltage. Where would I hook it up on that machine?
Great Video... Thank you for taking the time to teach us... Very Helpful...
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I agree with everyone here. The video is amazing. You are easy to understand and follow. In my case my machine is completely dead. No lights or noises. From your video, I think my problem is somewhere on the board with the 4 large capacitors. I have checked for power going to that board and it is good. Have you any idea or tests a non pro can do at this point?
Power supply board issue, or bad connection.
Fantastic explanations and demonstrations mate.
Top class video, the dislikes are probably from ppl who do not have a good grip on electronics components and testing procedures...
Prefect level of diagnostics for those that do!! Cheers.
Glad you enjoyed the video John!
Nice work . Very thorough .
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This is such a good analysis! Great job
Thanks mate
Just picked up a second hand unit similar to yours.
The pilot arc was very intermittent. Cleaned and opened the spark gap and is now much better. Not 100% but useable.
Pilot arc is not as strong as others Ive seen so may another look possible a sick cap? Will now search for a cct.
Cheers
Keep playing around with that gap. :-) I have a lot of excellent videos on my channel that cover many different subjects, so be sure to check out my extensive video playlists for other videos of interest to you, rate thumbs up, and most importantly share my channel with others. Thank You
what a great video! I have a Hypertherm Powermax 600 and it's acting like my ground cable isn't connected. It arcs but doesn't penetrate. I have not opened it up so the problem might be obvious, but until i do... any ideas and suggestions will be greatly appreciated. New electrode nozzle and drag shield cap from Amazon. also I just subscribed may not mater but it's refreshing to listen to someone who knows what he's talking about instead of blowing smoke.
Thank you! I look forward to more of your videos and learning from them.
Jim M You're welcome! Be sure to check out my extensive video playlists, rate thumbs up, and share my channel with others. Thanks
Perfect explanation, thank you !
Thanks for the video, it was really insightful.
You are very clever, I wish I knew what you know, keep up the great work. Regards from Denmark
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I have a thermal dynamics dynamics pak 4xi that I just bought used only to find it didn't have a pilot arc when I got it home. since I came across this video and you mentioned a relay in there that controls it come to find that was the case with mine cleaned it with sand paper and good to go great video!!!!!!!!
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I very much enjoy your videos. I am learning basic electronics and want to turn an old PC power supply into a bench power supply. There are of course loads of videos doing such things. But it would be great if you should show how to safely test and indeed discharge such power supplies or capacitors (you only mentioned it here) as well as any other potential danger things to look out for in such a project for a noob like me. It is something I worry about a little because I don't yet know enough and I would just like to be safe.
BTW. I am asking you because as mentioned, your instructions are very detailed, and you speak very clear and concise. I very much enjoy your videos.
Hi. In my (2) popular microwave oven repair videos I explain how to safely discharge capacitors. :-)
Thank you. I will check those videos now. Keep up the great work. I learn a lot from you. :-)
Thank you so much sir for very instructive video,i bought a plasma cutter from tosense from China its look like others brands,it was runing ok till it doesnt start,i am not an electronic trouble shooter but i found these twoo electrodes was not enough tightened and since this video i know now how to adjust it
You're welcome! Please share my videos with others. Thanks
Hello Doug. Has always an outstanding How to video. I think I have the same model. it's duty cycle isn't 100% So I let mine cool for a bit between cuttings. If you didn't get a manual with it I will try and make a PDF for you,no charge.
All my very best.
Bobby
Hi Bobby. I think the duty cycle is 60%. I downloaded a pdf manual online. Thanks
Thank you for sharing your Knowledge friend. A Cal Electric cut 50 has the same boards. I will need to refer back to this Awesome video when i hook mine up to a cnc table and have to hook up a torch height adjustment into the mix (adjusts height for optimum efficiency by reading torch voltage).
Nick Vee Thanks for watching Nick!
I bought this same plasma cutter and would like to use a torch height controller for CNC machine cutting. A torch height controller is a feedback system that locks onto a desired analog voltage level provided by the plasma cutters arc. This voltage is dependent on the material being cut, so the THC has to be set at a certain voltage depending on the thickness of metal. If the gap gets bigger it results in rising resistance due to the increase of arc gap. If the gap gets smaller voltage drops because of less air gap. The z axis uses arc voltage sensing to maintain the proper distance. Metal sheets are not flat enough to just set the height of the torch above the machine and start cutting. I need to hook the torch height controller to the arc voltage of the machine. Is there a voltage divider in the machine or some way to get a arc voltage reading from this machine?
My new Ramsond CUT70DY wont pilot arc...drag tip and it will start. I think maybe gap between points needs set? Thanks for any help.
This was very educational thank you.
Great job! You made the unit look brand new like freshly out of the box :)
Yes. I like everything to look nice, including my equipment/tools. :-)
Funny is that i see that the pcb on the top is the same or almost identical to his "stahlwerk" plasma/tig welder also a china made unit but the fault on his was the dc dc converter where the thick black/red cables are connected on the circuitboard R210 was burnt so it could not start to oscillate but if you gave the gate a touch with 9V thru a 10k resistor then it started up
So replaced the resistor and it works now.
