00 480V ULTRA-CUT 100 XT ™ PLASMA CUTTING SYSTEM AUTOMATED GAS CONTROL Operating Manual Revision: AD Issue Date: January 16, 2014 Manual No.: 0-5303 VictorThermalDynamics.
WE APPRECIATE YOUR BUSINESS! Congratulations on your new Victor Thermal Dynamics product. We are proud to have you as our customer and will strive to provide you with the best service and reliability in the industry. This product is backed by our extensive warranty and world-wide service network. To locate your nearest distributor or service agency call 1-800-426-1888, or visit us on the web at www.thermal-dynamics.com.
! WARNINGS Read and understand this entire Manual and your employer’s safety practices before installing, operating, or servicing the equipment. While the information contained in this Manual represents the Manufacturer's best judgement, the Manufacturer assumes no liability for its use. Plasma Cutting Power Supply with Automated Gas Control, Ultra-Cut 100 XT™ Operating Manual No. 0-5303 Published by: Victor Technologies 82 Benning Street West Lebanon, New Hampshire, USA 03784 (603) 298-5711 www.
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TABLE OF CONTENTS SECTION 1: GENERAL INFORMATION............................................................................ 1-1 1.01 1.02 1.03 1.04 1.05 1.06 1.07 1.08 Notes, Cautions and Warnings......................................................................... 1-1 Important Safety Precautions.......................................................................... 1-1 Publications.....................................................................................................
TABLE OF CONTENTS SECTION 4: OPERATION.................................................................................... 4-1 4.01 4.02 4.03 4.04 4.05 4.06 4.07 4.08 4.09 4.10 4.11 4.12 4.13 4.14 Power Supply Control Panel............................................................................ 4-1 System Operation............................................................................................ 4-1 TSC-3000 Navigation Functions.................................................................
TABLE OF CONTENTS APPENDIX 1: CNC - Control Module PCB Connections................................................ A-1 APPENDIX 2: CNC .......................................................................................... A-2 CNC functions................................................................................................................ A-2 CNC Input / Output Descriptions.................................................................................... A-4 Simplified CNC Circuit..........
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ULTRA-CUT 100 XT SECTION 1: GENERAL INFORMATION Gases and fumes produced during the plasma cutting process can be dangerous and hazardous to your health. 1.01 Notes, Cautions and Warnings Throughout this manual, notes, cautions, and warnings are used to highlight important information. These highlights are categorized as follows: NOTE An operation, procedure, or background information which requires additional emphasis or is helpful in efficient operation of the system.
ULTRA-CUT 100 XT * These values apply where the actual arc is clearly seen. Experience has shown that lighter filters may be used when the arc is hidden by the workpiece. FIRE AND EXPLOSION Fire and explosion can be caused by hot slag, sparks, or the plasma arc. ! • Be sure there is no combustible or flammable material in the workplace. Any material that cannot be removed must be protected. • Ventilate all flammable or explosive vapors from the workplace.
ULTRA-CUT 100 XT 12. CSA Standard W117.2, CODE FOR SAFETY IN WELDING AND CUTTING, obtainable from the Canadian Standards Association, Standards Sales, 178 Rexdale Boulevard, Rexdale, Ontario, Canada M9W 1R3 1.05 Precautions De Securite Importantes AVERTISSEMENTS 13.
ULTRA-CUT 100 XT • Ce produit, dans le procéder de soudage et de coupe, produit de la fumée ou des gaz pouvant contenir des éléments reconnu dans L’état de la Californie, qui peuvent causer des défauts de naissance et le cancer. (La sécurité de santé en Californie et la code sécurité Sec. 25249.5 et seq.) CHOC ELECTRIQUE Les chocs électriques peuvent blesser ou même tuer. Le procédé au jet de plasma requiert et produit de l’énergie électrique haute tension.
ULTRA-CUT 100 XT 1.06 Documents De Reference Consultez les normes suivantes ou les révisions les plus récentes ayant été faites à celles-ci pour de plus amples renseignements : 1. OSHA, NORMES DE SÉCURITÉ DU TRAVAIL ET DE PROTECTION DE LA SANTÉ, 29CFR 1910, disponible auprès du Superintendent of Documents, U.S. Government Printing Office, Washington, D.C. 20402 2. Norme ANSI Z49.
ULTRA-CUT 100 XT 1.07 Declaration of Conformity Declaration of Conformity Manufacturer: Address: Victor Technologies International Inc. 16052 Swingley Ridge Road Suite 300 Chesterfield, MO 63033 U.S.A. Type of Equipment: Plasma Cutting Controller Model /Number: Ultra-Cut 100 XT Serial Number: Serial numbers are unique with each individual piece of equipment and details description, parts used to manufacture a unit and date of manufacture.
ULTRA-CUT 100 XT Classification: The equipment described in this manual is Class A and intended for industrial use. ! WARNING This Class A equipment is not intended for use in residential locations where the electrical power is provided by the public lowvoltage supply system. There may be potential difficulties in ensuring electromagnetic compatibility in those locations, due to conducted as well as radiated disturbances.
ULTRA-CUT 100 XT 1.08 Statement of Warranty LIMITED WARRANTY: Victor Thermal Dynamics® Corporation (hereinafter “Thermal”) warrants that its products will be free of defects in workmanship or material.
ULTRA-CUT 100 XT SECTION 2: SPECIFICATIONS 2.01 General Description Of The System A typical Ultra-Cut XT™system configuration includes: • One Power Supply • Remote Arc Starter • Gas Control - Digital manifold Control (DMC) • Gas Control - Digital Pressure Control (DPC) • Precision Plasma Cutting Torch • Set Of Connecting Leads • Torch Spare Parts Kit • Touch Screen Control (TSC), Optional • Heat Exchanger, Optional The components are connected at installation. 2.
ULTRA-CUT 100 XT 2.05 Precision Plasma Cutting Torch The torch delivers the controlled current to the work through the main arc, causing the metal to be cut. 2.
ULTRA-CUT 100 XT 2.07 Power Supply Dimensions 47.77 inch 1213 mm 35.97 inch 914 mm 100A 420 lb / 190 kg 27.
ULTRA-CUT 100 XT 2.08 Power Supply Rear Panel Features TSC/Comm Customer Optional Ports Circuit Breakers GCM Connector CNC Connector J55 - GCM USER INPUT Coolant Return C.C.M.
ULTRA-CUT 100 XT 2.09 Gas Requirements The customer will provide all gases and pressure regulators. Gases must be of high quality. Pressure regulators shall be double stage and installed within 3 meters from the Gas Console. Ultra-Cut 100 XT™ Power Supply: Gas Pressures, Flows, and Quality Requirements Gas Quality Minimum Pressure Flow O2 (Oxygen) 99.5% Purity (Liquid recommended) 120 psi 8.3 bar / 827 kPa 70 scfh (2000 l/h) N2 (Nitrogen) 99.
ULTRA-CUT 100 XT 2.11 XT Torch Specifications A. Torch Dimensions Art # A-04897 End Cap 19.00" 482.68 mm 2.25" 57.15 mm Mounting Tube 2.0" 50.8 mm 15.50" 393.78 mm 6.30" 160.10 mm 2.39" 60.81 mm 3.54" 89.87 mm 2.74" 69.55 mm 1.57" 39.96 mm 1.49" 37.8 mm B. Torch Leads Lengths Torch Lead Assembly Lengths ��� Feet Meters 10 3.05 15 4.6 25 7.6 50 15.2 75 22.9 100 30.
ULTRA-CUT 100 XT C. Torch Parts (Generic Parts Shown) Art # A-04741_AB Plasma Gas Distributor Shield Gas Distributor Tip Shield Cap Electrode Cartridge Shield Cup D. Parts - In - Place (PIP) The torch is designed for use with a power supply which senses coolant return flow to confirm that torch parts are in place. If coolant return flow to the power supply is absent or insufficient the power supply will not provide power to the torch.
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ULTRA-CUT 100 XT SECTION 3: INSTALLATION 3.01 Installation Requirements Electric Supply The electrical supply network, the gas and water supply system must meet local safety standards. This conformity shall be checked by qualified personnel. Ultra-Cut 100 XT™ Power Supply Input Power Input Current Suggested Sizes (See Note) Voltage Freq.
ULTRA-CUT 100 XT 3.02 System Layout Refer to section 3.04 for ground connections and ground cables. 175’ / 53.3 m Maximum Length 100’ / 30.5 m Maximum Length 125’ / 38.
ULTRA-CUT 100 XT 3.
ULTRA-CUT 100 XT 3.05 Lift the Power Supply WARNINGS Do not touch live electrical parts. Disconnect input power conductors from de-energized supply line before moving unit. FALLING EQUIPMENT can cause serious personal injury and equipment damage. Use a forklift, crane, or hoist to lift the unit off the shipping pallet as shown. Keep the power supply steady and vertical. Do not lift it any further than necessary to clear the shipping pallet. Ensure all panels and screws are secure prior to lifting.
ULTRA-CUT 100 XT 3.06 Connect Input Power and Ground Cables Connect Input Power and System Ground Cables 1. Remove the input power cover to the right of the coolant filter at the rear of the power supply. To do this remove the two screws then lift up and pull away. 2. Carefully cut back the outer sheath on the primary input power cable to expose the individual wires. Cut back the insulation on the individual wires. Route the cable upward through Input Power Port at the bottom of the panel.
