Owner manual

ULTRA-CUT 100 XT
Manual 0-5272 APPENDIX A-51
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rst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. The pilot is enabled near
theendofpreowtimeandremainsonuntilthetransferisestablishedorfor15secondsafterwhicha102
code is displayed. If D2 performs as expected you know the CCM, Relay board and work current sensor
are not causing the problem.
2. IfD11onthePilotboardisnotoncheckifthe10pinribboncableisconnectedbetweenthePilotboard(J42)
andtheRelayboard(J3).Measurefor24VDConthePilotribboncabletestconnectorpin2(+)andpin10
(-).If24VispresentandneitherD11norD2lightsthenthePilotboardmaybedefective.Pilotboardend
of the ribbon cable could also be the cause.
 WhatshouldhappenontheRelayboardisLEDsD12,workCurrentDetected&D11,PilotCurrentDetected
shouldbothbeoff.WhenyouapplySTARTafter2seconds(Preowtime)D7,PilotEnable,shouldcomeon.
Also D23, RF ON, should come on indicating the Arc Starter is being enabled. Normally D23 would only
be on for a moment until pilot current is detected. Then D11 would be on (and D23 off) until arc transfer or
pilot timeout (15 sec.) Since a pilot has not been detected D11 should not come on.
3. Iftheworkcurrentsensorisdefectiveitcouldbetellingtherelayboard(andthustheCCM)thatthereis
already a transferred arc so no need for pilot. D12, a green LED on the Relay board, is on if work current is
detected.IfD12isnotonskiptostep5,otherwisedisconnectJ1,theworksensorconnector.IfD12isstill
ontheRelayboardisdefective.
4. IfD12goesoutwhenJ1isdisconnected,plugitbackinandmeasurevoltagefromTP1(common)toJ1-1,
shouldbepositive12-15VDC.NowmeasureJ1-2,shouldbenegative12-15VDC.NowmeasureJ1-3,should
be0+/-0.05V.IfanyofthesearewrongdisconnectJ1andmeasureagain(ontherelayboard,notthehar-
ness).Ifstillwrongtherelayboardisdefective.Otherwiseit’stheworksensor.
5. PilotEnablesignalcomesfromtheCCMonpin15ofthe40pinribboncablebetweentheRelayboard(J4)
andtheCCM(J23).Itshouldbelow,lessthan2VrelativetoTP1oneithertheCCMI/OboardortheRelay
board.YoucanalsomeasurethisonTP11oftheI/Oboard.Ifthesignaldoesnotgolowwhenthepilot
shouldbeenabledattheendofpreowtimethentheCCMisprobablydefective.Youcanalsojumper
TP11ontheCCMI/OboardtoTP1,alsoontheI/O,toseeifthatwilllightD7,thePilotEnableLED,onthe
Relayboard.Ifitdoes,thatfurtherconrmstheCCMisbad.IfjumpingTP11toTP1doesnotlightD7on
the Relay board, the problem is likely the Relay board or possibly the ribbon cable.
103 Lost Pilot
Code 103 occurs when Pilot has ignited as sensed by the pilot current sensor on the Pilot board , but went out
onitsownwhileCNCStartisstillactivebeforethepilottimeout(85ms.or3sec.).
Possible causes:
• Preowgaspressuretoohigh,formanualgascontrolscheckcutchartsforpropersetting.ForDFC3000
check that the process is correct for the consumables.
• Cuttingcurrentsettoolowforthetorchpartsbeingused.Pilotcurrentlevelisautomaticallysetbasedon
the cutting current. A low cutting current results in a lower pilot current that may not be able to sustain
a pilot for higher current torch parts.
• RemoteAnalogCurrentControlswitchessetwrongcanalsoresultinlowerthannormalpilotcurrent
setting.Seesectionontheseswitchsettingsundernextsectionforcode104.
• Brokentorchpilotwire.
• DefectiveInvertermoduleputsoutlesscurrentthanit’ssetfor.