Thermal Dynamics CUTMASTER 60i Service Manual page 64

CUTMASTER 60i
e. E002 at Transfer:
i. An AC line that can't supply enough current can cause the incoming voltage to sag as discussed in
step a. Assuming that is not the case it is likely only half of the PFC is working. Check the routing of
the inductor leads as explained in d. ii. above. If the routing is OK as shown in the pictures above
replace the PFC board.
!
3. E004, Parts in Place (PIP) fault
The torch shield cup, when fully screwed in place activates a micro switch that closes the connection between
pins 1 & 2 of the ATC. The most common cause of E004 fault is the shield cup not in place or the torch not con-
nected to the plasma supply.
a. The ATC pins 1&2 connect to J607 pins 1&2. Either remove the torch from the plasma supply and check
pins 1&2 for continuity or remove J607 and measure on the harness connector for continuity on pins 1&2.
b. If everything is OK up to J607, with J607 still disconnected, measure voltage at the J607 PCB header pin
1 (+) to pin 2 or work lead (common). Should be 12 to 15V. If not replace the Inverter board.
i. If voltage is correct reconnect J607 and measure voltage at pin 1 again. It should be near zero. If not
there is still an open between pins 1&2. Go back to step a.
ii. If it is correct, near zero, and still showing E004, either the Inverter board or the Control & Display
is defective.
4. E005, Parts in Contact (PIC)
This tests if all the torch parts, tip, electrode and start cartridge, are in place and there is electrical contact be-
tween them when no gas is flowing.
A circuit applies -12 to -15V on the TIP and looks for the voltage to be present at the electrode. If there is no
contact it causes the E005 fault. Most common cause is the tip and/or start cartridge is worn, arced and pitted,
so there is no electrical contact. Also a weak spring in the start cartridge along with the shield cup not fully
screwed on tight may not allow electrical contact.
5-30
CAUTION
Single phase and 3 phase PFC boards are different, have different
catalog numbers! Using the wrong one may cause it to fail
NOTE!
If the inlet gas pressure is higher than the 125 PSI max specification, gas
could be forced through the closed solenoid keeping the parts open. There
should be no gas flow, except for 20 sec postflow following pilot or cut,
when in RUN mode and the system is idle.
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SERVICE
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Manual 0-5475