ESAB Cutmaster 120 Operating Manual page 101

Problem - Symptom Possible Cause
FAULT & 80 PSI 1. Torch shield cup is loose.
indicators flashing. 2. Torch tip, electrode or starter
Gas flow is cycling cartridge missing.
ON and OFF. 3. Torch starter cartridge is stuck.
4. Open conductor in torch leads.
5. Problem in the torch and leads
switch circuit.
6. Failed components in unit.
Nothing happens 1. Problem in the torch and leads
when torch switch switch circuit (Remote pendant switch
or remote switch circuit).
is closed (Or CNC 2. CNC Controller device not providing
START signal is Start signal.
active) No gas flow, 3. Failed components in unit.
DC LED OFF.
FAULT and 85 PSI 1. Upper O-Ring on torch head is in
indicators flashing. wrong position.
2. Torch starter cartridge is stuck.
3. Worn or faulty torch parts.
4. Shorted Torch.
5. Temporary Short indicated by 5
blinks per second.
6. Power Supply Failure (Standard
rate of blinking)
No Fault lights ON, 1. Failed components in unit.
no arc in torch.
Fault and 90 PSI 1. Internal Error
indicators flashing
Pilot arc is ON but 1. Work cable not connected to work
cutting arc will not piece.
establish 2. Work cable/connector broken.
3. Failed components in unit.
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.
300X5398
ESAB CUTMASTER 120
Recommended Action
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 starter cartridge. Check starter
cartridge lower end fitting for free movement. Replace if fitting
does not move freely.
4. Replace torch and leads or return to authorized service
center for repair or replacement.
5. Replace torch and leads or return to authorized service
center for repair or replacement.
6. Return to authorized service center for repair or replacement.
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.
5. Release torch switch and reactivate.
6. Return to authorized service center for repair or replacement.
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. 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
5-5