Hagis2k
Not surprising if the boards are very similar. US companies use Chinese companies to make their products. The Chinese then copy the product and sell it for less. LOL. Not good.
So true then the specs and quality on parts are lower too most often with shitty ChonX capacitors that work a year or so until they are cooked, yeah most products are designed either in us or europe then manufactured in china... And as we all know they do not give a hit about copyrights and so lol same with CE mark.. Oh that must mean Chinese Export :D
It is kind of shocking when you buy items on ebay etc sometimes you can recieve really good quality almost for free then like the last powersupply 230V to 12V 1A which i dismantled in pieces as i always do... to find the small cap for the startup almost dagling free and then the optocoupler was almost not soldered in... Quality control? Wont pay for this item for sure.
Hagis2k
I can say that Chinese product quality is getting better, they're forced to produce better quality items.
Excellent as always. Thanks for sharing.
Glad you enjoyed the video!
Excellent information - you are terrific presenter!
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Hi very good video. Just like to ask you do you test boards separately from welders .
Yep thanks for this info, it was very well put together, and I’ll just stay with what I’m good at, thumbs up
You're welcome Steve! Please share. Thanks
Fantastic job! I have the same brand, different model..runs fine on 240 volt, serious power loss on 208. My mobile generator is a 208 3 phase so could I use a 3 phase full bridge rectifier to feed this unit with DC? That way my generator sees a balanced load over all three phases. This is a 12 kW Lima MAC generator, more than enough kVA for the advertised power factor of 0.93.
This generator does fine on my Miller Dynasty which is 3 phase.
sir i have 200a dc inverter welder and iwant to get ac output can i directly wired up the two ac output leg of the main toroid transformer???
Thanks for the excellent video.
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Hi well done very informative video.
Just one question from me.
I have a three phase SAF nertazip plasma cutter and when I switch on the machine only the fan works but nothing else.
The two contacts that must have a distance between them they are exist in all the machines even they are inverter or transformer?
All the plasma cutters I've seen have a discharge electrode gap.
electronicsNmore thank you very much for your help.
My Plasma cutter pulses when it makes the ark with the cutting surface. what would you recommend? Has a good ground and accurate air pressure. Its the same unit in your video. Its a week old. it also doesn't seem to be cutting very good, i can only cut very this stuff. pilot ark seems to be working fine.
Yeah I have a lotos had many learning curves or so it may seem not to be about me for a change
Upon veiwing your video on this machine I can try and give it another change as it has been sitting in silence for many months
Not knowing what could be the function that can render it a paper weight you ideas on how to troubleshoot possible problems was what I needed now we hope to do some cutting once the rest of my trouble shooting is complete
Thank you
David Steinfeld You're welcome Dave.
Very nice video and explanation. Thanks.
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Very informative. Thank you.
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Hi, it is possible to use TIG machine for plasma cutting? i have very similar machine for TIG welding, but i do not have installed all diodes. on your machine you have 24 of them, and i have only 16(they did not installed from factory)
Very good and informative video.
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Hey, great video, however, I get no arc from the two contact behind the resister. Any sugestions or direction to a previous vid. Thanks. althoug mines is not the same model, they seem to be quite simular in design.
Try making the gap smaller.
Bravo, great job!!!
Thank you! I have many great videos on my channel that cover a wide range of subjects, so be sure to look over my video playlists and most importantly share with others. Thank you
excellent tutorial- Thanks!
You're welcome!
Great video. Ask you a question can you convert a non-pilot arc to a pilot-arc. Thanks
Hello. I don't think kits are available.
I'm having some issues with the pilot arc on my plasma it sputters a bit, sparks sometimes will start an arc when the metal is clean without touching most of the time, I checked the gap between the contacts and the arc jumps across I gapped them out a bit and it made no difference in the pilot arc. Any ideas? Thanks a lot.
Hello, Thanks for useful repair video! I have plasma cutter kind of like this, brand Trexus Welbach with pilot arc. Also quit working, no arc anymore. Sparking relay is pulling but makes no arc between gap. Fan/air work ok. I checked diodes and transistors for shorting. Indicator light in the front panel is flashing when push the torch switch. Before my unit died, arc was cut out many times during use. Any ideas where to look for?
Do you have a spark gap?
Yes, about 0.7mm. Relay looks different comparing to your unit. It looks like this. www.tme.eu/en/details/g2r-1-230ac/miniature-electromagnetic-relays/omron/g2r-1-230vac/
Excellent video!
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nice job of troubleshooting!
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So in your best opinion why did these components go out in the first place. Thanks for explaining In such detail. Very good.
