CUTMASTER 60i
SERVICE Manual 0-5475
5-6
Problem - Symptom Possible Cause Recommended Action
Nothing happens
when torch switch
or remote switch
is closed (Or CNC
START signal is
active) No gas flow,
DC LED OFF.
1. Problem in the torch and leads
switch circuit (Remote pendant
switch circuit).
2. CNC Controller device not
providing Start signal.
3. Failed components in unit.
1. Take Torch and Leads (Remote Pendant) to Authorized Repair
Facility.
2. Contact Controller manufacturer.
3. Return to authorized service center for repair or replacement.
FAULT indicators
flashing. Error code
E012
1. Upper O-ring on torch head is in
wrong position.
2. Torch starter cartridge is stuck.
3. Worn or faulty torch parts.
4. Shorted Torch.
1. Remove shield cup from torch; check upper O-ring position;
correct if necessary.
2. Turn OFF power supply. Bleed down system pressure. Remove
shield cup, tip and starter cartridge. Check starter cartridge lower
end fitting for free movement. Replace if fitting does not move
freely.
3. Inspect torch consumable parts. Replace if necessary.
4. Replace torch and leads or return to an authorized service
center for repair.
No Fault lights ON, no
arc in torch.
1. Failed components in unit. 1. Return to an authorized service center for repair.
FAULT indicators
flashing Error code
E024 or E031
1. Internal Error 1. Turn the ON / OFF switch OFF then back ON again. If that does
not clear the fault, return to an authorized service center for
repair.
Pilot arc is ON but
cutting arc will not
establish
1. Work cable not connected to
work piece.
2. Work cable/connector broken.
3. Failed components in unit.
1. Connect work cable.
2. Replace work cable.
3. Return to an authorized service center for repair.
FAULT indicator.
Work Lead Current
is less than output
current setting. Error
code E010 Low
Output Current.
1. Inverter board pilot IGBT may be
shorted
2. HCT1 Current Sensor or harness
is bad.
1. Perform the resistance tests at #7 in section "Power Off Tests".
2. With the ouput current set at 60A, test the voltage at J601-3
(J601-4 common). It should be 2.4V. If it is, then the sensor
is bad. If it is higher than 2.4V then check the harness for
continuity.
Torch cutting is
diminished
1. Incorrect current setting.
2. Worn torch consumables.
3. Poor work cable connection to
work piece.
4. Torch being moved too fast.
5. Excessive oil or water in torch.
6. Failed components in unit.
1. Check and adjust to proper setting.
2. Check torch consumables and replace as needed.
3. Check the connection of the Work Lead to the work piece.
4. Reduce cutting speed.
5. Refer to "Check air quality" in Section 3 Torch.
6. Return to an authorized service center for repair.
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