ESAB POWERCUT-1500 Instruction Manual download pdf (Page 27)

165

SECTION 5 TROUBLESHOOTING

Refer to system schematic. 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 monitor conditions necessary for the safe operation of the

Powercut-1500. 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

flow 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. If no air pressure, check the air at the supply

point. Also, check for any obstructions in the air hose.

b. Air flow may be blocked at the torch tip. Check the torch

consumables (see Figure 3.3). 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 flow through

torch. If not, and air pressure is set at required 80 PSIG, check

gas Solenoid (SOL1) for proper operation.

d. Air Check switch may also be malfunctioning if the air is flowing

continuously or putting in the On position does not turn air on.

3. Over Temperature indicator . The fault light will blink to indicate that

the machine is overheated. This generally indicates that the air flow

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 off, 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 installing 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 initiation. 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 off 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.

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ESAB POWERCUT-1500 Instruction Manual Page 27

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