ULTRA-CUT 100 XT 3.07 Connect Work Cable and Pilot and Negative Leads 1. Remove the output power cover to the left of the coolant filter at the rear of the power supply. To do this remove the two screws then lift up and pull away. 2. Route the ends of the work cable, pilot and negative/torch leads upward through the leads strain relief at the bottom edge of the left rear panel. 3. Refer to the illustration. Connect the leads as shown. Tighten securely. Do not overtighten.
ULTRA-CUT 100 XT A. Electromagnetic Interference (EMI) Pilot arc starting generates a certain amount of electromagnetic interference (EMI), commonly called RF noise. This RF noise may interfere with other electronic equipment such as CNC controllers, remote controls, height controllers, etc. To minimize RF interference, follow these grounding procedures when installing mechanized systems: B. Grounding 1. The preferred grounding arrangement is a single point or “Star” ground.
ULTRA-CUT 100 XT Creating An Earth Ground 1. To create a solid, low resistance, earth ground, drive a 1/2 in (12 mm) or greater diameter copper clad ground rod at least 6 - 8 ft (1.8 - 2.4 m) into the earth so that the rod contacts moist soil over most of its length. Depending on location, a greater depth may be required to obtain a low resistance ground (see NOTE). Ground rods, typically 10 ft (3.0 m) long, may be welded end to end for greater lengths.
ULTRA-CUT 100 XT 3.09 Connect Coolant Leads 1. Connect the color-coded coolant hoses to the coolant connections on the power supply rear panel. The supply line (out) is flagged green, the return line (in) is flagged red.
ULTRA-CUT 100 XT 3.10 Connect Cables for CNC, Remote Arc Starter, DMC-3000 and HE 400 1. Connect one end of each cable to the power supply. 2. Connect the other end of the CNC cable to the CNC device. 3. The CNC cable shield must be attached to ground at the CNC end.
ULTRA-CUT 100 XT 3.11 Handling and Installation of Fiber Optics General Information This kit is for proper handling and installation of Fiber Optic Cables used in Thermal Dynamics Ultra-Cut® and Auto-Cut O2® automated gas boxes and Gas Control Modules. Fiber Optic cable is used in place of wire because it offers far superior immunity to electrical noise but it is more delicate and requires careful handling. With fiber optics, electrical signals are converted to light with a transmitter LED.
ULTRA-CUT 100 XT Avoid the following: 1. If you need to pull the cable through a power track do not fold the fiber back on itself making a sharp bend where it exits the hose. Art # A-09417 2. Do not hook onto the fiber to pull on the cable. Art # A-09418 3.
ULTRA-CUT 100 XT Correct installation: Correct way to pull the cable is to use a snake or a wire or another cable and attach it securely to the hose behind the strain relief. Then secure the fiber connector to the pulling device leaving some slack in the fiber. Keep the protective end covers on the fiber until you are ready to connect it to the PCB in the CCM or gas control.
ULTRA-CUT 100 XT Unplugging the fiber optic connector. Do not pull on the fiber cable! Art # A-09423 For the CCM grip the fiber connector front and back squeezing the latch lever and remove from the socket.
ULTRA-CUT 100 XT 3.12 Connect TSC-3000 Cable and DMC-3000 Fiber Optic Cable to CCM 1. Remove the bottom plastic plug in the CCM at the rear of the Power Supply.
ULTRA-CUT 100 XT Fiber Optic Cable Plug Thin nut securing the through hole protector Art # A-11998 ���� INSTALLATION Manual 0-5303
ULTRA-CUT 100 XT 3.13 Set Switches on the Command - Control Module Remove the power supply upper right side. Set switches on the CCM (Command-Control Module) per the illustrations. Switch settings and connection details are provided in the Appendix. Any changes made require a restart of the power supply. CAUTION Printed circuit boards in the Command - Control Module are static - sensitive. Discharge any built-up static charges in your body or surroundings before touching the printed circuit boards.
ULTRA-CUT 100 XT CAUTION Printed circuit boards in the Command - Control Module are static - sensitive. Discharge any built-up static charges in your body or surroundings before touching the printed circuit boards. SW11 SW6 SW12 SW13 SW-6: OK-to-Move: Contact closure, 120VAC @ 1A (Factory default setting) or DC Volts (16-18vdc@ up to 100 ma.) SW-11: Set “B” position, (up) for default SW-11: Set “A” position (down) for remote analog current control. SW-8-2 must be set to “ON”.
ULTRA-CUT 100 XT 2 - Wire and 4 - Wire settings When used with the TSC-3000 the plug should be in the 2 wire (2W) position shown below. Art # 12322 For other CNC controls using 4 wire communication such as the XT iCNC, place the jumper in the 4W position. 3.14 Height Control Connections The terminal strip provides connections to negative Arc Volts (Torch or electrode), Tip Volts (Pilot) and Work. These are for a height control that requires connection to the full non-divided arc voltage.
ULTRA-CUT 100 XT NOTE There are holes added in the rear panel for customer wiring. This, rather than the one in the CCM will be the preferred place for customer added wiring (and strain relief) for connections to height controls, etc.. 3.15 DMC-3000 Gas Manifold Control Installation The DMC-3000 Gas Control must be installed in a suitable location where it is easily accessible to the system operator. The unit must be mounted to a flat horizontal surface.
ULTRA-CUT 100 XT Preparation 1. Remove the screws securing the Cover Panel to the Module. Art # A-09139_AC Remove 2 Screws Loosen or remove 2 screws Cover Removal 2. Carefully remove the cover from the module noting the attached wire harness that connects to J1. Remove the wire harness and then set the cover to the side.
ULTRA-CUT 100 XT 3. Attach all hoses and cables to the front of the DMC-3000 except the Fiber Optic cable which will be covered a little later. Avoid turning any fittings already mounted in the unit by placing a wrench on it before tightening the hose fitting to it. Art # A-09141_AB NOTE Argon must be used for the “Marking” gas. If replacing existing fittings in the base, apply thread sealant to the fitting threads, according to manufacturer’s instructions.
ULTRA-CUT 100 XT Art # A-09655 6. Install WMS Water Softener Kit in the line that feeds the inlet side of the DMC-3000. Mount the softener and bracket on the power supply where the provided 2’ hose can reach to the DMC-3000. Mounting in another location is possible with a customer provided hose. Below is typical customer added hose and installation. 7.
ULTRA-CUT 100 XT 3.16 DPC-3000 Gas Pressure Control Installation The DPC-3000 Gas Control must be installed in a suitable location close to the Torch such as the gantry. The unit must be mounted to a flat horizontal surface. If the Module is mounted to any support subject to vibration or motion, the installer must fasten the module to the support securely. The Module should be located as far away as possible from the Arc Starter due to possible electromagnetic interference.
ULTRA-CUT 100 XT Preparation 1. Remove the screws securing the Cover Panel to the Module. Art # A-09144_AB Remove 2 Screws Loosen or remove 2 screws 2. Carefully remove the cover from the module noting the attached wire harness that connects to J4. Remove the wire harness and then set the cover to the side.
ULTRA-CUT 100 XT 3. Attach all hoses and cables to the back of the DPC-3000 except the Fiber Optic cable which will be covered a little later. Avoid turning any fittings already mounted in the unit by placing a wrench on it before tightening the hose fitting to it. Do not connect Fiber Optic cable until later Art # A-09146_AB 4. Connect hoses from the front of the DMC-3000 where shown below to the torch. NOTE One fitting with the notches is left hand thread and the other is standard right hand thread.
ULTRA-CUT 100 XT 3.17 Fiber Optic Cable Installation from CCM to DMC-3000. CAUTION Avoid kinking, twisting, or bunching the fiber optic cable. The cable can be damaged by being forced into tight-radius turns. Review section 3.10 for proper handling and installation of fiber optic cable. 1. Remove outer thin nut from through hole protector at the end of Fiber Optic Cable (L) that is connected to the CCM. 2.
ULTRA-CUT 100 XT 4. Secure the thin nut on the through hole protector so both nut faces are tight against the sheet metal inside and out. Art # A-09149_AB 5. Plug the Fiber Optic Cable into the PCB as shown below. Make sure the locking tabs are engaged.
ULTRA-CUT 100 XT 3.18 Fiber Optic Cable Installation From DMC-3000 to DPC-3000 1. Remove outer thin nuts from through hole protector at both ends of Fiber Optic Cable (L) that connects between the DCM-3000 and DPC-3000. CAUTION Avoid kinking, twisting, or bunching the fiber optic cable. The cable can be damaged by being forced into tight-radius turns. 2.
ULTRA-CUT 100 XT 4. Secure each of the thin nuts on the through hole protectors so both nut faces are tight against the sheet metal inside and out. 5. Plug the Fiber Optic Cable into the PCB as shown below for the DMC-3000. Make sure the locking tabs are engaged. Plug Fiber Optic cable to/from DPC-3000 here Art # A-09154 6. Plug the Fiber Optic Cable into the PCB as shown below for the DPC-3000. Make sure the locking tabs are engaged. Fiber Optic to/from DMC-3000 plugs in here Art # A-09155 7.
ULTRA-CUT 100 XT 3.19 Install TSC-3000 Touch Screen Control Mounting Dimensions TSC-3000 Profile TSC-3000 Top 1.11 in [28.2 mm] 2.35 in [59.69 mm] 5.58 in [141.7 mm] 6.99 in [177.5 mm] .25 in [6.35 mm] 10.83 in [275.0 mm] 11.80 in [299.7 mm] Art # A-09156 12.45 in [316.2 mm] Preparation 1. Select a clean, dry location with good ventilation and adequate working space around all components.
