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 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.
What to do if the ESAB Welding System shows 'Transfer Lost'?
If the ESAB Welding System displays 'Transfer Lost', it means the arc was transferred to the work but then went out while Start was still active. This can happen if the arc loses contact with the work (e.g., running off the edge or over a hole), the standoff is too high, or the cut process or manual settings (current control, gas pressures) do not match the consumables. Verify these conditions and settings.
What does 'Unexpected current in work lead' mean on ESAB 200i Welding System?
If your ESAB Welding System reports 'Unexpected current in work lead', it indicates that there is current above 8A in the work lead prior to pilot ignition or transfer. This can be caused by a negative lead short to ground or the arc starter chassis, a defective HCT1 work lead current sensor, or a defective Relay PCB.
What does 'Unexpected current in pilot circuit' mean on ESAB Welding System?
If the ESAB Welding System displays 'Unexpected current in pilot circuit', it means the current is above 6A in the pilot circuit prior to ignition. This can be caused by wrong or mismatched consumables causing a tip-electrode short, a pilot lead shorted to negative in the torch tube, a defective Relay PCB, a defective Pilot PCB, or a possible shorted torch. Check these components and connections.
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 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 '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.
Why ESAB 200i shows 'Tip to Electrode voltage fault'?
The 'Tip to Electrode voltage fault' on your ESAB Welding System could be caused by worn-out torch consumable parts, wrong consumables installed (causing a tip to electrode short), an incorrect process selected, or wrong manual settings for plasma gas or cutting current. Other possible causes include a leak in the plasma hose to the torch, a defective Pilot PCB, or a shorted torch body. The suggested solution is that the tip voltage is too close to the electrode voltage.
What to do if the ESAB Welding System shows 'Missing AC Phase'?
If the ESAB Welding System displays a 'Missing AC Phase' error, the possible causes include a blown wall fuse, a blown unit fuse F1 or F2 on the rear panel, a bad power cable connection, or a defective System Bias PCB. Check these components to resolve the issue.
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 |
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