Owner manual

ULTRA-CUT 100 XT
A-58 APPENDIX Manual 0-5272
2. 208codecomesonduringpreow:
IM#1andthePilotboardareenabledneartheendofpreow.Tohaveunwantedcurrenttheremustbeapath
(short)forcurrenttoowbetweentheinverternegativeoutput(negativecable/torchelectrode)andthePilot
return/tipbeforethearcstarterisenabledforpilotignition.
Possible causes are:
• Shortbetweenelectrodeandtipduetomismatchofconsumables,damagedconsumablesorforeignmat-
ter between tip and electrode. An electrode at the end of its life may lose material that can short between
electrode and tip.
• Defectiveorincorrectlyinstalledusersuppliedequipmentsuchastorchheightcontrolsthatmakecon-
nections to power supply output.
• Shortbetweenpowersupplynegativeoutputcableandpilotcable.
• Shortedtorchbody.
Troubleshooting:
1. Removeandinsulate(mayhavevoltageonit)thepilotcablefromtherearoftheunit.Attempttopilot.If
no208codeshows,itconrmsproblemisoutsidethepowersupply.
2. Removeandcheckconsumablefordamage,cleanlinessandmissing(gasdist,etc.)orwrongcomponents.
3. Disconnect user supplied equipment and see if fault still exists.
4. InspectArcStarterforbroken/disconnectedwiresorburntcomponents.
5. Inspect inside the torch mounting tube for shorts.
6. Ifallelsefailsdisconnectthepilotwirefromthebackofthetorchhead.Insulateitwellorkeepitaway
fromanymetal,itmayhaveHF(highfrequency)onitwhenyoutrytostart.Trytostart,ifthe208isgone
now the torch head is shorted.
209 Not used. Reserved codes from the earlier product.
210–211 Output current, measured by the work lead current sensor, is too high (210) or too low (211).
These are warnings and do not shut down the process but may explain poor cut quality or poor parts life.
Individualinvertersectionshavetheirowncurrentsensorsandtheworkleadhasacurrentsensorwhose
signalshouldequalthesumoftheindividualinvertersections.Eachsectionissettooutputacertaincurrent
basedonits”demand”signal.Ifthecurrentdiffersfromthetotal“demand”,sumoftheindividualdemands,
theindividualsectionsarecheckedtodetermineiftheiroutputiscorrectcomparedwiththeirdemandsignals.
Iftheindividualsectionsarecorrectbuttheworkcurrentsensorsignaldiffersfromthetotaldemandbymore
than16%code210(toohigh)or211(toolow)isdisplayed.
Ifanindividualinvertersectionwasfoundtobeinerrorcausingthetotalcurrenttobewrong,adifferentcode
would be displayed in the range of 212 to 223 depending on which section was at fault.
Possible causes for work current signal too high:
• HCT1WorkCurrentSensor
• RelayPCB
• CCM
Possible cause for work current to low.
• Alltheaboveplusashorttochassiscausedby:
o User installed equipment connect behind the current sensor that makes a connection to work or earth
allowingcurrentowtobypassworksensor.
o Inverter+outputshortedtochassis.