ULTRA-CUT 100 XT 3.20 Install Remote Arc Starter Site Location Select a clean, dry location with good ventilation and adequate working space around all components. Review the safety precautions in the front of this manual to be sure that the location meets all safety requirements. Interconnecting cables and hoses attach to the Arc Starter. There must be adequate space around the Arc Starter for these connections without excessive kinking or bending. Mounting Dimensions NOTE Height not shown is 7.
ULTRA-CUT 100 XT Installation The Remote Arc Starter must be installed in a suitable location near the torch head. If the Arc Starter is mounted to a gantry or to any other support subject to motion or vibration, fasten the Arc Starter to the support securely. 1. Loosen, but do not remove, the lower screws securing the cover to the Arc Starter. Remove the upper screws securing the Cover Panel to the Arc Starter. NOTE A ground wire connects the cover to the Arc Starter base. This wire must remain in place.
ULTRA-CUT 100 XT Input Connections 1. Refer to the illustrations. Make the following input connections to the Arc Starter. • Coolant Supply and Return Hoses (from HE-400 Heat Exchanger). Hoses and connectors are colorcoded; Red for Return, Green for Supply.
ULTRA-CUT 100 XT 2. Refer to illustration. Connect the Pilot wire and Negative cables using a star washer on each. NOTE * Slave and Master refer to only those set ups using two power supplies in parrallel. Slave is not used in single system operations.
ULTRA-CUT 100 XT Output Connections 1. Refer to the illustrations. Make the following output connections to the Arc Starter. Pilot Lead Coolant Return (Red) Coolant Supply (Green) Red Green Art # A-12065 Pilot Return Cable, Coolant Supply and Return Hoses (from Torch) 2. Reinstall the Arc Starter Cover. Ensure that the ground wire is not crimped between the cover and the base.
ULTRA-CUT 100 XT 3. The Arc Starter must be grounded; the grounding terminal is marked grounding details. . Refer to the previous section for Art # A-04758 Torch Leads 1 Nut and 1 Washer Remain in Place Ground Cable 4. Use a clamp to secure the Torch Lead Shield braid brass ring to the port on the Remote Arc Starter as shown.
ULTRA-CUT 100 XT Connect Control Cable 1. Connect the Remote Arc Starter cable to the Remote Arc Starter receptacle.
ULTRA-CUT 100 XT 3.21 Connecting Torch Connect the Torch as follows: Coolant Supply, Coolant Return, and Pilot Leads Leads Cover Torch Leads End Cap Shield Gas (Right Hand Thread) Groove for O-Ring O-Ring Pilot Lead Mounting Tube Plasma Gas To Torch Valve (Left Hand Thread) Coolant Supply & Power Lead (-) Pilot Lead Connector Torch Head Assembly Art # A-09198 1. Lay out the torch leads on a clean, dry working surface. 2. Hold the Torch Leads End Cap stationary. Pull approximately 18” (0.
ULTRA-CUT 100 XT CAUTION The gas and coolant leads include compression fittings. Do not use sealant on these connections. Slowly apply pressure to the gas lines. Check for leaks at all connections before continuing. If there are no leaks, shut off the gas supplies and continue with installation. 7. Connect the pilot lead to the Torch Head. Press the two ends of the connector firmly together. Thread the plastic lead cover/connector onto the mating Torch Head connector. 8.
ULTRA-CUT 100 XT 4. Insert the stack of consumable parts into the cartridge. Ensure that the large O-ring on the torch tip fits completely into the cartridge. If any part of the O-ring protrudes from the cartridge, the parts are not seated properly. 5. Use the cartridge tool to hold the cartridge assembly, while turning the shield cup (and shield retainer for 200 Amp parts) onto the cartridge assembly. For 300 Amp parts turn the shield retainer onto the shield cup now.
ULTRA-CUT 100 XT 30 - 100 Amp Parts Assembly 1: Stack Parts 2: Press Cartridge onto Stacked Parts Electrode Plasma Gas Distributor O-Ring on Tip No Gaps Between Parts Tip Shield Gas Distributor Cartridge Covers O-Ring on Torch Tip Shield Cap 3: Thread Shield Cup onto Cartridge 4: Check Shield Cap Protrusion Shield Cup Shield Cap Shield Cap Protrudes 0.063-0.083" (1.6 - 2.
ULTRA-CUT 100 XT 3.23 Voltage Divider for iHC Torch Height Control For best plasma cutting performance it is necessary to maintain a constant height (standoff) above the metal while cutting. Cutting tables use a Torch Height Control (THC), also called a Z axis control, most of which use feedback from the arc voltage to control the height.
ULTRA-CUT 100 XT Control Cable. The iHC board can be supplied with a wire harness and connector (shown in previous image), to be installed in the rear panel hole labeled “Height Control” . The connector mates with a cable from the iHC. For other height control V-D boards a strain relief can be installed in this hole for those cables. Refer to Appendix for wiring diagram.
ULTRA-CUT 100 XT 3.24 Complete the Installation 1. Remove the cap from the coolant tank. Fill the coolant tank to the level shown, with Thermal Dynamics coolant. The coolant level is visible through the translucent coolant tank. The amount of coolant required varies with torch leads length. Coolant Capabilities Cat.
ULTRA-CUT 100 XT 2. After the complete system has been installed, check that the coolant has been pumped through the system as follows (see NOTE): NOTE Depending on the length of the torch leads, the system may require more coolant after turning the system ON for the first time. a. Place the ON/OFF Switch to ON. b. After about 4 minutes the system may shut down if the leads are not full of coolant. c. Place the ON/OFF switch to OFF. Add more coolant if needed d.
ULTRA-CUT 100 XT SECTION 4: OPERATION 4.01 Power Supply Control Panel A/ Gas Indicator AC Indicator Temp Indicator Status Indicator DC Indicator A/ Art # A-11541_AB AC Power Lamp Indicates unit has passed the input power tests and AC power is being supplied to the inverter modules via the input contactor when the ON/OFF switch is in ON position. TEMP Lamp: Normally OFF. Lamp will come ON when the internal temperature sensors detect temperatures above normal limits.
ULTRA-CUT 100 XT NOTE Prior to starting the system determine the process to be used. The process is determined by the type and thickness of the metal to be cut. Select and install the required consumables, connect the required gasses to the system. 1. Connect system to primary input power. An indicator will light on the rear panel when AC power is applied to the unit. Place the Plasma Enable Switch (TSC 3000; user installed Plasma Enable/E-Stop) in the “Enable” position 2.
ULTRA-CUT 100 XT 4.
ULTRA-CUT 100 XT 4.04 TSC-3000 Initial Setup ONLY Initial steps required before First operation only. Note 400 Amp system requires a Height Controller with Elevation Height (EH) feature. When power is turned on TSC 3000 goes to the Home screen. For new installation it is required to perform initial SETUP. Press SETUP button (1). Enter Initial default PASSWORD 00000 (2) ENTER/CHANGE PASSWORD HOME 1 2 SETUP 1a To change Password press SET PASSWORD enter new 5 digit password (1a).
ULTRA-CUT 100 XT 4.05 TSC-3000 Selecting New Process Select new standard process by material; thickness; amperage (1) or enter process # using pop-up number pad (2). SELECT MATERIAL, THICKNESS HOME Material – Scroll to select, Thickness – Scroll to select, Accept & advance (1). 1 2 SELECT PROCESS NUMBER Select process by # (2) or by name (3). If by name, first select process type; best cut, fastest, MAX Pierce, etc. Then press To accept & advance to Torch Consumables. (4).
ULTRA-CUT 100 XT 4.06 TSC-3000 Selecting Recently Used Process Home screen shows some of the most recently used processes with the last one used highlighted. Select the highlighted process by pressing the Green arrow or scroll with up/down arrows to select another recent process then press the green arrow. HOME TORCH CONSUMABLES Check that you have the correct torch consumables. (1) 1 If you already know the settings and consumables 1a to you can go directly Process Monitor using CUT MONITOR button.
ULTRA-CUT 100 XT 4.07 TSC-3000 Creating a Custom Process Considerable effort has been made to define the best parameters for each cutting and marking process. However for various reasons, variations in material composition, variations in cutting table performance, user preferences, etc. you may desire to modify one or more processes. Or perhaps you want to keep the same cutting current and gas pressures but save different THC / CNC parameters such as cutting speed, arc voltage, pierce height, etc.
ULTRA-CUT 100 XT CUSTOM PROCESS SETUP HOME Customize Recent Cut. Highlight the process closest to what you want to use then press CUSTOM CUTS button. Or Select NEW CUT then MATERIAL & THICKNESS. SELECT MATERIAL/THICKNESS Select value to change using UP/DN arrows. Change value with +/- buttons. TORCH CONSUMABLES LIST Shows List of consumables to use. SELECT CUT If the custom process requires different setting, speed, arc voltage, etc., edit it here.
ULTRA-CUT 100 XT 4.08 Back up and Restoration of Custom Processes. Users can create their own custom cut processes. These can be lost by accidentally deleting them on the TDC 3000 or they can be over written when updating programs. They can also be lost if the DSC 3000 should be replaced. We recommend you back up your custom processes every time a new one is created. To back up you will need a USB Flash drive. Backing Up Custom Process: 1.
ULTRA-CUT 100 XT Restoring Custom Processes: During file backup (see previous process) a folder and sub folders called “TD” were placed on your flash drive. You should copy this folder with its subfolders to some secure place. Making more than one copy is advised. If the need arises to restore from this backup, place the entire TD folder in the root directory (not in another folder) on a USB flash drive and plug it into the USB port on the TDC 3000. 1.
