Thermal Dynamics CUTMASTER 60i Service Manual page 39

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. Faulty components in unit.
Fault indicator 1. Primary input voltage problem.
flashing, Error Code
E002
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. Error Code exceeded.
E001 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. Error Code 3. Gas supply pressure too low.
E016
4. Failed components in unit.
FAULT and indicators 1. Shield Cup loose.
flashing. Error Code 2. Torch not properly connected to
E004 power supply.
3. Problem in torch and leads PIP
circuit.
4. Failed components in unit.
FAULT and indicators 1. Start signal is active when ON/
flashing. Error Code OFF SWITCH is turned to ON
E014 position.
2. Problem in the torch and leads
switch circuit.
3. Failed components in unit.
FAULT indicators 1. Torch shield cup is loose.
flashing. Error code 2. Torch tip, electrode or starter
E005 cartridge missing.
3. Torch start cartridge is stuck.
4. Unit inlet gas pressure is too
high causing continuous gas flow.
5. Open conductor in torch leads.
6. Problem in the torch and leads
switch circuit.
7. Failed components in unit.
Manual 0-5475
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. 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. Return to authorized service center for repair or replacement.
1. Refer to clearance information – see Section "2.04 Power
Supply Specifications" on page <?>
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. Set leads
length to match the actual length being used.
4. 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.
1. Tighten shield cup by hand. Do not overtighten.
2. Turn OFF power supply. Remove shield cup. Install missing
parts.
3. Turn OFF power supply. Bleed down system pressure.
Remove shield cup, tip and start cartridge. Check start cartridge
lower end fitting for free movement. Replace if fitting does not
move freely.
4. Decrease gas supply pressure to 125 PSI or less.
5. Replace torch and leads or return to authorized service center
for repair or replacement.
6. Replace torch and leads or return to authorized service center
for repair or replacement.
7. Return to authorized service center for repair or replacement
SERVICE
CUTMASTER 60i
Input Wiring
5-5