Owner manual

ULTRA-CUT 100 XT
Manual 0-5272 APPENDIX A-75
Coolantowiscorrectbutsystemdoesn’tdetectitduetodefectivecomponents:
• DefectiveordisconnectedFS1owswitch.
• Relayboard.
• CCM.
FlowSwitchFS1disconnected–FS1comeswithwireabout1ft.longandaconnectorthatconnectstoa3wire
harness.Thiscouldbedisconnectedateitherend,J74orJ5ontherelayboard.
DefectiveFS1–Theowswitch,normallyopen,closeswhenowthroughitexceeds0.75GPM,couldbeopen.
EasiestplacetomeasuretheswitchisattheJ5harnessconnectorthatplugsintothePilotboard.Assumingyou
havepreviouslydeterminedowissufcient,disconnectJ5fromthePilotboard,starttheunitsothecoolant
isowingandmeasurecontinuitybetweenthe2pinsofJ5.
• IfthereisnocontinuityeithertheswitchisopenortheharnessbetweenJ5andJ74atFS1isopen.
• IfthereiscontinuitybetweentheJ5pinswithsufcientcoolantowtheneitherrelayboardortheCCM
is faulty.
• Relayboard
• CCM
405 Low Coolant Level Warning
Ifthecoolantlevelbecomeslowwhilecuttingitisnotnecessarytoimmediatelystopthecutasthereisstill
enoughcoolanttocontinuesowedisplayE405asawarning.Oncethecutstopsifthecoolantisstilllowthe
displaychangestoE401andpreventsstartinganothercut.Refertothesectionforcode401fortroubleshooting.
406 Coolant Flow Low Warning
Ultra-CutXTunits,inadditiontoacoolantowswitch,includeaturbineowsensorFL1,referredtointhe
plumbingdiagramasa“bubblesensor”,withapulseoutputthataccuratelymeasurescoolantowandin
addition can detect the presence of gas bubbles in the coolant. Gas bubbles from leaking seals in the torch or
hosettingshavebeenproventoreduceconsumablelife.Thiscodeisawarning,itdoesnotpreventcutting
butifitpersiststhecauseshouldbeinvestigated.
407 Coolant Overheated due to High Ambient
Asdescribedinthesectionforcodes259-264theCCMmeasurestheambienttemperatureusingsensorTS2
and,likewiththeinverters,ifthecoolantisovertemperaturewerstchecktheambientandifitisabove40
degCweattributethecauseofthecoolantovertemperaturetohighambientandofcoursethesolutionisto
lower the ambient or reduce the duty cycle.
Theotherpossibilityistheambientmeasuringcircuitisdefectiveandthecoolantisoverheated.Inthatcase
youwouldhavetogotothesectionforcode403tondthecauseofthecoolantoverheatingandgotosection
forcodes259-264todeterminewhatiswrongwiththeTS2circuit.
The 5 Group relates to CANBUS (Fiber optic) communication errors
501 CANBUS Failure to Acknowledge fault.
TheCCMcommunicateswiththegascontrols(exceptGCM1000XT)overaber-opticcableusingtheCANBUS
protocol.TheCCMislookingforasignalfromthegascontrol(GCM2010orDMC)overtheber-opticlink.
No signal has been detected. Communication with the DPC which is relayed through the DMC sets a different
code, 301, if there is a problem with it.
Possible causes:
• GascontrolisGCM1000XT(Auto-Cut300XT)whichhasnober-optic,withBasicIDproblem.
• CANBUS/Fiber-opticproblemtoeithertheGCM2010ortheDMC(partofDFC3000).
• ControlCabletoDMCorGCM2010defective.
• Gascontrol(DMCorGCM2010)mainPCBblownfuseordefective.
• DMCpowersupplyPCBblownfuseordefective.
• CCMdefective.