Basic Troubleshooting Guide - ESAB CUTMASTER 50+ Operating Manual

5.04

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
Main Switch is ON 1. Primary power disconnect is in OFF
but the LCD does position.
not light 2. Primary fuses / breakers are blown
or tripped.
3. Faulty components in unit.
Overheating 1. Air flow through or around the unit is
communication obstructed.
screen 2. Duty cycle of the unit has been
exceeded.
3. Failed components in unit.
Air pressure 1. Gas supply not connected to unit.
communication 2. Gas supply not turned ON.
screen 3. Gas supply pressure too low.
4. Failed components in unit.
Torch installation 1. Shield Cup loose.
or cover assembly 2. Torch not properly connected to power
communication supply.
screen (PIP) 3. Problem in torch and leads PIP circuit.
4. Failed components in unit.
Electrode or 1. Torch shield cup is loose.
tip installation 2. Torch tip, electrode or start cartridge
communication missing.
screen (PIC) 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.
Start errror 1. Start signal is active when ON/OFF
communication SWITCH is turned to ON position.
screen
2. Problem in the torch and leads switch
circuit.
3. Failed components in unit.
0700 402 229
CUTMASTER 50+, CUTMASTER 70+
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. Allow unit to cool.
2. Refer to clearance information – see Section "2.04 Power Supply
Specifications CE & RCM" on page 16 or Section "2.07 Power Supply
Specifications ETL" on page 19.
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 /8.27 bar /827 kPa. 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. 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 / 8.62 bar / 862 kPa 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.
1. Start can be active for one of the following:
• Hand torch switch held closed
• CNC START signal is active low
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.
SERVICE
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