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. If possible, do a continuity check on the torch lead with a Hypertherm cartridge installed.
    1. Make sure that a Hypertherm cartridge is installed on the torch and that the torch is not connected to the plasma power supply.
    2. Do a check for continuity between pin 1 in the torch connector and the nozzle on the Hypertherm cartridge.
    3. Do a check for continuity between pin 2 in the torch connector and the nozzle on the Hypertherm cartridge.
    4. Is there continuity on both pins? OptionDescription
      If yes... There could be a problem with the plasma power supply instead of the torch.
      If no... It is possible that a new torch lead is necessary.

Corrective action for the torch

  1. Press-and-hold the Mode button for approximately 5 seconds to start a gas test, and keep the system in gas test mode for 2 minutes.
  2. Monitor the gas pressure while the gas is flowing.
    If the pressure decreases gradually, look for the following conditions that can cause the pressure to decrease:
    • Does the torch lead have any kinks?
    • Are there cable ties around the torch lead that are too tight?
    • Is there heavy equipment putting too much weight on part of the torch lead?
    • Are there signs of damage to the torch lead that can cause gas pressure leaks?
  3. Connect a different torch to the plasma power supply that is known to operate correctly.

    Does the Torch Cap fault go away?

  4. Do a check for continuity on the original torch:
    The image shows the pin layout on a torch lead.
    1. Make sure that a Hypertherm cartridge is installed on the torch and that the torch is not connected to the plasma power supply.
    2. Do a check for continuity between pin 1 in the torch connector and the brass in the center of the connector.
    3. Do a check for continuity between pin 2 in the torch connector and the brass in the center of the connector.
  5. Is there continuity on both pins? OptionDescription
    If yes... The problem can be with the plasma power supply, not the torch. Continue with Corrective action for the plasma power supply.
    If no... Replace the torch lead.

Corrective action for the plasma power supply

  1. Set the power switch to OFF (O), and disconnect the power cord from the power source.
  2. Remove the plasma power supply handle and cover.
  3. Remove the component barrier.
  4. Measure the resistance between the red wire group and the white wire from the torch receptacle.

    These wires have the labels RED and WHT on the power Printed Circuit Board (PCB).

    The image shows where the red wire group and the white wire from the torch receptacle connect to the power Printed Circuit Board.
    If you see this condition...Do these steps...
    The resistance is very low. Continue with the next step.
    The resistance is open.
    1. Install a different Hypertherm cartridge.
    2. Examine the torch lead to find if one of the wires in the lead is broken. Replace the torch lead if necessary.
  5. Reconnect the power cord.
  6. Set the power switch to ON (I).
  7. Press-and-hold the Mode button for approximately 5 seconds to start a gas test.
  8. Is gas flowing? OptionDescription
    If yes...

    Measure the resistance again between the red wire group (RED) and the white wire (WHT) from the torch receptacle to make sure that the resistance is very high (open circuit).

    If the resistance is very low (closed circuit) with the gas flowing, the nozzle and electrode are touching or a short-circuit occurred in one of the wires in the torch lead. Replace the Hypertherm cartridge or the torch lead, as necessary.
    If no... Examine the solenoid valve to make sure that it is operating correctly. Do the steps in Troubleshooting for missing gas input faults and Troubleshooting for low gas pressure faults.
  9. If possible, connect a different torch that is known to operate correctly.
  10. If you continue to get the same fault condition, replace the power PCB.

Verification

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