Troubleshooting for TSO and TSC faults

A flashing Torch Cap fault Light Emitting Diode (LED) identifies either a Torch Stuck Open (TSO) or a Torch Stuck Closed (TSC) condition.

TSO
The nozzle and electrode components inside the Hypertherm® cartridge are not touching after a Start signal is received.
TSC
The nozzle and electrode components inside the Hypertherm cartridge will not disconnect from each other after a Start signal is received.

Fault codes and fault LEDs

Fault code Fault LEDs Torch LED Description Stops the system from operating?
None The image shows the Torch Fault Light Emitting Diode flashing.

Flashes slowly

 The image shows the torch Light Emitting Diode illuminated yellow.

Yellow

 There is a TSO condition. Yes. These faults stop the torch from firing a plasma arc. In some conditions, you can fire the torch again and continue to cut.
None The image shows the Torch Fault Light Emitting Diode flashing.

Flashes quickly

 There is a TSC condition.

Corrective action for the Hypertherm cartridge

  1. If the Hypertherm cartridge became loose or was removed while the plasma power supply was ON and the torch-lock switch was set to the green "ready to fire" position, set the power switch on the plasma power supply to OFF (O), correct the problem, and set the power switch to ON (I) to remove the fault.
  2. Examine the Hypertherm cartridge to make sure that it is not worn and does not have damage.
  3. Are you using a hand torch or a mechanized torch? OptionDescription
    Hand torch
    1. Move the torch-lock switch to the yellow lock position, then move the torch-lock switch to the green "ready to fire" position.
    2. Fire the torch one time to get the warning puffs of air. This can clean away unwanted material that has collected around the tip of the Hypertherm cartridge.
    Mechanized torch Continue with the next step.
  4. Remove the Hypertherm cartridge and carefully shake it to remove unwanted material that has collected inside the Hypertherm cartridge.
  5. Install a new Hypertherm cartridge.

Corrective action for TSO faults that occur during postflow

A Start signal during postflow causes the remaining air pressure in the torch lead to quickly decrease. If the pressure does not decrease quickly enough, the electrode will possibly not return to its closed position in time to form the pilot arc. A TSO fault occurs.

After each step, try to fire the torch again.

  1. Move the torch lock switch to the LOCK position and then back to the "ready to fire" position to reset the torch.
  2. Try a different Hypertherm cartridge.
  3. Do an inspection of the torch lead.
    • If the torch lead is installed in a track, remove the torch lead from the track.
    • Does the torch lead have any kinks or bends? Do not bend the torch lead around a radius that is less than the minimum bend radius of 76 mm (3.0 inches).
    • Are there cable ties around the torch lead that are too tight?
    • Are there any signs of a gas leak?
    The image shows the bend radius of a torch lead.
  4. Do a gas test to make sure that the inlet gas pressure is sufficient.
  5. Try a different torch.

    If the torch does not fire, there could be a problem with the plasma power supply instead of the torch. Speak to your distributor or authorized repair facility.

Verification

  • Because TSO and TSC faults can be intermittent, do these troubleshooting steps as many times as necessary.