Owner manual

ULTRA-CUT 100 XT
Manual 0-5272 APPENDIX A-59
Troubleshooting:
1. For current too low due to a short disconnect work lead from back of unit. Check for continuity to chassis,
there should be none. Inspect for incorrectly connected user equipment.
2. If no shorts were found or if fault was current signal too high see section on code 207 for detailed description
of the power and signal paths for the work lead current sensor.
3. In the section on code 207 for Relay PCB it describes measuring the work current sensor signal when there
isnocurrent.Thesignalshouldbezeroandweassumeitisorelseyoushouldhavegottenthe207code.If
thezerocurrentsignaliscorrectbutthereisanerrorwhilecutting,measurethesignalonthe40pinribbon
cable(RelayboardJ4toCCMJ23)pins27(-)&28(+).Thesignalvoltageshouldequalthecuttingcurrent
*0.0266.Forexamplefor100A(100*0.0266)=2.66V.
• IfthissignaliscorrectthefaultistheCCM
• Ifit’snotcorrecttheerrormaybeintheRelayboardorsensor.Followtheinstructionsforcode207to
measurethevoltagetoandsignalfromthecurrentsensoratJ1ontheRelayboard.Thesignalvoltage
shouldequalthecuttingcurrent*0.0133.Forexamplefor100A(100*0.0133)=1.33V.For400Awouldbe
400*0.0133=5.33V.
• IfpowerandsignalarecorrectRelayboardisfaulty.IfnotcorrecttheHCT1workcurrentsensorisbad.
212-223 Incorrect output from an inverter section.
Workcurrenthighorlowduetowrongoutputfromoneinvertersection.Individualcodeindicateswhichsection.
Causes may be:
• Thenamedinvertersectionoutputconnector,J102AorB,isnotpluggedinorisdamaged.
• Ribboncablewithbadconnection,perhapsnotfullylockedinplaceateithertheinverterortheCCM.
• Defectiveinvertersection.
Troubleshooting:
1. Ifitreportsthecurrentofanindividualinvertersectionistoohigh,theproblemistheinverter.
2. If the report is current too low (which included no current) check the connections.
3. Theribboncablefortherstinvertersection(IM#1A)mustconnecttothatsectiononlybutifthereare2
additional sections, unit is 200A or greater, swap the ribbon cable going into those sections.
a. Ifitnowreportsadifferentsectionasbad,theonewhosecablewasmoved,thentheoriginalsectionwas
bad.
b. If it still reports the original section the ribbon cable or the CCM is bad (unlikely).
c. Swap both ends of the ribbon cable with one next to it. If still reports the original section then the problem
iswiththeCCMifnotthenit’stheribboncable.
4. Ifit’stherstinvertersectionorit’sa100Aunitsothere’snootherinvertertoswapcableswith,replacethe
inverter.
Additionalhint:InvertercontrolPCBshaveagreenLED,D24,PWMON,thatlightswhenthatsectionisenabled
andhasademandsignal.TheLEDbrightnessisrelativetotheoutputsomaybeverydimifoutputislow.If
thatLEDdoesn’tlightmayindicateadefectiveinverter(controlboard).