Thermal Dynamics Ultra-Cut 300 XT, Operating Instructions Manual

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ULTRA-CUT 400 XT
Manual 0-5275 APPENDIX A-83
No Fault Codes showing. Some problems may not result in fault codes such as:
1. Failure to respond to the 1Torch Trigger. To operate the 1Torch trigger the automation torch must be in idle
state, not preflow, post-flowing, etc. When the XT automation torch is idle K200 in the 1Torch module should
be energized connecting the torch trigger through to the Relay Board and CCM. On the CCM I/O board
find D70, 1Torch Start LED, just to the left of J28. This should light whenever the 1Torch trigger is pressed.
If not, check that the shield cup and consumables are in place. Check that the 1Torch ATC connector is fully
seated.
a. If D70 is not on, first remove J11 from the Relay Board. Measure for 400-800 ohms (do not use meter’s
diode scale) between pins 2 & 3 of the J11 harness connector. If open or shorted then problem is in the
1Torch module.
b. If resistance at J11-2&3 is OK reconnect J11 and measure the voltage on J11-2 relative to TB1 on the Relay
Board. It should be 24VDC. Next measure on J11-3. This should be low, less than 2 volts. If it’s not low
but instead is 24VDC then K200 is not turned on and the problem may be in the Relay board or the CCM.
c. Measure pin 5 on the 40 pin ribbon cable (J23/J4), if it is high, about 15VDC, the CCM may be faulty, not
detecting that the automation torch is idle. If pin 5 is low, less than 2VDC, and J11-3 was not low then
the Relay board is faulty.
2. W5 Contactor not energized. This will actually show a fault code 102, failure to pilot, after a few seconds
because if W5 isn’t on, power will not be connected to the 1Torch so there will be no pilot.
a. Measure for 24VAC on J11-1 to J11-12. If OK you will have to open the 1Torch module to investigate
further.
b. If no 24VAC check that the rear panel circuit breaker CB3 is not tripped. Next measure the signal “/
Contactor Enable 1Torch” on pin 20 of the 40 pin ribbon cable (J23/J4). It should be low, less than 2VDC.
If it is, the Relay Board is faulty. If pin 20 is not low the CCM is likely the cause.
3. W4 Contactor does not close when system is in idle or automation mode. This will prevent piloting with
XT torch and sets 102 code after 15 seconds of trying to pilot.
Bypass the W4 to see if that allows XT torch pilot. Remove J41 (2 pin connector from W4 to the Pilot board) from
the Pilot board. Remove connector J41(J87) that has wires 52A-1 & 52A-2, connecting to J87 on the other side
of W4 and plug it into J41 on the Pilot board. This returns the unit to the way it was without the 1Torch Option.
If it pilots now there was a problem with W4. The XT automation torch may be operated with W4 bypassed.
Troubleshoot W4.
1. W4 coil measures 10-15 ohms at room temperature, typically 12-13 ohms. Remove one wire #210 or 210A
from the coil before measuring resistance. If open or shorted replace W4.
2. W4 is powered by 24VAC. On the Relay Board J11 measure between pin 10 (wire 210A on W4 coil) and 12.
Should have 24 VAC, if not check that the circuit breaker CB3 on the rear panel is not tripped.
a. Remove power and remove J11 from the Relay Board. Measure resistance from the J11 harness connec-
tor to the other side of W4 coil (wire 210). It should have continuity, near zero ohms. If not the normally
closed W5 auxiliary contact (W5 AUX) may be open. You will have to open the 1Torch module. Refer to
the section Removing and opening the 1Torch module near the beginning of this section.
b. Determine if W5 is stuck on keeping its AUX SW open. Find the contactor; it’s big and black. In the middle
of the cover is a 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. The AUX contact is on the
side of the contactor toward the rear of the box. Determine if it is properly secured to the contactor. It
snaps in place. If it is defective and cannot be fixed you have to replace the complete contactor.