Thermal Dynamics ULTRA-CUT 200 XT, Operating Manual

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ULTRA-CUT 200 XT
Manual 0-5304 APPENDIX A-87
701 Isolation Contactor (W5) Fault.
This fault occurs if one or more of W5 contacts are closed when they should not be. Either because W5 is ener-
gized when it shouldn’t be due to a faulty circuit board or the contact(s) is physically stuck.
1. 1Torch tip contacting work piece or earth ground
a. If the 1Torch standard standoff tip is touching work or ground at power up the pump will not start, will
not prime the cooling system. If while priming, the tip contacts work or ground the pump stops. Both
cases show E701 fault which in this case is not W5 fault but is an artifact of the circuit that checks for the
W5 fault.
b. After priming is finished the standoff tip contacting work does not stop the pump but does show E701.
c. Drag cutting with 1Torch. For best consumable life, drag cutting should use the special Drag Shield Cap
or the Shield Cup Standoff guide which does not allow tip to work contact, does not set the 701 fault and
allows cutting at the full 100A.
With the standard standoff tip, if it comes in contact with the work the current is reduced to 40A to pre-
vent damage to the tip. You may drag cut this way at the reduced current but tip life may be reduced.
With the standoff tip, because of the 701 fault, you must trigger the 1Torch with the tip above the work to
start the preflow. At this Point the tip may be brought into contact with the work for cutting at reduced
current.
2. W5 is not energized or stuck.
a. The Relay board LED, D40, should be on when W5 is OK. If it is not on, remove J84 from the Relay board.
If D40 still does not come on the Relay board is defective.
b. If D40 is on with J84 removed and you still get a 701 fault, measure the 40 pin ribbon cable (CCM J23 to
Relay J4) pin 20, relative TP1 on either the CCM or the Relay board. If pin 20 is low, less than 2VDC, then
the CCM is likely at fault. If pin 20 is high with J84 removed the Relay board is bad.
3. W5 is energized. Before disassembling the 1Torch Module to inspect W5, look on the Relay Board to see if
the green LED, D26, just above K3, is on. This would indicate the Relay Board or perhaps the CCM is turn-
ing W5 on when it shouldn’t be. You could also measure for 24 VAC coming from the Relay Board at J11-1
and J11-12.
a. On the 40 pin ribbon cable (CCM J23 to Relay J4) if pin 20 is low, less than 2V, relative to TP1 on either
the CCM or the Relay Board then the CCM is turning on W5. Replace the CCM.
b. If pin 20 is high, about 15VDC, but D26 is on, the Relay board is defective.
4. W5 is not energized but is stuck closed. You will have to open the module to inspect and probably replace
W5. Remove all power from unit before disassembling.
a. Find the contactor; it’s big and black. In the middle of the cover is rectangular hole with a slightly recessed
plastic piece in it. This should move down and spring back up freely as you push and release it. If not replace
the contactor. Remove the contactor cover, 2 screws, and inspect the contacts. They should not be burned
excessively and should move freely. If not replace the contactor.