Hypertherm HPR260 Manual Gas Preventive Maintenance Program Rev.5 - Manual (Page 161)

MAINTENANCE
HPR260 Auto Gas Instruction Manual 5-17
Error code troubleshooting – 7 of 10
Error code
number
Name Description Corrective action
104
High current
on CS2
A current greater than
35 amps has been
detected by
current sensor 2.
1. Verify that there is not a short on the I/O PCB, between the
work lead and the negative lead.
2. Remove fuse F4 and check for a short on Chopper B from
wire 38 to wire 39.
3. Verify fuse (F4).
105
Low current
on CS1
A current less than
10 amps has been
detected by
current sensor 1.
1. Verify the connections on CS1.
2. Verify that +/- 15 VDC is present at the CS1 connector.
3. Verify fuse (F3).
4. Verify that contactor CON1 is closing.
5. Remove fuse F3 and check the open circuit voltage (OCV)
on wire 38 and wire 39 at chopper A when CON1 closes.
106
Low current
on CS2
A current less than
10 amps has been
detected by
current sensor 2.
1. Verify the connections on CS2.
2. Verify that +/- 15 VDC is present at the CS2 connector.
3. Verify fuse (F4).
4. Verify that contactor CON1 is closing.
5. Remove fuse F4 and check the open circuit voltage (OCV)
on wire 38 and wire 39 at chopper B when CON1 closes.
108
Transfer at
power-up
The system has detected
current on the work lead
during power-up.
1. Verify that the electrical connections to current sensors CS1
And CS3 are correct and not damaged.
2. Replace PCB 3 if connections are correct and not
damaged.
109
Coolant flow
at power-up
“Coolant flow OK” signal
is active during power-up
and before pump motor
is activated.
1. Either coolant flow sensor was bypassed or the flow switch
is faulty.
111
Coolant
overtemp at
power-up
Coolant is indicating an
overtemp at power-up.
1. Verify that the coolant temperature sensor has not been
jumped out or the wires to the sensor are not shorted out in
the harness.
2. If not, the coolant temperature is over the set point and
needs time to cool to 70° C (158° F).
116
Watchdog
interlock
An error occurred with the
CAN communication
system.
1. Verify that cable number 5 (power supply-to-gas console
control cable) is not damaged and is properly connected to
PCB3 and the rear of the gas console.
2. Verify that cable number 6 (power supply-to-gas console
power cable) is not damaged and is properly connected
inside the power supply and to the rear of the gas console.
3a. (Manual gas console) Verify that D1 (+5 VDC) and D2
(+3.3 VDC) are illuminated on PCB2 inside the gas
console. These LEDs indicate power to PCB2.
3b. (Auto gas console) Verify that D17 (+5 VDC) and D18
(+3.3 VDC) are illuminated on PCB2 inside the gas
console. These LEDs indicate power to PCB2.
4. If power is present at PCB2 and PCB3 and both gas
console cables are good, then PCB2 or PCB3 has failed.
Use the CAN tester to verify which board needs to be
replaced.
5