ULTRA-CUT 100 XT Renaming Custom Files You cannot rename the files while on the TSC 3000 but once you backup a file on the flash drive you can use a computer to rename the file on the flash drive and perform the restore to put the renamed file back on the TSC 3000. 1. Use Windows Explorer to find the folder TD in the root directory of the flash drive. Then find and open the folder CustomFiles. Here you will find all the custom processes saved. Art # A-09236 2.
ULTRA-CUT 100 XT 4.09 Sequence of Operation Ultracut with DFC 3000 using TSC 3000 The purpose of this section is to explain the steps an operator should follow when using the DFC 3000 with the TSC 3000 touch screen control panel for a specific cutting process. Also included are steps to follow for changing torch consumables.
ULTRA-CUT 100 XT g) Following the firmware version indication, while CCM establishes communication with the gas control (Step e.), the coolant pump and fans come on to “prime” the system. The “gas” indicator on the front panel blinks until correct coolant flow is detected. Normally this takes only a few seconds but can last up to 4 minutes if there is a problem.
ULTRA-CUT 100 XT 10. Changing torch consumables: Following a consumables change or inspection the system will initiate a purge of the gas. This serves two purposes: a) b) Remove the coolant that gets into the consumables when they have been removed. If the gas type has changed “Purge” removes the old gas from the lines and replaces it with the new gas.
ULTRA-CUT 100 XT 4.10 Gas Selection A. Plasma Gases 1. Air Plasma • Most often used on ferrous or carbon base materials for good quality at faster cutting speeds. • Air plasma is normally used with air shield. • Only clean, dry air is recommended for use as plasma gas. Any oil or moisture in the air supply will substantially reduce torch parts life. • Provides satisfactory results on nonferrous materials. 2. Argon/Hydrogen (H35) Plasma • Recommended for use on 3/4 in (19 mm) and thicker stainless steel.
ULTRA-CUT 100 XT B. Shield Gases 1. Compressed Air Shield • Air shield is normally used when operating with air or oxygen plasma. • Improves cut quality on some ferrous materials. • Inexpensive - reduces operating costs. 2. Nitrogen (N2) Shield • Nitrogen shield is used with nitrogen (N2) or Ar/H2 (H35) plasma. • Provides smooth finishes on nonferrous materials. • May reduce smoke when used with Ar/H2 plasma. 3. Water Shield • Normally used with nitrogen. • Provides very smooth cut surface.
ULTRA-CUT 100 XT 4.11 CCM Status Codes NOTE See the Appendix for Advanced Troubleshooting On start-up and during operation, the power supply control circuitry performs various tests. If the circuitry detects a condition requiring operator attention, the status display on the front panel shows a 3 digit number code preceded by either letter “E” (currently active fault) or letter “L” (last or latched fault) meaning a fault occurred during the process but is not currently active.
ULTRA-CUT 100 XT CCM Status Code Group 2 -- Plasma Power Supply Code ���� Message Remedy / Comments 201 Missing AC Phase Blown wall fuse, Blown unit fuse F1 or F2 or rear panel, Bad power cable connection; Defective System Bias PCB.
ULTRA-CUT 100 XT 222 Inverter 3A Output Current High Plasma work current high during cutting and attributed to Inverter Module 3 Section A output high; If problem persists replace Inverter Module 3 223 Inverter 3B Output Current High Plasma work current high during cutting and attributed to Inverter Module 3 Section B output high; If problem persists replace Inverter Module 3 224 Inverter 1 Not Found Inverter Module 1 Section A required for Piloting; Bad ribbon cable connection to CCM J31 to Inver
ULTRA-CUT 100 XT ���� 242 Inverter Input Voltage fault; voltage out of range or missing phase at AC Input of InInverter 1B Input Volt- verter Module 1 Section B; Poor AC Power Quality; Defective W1 contactor; Loose or age Error open connection between input terminals and W1 contactor or contactor and input of Inverter Section; Defective Inverter module 243 Inverter Input Voltage fault; voltage out of range or missing phase at AC Input of InInverter 2A Input Volt- verter Module 2 Section A; Poor AC
ULTRA-CUT 100 XT 259 Inverter circuitry is over temperature likely cause is ambient greater than 40 deg Inverter 1A Over Temp C; Reduce power supply cutting Duty Cycle; Reduce ambient air temperature; Add Ambient auxiliary cooler. 260 Inverter circuitry is over temperature likely cause is ambient greater than 40 deg Inverter 1B Over Temp C; Reduce power supply cutting Duty Cycle; Reduce ambient air temperature; Add Ambient auxiliary cooler.
ULTRA-CUT 100 XT CCM Status Code Group 3 -- Gas Controller Status & Protocol Code Message Remedy / Comments 301 Problem with fiber optic cable to GCM 2010 or DMC or DPC; Dirt on fiber ends Gas control communication or in connectors; blow out with clean dry air.
ULTRA-CUT 100 XT CCM Status Code Group 4 -- Torch Coolant System Code Message 401 Coolant Level low 402 403 Low coolant flow Coolant overheated Remedy / Comments Check coolant level, add as needed. Defective or disconnected level sensor. Coolant flow as measured by flow switch FS1 is less than 0.7 gpm; Clogged filter; Restriction in torch lead or head; Wrong style consumables; broken or defective torch coolant tube/check valve; Defective pump or bypass valve.
ULTRA-CUT 100 XT CCM Status Code Group 6 -- CCM Code Message Remedy / Comments 601 Analog Voltage Error Defective CCM, replace. 602 ADC or DAC error Defective CCM, replace. 603 Reserved No information available; Contact customer service 604 Data Memory error Defective CCM, replace. 605 Program memory fault Defective CCM, replace. 606 +5V Logic supply low Defective CCM, replace.
ULTRA-CUT 100 XT Status Indicators on the DMC & DPC modules flash a 2-part code. Both green and red flash the firmware version at power up. Only the red flashes for a fault. First part of the code indicates a code group, the second part a particular condition within that group. DMC and DPM may flash codes at the same time and they may be different codes. For example, a power supply fault, such as 1-3, in the DMC could prevent communicating with the DPM so the DPC would flash one it’s group 2 codes.
ULTRA-CUT 100 XT Group 5 - Shorted Solenoid Faults 5-1 Sol 1 – H35 Plasma Replace solenoid; Shorted wire harness; Defective DMC Control PCB 5-2 Sol 2 – Oxygen Plasma Replace solenoid; Shorted wire harness; Defective DMC Control PCB 5-3 Sol 3 – Air Plasma Replace solenoid; Shorted wire harness; Defective DMC Control PCB 5-4 Sol 4 – Nitrogen Plasma Replace solenoid; Shorted wire harness; Defective DMC Control PCB 5-5 Sol 5 – Aux Plasma Replace solenoid; Shorted wire harness; Defective DMC Cont
ULTRA-CUT 100 XT Group 3 - Inlet Pressure Faults 3-1 Plasma Gas High (>145 PSI) Reduce pressure from gas supply; defective pressure sensor (PS4). 3-2 Pilot Gas High (>145 PSI) Reduce pressure from gas supply; defective pressure sensor (PS3). 3-3 Shield Gas High (>145 PSI) Reduce pressure from gas supply; defective pressure sensor (PS1). 3-4 Shield H2O High (>145 PSI) Reduce pressure from gas supply; defective pressure sensor (PS2).
ULTRA-CUT 100 XT DPC Status Code Key Code Message Cause/Remedy Group 6 - Plasma Low Proportional Valve (V4) 6-1 Valve open Check for open connection; Replace valve. 6-2 DPC inlet Supply pressure low Raise plasma inlet pressure; check for DMC valve not open; restriction in gas supply/hoses. 6-3 Outlet pressure too low Valve full open but pressure still too low.
ULTRA-CUT 100 XT 4.14 Remote Arc Starter Trouble Shooting Arc Starter Trouble Shooting Symptom Cause Visual inspection, continuity check Connect Wire or replace leads. Coolant has become conductive Use conductivity meter Flush system, replace coolant. Use capacitance meter Reconnect or replace. Negative supply cable not connected correctly Visual inspection Reconnect Pilot return wire not connected or loose in arcstarter. Visual inspection Connect Wire.
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ULTRA-CUT 100 XT SECTION 5: MAINTENANCE 5.01 General Maintenance Perform the following checks periodically to ensure proper system performance. Power Supply Maintenance Schedule Daily Check coolant level; add coolant as needed. Check gas hose connections and pressures. UC-AC Maintenance schedule Monthly Check cooling fan and radiator; clean as needed. Check gas hoses for cracks, leaks, or abrasion. Replace as needed. Check all electrical connections for cracks or abrasion. Replace as needed.
ULTRA-CUT 100 XT 5.03 Coolant Replacement Procedure Replace coolant as follows: 1. Disconnect the system from main input power. 2. Remove the two right side panels. 3. Locate the coupling in the coolant line that comes from the bottom of the coolant tank, #1 in the following illustration. Disconnect the coolant line at this fitting and drain the coolant into a disposable container of sufficient size. Remember you will be draining more than the contents of the coolant reservoir. 4.
ULTRA-CUT 100 XT SECTION 6: REPLACEMENT ASSEMBLIES & PARTS 6.
ULTRA-CUT 100 XT 6.02 System Layout Refer to section 3.05 for ground connections and ground cables. 175’ / 53.3 m Maximum Length 100’ / 30.5 m Maximum Length 125’ / 38.
ULTRA-CUT 100 XT 6.
