Troubleshooting Tables

No activity, no display, internal fans not running.

No input power.

Ensure Power cable is correctly plugged in at MSU and power outlet. Turn the power switch to ON. Verify voltage from outlet

System displays low water level error.

Water is below minimum level.

Refer to section 3.6. System “Top Off”

Initial top off routine ends prematurely. Pressing the button again causes more top off, as if previous top off ended prematurely.

Normal behavior. Since the top off routine is vacuum driven, when the vacuum stops the level drops slightly below its previous height during filling. Level is ok after the initial automatic stop.

Cutting occurs but Vacuum Pump does not start

Supply voltage too low.

Check facility power output.

Pump damaged from flooding.

MSU requires service Contact PPedm Customer Service Hotline for assistance

Mobile Service Unit makes loud screeching noise.

Air entrapped in the Mobile Service Unit Pressure Regulator.

Bleed DI system (See Ch. 3 System Maintenance, Section

3.9 System Bleeding and Charging)

System overflows during Top Off routine causing water puddle under the MSU.

System Sediment Tank Level Sensor is stuck.

Contact PPedm Customer Service Hotline for assistance

No cutting occurs, vacuum pump does not start.

If green light on hand-tool is flashing, the Electrode needs replacement.

Replace electrode.

Flashing red light on Hand-Tool indicates a System error

Observe error displayed on control terminal. Check the water level. Contact the PPedm Customer Service Hotline for support.

Hand-tool not connected to utility cabinet.

Recheck hand-tool connection on rear of cart. Ensure locking bezel is fully rotated.

No cutting occurs, Pressure pump does not start.

Fastener surface is not conductive.

Check correct location of Hand-Tool over fastener. Verify that all surface coatings have been removed

CG Hand Tool will not cut.

Ground pin incorrectly adjusted or damaged.

Check ground pin for wear and replace if necessary

EG Hand Tool will not cut

Bad ground connection.

Check for bad or lose ground clamp connection.

Cutting occurs but system shows red warning LED at end of cut.

Hand-tool trigger was released prematurely.

Re-cut fastener ensuring to hold down trigger until system finishes cutting.

Cutting process ended prematurely.

Check library setting for correct fastener type. Make an additional cut by squeezing trigger a second time while still in-place over fastener. The system will likely repeat the same error since less cutting is required in the second cycle.

Cut does not reach correct depth.

Hand-tool not firmly and consistently held in contact with fastener and airframe surface throughout cut.

Press hand-tool firmly over fastener and maintaining consistent pressure until cut is complete.

Cycle time excessively long.

Cutting too deep.

Hand-tool is not held stable during cut.

Hold hand-tool in a fixed position during cutting.

Electrode is not tight.

Tighten electrode with electrode torque wrench.

Cut slower than expected.

Electrode is not tight.

Check electrode tightness with electrode torque wrench.

Air in system.

Bleed DI system.

Leaks in water system.

Check visually for leaks in water system or for kinked hoses.  Use Purge Kit to check correct operating pressure as in section 3.10.2.

Wrong fastener selected.

Check fastener settings.

Wrong electrode type.

Check electrode material application.

Operator error.

User lifted or moved E-Drill during cut sequence.

Water sprays excessively out of hand-tool. Hand-tool cannot be held easily against work surface.

Vacuum and water connections incorrect.

Check water tube connections.

No cutting occurs. No water evident.

Burning smell around electrode

Wrong Adapter in use for the fastener being removed; resulting in the ground pin not being fully depressed – typically a button-head tip is being used for a flush head fastener. Incorrectly adjusted or damaged Ground Pin.

Select the correct adapter configuration for the fastener. If the wrong tip is used, then the depression of the ground pin will not be sufficient for water flow, resulting in overheating and damage to the equipment.

Fastener does not punch out.

Wrong fastener settings.

Check all settings in the HMI.

Wrong electrode size.

Check electrode against fastener application.

Insufficient cut depth programmed in fastener library.

Check fastener size.

User Error

User lifted hand-tool during cut sequence.

E-Drill stops within a second of starting and does not go to cut depth.

Ground Pin protrusion is significantly out of adjustment or worn beyond its life.

Paint, corrosion, or sealant on fastener head has not been fully removed.

Adjust Ground Pin protrusion with Ground Pin Setting Tool. Clean fastener head for proper grounding.

Cutting a depressed center fastener (such as a Torx or Phillips head) without specially adjusting the Ground Pin protrusion to match the fastener depth.

Electrode advances to limit and Hand Tool emits a constant buzzing noise.

E-Drill Trigger is stuck in the on position.

Power off system. Check operation of trigger, clean surrounding area to attempt to free the trigger assembly.

Trigger should “click” when depressed. Contact PPedm Customer Service Hotline if the problem persists.

Cutting or Cutting Time is intermittent and/or taking longer than usual

Electrode has come loose in E-Drill.

Remove adaptor and drive electrode forward using the trigger. Using the Electrode Torque Tool re-tighten electrode.

Water leaking from E-Drill retract button or ground pin adjusting hole.

E-Drill seal failure

Call the PPedm Customer Service Hotline and obtain an RMA and return E-Drill to PPedm for service.

Vacuum pump does not stop operating after 3 seconds of trigger release. E-Drill “buzzing” and does not stop automatically at the end of cut.

Water inside of E-Drill.

Call the PPedm Customer  Service Hotline and obtain an RMA and return E-Drill to PPedm for service.