Owner manual

ULTRA-CUT 100 XT
Manual 0-5272 APPENDIX A-73
Reasons for 404 faults (Coolant not flowing):
• Innewinstallation,coolanthasnotcirculatedallthewaythroughtheleads.Addmorecoolantifneces-
saryandrecyclethepowertorestartthepumpand4minutetimer.
• Coolantsupply&returnleadsarereversed,checkvalveintorchcoolantreturnpreventsreverseow.
• Torchpartsremovedorarewrongstylesotorchcheckvalveshutsoffow.
• Torchcoolanttubedamagedorthetubeextension(ifrequired)missing.
• Nopowertopumpmotor.
• Pump/motorfailure.
• Bypassvalvedefectiveoradjustedincorrectly.
Damaged Coolant Tube
Coolanttubeincludesacheckvalveatitsupperend.Whencartridgewithconsumablesisnotinstalledthe
springloadedcoolanttubeisfullyextendedclosingthecheckvalvepreventingcoolantfromleakingout.
Whenconsumablesareinplacetheypushthetubeinward,openingthecheckvalve,allowingcoolanttoow.
Thecoolanttubehasngersontheendtocontacttheinsideoftheelectrodeandallowcoolanttoowthrough
theopeningsbetweenthengers.
Thengerscanbebentoverorbrokenifreasonablecareisnottakenwhenthecartridgeisnotinplace.Ifthe
ngersarebentorbrokenitshortensthetubesotheconsumablesmaynotpushthetubeinenoughtoopen
thecheckvalveresultinginnocoolantow.Thecoolanttubeassemblymaybereplacedseparatelyfromthe
torchhead.
Someconsumablesuseanextensiononthecoolanttube.Amissingextensionwillnotallowthecheckvalve
toopen.
Art # 12312
Coolant Tube Extension
Fingers
Internal Check Valve
No Power to the Pump Motor
Thepumpmotorispoweredby230VACcontrolledbytheMC3controlrelay.Duringthe4minutesafterturning
onpower,beforethe404faultcodeisdisplayed,measurefor230VACatthemotorconnectorJ16pin1topin3.
a.Ifthepumpmotorisnotgetting230VAC,measurefor24VAConthecoilofMC3.Ifpresentandtherelay
contactsaren’tclosedtherelayisdefective.Note,thecoilisrectiedsoyouwon’tmeasurecontinuityof
evenagoodcoil.
b.If24VACisnotontheMC3coilcheckforD27ontherelayboardbeingON.Ifit’sontheRelayboardshould
beprovidingthe24VACsoifit’snottheRelayboardmaybedefective.Measurefor24VACatJ9-6toJ9-12
ontheRelayboard.If24VACispresentandD27ison,theRelayboardorthewireharnessisdefective.
c.IfD27isnoton,measureontheCCMI/OboardbetweenTP3andthecommonatTP1.Itshouldbelow,
nearzerovolts.IfnottheCCMisprobablydefective.JumperTP3(I/Oboard)toTP1.Ifthepumpcomes
onnowreplacetheCCM.
d.IfjumpingTP3toTP1doesnotturnthefansonthentheRelayboardorthe40pinribboncablepin13isatfault.