High currents cause components to fail over time. Nothing lasts forever. Glad you enjoyed my video! Please be sure to look over my extensive video playlists below for other great videos of interest to you. Thanks
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Boy I wish I had Your knowledge. Bought a Chinese (Infinity) 200amp TIG welder and it had no HF start from day 1. It was going to be such a pain to return and take too long (I have work waiting) that I just brought it to "Toll Welding" to have them hopefully fix it. I checked the points gap Myself (.029 I thought was a decent gap) and looked for burning etc on the boards I could see. I had very light voltage across the points (did not measure it) and got a light spark when I placed a screwdriver across the two. Frustrated. I sold My old welder to buy this so i am stuck without a welder until it's fixed. I hope they can fix it, if Not I call Infinity in California and order a new HF board and fix it Myself-I hope.
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Great video with lots of information 👍
Do you have a repair shop I can send my plasma cutter to?
Great video! Thank you!
You're welcome!
i can recoomend this video!!! excellent fix
I'm tom, can i ask a question about my lotus LTPDC2000D .I WAS USING THE PLASMA CUTTER AND IT STOP WORKING.NO POWER TO ANY THING BEYOND SWITCH WIRES ON THE MOTHER BOARD.I WOOD REALLY APPRECIATE IT. THANKS APPRECIATE IT
Hello. You need to follow my video. Thanks for watching
Nice repair. How long did it take you to find the faulty relay?
Not too long, I noticed the bubble in the plastic while testing another component.
I have a dead Supercut 50. Is this similar in design? How do you feel about the Infineon warp speed IGBT direct replacements for the MOSFETs?
Hello. I'm unfamiliar with that unit, but the working principle is the same.
I looked inside, and it is almost the EXACT same unit lol. Ever do a MOSFET to IGBT conversion with Warp speeds?
Excellent video you have great skills in electronics i wish you good luck and making more great videos.
Regards.
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+electronicsNmore
Ok.
Hey man I have the brown machine like this and when I turn it on it tries to power up but just keeps going on and off over and over like it not getting enough power can you give me a tip or pointer
Great video, there have been literally hundreds of thousands of Chinese plasma cutters & welders sent back to the manufacturer or dealers because of little problems. There is almost always a few on Ebay for parts because they claim the boards are bad but in truth they just have no idea how to test and replace what actually is broken.
Glad you enjoyed the video!
that is the problem these days. just trow it away. i try to fix it first. its broken anyway 😂
Awesome vid
How lucky I'm found your video, I'm repairing plasma cutter unit, thank You
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Dear friend, I watch your video again & again, very enjoyable video, nice & clear expalained, Thank You so much
So, it is auxilary psu issue, right?
Hope you'll explain about pin8 0v on sg3525 someday, it will be geart.
Thx You anw
Thanks for that video, very interesting,
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I have a question, maybe you could give me some advice. I would be very appreciate . I bought a Longevity Force Cut 40d and found it not working, but after bridging the overheat fuse it started and working. However, when I press the switch in the gun, nothing happens, but this does not mean that it is damaged, because I checked it with a multimeter and the switch works properly. I think something is damaged on the bottom PCB board and the relays are not turning on. I took out the board but I don't know how to check it with a multimeter. Can you help please.
Hi great video one question, every time I change the Chanel mosfet when we turn on the machine always one or two will explode do you know why will that happen¿
Make sure you test all other mosfets, and be sure to use exact replacements,
electronicsNmore thanks I will and let you know if that fix it
Will someone clear up a question for me on the Plasma torch? I have heard both ways on this and what I hear is: Some say there is a wire in the torch lead that feeds Positive charge to the tip of the torch to create the arc. Others say, there is no wire and that the positive charge is initiated by the ionization of the compressed air as it swirls at the end of the torch. Which one is true? Wire in the torch or ionization to make the arc? Thanks
any tips on how to troubleshoot the pilot arc not working, everything seems to be working fine except for the pilot arc. thank you
Try cleaning the contacts and inspecting that board more closely.
@@electronicsNmore when i checked the voltage output from the pilot arc terminal on the machine when i squeeze the trigger, it puts out a voltage of at least 180 to 200v but there still no pilot arc.
Did you ever find your problem? I have the same issue
I’ve got a primeweld ct520d green light is on fan on all functions work except the plasma cutter, won’t arc any advice?
Not familiar with that model.
Liked your video! Steve called, he wants his plasma cutter back : )
:-). Thanks for watching Matt!
@@electronicsNmore when you tested the relay did you just measure continuity between the two non coil points
@@anthonylester3247 Yes. Making sure they open and close properly at a very low level of resistance.
@@electronicsNmore ok man thanks what would be a low resistance value on those or one like it? 14v or something
Tngks for the video tutorial god bless...
Welcome 😊
My cut 50df stopped working as well. I used it once. I have power and air to the front gauges, but no spark or air when I squeeze the trigger any thought? I have cooling fan also.
Make sure the trigger switch isn't faulty. Test for continuity when the trigger is squeezed.
I will check that this weekend for sure.
i have just got a icut 60 pilot from ebay , it cuts with or with out the ground connected to the work piece , i do not want to damage the machine , i wonder what your thoughts are , :)
I'm not familiar with that.
Thank you great video