Troubleshooting for an ignition timeout

Diagnostic code 520

A 520 diagnostic code is an alert that shows after an ignition timeout when there is no pilot arc.

Symptoms

Code Symptoms XPR® models XPR action Code cancels with...
520 The sensor in Chopper 1 does not measure current during the 600 millisecond ignite period because no current path completes between the nozzle and the electrode. All models End of cycle
  • Start
  • Set process
  • Remote on-off

Corrective action

  1. Make sure that the transfer height is correct and that the torch is not in contact with the workpiece.
  2. Examine the consumables, and replace any that have damage or excess wear.
  3. Make sure that the spark gap Printed Circuit Board (PCB) is correctly connected to the ignition PCB.

    Refer to Gas connect console high-voltage side parts (CorePlus shown).

    1. Make sure that the spark gaps illuminate brightly.
    2. If they do not, replace only the spark gap PCB.
  4. Examine the main contactor:
    1. Look for black or rough surfaces that are difficult to remove.
    2. Make sure that the contactor closes immediately after the Start command is applied.
  5. If the contactor is defective, replace it.
  6. Examine the pilot-arc relay to make sure that it closes.
  7. Examine the wiring to make sure that the coil receives 24 VDC.
  8. Examine the start circuit PCB, and replace it if it is defective.
  9. Do a torch lead test: Do a test for continuity between the nozzle and workpiece.