Thermal Dynamics ULTRA-CUT 200 XT, Operating Manual

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ULTRA-CUT 200 XT
Manual 0-5304 APPENDIX A-61
E201:
• Phase missing from the wall fuse box, blown fuse.
• F1 or F2, 8A 500V slow blow fuses blown.
• CB1 one phase open.
• System Bias board defective.
• I/O board defective.
Troubleshooting:
1. System Bias board has a red LED, D3, that lights if it detects a missing phase. If D3 is on, check J60 for all 3
phases.
a. If all 3 phases are not present at J60 check for incoming power, then the F1 & F2 fuses. Finally the CB1.
b. If all 3 phases present and about equal voltage then change the System Bias board.
2. If D3, Missing Phase LED, is not on check for voltage at J27-3 & 4 on the CCM. Normal voltage, with no
missing phase, at J27 (or J62 on the System Bias board) pin 3 and pin 4, relative to I/O PCB ground. (TP1)
should be between 10-14VDC with pin 3 being a couple volts higher than pin 4. If this is normal, problem
may be in the CCM.
3. If the voltage at J27-3 & 4 is higher than 10-14VDC and up to 20-24VDC, make the same measurement at
J62 pin 4. If still high there and you have confirmed all 3 phases are present at J60 then the System Bias is
defective.
4. If the voltage at J62-4 is not high the wires between J27 and J62 may be broken.
202-204 Not used. Reserved codes from the earlier product.
205
DC Output Low
DC output (voltage) low means one or more inverter sections are enabled but the output voltage is below a
preset voltage. Shortly after receiving the Start signal from the CNC, but before the end of preflow, both sections
of IM#1 are enabled and CCM measures the power supply output voltage between negative (Torch) to positive
(Work) at the output terminals. If this is less than a set value during preflow or if at any time during piloting
or cutting it drops to below that value for a short time, the inverters are shut off and code 205 is set. 205 will
almost always be indicated as an “L”, not an “E” fault because as soon as it’s detected the inverters are shut off
and so no longer have the fault of low output voltage. Currently the low voltage value is -60VDC.
Causes of 205 code can include shorts outside the plasma power supply, shorts inside the plasma power supply
and measurement errors.
a. Short external to the plasma power supply:
• The negative lead goes from the rear of the power supply to the remote arc starter or to the GCM 1000 XT
in the case of the AC 3000 XT.
o Cable pinched in or exiting the power track
o Short inside the Arc Starter such as a wire coming loose and grounding to the chassis.
o Short inside the torch mounting tube.
• Trouble shoot for external negative lead shorts by removing the lead from the rear of the power supply
and try to start. It won’t start but if you get the same 205 code the problem is inside the unit.
b. Short inside the supply:
• All the inverters outputs except that of IM1A are in parallel. If any inverter’s output is shorted it will
appear as a short across the power supply output.
Troubleshoot by removing all (or one at a time) of the inverter output connectors except those on IM1A.
Then apply Start to the unit. If it starts now one of the other inverters had shorted output. To find
the defective one reconnect one at a time until the fault reappears.
206 Not used. Reserved codes from the earlier product.