ULTRA-CUT 100 XT Ultra-Cut 100 15 ft 4.5 m 9-7360 9-9426 9-4785 9-4768 9-4786 9-7361 9-4792 4-3031 50 ft 15.2 m 9-4769 9-4787 9-7362 9-4793 4-3032 75 ft 22.8 m 9-4770 9-4788 9-7363 9-4794 4-3033 100 ft 30.5 m 9-7364 9-4796 4-3034 125 ft 38.1 m Leads Length 4-3029 9-4791 9-4784 9-4767 150 ft 45.7 m 10 ft 3.05 m 9-7359 9-4783 9-4766 9-4922 Description 4-3028 9-4790 9-4782 9-4765 9-4944 9-4930 Key 4 ft 1.
ULTRA-CUT 100 XT 6.
ULTRA-CUT 100 XT 6.06 Power Supply Replacement Parts - Upper Right Side Item # Qty Description 1 1 System Bias PCB 9-9253 2 1 Pilot PCB 3 1 CCM Assembly 9-7335 4 1 Relays, Pump / Fan MC3 / MC2 9-7314 5 1 Relay, Inrush Control K1 9-7336 6 1 Relay, Inrush MC1 9-7337 7 1 Resistor, Inrush R2 9-7376 8 1 Display PCB 9-9252 9 1 Auxiliary Transformer T1 9-7315 10 1 On/Off Switch Breaker CB1 9-7316 11 1 Ref. Des.
ULTRA-CUT 100 XT 6.07 Power Supply Replacement Parts - Lower Right Side Item # Qty Description Ref. Des.
ULTRA-CUT 100 XT 6.08 Power Supply Replacement Parts - Rear Panel Item # Qty Description Breaker Rating Circuit Rating Ref. Des.
ULTRA-CUT 100 XT 6.09 Power Supply Replacement Parts - Left Side Item # Qty 1 2 3 1 1 1 Description Ref. Des.
ULTRA-CUT 100 XT 6.
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ULTRA-CUT 100 XT SECTION 7: TORCH MAINTENANCE 7.01 Consumable Removal 1. Use the removal tool to hold the Shield Cup & Cartridge Assembly stationary. Turn the Shield Cup to remove it from the Cartridge Assembly. Cartridge Tool Assembled Cartridge Art # A-04344_AB Shield Cup 2. Take the Removal Tool off the back of the Cartridge Assembly Use the removal tool to push the consumable parts out of the Cartridge.
ULTRA-CUT 100 XT 7.02 O-Ring Lubrication Lubricate all three O-Rings on the Cartridge Assembly and all three O-Rings on the Torch Head periodically with O-Ring Lubricant supplied. Remove the snap ring on the cartridge assembly and slide the locking ring downward for access to the O-Ring under the locking ring. Inner O-Ring (Cat. No. 9-3030) Location (Under Locking Ring) O-Rings Torch Head Cat. No. 9-9041 O-Ring, Cat. No. 9-3029 O-Ring, Cat. No. 9-3028 Cat. No. 9-3027 Cartridge Assembly Cat. No.
ULTRA-CUT 100 XT 7.04 Torch Consumables Installation WARNINGS Do not install consumables into the Cartridge while the Cartridge is attached to the Torch Head. Keep foreign materials out of the consumables and Cartridge. Handle all parts carefully to avoid damage, which may affect torch performance. Art # A-03887 1.
ULTRA-CUT 100 XT 2, Remove the Removal Tool from the Cartridge and install the assembled Cartridge onto the Torch Head. CAUTION The cartridge assembly must cover the O-Ring on the torch head. Do not force the cartridge if it will not tighten fully. Remove the cartridge assembly and gently clean the threads on the torch head with a wire brush. Apply oxygen-compatible lubricant (supplied with the torch) to the threads. Torch Head Torch Head O-Ring 0.063 - 0.083" (1.6 - 2.
ULTRA-CUT 100 XT 7.05 Coolant Leak Trouble-Shooting Never operate the system if coolant leaks from the torch. A steady drip indicates that torch parts are damaged or installed improperly. Operating the system in this condition can damage the torch head. Refer to the following chart for guidance on coolant leakage from the torch head.
ULTRA-CUT 100 XT Torch Electrodes Art # A-09653 Amperage 30 50 70 100 ��� Plasma Gas Recommended Wear Depth for Electrode Replacement Inch mm O2 0.04 1 Air 0.04 1 N2 0.04 1 O2 0.04 1 Air 0.08 2 N2 0.04 1 O2 0.04 1 Air 0.08 2 N2 0.04 1 O2 0.04 1 H35 0.08 2 N2 0.
ULTRA-CUT 100 XT APPENDIX 1: CNC - Control Module PCB Connections TB1 (LV) OK To Move 2 High +10V 10K Analog Current Control Wiper / Input Low (-) Divided Arc Volts Output Start/Stop Input 12 11 10 9 (+) 8 (-) 7 (+) 6 (-) 5 Stop (NC) 4 (LV) OK To Move 2 3 (+) 2 (-) 1 CNC Plasma Enable TB2 OK To Move (+) SW6 DC 12 11 10 9 Pilot On Output (Contacts) Preflow On Hold Start 8 7 6 5 (+) 4 (-) 3 (+) 2 Art # A-11512_AB (-) 1 TB3 Spare #2 Output Normally Open Contacts 12 Spare #2 Output Normal
ULTRA-CUT 100 XT APPENDIX 2: CNC CNC functions CNC I/O circuits provide at least 1000V galvanic isolation from the plasma power supply. While the CNC circuits are isolated from the power supply, many of the signal returns on J15 and TB1, TB2 & TB3 are common to each other. J15 pins 1, 4, 5, 10, 17, and TB1-1, 5, 7, 9, and TB2-1 & 3 are all common. J15 pin 12 and TB2-10 are also connected to the others when SW6 (OK to Move select) is set for voltage.
ULTRA-CUT 100 XT Internal CNC connections. TB1, TB2 & TB3 on CCM module. Connections are provided on the CCM module TB1, TB2 & TB3 terminal blocks including most of the rear panel functions plus some additional features. All these signals are isolated from the plasma power supply but signals marked (comm.) and (-) are common to each other. Users are expected to install their own CNC cable to these connections. Knockout hole is provided in rear panel of CCM module.
ULTRA-CUT 100 XT CNC Input / Output Descriptions E-Stop input— Requires closed connection rated for 35ma. @ 20VDC for unit to operate. Factory installed jumper between TB1-1&2 must be removing when connecting user supplied E-Stop circuit. 4 Start/Stop input—Switch (momentary or sustained) rating 35ma. @ 20 VDC Start / Stop circuit configurations. Momentary Start / Stop (Latched) is only available at TB1.
ULTRA-CUT 100 XT OK to Move2 – Provides a second set of N.O. contacts that close when arc transfer is detected. Contacts are rated for maximum of 24 VAC/DC @ 1A. Simplified CNC Circuit. 5 +10V @ 10ma. For Remote CC Pot – Previously CCM versions if one wanted to use a potentiometer for the Remote Analog Current Control (CC) input an external 10 V supply was required for Pot High.. Now an isolated (from main plasma circuits) 10V supply is provided. Recommended value of the pot is 5K or 10K. 5 TB1 Ext.
ULTRA-CUT 100 XT Simplified CNC Circuit.
ULTRA-CUT 100 XT J54 - Rem ote HM I & CN C CO M M (100) (101) (102) Harness to Relay PCB (109) (108) (115) Harness to CPU PCB 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 G ND SPA RE #1a (142) (116) (117) (118) (119) (120) (133) (134) (137) (139) (138) (143) J22 C hassi s (140) (141) (136) (135) (132) (153) (133) (134) (135) (136) (137) (138) (139) (140) (141) (142) (143) (144) (145) (144) (145) (146) (147) (148) (149) (150) (151) (146) (147) (148) (149) (150) (151) (152) (154) (155) (132)
ULTRA-CUT 100 XT CNC Connections. Cutting Machine CNC Cable Power Supply J15 START/STOP 1 2 3 4 5 6 7 8 9 10 11 (9) (10) (11) Start Motion (OK-To-Move) { (12) * NC .......... Source, 16 VDC, 10 ma. ... Divided Arc V (-) .......... Divided Arc V (+) .......... Pre Flow ON (+) .......... Pre Flow ON (-) .......... ... Corner Current Reduction (+) Corner Current Reduction (-) 12 13 * (14) 14 (16) 15 16 (17) DC (+) * (1) ( 2) (3) (4) ( 5) (6) ( 7) SW6 .......... /Hold Start(+) ........
ULTRA-CUT 100 XT APPENDIX 3: DMC-3000 Control PCB Layout J6 TP5 TP4 SW2 SW1 TP3 J5 TP6 TP2 J1 TP7 J2 J8 TP1 J3 LED D1 D-17 D21 D22 LED D_E1 D_E15 J4 Art # A-09188_AB J9 Manual 0-5303 APPENDIX A-9
ULTRA-CUT 100 XT APPENDIX 4: DPC-3000 Control PCB Layout D7 J9 J6 TP3 D11 TP7 D10 D12 J5 TP1 D6 TP6 D5 D4 D3 TP4 J4 SW2 J3 J8 D2 TP8 D1 TP11 D9 D8 J2 SW1 TP2 J1 TP10 TP9 J10 Art # A-09189_AB TP5 ���� APPENDIX Manual 0-5303
ULTRA-CUT 100 XT APPENDIX 5: DMC-3000 / DPC-3000 Power Supply PCB Layout J2 D9 D7 D6 TP1 TP6 D5 F2 TP3 TP7 TP2 TP8 D16 TP5 TP4 Art # A-09597 F1 J1 Manual 0-5303 APPENDIX A-11
ULTRA-CUT 100 XT APPENDIX 6: TSC-3000 PCB Layout D1 TP4 D11 TP3 D13 TP1 D14 D15 J1 J5 J2 ���� TP2 J4 J3 APPENDIX Art # A-09190_AB Manual 0-5303
ULTRA-CUT 100 XT This Page Intentionally Blank Manual 0-5303 APPENDIX A-13
ULTRA-CUT 100 XT APPENDIX 7: CCM CPU PCB Layout = Test Point = Test Point Art # A-11675 ���� APPENDIX Manual 0-5303
ULTRA-CUT 100 XT CCM CPU PCB Test Points TP1 GND TP2 ISO +5.0V TP3 +24V TP4 +3.3V TP5 ISO GND TP6 +5.0V TP7 TOTAL DEMAND 3.3V=400A TP9 /WR TP10 /RD TP11 CPU TEMP SENSE TP12 +3.
