Troubleshooting for an RF communication fault (0-98-1)

An 0-98-1 fault code identifies a Radio Frequency (RF) communication failure between the Hypertherm® cartridge and the torch.

When this fault occurs, the Hypertherm cartridge is not sending data to the system, so the system cannot collect data about the Hypertherm cartridge. The problem can be with the Hypertherm cartridge or with the SmartSYNC® torch.

Fault codes and fault LEDs

Fault code Fault LEDs Torch LED Description Stops the system from operating?
0-98-1 The image shows the general fault Light Emitting Diode.

ON

 The image shows the torch Light Emitting Diode illuminated yellow.

Yellow

 An RF communication failure occurred between the Hypertherm cartridge and the torch. No. You can continue to cut or gouge, but you must set the output current (A) and the operating mode manually.

Corrective action for the Hypertherm cartridge (0-98-1)

  1. Make sure that the Hypertherm cartridge is installed correctly.
  2. Make sure that the green ring inside the Hypertherm cartridge is not broken.
    The images shows the green ring inside the Hypertherm cartridge.
  3. If you have a Hypertherm cartridge reader (528083), do a test to identify if the reader can pull data from the Hypertherm cartridge.
  4. Install a new Hypertherm cartridge.
  5. If a new Hypertherm cartridge does not remove the fault condition, continue with the next procedure.

Corrective action for the torch (0-98-1)

  1. Disconnect the SmartSYNC torch from the plasma power supply.
  2. Put the torch on its side, and remove the left side of the torch shell.
  3. Are the two antenna wires securely connected to the torch Printed Circuit Board (PCB)? OptionDescription
    If yes... Continue with the next step.
    If no... Adjust the antenna wires as necessary until they connect fully and securely in the connector on the torch PCB.
  4. Disconnect the two antenna wires from the torch PCB.
    The image shows the removal of the antenna wire.
    1. Lightly push down the tabs on the antenna connector on the torch PCB with your thumb or fingers.

      You can also use a tool to push down the tabs if the points are not too sharp. The pliers shown are one example.

    2. While you hold down the tabs, pull the antenna wires out of the connector.
    Note:

    If the antenna connectors look like the one shown here, insert an object such as a paper clip into the holes to release the antenna wires.

    New 2-wire connector.
  5. With the antenna wires disconnected, measure the resistance of the antenna coil in the connector on the torch PCB.

    Is the resistance less than 1 ohm (Ω)?

    OptionDescription
    If yes... the antenna wires have possible damage. Replace the torch body.
    If no... the antenna on the torch PCB has possible damage. Replace the torch PCB.
    The image shows a close up view of the torch Printed Circuit Board.