Owner manual

ULTRA-CUT 100 XT
Manual 0-5272 APPENDIX A-57
Relay PCB
• RelayboardLEDD12,WorkCurrentDetected,willlightifthecurrentsensorsignalexceeds0.05V.If
D12ison,measurethesensoroutputsignalatJ1-3withsignalcommononJ1-1.Thissignalshouldbe
0V+/-0.04VDC.Ifgreaterthan+/-0.04VDCwithnoworkleadcurrent,thesensorisdefective.Ifthe
signalvoltageiswithinthelimitsandD12ison,thentheRelayboardisdefective.
• IfD12isnotonandthe207codeisstillactive,eithertheRelayboardortheCCMisdefective.
CCM or ribbon cable
• Theworkcurrentsignalleavingtherelayboardisonthe40pinribboncable(RelayJ4toCCMJ23)pins
27(-)&28(+).Ifthevoltagehereexceeds0.1VDCwithnoworkcurrenttheRelayboardislikelydefec-
tive.Anotherpossibilityisinthe40pinribboncableeitherpin27or28isshortedtoanadjacentpin.
OtherwisetheCCMisdefective.
2. 207codeafterSTARTapplied(duringpreow):
• ShortbetweenpowersupplynegativeoutputandWorkcircuit.
• Shortbetweenpowersupplynegativeoutputandearthground.
• Defectiveorincorrectlyinstalledusersuppliedequipmentsuchastorchheightcontrolsthatmakecon-
nections to power supply output.
ShortsaremorelikelytocauseDCoutputvoltagelow(code205).However,iftheshorthasenoughresistance
itispossibletoshowcode207.Totest,removenegativeoutputcableandreapplyStart.If207codedoesnot
appear problem is a short somewhere outside the power supply.
User Installed Equipment
Foruserinstalledequipmenttocause207codeitwouldhavetobeconnectedontheoutput(totherear)ofthe
current sensors. To test, disconnect user equipment and apply CNC START. If code 207 is gone user equipment
wasdefectiveorconnectedincorrectly.
208 Unexpected current in Pilot Circuit
The Pilot board includes a current sensor to measure the pilot current. There should not be any pilot current
untiltheinvertersandthepilotboardareenabledandthearcstarterhasredtoignitethepilot.Pilotcurrent
orthesignalindicatingpilotcurrentshouldnotbepresentuntilthearcstarterhasred.
Unwantedcurrentsignalduetodefectivesensorordefectivecircuitboardswillmostlikelybepresentassoon
asthepowerupsequencecompletesandwillbeindicatedasanactivefault,E208.Anactualshortallowingreal
currenttoowinthepilotcircuitwillnotoccuruntiltheinverterandpilotboardareenabledneartheendof
preow.Thiswillresultintheinvertersimmediatelybeingshutoffanddisplayinga“last”or“latched”fault,
L208. An LED, D2, on the Pilot board lights when the Pilot Board is enabled.
1. 208 code before START applied:
• DefectivePilotboard(currentsensorcircuit).
• DefectiveRelayPCB
• DefectiveCCM
Pilot PCB
Pilotcurrentsignalisonthe10pinribboncable(PilotJ42,RelayPCBJ3)betweenpins8(-)and9(+).Withno
current,thesignalshouldbezero+/-0.05V.AlsotheRelayboardhasanLED,D11,“PilotCurrentDetected”,
which will light if the pilot current signal exceeds 0.15V. If the signal is not zero V.Pilot PCB is likely the cause.
Tobesure,disconnectthePilotboardribboncablefromtheRelayboardatJ3.IfD11goesout,thePilotboard
wasthecause.Doublecheckbymeasuringpin8&9again.Ifit’szeroV.now,thePilotboardisdefective.If
D11isstillonorpin8&9voltagestillhighchecktheRelayboard.
Relay Board or CCM
IfD11ontheRelayPCBisstillonaftertheprevioustests,measuretheoutputtotheCCMonthe40pinribbon
cable(RelayJ4toCCMJ23)betweenpins23(-)and25(+).Itshouldbelessthan0.1V.Ifnot,theRelayboard
isbad.IfvoltageiszerothentheCCMisdefective.