ESAB 100i Service Manual page 80

iSERIES 100 /200 /300 /400
b. If the Pilot current signal on the pilot ribbon cable was zero, measure between pins 23 (-) and 25 (+) on
the 40 pin ribbon cable between the Relay board and the CCM. This would also normally be zero if there
is no pilot current. Anything else would indicate the Relay board is faulty.
CCM I/O Board
J23
TO RELAY BOARD
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
/ RAS ON
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
TP1
34
GND
35
36
37
38
39
40
8. If " /RAS ON" signal is low on pin 16 of the 40 pin ribbon cable, relative to TP1 on the CCM I/O board,
during the ignition time then we need to determine if the Relay board is defective. If /RAS ON signal is
not low the CCM or the 40 pin ribbon cable may be defective.
a. If the Relay board RF ON LED, D23, is not on while the /RAS ON signal is low, then the Relay board is
defective.
b. Is D23 is on, measure for 120 VAC on J8-3 to J8-11. If not present the Relay board is defective.
c. If 120 VAC is present at J8 during the ignition time go back and perform steps 2-4.
Troubleshooting Pilot Board problems.
1. The Pilot board is behind the CCM in the iSeries has two LEDs. The first one, D11, a green LED, indicates
the board has bias power and should be on all the time when the unit is turned on. The second LED, D2,
also green, is on when the pilot is enabled, that is the pilot IGBT switch is turned on. The pilot is enabled
near the end of preflow time and remains on until the transfer is established or for 15 seconds after which a
102 code is displayed. If D2 performs as expected you know the CCM, Relay board and work current sensor
are not causing the problem.
2. Test pilot IGBT operation. D2 on shows the pilot is enabled but you don't know if the pilot switch (IGBT
transistor) actually closes the circuit. To test attach a jumper, 18 AWG or larger as follows:
a. iSeries: connect a jumper wire from TB4-7 (arc volts) to TB4-6 (tip volts).
Apply CNC Start. If the pilot switch closes as it should, you'll get either 106 or 208 fault code within 3-5
seconds. If not, keep the CNC Start on for up to 20 seconds. The front panel DC LED will stay on for 15
seconds then shows 102 code again. This likely indicates the Pilot board is bad but If the XT supply includes
the 1Torch option it could be the W4 contactor is not closing. Go to the 700 group instructions to bypass the
W4 contactor.
A-60
Relay & Interface Board
J4
120 VAC_1
From I/O PCB From J9-1
1
2
3
4
24VDC_SW
5
6
7
D21
K2
8
9
1
10
11
3
12
D23
13
4
14 GREEN
15
5
16
17
RAS CONTROL
RF ON
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
TP1
35
36
GND
37
38
39
40
APPENDIX
120 VAC_RET
From J9-7
J8
16
15
14
13
12
11
10
9
8
7
6
5
4
120 VAC to RAS
3
2
1
AC200XT only
J59 - RAS
(Rear Panel)
1
2
3
4
5
(99)
6
7
(98)
8
9
10
11
12
13
14
T2
(99) 6.5K 1W
(98)
6.5K 1W
120 / 6000 VAC
Art # 12307
Manual 0560956456