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hbishopAug 30, 2025
What does 'Tip Saver Fault' mean on ESAB 100i?
- KKevin StevensonAug 30, 2025
The 'Tip Saver Fault' on the ESAB Welding System indicates that the tip remained in contact with the work for more than 15 seconds.
What does 'Tip Saver Fault' mean on ESAB 100i?
The 'Tip Saver Fault' on the ESAB Welding System indicates that the tip remained in contact with the work for more than 15 seconds.
What does 'Work Current Too Low' mean on ESAB 100i Welding System?
If the ESAB Welding System displays 'Work Current Too Low', it means the work current detected is more than 16% below the process setting. This can be caused by a defective HCT1 work lead current sensor or Relay PCB, or a possible defective pilot PCB (shorted IGBT).
What does 'Work Current Too High' mean on ESAB 100i?
If the ESAB Welding System displays 'Work Current Too High', it means the work lead current detected is greater than 16% above the process setting. Possible causes include a defective HCT1 work lead current sensor or Relay PCB, or a defective CCM.
What to do if the ESAB 100i Welding System displays 'Inverter 1B VAC Mismatch'?
If the ESAB Welding System displays 'Inverter 1B VAC Mismatch', it means the inverter AC voltage rating is incompatible with the power supply voltage rating. Check the ribbon cable connection from CCM J32 to Inverter Module 1 Section B for any issues. Ensure the correct voltage Inverter Module 1 is installed, and if the problem persists, the inverter module may be defective.
What to do if the ESAB Welding System displays 'BIAS VAC Invalid'?
If the ESAB Welding System displays 'BIAS VAC Invalid', it could be due to an invalid AC voltage selection, a damaged or loose connection at J61 of the System Bias Supply, or a defective System Bias PCB. Check these components and connections.
Why is the neon indicator not illuminated during pilot ignition in my ESAB Welding System?
If the neon indicator is not illuminated on your ESAB Welding System, there could be several reasons: * **No 120V supply:** Check if CB4 on the plasma rear panel has tripped. Look for shorted cables, a defective circuit breaker, or a shorted ignition module input. * **Electronic Ignition module shorted input:** Replace the faulty module. * **Faulty Electronic Ignition module:** If 120 VAC is present but the neon light is not illuminated, the module is likely defective and needs replacement. * **Loose fitting(s):** Ensure all fittings are tightened. * **120V supply issues:** If CB4 hasn't tripped, check if 120V is present. If it is, there may be an open control cable. If not, there's a fault in the plasma power supply.
What to do if ESAB 100i Welding System shows 'Pilot Timeout, no Transfer'?
If the ESAB Welding System displays 'Pilot Timeout, no Transfer', it means the system did not transfer from the pilot arc to the cutting arc within 0.085 seconds (SW8-1 OFF) or 3 seconds (SW8-1 ON). This could be due to the standoff being too high, a void in the work under the torch, the wrong cut process selected, or incorrect manual settings such as current control set too low or wrong gas pressure. Check these settings and conditions.
Why ESAB 100i Welding System has 'Lost Pilot'?
The 'Lost Pilot' error on your ESAB Welding System could be due to worn torch consumable parts or plasma pressure being too high. Ensure the cut process or current control setting matches the consumables.
What to do if the ESAB 100i displays 'DC Output Low'?
If your ESAB Welding System displays 'DC Output Low', and the voltage is less than 60 VDC, there may be a negative lead short to work or ground. Other potential causes include a defective inverter (output shorted), a disconnected or broken CCM voltage sense (J24) wire, or a defective CCM. Check these components to troubleshoot the issue.
What causes ESAB 100i Welding System to show 'Pilot Ignition Failure'?
If you're experiencing 'Pilot Ignition Failure' with your ESAB Welding System, it could be due to worn torch consumable parts. Ensure the correct process is selected, or manual settings, including the current control setting, match the consumables. Also, check for high plasma pressure, a defective arc starter, a defective Pilot PCB, or a defective Inverter section 1A. Verify that the ribbon cables are correctly connected on INV1 sections 1A and 1B.
Essential safety precautions for installation and operation.
Hazards related to electrical shock, EMF, fumes, and gases.
Detailed specifications and electrical requirements for power supply amperages.
Electrical, gas, and water supply requirements meeting local safety standards.
Steps for lifting, connecting input power, ground, and work cables to the power supply.
Procedures for proper grounding and routing to minimize electromagnetic interference.
Instructions for connecting the torch and installing consumable parts.
Description of control panel indicators and general system operation procedures.
Explanation of CCM, Gas Selection Console, and Gas Control Unit status codes for troubleshooting.
Troubleshooting guide for common issues with the Remote Arc Starter.
Periodic checks and tasks to ensure proper system performance and longevity.
General| Brand | ESAB |
|---|---|
| Model | 100i |
| Category | Welding System |
| Language | English |
