Basic Troubleshooting Guide - ESAB THERMAL DINAMICS CUTMASTER 60i Operating Manual

CUTMASTER 60i
5.05

Basic Troubleshooting Guide

WARNING
There are extremely dangerous voltage and power levels present inside this unit. Do not attempt to diagnose or repair
unless you have had training in power electronics measurement and troubleshooting techniques.
Problem - Possible Cause
Symptom
ON / OFF Switch 1. Primary power disconnect is in OFF
is ON but the A/C position.
Indicator does not 2. Primary fuses / breakers are blown
light 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 unit is
indicator ON.
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 unit.
FAULT and MIN 2. Gas supply not turned ON.
pressure indicators 3. Gas supply pressure too low.
flashing. Error Code
E016 4. Failed components in unit.
FAULT and 1. Shield Cup loose.
indicators flashing. 2. Torch not properly connected to power
Error Code E004 supply.
3. Problem in torch and leads PIP circuit.
4. Failed components in unit.
FAULT and 1. Start signal is active when ON/OFF
indicators flashing. SWITCH is turned to ON position.
Error Code E014
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 cartridge
E005 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.
56
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 Input Wiring Specifications" on page
19.
2. Return to authorized service center for repair or replacement.
1. Refer to clearance information – see Section "2.04 Power Supply
Specifications" on page 18
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 over tighten.
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 0-5561