ULTRA-CUT 100 XT APPENDIX 8: CCM I/O PCB Layout = Test Point 19 Art # A-11676_AB WORK CURRENT = Test Point ���� APPENDIX Manual 0-5303
ULTRA-CUT 100 XT CCM I/O PCB J23 RELAY - INTERFACE BOARD Test Points J24 ARC / TIP VOLTS TP1 GND J25 TEST TP2 /COOLANT FANS ON J26 GAS BOX TP3 /TORCH PUMP ON J28 TO CPU TP4 LOW COOLANT FLOW (SW) J29 TO CPU TP5 COOLANT FLOW SIGNAL (PULSE) TP6 +15V ISOLATED TP7 -15V ISOLATED TP8 +18V ISOLATED TP9 ANALOG CURRENT CONTROL 0-3.
ULTRA-CUT 100 XT APPENDIX 9: Pilot PCB Layout = Test Point = Test Point Art # A-11677 ���� APPENDIX Manual 0-5303
ULTRA-CUT 100 XT Pilot PCB Test Points TP1 GND TP2 PILOT GATE TP3 +5V TP4 TIP LED Reference D2 Green PILOT ENABLE D11 Green +5V Manual 0-5303 APPENDIX A-19
ULTRA-CUT 100 XT APPENDIX 10: Relay and Interface PCB Layout = Test Point = Test Point Art # A-11678 ���� APPENDIX Manual 0-5303
ULTRA-CUT 100 XT Relay and Interface PCB Test Points TP1 GND TP2 -15V TP3 +5VDC TP4 +12V TP5 +24V TP6 +15V TP7 +5VDC LED Reference D2 Green 1 TORCH GAS ON D7 Green PILOT ENABLE D11 Green PILOT CURRENT DETECTED D12 Green WORK CURRENT DETECTED D22 Green CONTACTORS ON D23 Green RF ON D24 Green FANS ON D25 Green PLASMA ENABLED D26 Green 1 TORCH ON D27 Green TORCH COOLANT ON Manual 0-5303 APPENDIX A-21
ULTRA-CUT 100 XT APPENDIX 11: Display PCB Layout = Test Point = Test Point Art # A-11679 ���� APPENDIX Manual 0-5303
ULTRA-CUT 100 XT Display PCB Test Points TP1 GND TP2 +5VDC TP3 +24VDC Manual 0-5303 APPENDIX A-23
ULTRA-CUT 100 XT APPENDIX 12: System Bias PCB Layout = Test Point = Test Point Art # A-11680 ���� APPENDIX Manual 0-5303
ULTRA-CUT 100 XT System Bias PCB Test Points TP1 GND TP2 24VDC TP3 DC INPUT POSITIVE TP4 Vcc1 TP5 Vcc2 TP6 GATE TP7 PRIMARY GND TP8 +12V PRIMARY TP9 P_ISOL_GND TP10 DC SENSE POSITIVE LED Reference D3 Red MISSING PHASE D4 Red AC V HIGH D14 Red AC V LOW D15 Green VAC_IDA D26 Green +12V PRIMARY D27 Green VAC_IDB D30 Green 24VDC D44 Green TRANSFORMER ON Manual 0-5303 APPENDIX A-25
ULTRA-CUT 100 XT APPENDIX 13: Main Inverter Bottom PCB Layout ���� Art # A11681 = Test Point = Test Point APPENDIX Manual 0-5303
ULTRA-CUT 100 XT Main Inverter Bottom PCB Test Points TP1 GND TP2 GATE 2A TP3 GATE 1A TP4 GATE 3A TP5 GATE 4A TP6 GATE 2B TP7 GATE 1B TP8 GATE 4B TP9 GATE 3B TP10 +12VP TP11 +12VDC TP12 THERMISTOR SIDE A TP13 THERMISTOR SIDE B TP14 +5VDC TP15 PGND LED Reference D3 Red D4 Green READY Manual 0-5303 CAP IMBALANCE APPENDIX A-27
ULTRA-CUT 100 XT APPENDIX 14: Main Inverter Top PCB Layout ���� Art # A11682 = Test Point = Test Point APPENDIX Manual 0-5303
ULTRA-CUT 100 XT Main Inverter Top PCB Test Points TP1 GND TP2 GATE 2A TP3 GATE 1A TP4 GATE 3A TP5 GATE 4A TP6 GATE 2B TP7 GATE 1B TP8 GATE 4B TP9 GATE 3B TP10 +12VP TP11 +12VDC TP12 THERMISTOR SIDE A TP13 THERMISTOR SIDE B TP14 +5VDC TP15 PGND LED Reference D3 Red D4 Green READY Manual 0-5303 CAP IMBALANCE APPENDIX A-29
ULTRA-CUT 100 XT APPENDIX 15: Control and Fault PCB Layout = Test Point = Test Point /230V Art # A11683 ���� APPENDIX Manual 0-5303
ULTRA-CUT 100 XT Control and Fault PCB Test Points TP1 GND TP22 +12VDC TP23 +5VDC TP24 GATE 1+ TP25 A_OUT1 TP26 B_OUT1 TP27 GATE 1- TP28 I_SNS1 TP29 GATE 2+ TP30 I_DMD1 0.5V-6.
ULTRA-CUT 100 XT APPENDIX 16: Cap Bias Bottom PCB Layout Art # A-11685 ���� APPENDIX Manual 0-5303
ULTRA-CUT 100 XT APPENDIX 17: Cap Bias Top PCB Layout Art # A-11686 Manual 0-5303 APPENDIX A-33
ULTRA-CUT 100 XT APPENDIX 18: Suppressor PCB Layout Art # A-11684 ���� APPENDIX Manual 0-5303
Manual 0-5303 APPENDIX Art # A-12268 Over Flow Supply Coolant tank Cold Plate 1 Cold Plate 2 Cold Plate 3 Pump Pressure Relief Level Switch Coolant Return Radiator HS1 Temp Sensor Flow Flow Bubble Sensor Flow Switch DESCRIPTION ECO B2502 Torch Coolant Supply Torch Coolant Return Filter 1 REV AA APPROVED AJR XT-300 RAS 1000 **FOR 400 AMP SYSTEMS HE400 DATE 8-8-2013 ULTRA CUT XT POWER SUPPLIES 100A-400A ULTRA-CUT 100 XT Appendix 19: COOLING DIAGRAM A-35
ULTRA-CUT 100 XT APPENDIX 20: Remote Arc Starter Schematic 2 Jumper in cable to I D Arc Starter is connected. A PL ASMA POW ER SUPPL Y J59-R AS 1 2 3 4 5 6 7 8 9 10 11 12 13 14 GN D 3 4 5 6 A R AS 1000 XT IGNI TI ON UNI T SIG 4.5 J58 Chassis gnd 120 V AC 120 V AC R ET 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 115 V ac GN D 115 V ac R E T Ho Hb (99) (98) (49) (52) Torch Shield NE G NEG 0.047 uf CGND PU 100K Neon 0.047 uf GN D B R AS Capacitor PC B 0.
