ESAB 100i Service Manual page 106

iSERIES 100 /200 /300 /400
This is a warning, does not shut the system down but is an indication that it probably will shut down soon (502
code). Troubleshooting is same as for 501.
504 Reserved for future use.
Should not get this but if it happens may be due to EMI. Contact customer service.
Group 6 codes relate to the CCM and program updates. One exception is 619 which is a
coolant flow switch FS1 fault.
601-611 Various CCM CPU board internal faults.
For most of these faults try recycling the power but if the problem returns only thing to do is replace the CCM.
Exceptions are:
1. 603 This is one of the reserved codes from the earlier product. Not used so it should never appear, if it does
contact customer service.
2. 607 Processor over temperature could occur if the ambient in the area of the CCM is too high. Try opening
the upper right side panel, perhaps blow some air to cool it off. If that doesn't help or the ambient was not
too hot to begin with, replace the CCM.
3. 611 Code has various causes most of which require replacing the CCM. However, one possible cause is
the programming jumper on the CPU board (under the Static suppression PCB) has been left in the PROG
position. This is a factory setting used during initial programming and should never be found in the field.
It is NOT used for application code updates However, if someone did move it 611 will be the result.
612 USB port power fault.
USB port supplies +5V to power some USB devices such as the flash drive (thumb drive, memory stick), used for
program updates. A flash drive is the only device currently being used with this USB port. This fault detected
no or low voltage to the port. This could be a shorted flash drive or some other device that draws too much
current exceeding the limits of the USB power supply.
Try another flash drive or if you know this one is OK (it works with a computer), then replace the CCM.
613 USB Log File Creation Fault
When updating the CCM, GSC and DPC programs from a flash drive, a log file called CCM_LOG.TXT is created
on the flash which reports on the results of the update including any problems. If that log file can't be created
you get 613. This may be a problem with the flash drive having too many other files on it or a problem with its
format that may not be compatible with the CCM.
1. Try putting the update files on a different, preferably empty, flash drive.
2. Or save all the flash drive files in another place on your computer, then delete all the files on the flash drive.
Now copy onto the flash drive only the files required for program updates.
3. If the above doesn't work, making sure you still have copies of the files, format your flash drive which erases
everything on it. Now load only the files required for program update.
614 No USF File
The file VTCCMFW.USF is required on the flash drive along with the program files when performing a program
update. If it's either missing or corrupted the display will show b614. The "b" indicates the fault is generated
by the Bootloader program rather than the normal application program code. Note that each new revision of
the program files is supplied with a new VTCCMFW.USF. Even though the name is the same it requires the
new version of this file that is supplied with the application code.
1. Install the correct VTCCMFW.USF on the flash drive.
2. If you already have the correct version of VTCCMFW.USF perhaps the flash drive is the problem. Follow
the instructions for code 613.
A-86 APPENDIX Manual 0560956456