Owner manual

ULTRA-CUT 100 XT
A-48 APPENDIX Manual 0-5272
102 Pilot Ignition Failure
Code102isactivatedwhenthereisnopilotcurrentafter15secondsofring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.
Possible Causes for 102 code:
• NoHFtothetorchduetobrokenpilotwireconnectioninthetorchleads.
• NoHFtothetorchduetodefectiveArcStarter.
• ArcStarternotreceivingpower.
• Pilotboardnotenabled.
• Pilotboarddefective.
• Relayboarddefective.
• Workleadcurrentsensordefective.
• CCMdefective.
Troubleshooting:
1. DetermineiftheproblemisalackofHF(ArcStarter)orifit’sduetothepilotcircuit.
Auto-cutXTArcStarter(insidemainchassisforAC200XT;intheGCM1000XTforAC300XT)hasopenspark
gap.Ifthesparkgapisringitisreceivingpower.AfewearlyUltra-CutXTunitswereshippedwiththe
RAS1000 Arc Starter. Troubleshoot them the same as the GCM1000XT below. Most Ultra-Cut XT units now
usetheRAS1000XTArcStarterwhichdoesn’tuseasparkgapandiscoveredinthenextsection.
Arc starter with Spark Gap (Auto-Cut)
No spark at spark gap
1. Checkthatsparkgapissetfor0.062”+/-0.002”.Ifgapistoohightheremaynotbeenoughvoltagefrom
T1torethegap.
2. Checkforpowertothehighfrequency(HF)transformer(T2inAC200XT;T1inGCM1000XT)duringthe15
seconds following prefow (ignition phase). Arc starter power comes through the rear panel circuit breaker
CB4,makesureitisn’ttripped.
a. FortheGCM1000XT(AC300XT)120VACfromJ59-7&9onthepowersupplyrearpanelconnectsto
J58-7&9ontheGCM1000XT.Seediagrambelow.FromJ58ontheGCM1000XTitgoesdirectlytothe
linelterandpassesthroughtheltertoprimaryofT1.Duringtheignitionphase,checkfor120VAC
ontheT1sideofthelinelter.
b. For AC200XT the HF transformer T2 has insulated Faston (also known as push on , stab-on, spade, etc.)
on its primary wires. Disconnect these and measure for 120 VAC on the harness side during ignition
phase.
3. If120VACnotpresentgotostep4.
a. If120VACispresentandstillnospark,T1(T2inAC200XT)maybebad.Removepowerandmeasure
resistance of T1 (T2 in AC200XT) primary and secondary. The primary should measure about 3-7 ohms.
Thesecondaryabout25-35Kohms.IfeithermeasurementnotcorrectreplaceT1(T2inAC200XT).
b. IfT1(T2inAC200XT)measuresOK,checkforshortedcapacitorsC1-C3(veryunlikely).
4. No120VACtoT1(T2inAC200XT)primaryduringtheignitionphase(15secondsfollowingPreow)check
for120VACintothelinelter(GCM1000XTonly).Ifit’stherereplacethelter.If120VACisn’tpresentat
thelinelterorifthisisanAC200XTgotostep5insectionEitherArcStarterbelow.