Manual

ULTRA-CUT 100 XT
Manual 0-5303 APPENDIX A-77
Coolant flow is correct but system doesn’t detect it due to defective components:
• DefectiveordisconnectedFS1ow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owswitch,normallyopen,closeswhenowthroughitexceeds0.75GPM,couldbeopen.
Easiest place to measure the switch is at the J5 harness connector that plugs into the Pilot board. Assuming you
have previously determined flow is sufficient, disconnect J5 from the Pilot board, start the unit so the coolant
is flowing and measure continuity between the 2 pins of J5.
• IfthereisnocontinuityeithertheswitchisopenortheharnessbetweenJ5andJ74atFS1isopen.
• IfthereiscontinuitybetweentheJ5pinswithsufcientcoolantowtheneitherrelayboardortheCCM
is faulty.
• Relayboard
• CCM
405 Low Coolant Level Warning
If the coolant level becomes low while cutting it is not necessary to immediately stop the cut as there is still
enough coolant to continue so we display E405 as a warning. Once the cut stops if the coolant is still low the
display changes to E401 and prevents starting another cut. Refer to the section for code 401 for troubleshooting.
406 Coolant Flow Low Warning
Ultra-Cut XT units, in addition to a coolant flow switch, include a turbine flow sensor FL1, referred to in the
plumbing diagram as a “bubble sensor”, with a pulse output that accurately measures coolant flow and in ad-
dition can detect the presence of gas bubbles in the coolant. Gas bubbles from leaking seals in the torch or hose
fittings have been proven to reduce consumable life. This code is a warning, it does not prevent cutting but if
it persists the cause should be investigated.
407 Coolant Overheated due to High Ambient
As described in the section for codes 259-264 the CCM measures the ambient temperature using sensor TS2 and,
like with the inverters, if the coolant is over temperature we first check the ambient and if it is above 40 deg C
we attribute the cause of the coolant over temperature to high ambient and of course the solution is to lower
the ambient or reduce the duty cycle.
The other possibility is the ambient measuring circuit is defective and the coolant is overheated. In that case
you would have to go to the section for code 403 to find the cause of the coolant overheating and go to section
for codes 259-264 to determine what is wrong with the TS2 circuit.
The 5 Group relates to CANBUS (Fiber optic) communication errors
501 CANBUS Failure to Acknowledge fault.
The CCM communicates with the gas controls (except GCM 1000 XT) over a fiber-optic cable using the CANBUS
protocol. The CCM is looking for a signal from the gas control (GCM 2010 or DMC) over the fiber-optic link.
No signal has been detected. Communication with the DPC which is relayed through the DMC sets a different
code, 301, if there is a problem with it.
Possible causes:
• GascontrolisGCM1000XT(Auto-Cut300XT)whichhasnober-optic,withBasicIDproblem.
• CANBUS/Fiber-opticproblemtoeithertheGCM2010ortheDMC(partofDFC3000).
• ControlCabletoDMCorGCM2010defective.
• Gascontrol(DMCorGCM2010)mainPCBblownfuseordefective.
• DMCpowersupplyPCBblownfuseordefective.
• CCMdefective.