ESAB 200i - Page 92

100i / 200i / 300i / 400i
92 OPERATION Manual PN: 0560956430
Group 3 - Inlet Pressure Faults
3-1 Plasma Gas High (>145 PSI) Reduce pressure from gas supply; defective pressure sensor (PS4).
3-2 Pilot Gas High (>145 PSI) Reduce pressure from gas supply; defective pressure sensor (PS3).
3-3 Shield Gas High (>145 PSI) Reduce pressure from gas supply; defective pressure sensor (PS1).
3-4 Shield H2O High (>145 PSI) Reduce pressure from gas supply; defective pressure sensor (PS2).
Group 4 - Proportional Valves & Solenoids Electrical Faults
4-1 Plasma High (V5) shorted Check for shorted wire harness; Replace valve
4-2 Plasma Low (V4) shorted Check for shorted wire harness; Replace valve
4-3 Pilot (V3) shorted Check for shorted wire harness; Replace valve
4-4 Shield Gas (V1) shorted Check for shorted wire harness; Replace valve
4-5 Shield H2O (V2) shorted Check for shorted wire harness; Replace valve
4-6 Vent (SOL2) shorted Check for shorted wire harness; Replace valve
4-7 Cut (SOL3) shorted Check for shorted wire harness; Replace valve
4-8 Mark (SOL1) shorted Check for shorted wire harness; Replace valve
4-9 Vent (SOL2) open Check for open connection; Replace valve.
4-10 Cut (SOL3) open Check for open connection; Replace valve.
4-11 Mark (SOL1) open Check for open connection; Replace valve.
Group 5 - Plasma High Proportional Valve (V5)
5-1 Valve open Check for open connection; Replace valve.
5-2 Gas Control Unit inlet Supply
pressure low
Raise plasma inlet pressure; check for Gas Selection Console valve not open; restriction in gas
supply / hoses.
5-3 Outlet pressure too low Valve full open. Leak in plasma hose to torch; defective control valve (V5); defective pressure
sensor (PS6); Gas Control Unit Control PCB
5-4 Outlet pressure low Tracking error Leak in plasma hose to torch; defective control valve (V5); defective pressure sen-
sor (PS6); Gas Control Unit Control PCB
5-5 Outlet pressure too high. Valve at minimun setting. Restriction in plasma hose, torch, Gas Control Unit manifold; defective
control valve (V5); defective pressure sensor (PS6); Gas Control Unit Control PCB
Group 6 - Plasma Low Proportional Valve (V4)
6-1 Valve open Check for open connection; Replace valve.
6-2 Gas Control Unit inlet Sup-
ply pressure low
Raise plasma inlet pressure; check for Gas Selection Console valve not open; restriction in gas sup-
ply/hoses.
6-3 Outlet pressure too low Valve full open but pressure still too low. Leak in plasma hose to torch; Defective control valve (V4);
Defective pressure sensor (PS6); Gas Control Unit Control PCB
6-4 Outlet pressure low Tracking error. Leak in plasma hose to torch; Defective control valve (V4); Defective pressure sensor
(PS6); Gas Control Unit Control PCB
6-5 Outlet pressure Too high Valve at minimum setting but pressure still too high. Restriction in plasma hose to torch; torch
or Gas Control Unit manifold; Defective control valve (V4); Defective pressure sensor (PS6); Gas
Control Unit Control PCB
6-6 Outlet pressure high Tracking error. Restriction in plasma hose; torch or Gas Control Unit manifold; Defective control
valve (V4); Defective pressure sensor (PS6); Gas Control Unit Control PCB
Group 7 - Pilot Proportional Valve (V3)
7-1 Valve open Check for open connection; Replace valve.
7-2 Gas Control Unit inlet Sup-
ply pressure low
Raise plasma inlet pressure; check for Gas Selection Console valve not open; restriction in gas sup-
ply/hoses.
7-3 Outlet pressure too low Valve full open but pressure still too low. Leak in plasma hose to torch; defective control valve;
defective pressure sensor (PS6); Gas Control Unit Control PCB
7-4 Outlet pressure low Tracking error. Leak in plasma hose to torch; defective control valve; defective pressure sensor
(PS6); Gas Control Unit Control PCB