ULTRA-CUT 100 XT This Page Intentionally Blank Manual 0-5303 APPENDIX A-37
ULTRA-CUT 100 XT APPENDIX 21: Schematic, DFC-3000 Auto Gas Box System 2 1 3 DMC3000 - MANIFOLD CONTROLLER ASSEMBLY E_STOP NO E_STOP COM See list by DPC 3000 Power Supply P1 (1) (3) 1 2 3 4 5 6 7 8 (2b) (5) (6) (8) (9) (5) (6) 1 2 3 4 5 6 7 8 9 10 11 12 13 14 2W 4W 2W SW14 - LINE SW14 TERMINATION normally on (refer to manual) 8 7 90 1 2 3 6 54 DMC3000 Control PCB LEDs SOLENOID DRIVE ON INDICATOR (GREEN LEDs) D1 - SOL_V1 (H35 PLASMA)) D2 - SOL_V2 (O2_PLASMA) D3 - SOL_V3 (AIR_PLASMA) D4 - SO
ULTRA-CUT 100 XT 4 6 5 DPC3000 - PRESSURE CONTROL ASSEMBLY 19X2383 PANEL INDICATORS Power Supply PCB (19X2384) LEDS STATUS LED (RED) POWER LED (GRN) MANIFOLD (partial) DPC3000 CONTROL PCB (WHT) D5 = +VDC Fused (24VDC ) D6 = +12VDC D7 = +24VDC SW (24VDC to Valves & Solenoids through E-Stop Relay D9 = +5VDC D16 = -12VDC (BLK) OPTION SWITCHES (1) 19X2384 (1) 120 VAC P1 1 120 VAC KEY PLUG J60 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 (2a) 120 VAC RET
ULTRA-CUT 100 XT APPENDIX 22: System Schematic 100A, 480V PG 1 1 3 2 5 4 A W1A B L1 L2 1 L3 1 J105B (1) 1 (23) INVERTER MODULE (IM) #1 (24) MAIN PCB LEDS D3, RED, CAP IMBALANCE D4, GREEN, READY 1 2 (24) J103B Earth (25) (3) 1 2 (25) CAP BIAS PCB LEDS D6, GREEN, -12V D11, GREEN, +12VP D13, GREEN, +12V 019X502700 W1C 1 IM #1 Section B (upper) AC INPUT J104B W1B (2) 1 2 (23) J105A AC INPUT IM #1 Section A (lower) 1 2 (23) J100 -- 30 CKT RIBBON CONTROL PCB LEDS D1,
ULTRA-CUT 100 XT 6 7 8 9 (49) (49) TEST POINTS TP1 GND TP2 PILOT GATE TP3 +5V TORCH 1 A C (49) J43 ELECTRODE RAS 1 PILOT BOARD LED'S D2 PILOT ENABLE D11 +5V 10 PILOT PCB J58A (52) J44 R3 & R4 PILOT 1 SHIELD EARTH GROUND 1 CHASSIS GND J58C 2 1 019X501600 WORK (+) (51B) TO RELAY BOARD TO I/O BOARD (+) TO CCM CPU PCB J31 Work TIP VOLTS To J24 on I-O PCB B Tip (53) (Sht 2, A5) (Sht 2, C3) J45 10 ckt Ribbon TO J3 on RELAY PCB J102B OUTPUT J42 L1 1 2 3 4 5 6 7 8 2
ULTRA-CUT 100 XT APPENDIX 23: System Schematic 100A, 480V PG 2 (89) r b g 1 2 1 5 2 6 3 7 4 8 J12 3 T1 Mini-Fit Jr 1 2 3 4 5 6 7 8 1 2 3 4 (81) (82) J49 460V 24V RET BLUE RED 24V B 400V YELLOW BLUE 120V_2 RET RED 120V-1 RET 12 11 10 9 8 7 6 5 4 3 2 1 (77) (78) CB2 5 A (76) 5 4 (74) (75) CB3 5 A (73) 3 2 YELLOW 120V_2 220V J6 (79) 6 (71) (72) CB4 5 A 1 J9 J14 0V SIGNAL (pulse) TORCH FLOW SENSOR 120VAC_2 24VAC D2, GREEN, 1TORCH GAS ON D7, GREEN, PILOT ENABLED D11, GREE
ULTRA-CUT 100 XT 6 7 TO PILOT PCB (Sht 1, B8) (162) / PILOT ENABLE / PILOT ENABLE RET (161) MC3 SA4 J8 SA1 ARC_SUPPRESSOR CONTROL OUTPUTS 120 VAC_1 J4 -- 40 CKT RIBBON CABLE (104) (62) (106) (63) (113) (61) AC 120V - GCM J19 120 VAC Ret (98) MC1 (107) (101) (102) (109) (108) (115) AC 24V Ret- GCM1 (63) AC 120V- Ret- GCM (116) (117) Harness AC 24V- Ret -TB4-1 (62) 1 AC 120V- Ret- TB4-3 (118) K1 (119) (120) 2 1 2 3 4 (63) 5 GND GND 4 WIRE RxTx+ Rx+ Tx- 1 2 3 4 5
ULTRA-CUT 100 XT Appendix 24: Advanced Troubleshooting System Overview The Auto-Cut 200 & 300 XT & Ultra-Cut 100, 200, 300 & 400 XT power supplies include one, two or three inverter modules (IM). Each IM may have either 1 or 2 inverter sections designated A or B sections. The IMs are mounted one over the other numbered from bottom to top. The sections are also designated from bottom to top with section A being on the bottom of each module.
ULTRA-CUT 100 XT will only have ribbon cables in J31 & J32; a 200A will have J31-J33 filled with the others empty. 300A will have J34 missing with the others filled. Other boards in the system include the System Bias Supply, the Relay & Interface PCB, Display PCB, Pilot PCB and AC Suppression PCB. The CCM has 2 boards, the I/O (input/output) and the CPU (central processing unit) board. The CE units will also have one or more EMI Filter boards on the input power.
ULTRA-CUT 100 XT The AC Suppression PCB has capacitors and other transient suppression components to protect the system from transients on the AC lines. It also provides power for the neon AC present indicators which illuminate when AC power is connected even with ON-OFF switch, CB1, off. Differences between various models.
ULTRA-CUT 100 XT Status codes. The codes for the power supply are displayed on the Display PCB 4 digit numerical display. Some codes refer to the Gas Controls but more detailed Gas Control codes will be found on the individual gas controls. The gas controls used with the XT family of plasma supplies have not changed. They have their own set of status codes which should be covered in another section.
ULTRA-CUT 100 XT Power Supply Status Codes Group 1, Process Codes 101 Plasma Enable Is Disabled Code 101 is activated by either an open circuit between TB1-1 & 2 on CCM I/O PCB or Plasma Enable switched off on the GCM 2010 or on the TSC 3000. TB1-1 & 2 comes from the factory with a jumper installed. An installer may remove the jumper and connect a separate Plasma Enable switch or use the Plasma Enable wires included in the 37 pin CNC cable used with the Ultra-Cut XT & Auto-Cut 300XT.
ULTRA-CUT 100 XT If a TSC 3000 is not connected or unit is an Auto-Cut, K7 on the Relay PCB is de-energized and GND is connected through its normally closed contacts. If the TSC is connected, 24 VAC through a jumper in the TSC 3000 energizes K7, opening its NC contacts and now GND connects through the TDC 3000 Plasma Enable switch.
ULTRA-CUT 100 XT 102 Pilot Ignition Failure Code 102 is activated when there is no pilot current after 15 seconds of firing the Arc Starter. Pilot ignition requires the Pilot board to be enabled, pilot switch (IGBT) turned on and high voltage pulses (HF) from the arc Starter (either the Remote Arc Starter RAS 1000 XT or GCM 1000 XT or the arc starter built in to the AC 200 XT) applied between the tip and the electrode of the torch.
ULTRA-CUT 100 XT Arc starter without Spark Gap (Ultra-Cut) 1. Check for power to the RAS 1000XT’s Ignition Module during the 15 seconds following preflow (ignition phase). Arc starter power comes through the rear panel circuit breaker CB4, make sure it isn’t tripped. a. During the ignition phase, measure for 120 VAC at the input terminals marked 120 VAC on the Ignition module, a gray rectangular box with screw terminals on one side.
ULTRA-CUT 100 XT Reasons why RAS Control relay would not close: 6. Pilot current flowing. There actually is pilot current flowing somewhere. Unlikely as it would normally set the 208 fault but we have to rule it out. a. Disconnect J41 on the Pilot board, if HF still doesn’t fire and the Relay board Pilot LED, D11, is still on, it’s due to a fault in the detection circuits. 7. Faulty detection circuit.
ULTRA-CUT 100 XT Troubleshooting Pilot Board problems. 1. The Pilot board is behind the CCM in the AC 300 XT and all Ultra-Cut XTs or on the upper section of the second inverter module in an AC 200 XT and has two LEDs. The first one, D11, a green LED, indicates the board has bias power and should be on all the time when the unit is turned on. The second LED, D2, also green, is on when the pilot is enabled, that is the pilot IGBT switch is turned on.
ULTRA-CUT 100 XT 104 Transfer Lost Arc transferred to metal for at least 50 ms. then went out. Causes for 104 code: • Cut demand set much lower than recommended for torch parts, i.e. 100A consumables in torch but cut current set for 30 or 50A (or zero). Current may be too low to keep arc on. • Torch standoff too high for cutting process being used. • Plasma gas flow too low due to a leak somewhere between the plasma regulator or the DPC 3000 and the torch. Check for leaks.
ULTRA-CUT 100 XT • Cut current set too low for torch parts being used. Pilot current is set based on cut current. If cut current is too low pilot current will be lower and may not transfer at the height used for higher current consumables. • Preflow pressure/flow too low. • Remote Analog Current Control switches set wrong can also result in lower than normal pilot current setting. See section on these switch settings under section for code 104. • Defective work lead current sensor circuit.
ULTRA-CUT 100 XT 109 Part Process not Configured. This represents a status, not a fault. This is used with the DFC 3000 only. It means the operator hasn’t loaded the cutting process from either the TSC 3000 or from the program embedded in the cutting table CNC controller. The solution is to load a process. The code will continue to be displayed until the CNC Start is applied at which time the code will clear. 110 Not Used. This is one of the reserved codes from the earlier product.
ULTRA-CUT 100 XT PWR Present • When power is first applied to the inverter (contactor closed) CCM checks for presence of the +12V bias on the Inverter Control and Fault board. If not present will set codes in the range of 265-270. IS_ID (A, B, or C) VAC_SEL (A or B) 201 Missing AC Phase The System Bias Supply board contains circuits to detect if one of the 3 AC input phases is missing. Along with that it can also detect if the AC voltage is too low or too high.
ULTRA-CUT 100 XT 202-204 Not used. Reserved codes from the earlier product. 205 DC Output Low DC output (voltage) low means one or more inverter sections are enabled but the output voltage is below a preset voltage. Shortly after receiving the Start signal from the CNC, but before the end of preflow, both sections of IM#1 are enabled and CCM measures the power supply output voltage between negative (Torch) to positive (Work) at the output terminals.
ULTRA-CUT 100 XT Relay PCB • Relay board LED D12, Work Current Detected, will light if the current sensor signal exceeds 0.05V. If D12 is on, measure the sensor output signal at J1-3 with signal common on J1-1. This signal should be 0V +/- 0.04VDC. If greater than +/- 0.04VDC with no work lead current, the sensor is defective. If the signal voltage is within the limits and D12 is on, then the Relay board is defective.
