Owner manual

ULTRA-CUT 100 XT
Manual 0-5272 APPENDIX A-53
• Cutcurrentsettoolowfortorchpartsbeingused.Pilotcurrentissetbasedoncutcurrent.Ifcutcurrent
is too low pilot current will be lower and may not transfer at the height used for higher current consum-
ables.
• Preowpressure/owtoolow.
• RemoteAnalogCurrentControlswitchessetwrongcanalsoresultinlowerthannormalpilotcurrent
setting.Seesectionontheseswitchsettingsundersectionforcode104.
• Defectiveworkleadcurrentsensorcircuit.Iftransferisnotsensedcutcurrentremainsatthelowerstart-
inglevelandpilottimer(85ms.or3sec)willtimeout.
107 Not Used. This is one of the reserved codes from the earlier product.
108 Tip to Electrode Voltage Fault
ThePilotvoltage,measuredbetweentipandelectrodevarieswithdifferentcurrentandgastype,owrateand
consumable design.
Oncethearcistransferredthepilotswitchopensleavingthetipbasicallyoating.Thevoltagethenisdeter-
mined by how much of a cold gas barrier surrounds the arc. Too much current or too little gas and the arc
startstocontactthetipreducingthevoltagedifferencebetweentipandelectrodeandleadingtoadoublearc
that destroys the consumables.
TheCCMmeasuresbothelectrodeandtipvoltageandcalculatesthedifference.Ifthedifferencebetweentip
andelectrodeisfoundtobelessthanaminimumvoltagewestopcuttingandsetafaultforthe108code.The
normaltiptoelectrodevoltageisdifferentfordifferentprocessessotheminvalueforeachprocessisembedded
in the cut charts when using the DFC 3000 or in the CCM code if using the GCM 2010 or for Auto-Cut XT gas
controls (GCM 1000XT or the built in one in the AC 200 XT).
New for the Auto-Cut XT units is a switch on the rear of the power supply that needs to be set according to the
plasma gas. If using an oxidizing gas (O2 or Air) set it as indicated for those gasses (left if AC 200 XT or up for
AC300XT) or if using a non-oxidizing gas (N2, H35 or other inert gas) set it to the right or down as indicated for
thosegastypes..Thisswitchadjuststherangeofvoltageforthegastypetobetterprotectthetorch.Awrong
setting could result in false setting of the 108 code.
During piloting and ramping (the time from transfer until the current reaches full cut current), we lower the
allowedtiptoelectrodevoltagetoabout80%ofthatallowedduringcuttingbecausethecurrentislowerand
thegasowislowerduringthattime.
Causes for 108 code:
• GasFlow/pressuretoolowforconsumablepartsbeingused.
o IfgassourcepressureisnotwellregulateditispossiblepressuremaybeOKattimesanddroptoo
low at other times such as during a cut.
o Aleakofthepreow/plasmagasafterthepressure/owcontrol(GCM2010,DPC,GCM1000XT)
canreducethepressure/owtothetorchbecausesomeifitisbypassingthetorch,whileseemingto
haveenoughpressure/owatthegascontrol.
• Cutcurrentsettoohighforconsumablepartsbeingused.
• WithDFC3000afaultycomponentwouldbeexpectedtosetafaultcodeineithertheDPCorDMC.
However,ifawrongprocessisselectedwhichdoesn’tmatchtheconsumabletypeorifusingacustom
process where pressure has been set too low or current too high that could cause 108 without setting any
faults in the DFC 3000.
• Abrokenpilotwireinthetorchleadmakingintermittentcontactcanallowpilotingorsometimesthe
torchcantransferusingonlyHF(highfrequency).Thisintermittentconnectionwillupsetthetipvoltage
measurement and can result in the 108 code. Symptom is - it may cut for a short time then fault. Check
foranopen/brokentorchleadpilotwire.
• Physicallyshortedtorchbodybetweenanode(tip)andcathode(electrode).
The fault resulting in a 108 code is measured while cutting. It is more likely a shorted torch body, depending
on the resistance of the short, it will set code 208 (Unwanted Current) as that is measured prior to starting cut
However,itmustbeconsideredasalastresort.