ESAB 100i Service Manual page 101

1. Check for air blowing out of the unit. Remember, the fans only run when CNC START is applied and for 4
minutes after cutting, you may have to apply start again to restart the 4 minute time. Fans may be forced
on by jumping TP2 on the CCM I/O board to TP1 (ground).
a. If using the external HE400XT heat exchanger, standard for 400A, check for air blowing out of it. Note
that the HE400XT fan, controlled by a thermal switch in the HE400XT, only runs if the coolant is over 60
deg C and the internal fans are operating. With the 100 & 200A if it has 2 fans make sure both fans are
operating by checking for air both top and bottom of the opening. The fans are difficult to see, perhaps
you can use an inspection mirror. Be careful not to get the mirror or your hands into the blades.
2. Fans are powered by 230 VAC. The 230 VAC for the fan(s) is switched by the MC2 control relay.
CCM I/O PCB
To test fan relay jump TP2 to TP1.
TP2
J4-19
+24
D24
3. Check for 230 VAC at either of the fan connectors, J72 & J73. It may also be measured at the rear panel con-
nector J70 for the HE400XT fan.
a. If the fans are not getting 230 VAC, measure for 24 VAC on the coil of MC2. If present and the relay
contacts aren't closed the relay is defective. Note, the coil is rectified so you won't measure continuity
of even a good coil.
b. If 24 VAC is not on the MC2 coil check for D24 on the relay board being ON. If it's on, the Relay board
should be providing the 24 VAC so if it's not the Relay board must be defective.
c. If D24 is not on, measure on the CCM I/O board between TP2 and the common at TP1. It should be low,
near zero volts. If not the CCM is probably defective. Jumper TP2 (I/O board) to TP1. If the fans now
come on replace the CCM.
d. If jumping TP2 to TP1 does not turn the fans on then the Relay board or the 40 pin ribbon cable pin 19
is at fault.
404 Coolant System Not Ready
When power is applied to the system with External Plasma Enable satisfied and Plasma Power Supply Enabled,
assuming there is enough coolant in the tank, after some initial tests taking about 15-20 seconds (see manual
section 4 for details of the Start-Up Sequence) the pump will start. Coolant will be pumped through the system.
Flow is measured by the FS1 flow switch placed in the torch coolant return path just before the radiator (see
plumbing diagram). If the flow doesn't reach at least 0.75 GPM (2.8 lpm) within 4 minutes it will set the 404
fault. The reason for the 4 minutes is a new dry system especially one with long torch leads will take some time
before the leads, hoses, radiator and cold plates are full of coolant. More coolant may have to be added. On a
Manual 0560956456
230 VAC from T1
J13
TP1
Relay PCB
J8
1
24 VAC
2
3
4
5
K4
6
1 7
2 8
9
4 10
11
3 12
5 13
14
15
Fan Bias Control
16
iSERIES 100 /200 /300 /400
MC2A
(65A) (69)
(70)
MC2B
(64A)
(69)
(70)
(161)
MC2
SA3
Fan Control
CHASSIS GND
ARC_SUPPRESSOR
(160)
APPENDIX
To J70-3
R BK
FAN1
C4
J72
BN
1
2 BL
3
R
J73
1
2
3
(70)
To J70-2
Art # 12311
A-81