Basic Troubleshooting Guide - ESAB Cutmaster 120 Manual De Instrucciones

ESAB CUTMASTER 120

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 - Symptom Possible Cause
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. Units internal fuse blown.
4. Faulty components in unit.
Fault indicator 1. Improper Input Voltage.
flashing, 65 PSI 2. Primary input voltage problem.
indicator flashing 3. Faulty components in unit.
TEMPERATURE 1. Air flow through or around the unit
indicator ON. FAULT is obstructed.
indicator flashing. 2. Duty cycle of the unit has been
exceeded
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. 4. AIR PRESSURE CONTROL
regulator set too low.
5. Failed components in unit.
FAULT and 70 PSI 1. Shield Cup loose.
indicators flashing. 2. Torch not properly connected to
power supply.
3. Problem in torch and leads PIP
circuit.
4. Failed components in unit.
FAULT and 75 PSI 1. Start signal is active when ON/OFF
indicators flashing. SWITCH is turned to ON position.
2. Problem in the torch and leads
switch circuit.
3. Failed components in unit.
5-4
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. a) Replace fuse.
b) If fuse blows again, return to authorized service center for
repair or replacement.
4. Return to authorized service center for repair or replacement.
1. Check for proper primary input voltage.
2. Have qualified person check primary voltage to insure it meets
unit requirements see section 2.05.
3. Return to authorized service center for repair or replacement.
1. Refer to clearance information – section 2.04
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.
4. Adjust regulator to set air pressure - see section 4.02.
5. 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.
SERVICE Manual 0-5398
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.
Manual 0-5398
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