Owner manual

ULTRA-CUT 100 XT
A-68 APPENDIX Manual 0-5272
Troubleshooting:
1. Checkthattheber-opticcableisfullypluggedintobothsockets.Cleanthecableendswithasoftcloth
and blow out the sockets with air.
2. Check gas control cables. If any of the gas control cables are not connected there will be no communication
as there will be no power to the control. This may show up as a 301 or 501 code. Also if the cable is broken
ordefectivesuchthatthegascontrolisnotenableditmayhavepowerbutinthecaseoftheDMCorDPC
its fault light will blink error 101 while the CCM will only detect that there is no communication and it will
show 301 or possibly 501.
302 Gas Control communications reply fault
Communication has been established but Gas Control did not reply to a request from the CCM in the time al-
lowed.LikelycauseisFiber-opticproblems(seecode501)orifproblempersistsdefectiveGasControlmainPCB.
303 Gas Pressure fault
Gaspressurefaultsonlyshowupwhenyoutrytostartthetorch,notduringpurgingorsettingows.
WiththeAuto-Cut200XTandtheAuto-Cut300XT(GCM1000XT),thegaspressuresensorisonlyonthe
plasmagasandisinserieswithRun/Setswitch.A303codehereindicateseitherplasmagasmissingorvery
lowpressure,lessthan50PSI,orRUN/SETswitchisinSETposition.
StartingwithGCM2010revisionAGwemeasureinletpressureofbothplasmaandshieldgasattheinletof
thegasselectionmanifold.Ifpressureiseithertoolowortoohighitsets303code.Earlierrevisionshouldnot
display 303 code. GCM2010 will display which gas is the problem and its actual pressure. The pressure at the
point where it is measured should be in the range of 100-135 PSI. Exception is for shield gas if the Gas switch
is set to Pressure then the min pressure can be 85 PSI.
In the GCM 2010 Gas Control, on the main PCB, measure between test points TP1 (ground) and TP18 (shield)
andTP19(plasma)tomeasuretheoutputofthepressuresensors.Voltageshouldbebetween2.6Vto3.5Vfor
100-135PSI.Withshieldswitchsettopressurelowlimitis2.1V.Whichevergasisoutsidethoselimitswill
betheonecausingthefault.Rememberthepressuremaydropduringoperation,setthecode,thenrecover
displaying L303 when you are measuring it.
• Totestforfaultypressuresensororinadequategassupplywithtoomuchrestriction.OntheGCM2010
place the Mode switch to SET Plasma & Shield, turn the mechanical pressure regulators to max pressure
andcomparemechanicalgaugeswiththepressuredisplay.Ifthepressuredisplaydoesn’tapproximately
matchthegaugethesensorislikelydefective.Ifthegaugeandthepressuredisplaybothshowlowpres-
sure the supply to the gas control has too much restriction. Perhaps the hose is too long or too small.
304 Gas Control not ready
This is the normal code when the gas control is conducting a purge at start up or when the process is loaded
orchangedorwhentheplasmasystemhasbeendisabledandisreturnedto“Enable”.IfitisaGCM2010the
Mode switch may not be set to the RUN mode.
Code304combinedwith204&402whenthePlasmaEnableontheGCM2010gascontrolissettodisablecan
indicateafaultintheCCMI/OPCB.WhenswitchingbacktoEnabledthepumpwillnotrestartsocontinues
todisplay4-2indicatingnocoolantowing.
Normallythecodeduringadisableshouldbe101.CircuitsontheI/OPCBdetectthePlasmaEnableisdisabled
andsendsignaltothemicrocontrollerintheCCM.IfafaultintheCCMpreventsthatsignalfromgettingsent
tothemicrocontrolleritdoesn’tknowthesystemisdisabledsoitsetstheseother3codes.
305 Gas Control Protocol Error
Applicationerrororrmwareincompatibilityfault.Consultfactoryforlatestrmwareupdate.Possibleelec-
tromagneticinterferencefromtheArcStarter;inspectgrounding,bonding,andisolation.
306 Not Used. This is one of the reserved codes from the earlier product.