Owner manual

ULTRA-CUT 100 XT
Manual0-5272 APPENDIX A-43
section(INV1A,INV1B,etc.).A100AunitwillonlyhaveribboncablesinJ31&J32;a200AwillhaveJ31-J33lled
withtheothersempty.300AwillhaveJ34missingwiththeotherslled.
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.
System Bias supply PCBispoweredfromthe3phaseACinputandworksfromabout150Vtoover600Vcovering
allthenormalvoltageranges.Itcanoperatefrom2phases(singlephase)soitstillprovidesbiaspowerandcan
reportafaultifaphaseismissing.Thesupply’soutputis24VDCwhichpowerstheRelayboard,theDisplay,the
Pilot board and the 2 boards in the CCM. System Bias also contains circuits to detect missing phase and determine
iftheACvoltageiswithinthecorrectrange,nottoohighortoolow.ItalsosignalstotheCCMwhatvoltagethe
unitisconguredfor.TheSystemBiassupplyPCBincludesarelay,K1,whichonlyappliesvoltagetoAuxiliary
transformer,T1,primarywhentheinputvoltageisinthecorrectrange.
The Relay and Interface PCB Accepts and distributed the output of the Aux Transformer. It has relay to control
the pump, fans, input contactors, the Arc Starter and the Inrush relays. A circuit on the Relay board accepts input
fromtheWorkcurrentsensor,HCT1,andPilotcurrentsensor(onthePilotPCB)andsendstheEnablesignaltothe
PilotboardsIGBTswitchesviatheJ3toJ42ribboncable.OtherinputsontheRelayboardincludethosefromthe
NegativeTemperatureCoefcient(NTC)ambientandcoolanttemperaturesensors.Coolanttanklevelswitchand
coolantowswitch,whichdeterminesiftheowisabovetherequiredminimumrate,alsosendsignalstotheRelay
Board.Ultra-CutunitsincludeaowsensorwhoseoutputtotheRelayBoardisaseriesofpulseswhosefrequency
indicatestheowrateandcandetectthepresenceofgasbubblesinthecoolant.AllthesesignalspasstotheCCM
viaa40conductorribboncablegoingtotheCCMI/Oboard.
The Display BoardHasLEDsforAC,TEMP,GAS&DC.Italsohasa4digit7segmentdisplayforstatusandfault
information.ACLEDindicatestheinputcontactorstotheinvertershavebeencommandedtoclose,butdoesnot
meantheyareclosed.TEMPmeansoneormoreinvertersorthecoolanthasexceededtheallowedtemperature.
GASmeansgasisowingandcoolantowisOK.DCmeanstheinvertersoutputvoltageisabove60VDC.
Therstdigitofthe7segmentdisplayshowstheletter,“C”;“E”;“L”orisblank.Duringtheinitialpowerupse-
quencetheletter“C”followedbytheother3digits,indicatestheCCMcoderevision.StatusorFaultcodeswhich
mayoccurduringthepowerupsequenceoranytimethereafterareprecededbyletters“E”foranactivefaultor
“L”fora“latched”or“last”faultthatstoppedtheprocessbutisnolongeractive.WhenthereisnoFaultoractive
Statuscode,theoutputcurrentsettingisdisplayedwiththerstdigitblank.IfthesystemisanUltra-CutXTusing
theAutoGasControl,DFC3000,thedisplaywillshow“0”untilaprocesshasbeenloaded.Ifthereisafaultor
other status showing the display will alternate between the current setting and the fault.
The Pilot PCB contains a pair of parallel IGBT transistors working as an electronic switch to connect and disconnect
thetorchtipfromthe1stinvertersection.
WhenthepilotelectronicswitchisclosedandthepilotisignitedbytheArcStarter,currentfromthe1stsection
owsbetweenelectrodeandtip.Thenastransferbegins,asmallcurrentfromthe2ndinverterowsfromelec-
trodetowork.Whentransferisdetectedthepilotswitchisopenedandcurrentfromthe1stsectionisfreetoow
to the work through the diode which is also on the Pilot board. The Pilot PCB also contains a pilot current sensor
todetectandmeasurethelevelofpilotcurrent.Additionalresistor/capacitor(RC)circuitsonthepilotPCBassist
and stabilize the pilot and transferred arcs.
Art # 12301