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nancy00Aug 30, 2025
What does 'Tip Saver Fault' mean on ESAB 200i Welding System?
- AadamsbrianAug 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 200i Welding System?
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 200i?
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 200i?
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 200i displays 'Inverter 1A VAC Mismatch'?
If the ESAB Welding System displays 'Inverter 1A VAC Mismatch', it means the inverter AC voltage rating is incompatible with the power supply voltage rating. Check the ribbon cable connection from CCM J31 to Inverter Module 1 Section A 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 200i 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 200i 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 200i 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 Welding System 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 200i 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 English-speaking users.
Safety precautions provided in French Canadian for user protection.
Technical specifications and electrical requirements for different system amperages.
Specifies the required gases, quality, pressure, and flow rates for system operation.
Outlines electrical, gas, and water supply requirements for installation.
Provides instructions and warnings for safely lifting the power supply unit.
Step-by-step guide for connecting input power and system ground cables.
Instructions for connecting the work cable, pilot, and negative leads.
Procedures for establishing proper grounding to minimize EMI and ensure safety.
Instructions for connecting the color-coded coolant hoses to the power supply.
Step-by-step instructions for connecting the plasma torch assembly to the leads.
Procedure for installing torch consumables to ensure proper operation and seating.
Explains the indicators and functions on the power supply control panel.
Contains operating information specific to the power supply, including startup sequences.
Lists and explains CCM status codes indicating active faults or conditions.
Troubleshooting guide for common symptoms and causes related to the Remote Arc Starter.
Periodic checks recommended for power supply maintenance to ensure performance.
Steps for cleaning the external coolant filter to maintain optimal coolant flow efficiency.
Detailed steps for draining and replacing the coolant in the system.
Procedure for removing consumables from the torch cartridge assembly.
Steps for installing torch consumables to ensure proper operation and seating.
Troubleshooting guide for identifying and resolving coolant leaks from the torch head.
Cutting data for mild steel, O2 plasma/shield, up to 100 amps.
Cutting data for bevel and robotic operations up to 100 amps.
Cutting data for mild steel, O2 plasma/shield, 150-200 amps.
Cutting data for robotic and bevel operations, 150-200 amps.
Cutting data for mild steel, O2 plasma/shield, 250-300 amps.
Cutting data for robotic and bevel operations, 250-300 amps.
Cutting data for mild steel, O2 plasma/shield, 400 amps.
Cutting data for robotic and bevel operations, 400 amps.
Procedure for installing consumables into the torch cartridge assembly.
General| Input Voltage | 230 V |
|---|---|
| Current Range | 5 - 200 A |
| Input Current | 16 A |
| Output Current Range | 5 - 200 A |
| Efficiency | 85% |
| Process | MMA/TIG |
