Thermal Dynamics CUTMASTER 60i Service Manual page 40

CUTMASTER 60i
Problem - Symptom
Nothing happens 1. Problem in the torch and leads
when torch switch switch circuit (Remote pendant
or remote switch switch circuit).
is closed (Or CNC 2. CNC Controller device not
START signal is providing Start signal.
active) No gas flow, 3. Failed components in unit.
DC LED OFF.
FAULT indicators 1. Upper O-ring on torch head is in
flashing. Error code wrong position.
E012 2. Torch starter cartridge is stuck.
3. Worn or faulty torch parts.
4. Shorted Torch.
No Fault lights ON, no 1. Failed components in unit.
arc in torch.
FAULT indicators 1. Internal Error
flashing Error code
E024 or E031
Pilot arc is ON but 1. Work cable not connected to
cutting arc will not work piece.
establish 2. Work cable/connector broken.
3. Failed components in unit.
FAULT indicator. 1. Inverter board pilot IGBT may be
Work Lead Current shorted
is less than output 2. HCT1 Current Sensor or harness
current setting. Error is bad.
code E010 Low
Output Current.
Torch cutting is 1. Incorrect current setting.
diminished 2. Worn torch consumables.
3. Poor work cable connection to
work piece.
4. Torch being moved too fast.
5. Excessive oil or water in torch.
6. Failed components in unit.
5-6
Possible Cause
1. Take Torch and Leads (Remote Pendant) to Authorized Repair
Facility.
2. Contact Controller manufacturer.
3. Return to authorized service center for repair or replacement.
1. Remove shield cup from torch; check upper O-ring position;
correct if necessary.
2. Turn OFF power supply. Bleed down system pressure. Remove
shield cup, tip and starter cartridge. Check starter cartridge lower
end fitting for free movement. Replace if fitting does not move
freely.
3. Inspect torch consumable parts. Replace if necessary.
4. Replace torch and leads or return to an authorized service
center for repair.
1. Return to an authorized service center for repair.
1. Turn the ON / OFF switch OFF then back ON again. If that does
not clear the fault, return to an authorized service center for
repair.
1. Connect work cable.
2. Replace work cable.
3. Return to an authorized service center for repair.
1. Perform the resistance tests at #7 in section "Power Off Tests".
2. With the ouput current set at 60A, test the voltage at J601-3
(J601-4 common). It should be 2.4V. If it is, then the sensor
is bad. If it is higher than 2.4V then check the harness for
continuity.
1. Check and adjust to proper setting.
2. Check torch consumables and replace as needed.
3. Check the connection of the Work Lead to the work piece.
4. Reduce cutting speed.
5. Refer to "Check air quality" in Section 3 Torch.
6. Return to an authorized service center for repair.
SERVICE
Recommended Action
Manual 0-5475