Owner manual

ULTRA-CUT 100 XT
A-70 APPENDIX Manual 0-5272
401 Coolant Level Low
Thecoolantreservoir(tank)hasanormallyopen(tankdry)oattypelevelswitch,LS1.Whenthecoolant
levelinthetankisbelowabout½fullthisfaultwillsignaltheneedtoaddcoolant.Itwillnotstoptheprocess
duringacutbutwillinsteadshowthe405faultasawarning.Assoonasthecutstopsitwillnotallowanother
to start until the issue is corrected.
Possible causes:
• Coolantislow
• Levelswitchdefective,disconnectedorinstalledupsidedown.
• RelayboarddefectiveorJ7disconnected.
• CCMdefective.
Troubleshooting:
1. Conrmvisuallythatthelevelswitchoatisbelowthecoolant,ifnotaddmorecoolanttothetank.
2. CheckJ7ontheRelayboard.
a. IfproperlyconnectedremoveJ7andcheckcontinuitybetweenpins2and4(pins2&3ofJ71onthe
switch itself).
b. IfnocontinuityatJ71ontheswitch,ifitisstillopen,replacetheswitch.
3. IftherewascontinuityatJ7plugitbackinandmeasurevoltageonpin9ofthe40pinribboncable(Relay
boardJ4toCCMJ23).CommonisTP1oneithertheRelayortheI/Oboard.
a. Pin9shouldbehigh,about+10to+15V.Ifit’snottherelayboardisbadortheribboncableisshorted.
b. Totesttheribboncableremovebothends,J4ontheRelayboardandJ23ontheI/Oboardandmeasure
from pin 9 of the ribbon cable to both pin 8 and pin 10 of the cable. Both should be open. If not replace
theribboncable.Otherwiseit’stheRelayboard.
4. Ifpin9ofthe40pinribboncablewashighinstep3.atheCCMisdefective.
402 Low coolant Flow
TheowswitchFS1ispositionedinserieswiththeradiatorwhereitmeasurestheowreturningfromthe
torch.Theowswitchservestwopurposes,onetoinsurethereisadequateowforcoolingneedsandtwo,
itinsuresthetorchconsumablesareinplacesothenegativeoutputofthepowersupplyisnotexposed.This
functioniscalled“PartsinPlace”orPIP.Theoutputcannotbeenabledifpartsarenotinplace.Thenormally
openowswitchrequires0.7GPM(2.65liter/min.)+/-about10%toclose.
Whenthesystemisturnedonandenabledandfailstoachievepropercoolantowafter4minutescode404
willbeset.Gettingcode402meansitinitiallyhadenoughowbutsomethinghascausedtheowtobere-
duced.Listedherearethingsthatmighthappenduringcuttingtocausereducedow.Forothercauseslike
componentfailuresrefertocode404.
Possiblecausesforlowow:
• Coolantlterclogged.
• Flowbypassvalveincorrectadjustmentordefective.Callthefactoryforinstructions.
• Defectivepump.
• Coolantsupplyorreturnhosetwistedorpinchedreducingow.
Ifcoolantowisnotlowbutcodeisbeingset,possiblecauses:
• Flowswitchdisconnectedordefective.
• RelayPCB.
• CCM.