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ESAB CUTMASTER 120
5.05
Basic Troubleshooting Guide
WARNING
There are extremely dangerous voltage and power levels present inside this unit. Do not attempt to diagnose or repair unless
you have had training in power electronics measurement and troubleshooting techniques.
Problem - Symptom Possible Cause
ON / OFF Switch
1. Primary power disconnect is in
is ON but the A/C
OFF position.
Indicator does not
2. Primary fuses / breakers are
light
blown or tripped.
3. Units internal fuse blown.
4. Faulty components in unit.
Fault indicator
1. Primary input voltage problem.
flashing, 65 PSI
indicator flashing
2. Faulty components in unit.
TEMPERATURE
1. Air flow through or around the
indicator ON.
unit is obstructed.
FAULT indicator
2. Duty cycle of the unit has been
flashing.
exceeded.
3. Failed components in unit.
GAS LED OFF,
1. Gas supply not connected to
FAULT and MIN
unit.
pressure indicators
2. Gas supply not turned ON.
flashing.
3. Gas supply pressure too low.
4. AIR PRESSURE CONTROL
regulator set too low.
5. Failed components in unit.
FAULT and 70 PSI
1. Shield Cup loose.
indicators flashing.
2. Torch not properly connected to
power supply.
3. Problem in torch and leads PIP
circuit.
4. Failed components in unit.
FAULT and 75 PSI
1. Start signal is active when ON/
indicators flashing.
OFF SWITCH is turned to ON
position.
2. Problem in the torch and leads
switch circuit.
3. Failed components in unit.
5-4
Recommended Action
1. Turn primary power disconnect switch to ON position.
2. a) Have qualified person check primary fuses / breakers.
b) Connect unit to known good primary power receptacle
3. a) Replace fuse.
b) If fuse blows again, return to authorized service center for
repair or replacement.
4. Return to authorized service center for repair or replacement.
1. Have qualified person check primary voltage to insure it
meets unit requirements see Section "2.05
Specifications" on page 2-3.
2. Return to authorized service center for repair or replacement.
1. Refer to clearance information – see Section "2.04 Power
Supply Specifications" on page 2-2
2. Allow unit to cool.
3. Return to authorized service center for repair or replacement.
1. Connect gas supply to unit.
2. Turn gas supply ON.
3. Set air supply inlet pressure to unit to 120 psi.
4. Adjust regulator to set air pressure - see Section "4. Air/Gas
Pressure Control" on page 4-1
5. Return to authorized service center for repair or replacement.
1. Hand tighten the shield cup until it is snug.
2. Insure torch ATC is securely fastened to unit.
3. Replace torch and leads or return to authorized service center
for repair or replacement.
4. Return to authorized service center for repair or replacement.
1. Start can be active for one of the following:
• Hand torch switch held closed
• Hand pendant switch held closed
• CNC START signal is active low
Release the START signal source
2. Replace torch and leads or return to authorized service center
for repair or replacement.
3. Return to authorized service center for repair or replacement.
SERVICE
Input Wiring
Manual 0-5389
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