ESAB 100i Service Manual page 77

Troubleshooting (General)
In many cases where the cause may be listed as a cable or wire disconnected but also includes loose or broken.
All Ribbon cables have an extra receptacle near one end for measuring signals on the cable.
A number of the measurements will require probing of some small connectors or measuring signal on ribbon cables.
For probing the small connectors, standard meter probes are usually too big. We suggest making a couple probes
using steel wire. Copper buss wire isn't stiff enough. A paper clip is a little too big. One idea is take a socket from
an Amp mate-n-loc or similar connector into which your meter probe will fit and crimp a small piece of steel wire,
(0.020 to 0.025" dia.; (0.5-0.6 mm) works best), into where wire would normally be crimped. The wire should be
soldered and crimped. The steel wire may be found in hobby stores that cater to model building.
Insulate all but the end of the wire and slide these onto your meter probe. If your meter has alligator clip adaptors
you could hold the wire in these as well, be sure they don't short together.
Not all problems are caused by the plasma system. If extra wires or other components have been added that were
not part of the original system, if possible, remove them to see if they are causing the problem.
Connections to TB4 or the other TBs on the CCM may be bringing in noise or forming unexpected current paths
that change how the system operates.
Problems that do not set Status or Fault codes:
Coolant Problems
1. Blinking Gas Indicator. At power on the GAS indicator on the front panel blinks continuously. No code is
showing. The actual Real problem is no, or low coolant flow but it takes 4 minutes before the code is set
and most people don't wait that long. Go to code 404 to troubleshoot.
2. Pump doesn't start. The R2 Inrush resistor is open which prevents power from being applied to the T1
transformer. This will not allow the pump to start. This will set 404 code after 4 minutes but most people
won't wait that long.
Pilot Problems.
3. Failure to start pilot. This actually sets failure code 102 after 15-18 seconds but it seems as though no code
was set if you don't wait that long. Go to code 102 to troubleshoot.
4. A weak pilot that will only transfer with the torch very close to the work may be caused by the 30 pin ribbon
cables being reversed on the A and B sections of inverter 1.
Start problems also reported as failure to pilot problems.
5. No response to the CNC Start or Pak200i torch trigger. Check on the CCM I/O board for the D6 CNC START
LED being on all the time. If it is on, either the external CNC Start signal is on or the CCM is faulty. Remove
the CNC cable from J15 or if Start is applied via the TB terminal strip on the CCM remove that. If D6 is still
on replace the CCM.
6. No response to the optional 1Torch trigger (Start). Go to the beginning of the 700 code group to troubleshoot.
Communication problems.
7. Failure to communicate with the TSC 3000 or the cutting table controller over the RS 485 could be due to
not having the J14 _ 4W / 2W (4 wire / 2 wire) jumper set right. TSC3000 needs 2W. The iCNC controller
needs 4W. Refer to section _____ in the manual.
Manual 0560956456
Art # 12302
APPENDIX
iSERIES 100 /200 /300 /400
Art # 12303
A-57