ULTRA-CUT 100 XT Relay Board or CCM If D11 on the Relay PCB is still on after the previous tests, measure the output to the CCM on the 40 pin ribbon cable (Relay J4 to CCM J23) between pins 23 (-) and 25 (+). It should be less than 0.1V. If not, the Relay board is bad. If voltage is zero then the CCM is defective. 2. 208 code comes on during preflow: IM#1 and the Pilot board are enabled near the end of preflow.
ULTRA-CUT 100 XT Possible cause for work current to low. • All the above plus a short to chassis caused by: o User installed equipment connect behind the current sensor that makes a connection to work or earth allowing current flow to bypass work sensor. o Inverter + output shorted to chassis. Troubleshooting: 1. For current too low due to a short disconnect work lead from back of unit. Check for continuity to chassis, there should be none. Inspect for incorrectly connected user equipment. 2.
ULTRA-CUT 100 XT 224 Inverter 1 not found. There must be an inverter connected in the 1st section, 1A, to be able to pilot. During the power up sequence, before power is connected to the inverters, the CCM does a continuity test to see if its section 1A ribbon cable (J31 on CCM) is connected. Causes & troubleshooting: • As this is just a continuity test it is very unlikely to be a bad inverter. Most likely a poor connection or defective ribbon cable.
ULTRA-CUT 100 XT Troubleshooting: 1. If System Bias board has either the wrong jumper or is defective it will call out the first inverter section, code 231, because all the inverters won’t match the incorrect signal and 1A is checked first. a. For the jumper Wire #48 should be connected from J61-1 to: i. J61-2 for 208-230 VAC ii. J61-3 for 400 VAC iii. J61-4 for 480 VAC Check for proper connection and continuity. b. System Bias may be defective reporting the wrong voltage ID.
ULTRA-CUT 100 XT 238 System Bias voltage identification is invalid. At power up the System Bias board measures the input voltage and sends signals to the CCM indicating which range of voltage it has detected. See section 231-236 for details. If one of the 3 voltage ranges, 208-230V, 380415V or 480V isn’t identified then both ID signals are high resulting in an invalid signal. Possible causes: • Unit is connected to voltage below the 208-230V range or above the 480V range.
ULTRA-CUT 100 XT Troubleshooting: 1. If the fault is L239 applying START will clear the fault unless it becomes active again. An occasional problem may be due to incoming voltage swells (voltage increases lasting from ½ cycle to as much as a minute). Usually, if the plasma is at fault the problem will be present all the time. 2. It is unlikely that an open connection on the J61 jumper would result in a 239 fault, more likely to be a Voltage Mismatch fault.
ULTRA-CUT 100 XT 4. If the incoming voltage is OK and the problem persists it may be System Bias, CCM or connection between J62 and J27. a. If the incoming voltage is OK and D14, ACV LOW, is on or the signal “AC V LOW b” on J62-10 is “high” (about 24VDC, relative to TP1 or J62-8 ) the System Bias board is defective. b. If D14 is not on and signal “AC V HIGH b” on J62-10 is “low” (about 10-14VDC, relative to TP1 or J62-8) then System Bias is OK and problem is in the CCM. c.
ULTRA-CUT 100 XT 253-258 Inverter Over Temperature. Each inverter section (IS) contains one or more temperature sensors. If any of these detect an over temperature condition it activates the signal “OVERTEMP_FLT going to the CCM over the inverter sections ribbon cable. Inverters semiconductors (transistors and diodes) are liquid cooled. Anything that increases the coolant temperature too high can cause overheating of the inverters.
ULTRA-CUT 100 XT Troubleshooting: 1. If room temperature exceeds 40 deg C, cool the room, or operate the unit at reduced duty cycle or lower current. 2. Confirm that air is exhausting from opening in the right side panel. As the fan(s) are behind the radiator it’s hard to see them to confirm they are turning but perhaps you can use an inspection mirror. Be careful not to get the mirror or your hands into the blades. 100 & 200A units have 2 smaller fans, 300 & 400A have one larger one. 3.
ULTRA-CUT 100 XT 3. On the Relay board D22, CONTACTOR ON LED (green) next to relay K1 lights if K1 is being told to energize. a. If it’s on check for 120 VAC between J8-1 and J8-9. If present the relay board is OK. b. If D22 is on but 120 VAC is not present at J8-1 and J8-9 (make sure meter is set for ACV) then the relay board is defective. c. D22 is not on, go to the 40 pin ribbon cable test connector and measure voltage on pin 17 (relative to TP1 on either the Relay board or the CCM I/O Board).
ULTRA-CUT 100 XT Troubleshooting: 1. Check that the fiber-optic cable is fully plugged in to both sockets. Clean the cable ends with a soft cloth and blow out the sockets with air. 2. Check gas control cables. If any of the gas control cables are not connected there will be no communication as there will be no power to the control. This may show up as a 301 or 501 code.
ULTRA-CUT 100 XT 307 Gas Control returns wrong command sequence. Firmware incompatibility. Consult factory for latest firmware update. Possible electromagnetic interference from the Arc Starter; inspect grounding; bonding; and isolation. 308 Mismatch between the CCM and gas control type. The Auto-Cut XT CCM is designed to work with the GCM 1000 (AC 300 XT) or the built in gas control of the AC 200 XT. Attempting to use a GCM 2010 or DFC 3000 Auto Gas Control on an Auto-Cut will result in a 308 code.
ULTRA-CUT 100 XT 401 Coolant Level Low The coolant reservoir (tank) has a normally open (tank dry) float type level switch, LS1. When the coolant level in the tank is below about ½ full this fault will signal the need to add coolant. It will not stop the process during a cut but will instead show the 405 fault as a warning. As soon as the cut stops it will not allow another to start until the issue is corrected.
ULTRA-CUT 100 XT Troubleshooting: 1. First note whether the fault is an “E” meaning it’s currently low or an “L” meaning it was low but isn’t now. Flow that remains low could indicate a failed component or a blockage such as clogged filter or pinched hose. It also means you should be able to measure the flow to determine if it is really low or the sensor has a problem. 2. First recycle power. If flow is still low or a component is defective the code should change to 404.
ULTRA-CUT 100 XT 2. Fans are powered by 230 VAC. The 230 VAC for the fan(s) is switched by the MC2 control relay (except the AC 200 XT where the fan(s) is powered directly from the T1 transformer at J13). To J70-3 1 TP1 2 TP2 J13 3 To test fan relay jump TP2 to TP1.
ULTRA-CUT 100 XT Reasons for 404 faults (Coolant not flowing): • In new installation, coolant has not circulated all the way through the leads. Add more coolant if necessary and recycle the power to restart the pump and 4 minute timer. • Coolant supply & return leads are reversed, check valve in torch coolant return prevents reverse flow. • Torch parts removed or are wrong style so torch check valve shuts off flow. • Torch coolant tube damaged or the tube extension (if required) missing.
ULTRA-CUT 100 XT d. If jumping TP3 to TP1 does not turn the fans on then the Relay board or the 40 pin ribbon cable pin 13 is at fault. TP3 1 2 J13 3 230 VAC from T1 To test Pump relay jump TP3 to TP1.
ULTRA-CUT 100 XT Coolant flow is correct but system doesn’t detect it due to defective components: • Defective or disconnected FS1 flow switch. • Relay board. • CCM. Flow Switch FS1 disconnected – FS1 comes with wire about 1 ft. long and a connector that connects to a 3 wire harness. This could be disconnected at either end, J74 or J5 on the relay board. Defective FS1– The flow switch, normally open, closes when flow through it exceeds 0.75 GPM, could be open.
ULTRA-CUT 100 XT Troubleshooting: 1. GCM 1000XT (also called a Basic Gas Control) does not use CANBUS (fiber-optic) communication. A jumper in the gas control connector J56 pins 8 & 9, gives the signal “Basic ID” telling the CCM not to expect any CANBUS. If somewhere this circuit is open, in the Gas Control cable, connector pins, connection from the rear panel GCM connector, J55, to the CCM (J26) CCM will expect to see a CANBUS connection and report this error because there is no CANBUS connected. 2.
ULTRA-CUT 100 XT The black end of the fiber cable is inserted into the transmitter which is the gray housing on the PCB. The other end of the transmitting fiber is blue and goes into the receiver with the black housing. A few seconds after power is turned on and when the pump has started up the CCM will try to transmit continuously for a while. You can unplug the fiber from the CCM and should see the transmitter red LED on the CCM PCB blinking.
ULTRA-CUT 100 XT 613 USB Log File Creation Fault When updating the CCM, DMC and DPC programs from a flash drive, a log file called CCM_LOG.TXT is created on the flash which reports on the results of the update including any problems. If that log file can’t be created you get 613. This may be a problem with the flash drive having too many other files on it or a problem with its format that may not be compatible with the CCM. 1. Try putting the update files on a different, preferably empty, flash drive. 2.
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ULTRA-CUT 100 XT APPENDIX 25: PUBLICATION HISTORY Cover Date Rev Change(s) April 29, 2013 AA First issue May 21, 2013 AB Updated with new RAS 1000 XT info per ECOB2428 July 2, 2013 AC Jan. 16, 2014 AD Updated section 3 with information about V-D Board installation for height controller per ECOB2488 Updated many items, text and art throughout the manual. Added Advanced Trouble shooting and plumbing diagrams to Appendix per ECOB2552.
THE AMERICAS Denton, TX USA U.S.
