Owner manual

ULTRA-CUT 100 XT
A-42 APPENDIX Manual 0-5272
Appendix 23: 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mod-
ules(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. An IM with one section is con-
sideredtobea½or“partial”modulewiththeupperor“B”
section missing. ½ modules are used with the 200A & 300A
power supplies and will always be in the middle position.
IMswith2sectionsareconsideredtobe“full”modules.
Eachinvertersectioncansupplyupto67Abutdoesnotdo
soinallcongurations:
A400Aunituses6sections.400A/6=66.67Apersection.
A300Aunituses5sections.300A/5=60Apersection.
A200Aunituses3sections.200/3=66.67Apersection.
A100Aunituses2sections.100/2=50Apersection.
Unit configurations.
WiththeexceptionoftheAC200XTallotherunitshavethe
same chassis with room for up to 3 IMs. The unused areas
haveblankpanelsllingthe emptylocationswhichare
requiredforproperairow.A100Asystemuses1fullIM;
200A uses 1 and ½ modules with a full module in the bottom
location and a ½ module in the middle position. A 300A
unit has full modules top and bottom with the ½ module
in the middle location. The AC 200 XT has only the bottom
and middle locations for IMs. An internal Arc Starter and
Gas Control are located in the place of the 3rd or upper IM.
Inverter module cooling.
Thepowersemiconductorsoftheinvertermodulesareliq-
uid cooled allowing us to get more power in a smaller area
and at lower cost. Each IM has a liquid cooled heatsink or
“coldplate”sharedbythe2invertersections.Themagnetic
components, transformers and inductors, are air cooled and
mounted on the back side of the IMs where they are exposed
tohighvolumesofairowfromthecoolingfanswhoseair
also cools liquid coolant in the radiator or heat exchanger.
It is important that lower right side panel be in place or the
airowwillnotbeproperforcoolingthemagnetics.
Inverter control.
Theinvertersectionsareoperatedas separateinverters
whose outputs are connected in parallel. They are controlled
independently from the Command and Control Module
(CCM)whichisthe“brains”ofthesystem.Eachinverter
section has a separate ribbon cable connected to it coming
fromtheCCMwhichhas6connectors,J31–J36correspond-
ingtotheinvertersections1Athrough3B.Theribboncables
arelabeledontheinverterendsasINVwiththenumberand
Art # 12299
Art # 12300