ESAB Cutmaster 40 - Basic Troubleshooting Guide

CUTMASTER 40
SERVICE 0-5570
42
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 Recommended Action
ON / OFF Switch
is ON but the A/C
Indicator does not
light
1. Primary power disconnect is in OFF
position.
2. Primary fuses / breakers are blown
or tripped.
3. Faulty components in unit.
1. Turn primary power disconnect switch to ON position.
2. a) Have qualied person check primary fuses / breakers.
b) Connect unit to known good primary power receptacle
3. Return to authorized service center for repair or replacement.
Fault indicator
showing Error
Code E02
1. Primary input voltage problem.
2. Faulty components in unit.
1. Have qualied person check primary voltage to insure it meets unit
requirements see Section "2.05 Input Wiring Specications" on page
19.
2. Return to authorized service center for repair or replacement.
TEMPERATURE
LED ON.
Communication
Fault showing HI
1. Air ow through or around the unit is
obstructed.
2. Duty cycle of the unit has been
exceeded.
3. Failed components in unit.
1. Refer to clearance information – see Section "2.04 Power Supply
Specications" on page 18
2. Allow unit to cool.
3. Return to authorized service center for repair or replacement.
GAS LED OFF,
Communication
Fault showing LoP
1. Gas supply not connected to unit.
2. Gas supply not turned ON.
3. Gas supply pressure too low.
4. Failed components in unit.
1. Connect gas supply to unit.
2. Turn gas supply ON.
3. Set air supply inlet pressure to unit to 120 psi. Set leads length to
match the actual length being used.
4. Return to authorized service center for repair or replacement.
FAULT and
Communication
Fault showing PIP
1. Shield Cup loose.
2. Torch not properly connected to power
supply.
3. Problem in torch and leads PIP circuit.
4. Failed components in unit.
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.
FAULT and
Communication
Fault showing PIC
1. Torch shield cup is loose.
2. Torch tip, electrode or starter cartridge
missing.
3. Torch start cartridge is stuck.
4. Unit inlet gas pressure is too high
causing continuous gas ow.
5. Open conductor in torch leads.
6. Problem in the torch and leads switch
circuit.
7. Failed components in unit.
1. Tighten shield cup by hand. Do not over tighten.
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 start cartridge. Check start cartridge lower end tting for
free movement. Replace if tting does not move freely.
4. Decrease gas supply pressure to 125 PSI or less.
5. Replace torch and leads or return to authorized service center for
repair or replacement.
6. Replace torch and leads or return to authorized service center for
repair or replacement.
7. Return to authorized service center for repair or replacement