Thermal Dynamics Ultra-Cut 300 XT, Operating Instructions Manual

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ULTRA-CUT 400 XT
A-72 APPENDIX Manual 0-5275
GCM 2010 Status Codes
GCM 2000 has an LED on the front panel which blinks various codes.
GCM 2010 has LCD display which displays many of the Status messages. However, there are a few relating to
communications that aren’t clear.
When there is a communication error it will be displayed but once it has recovered the display will show what
the error was by displaying:
^E4 – Low level CAN bus error where the CCM did not acknowledge receiving a message from the Gas Control.
^E5 – Low level CAN bus error where the bus is off.
^E6 – CAN bus communication (the fiber-optic) has timed out.
Group 4 codes relate to the Liquid Cooling System
Cooling system description. System includes a reservoir, a pump, one or more heat exchangers, flow switch,
level switch and flow sensor on some models. Also included are a filter and various fittings and hoses. New
coolant is installed into the reservoir or “tank” from an opening in the unit’s front panel where there is a visual
level indicator. Coolant flows to the pump inlet from the bottom of the tank, is pumped through a pressure
relief or “bypass” valve which limits MAX pressure to 150 PSI bypassing excess flow back into the reservoir.
The coolant temperature sensor, TS1, a linear NTC sensor, is mounted on the bypass valve.
From the bypass valve in most systems coolant is plumbed to the rear panel coolant supply fitting where it
goes to the torch via the RAS 1000 XT, the remote arc starter, The UC 400 XT had an additional external heat
exchanger, the HE 400XT in the supply line between the power supply and the remote arc starter. In the AC
200 XT with built in arc starter coolant goes to the water cooled HF (high frequency) coil and then to the torch
supply lead attached to the internal torch connection bulkhead. Coolant from the Torch returns to the RAS and
on to the return fitting on the rear of the power supply. For the AC 200 XT return is to the torch bulkhead built
in to the unit. Coolant returning from the torch is routed through the rear panel filter then through the radia-
tor (internal heat exchanger) and through the flow switch. Ultra-Cut models also have a flow sensor in series
the flow switch that can detect bubbles in the coolant. Upon leaving the radiator, coolant goes into the bottom
inverter “cold plate” or liquid cooled heat sink. It flows through the inverters in series and returns to the tank.
detect bubbles in the coolant. Upon leaving the radiator, coolant goes into the bottom inverter “cold plate” or
liquid cooled heat sink. It flows through the inverters in series and returns to the tank.
401 Coolant Level Low
The coolant reservoir (tank) has a normally open (tank dry) float 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 dur-
ing 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. Confirm visually that the level switch float 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.