457
2. Check transformer secondary voltages at the output diode modules. Refer to system sche-
matic. Replace the transformer module if the correct secondary voltages are not present.
3. If everything above checks out all right, then the PCB1 Control Board should be replaced.
D. Fault light activates when torch switch is closed.
The machine monitors conditions necessary for the safe operation of the Powercut. The fault
lights will glow under the following conditions and operations will come to a stop.
1. High/Low line voltage. The "AC LINE" light will blink to indicate that the input voltage is
outside the +/- 15% range of the nominal voltage.
2. Gas Flow indicator - The fault light will blink to indicate that the air ow is low or that the
torch is not providing any back pressure.
a. Check the air pressure at the machine regulator. It should be adjusted to 80 psig (5.5
bars). If no air pressure, check the air at the supply point. Also, check for any obstruc-
tions in the air hose.
b. Air ow may be blocked at the torch tip. Check the torch consumables (see Figure 3.4).
Also check for any obstructions in the torch leads.
NOTE: If above items check OK , the problem is internal. Send unit to an Authorized Repair
Station for repair.
c. Put the ‘Air Check’ switch to On position. Air should ow through torch. If not, and air
pressure is set at required 80 psig (5.5 bars), check gas Solenoid (SOL1) for proper op-
eration.
d. Air Check switch may also be malfunctioning if the air is owing continuously or put-
ting in the On position does not turn air on.
3. Over Temperature indicator . The fault light will blink to indicate that the machine has
overheated. This generally indicates that the air ow has been blocked. Clear blockage and
allow the power source to cool before operating.
a. Thermal Switch (TS1) may be open. It will open if the heat sink temperature reaches
80°C. With the machine power o, check the continuity between P6-7 and P6-8 of the
control board. If the switch is OK, then the ohmmeter should read a direct short. If not,
then it should read open.
b. If the switch is malfunctioning, replace it. Clean the surface of the heat sink before in-
stalling the switch.
4. Fault Indicator. When this light blinks, either the system failed to initiate a pilot arc after a
number of attempts, or there has been an over-current event within the system.
a. If the light blinks for 10 seconds and then stops, then the problem is pilot arc initia-
tion. Check the consumables in the torch.
b. If the light continues to blink, and the system does not reset, then the fault is an
over-current event. One likely source of an over-current fault is a nozzle to electrode
short. Turn o the machine and inspect the torch and its consumables. Replace the
consumables as needed. Turn the machine back on. If the problem occurs again, the
machine may require service.
SECTION 5 TROUBLESHOOTING
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