Tweco 300 XT Ultra-Cut Plasma Cutting System - Manual (Page 154)

ULTRA-CUT 300 XT
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102 Pilot Ignition Failure
Code 10� is activated when there is no pilot current after 15 seconds of firing the rc Starter. Pilot ignition
requires the Pilot board to be enabled, pilot switch (IGBT) turned on and high voltage pulses (HF) from the arc
Starter (either the Remote rc Starter RS 1000 XT or GCM 1000 XT or the arc starter built in to the C �00 XT)
applied between the tip and the electrode of the torch.
Possible Causes for 10� code:
• No HF to the torch due to broken pilot wire connection in the torch leads.
• No HF to the torch due to defective Arc Starter.
• Arc Starter not receiving power.
• Pilot board not enabled.
• Pilot board defective.
• Relay board defective.
• Work lead current sensor defective.
• CCM defective.
Troubleshooting:
1. Determine if the problem is a lack of HF (rc Starter) or if it’s due to the pilot circuit.
uto�cut XT rc Starter (inside main chassis for C�00 XT; in the GCM1000XT for C300XT) has open spark
gap. If the spark gap is firing it is receiving power. few early Ultra�Cut XT units were shipped with the
RS1000 rc Starter. Troubleshoot them the same as the GCM1000XT below. Most Ultra�Cut XT units now use
the RS1000XT rc Starter which doesn’t use a spark gap and is covered in the next section.
Arc starter with Spark Gap (Auto-Cut)
No spark at spark gap
1. Check that spark gap is set for 0.06�” +/� 0.00�”. If gap is too high there may not be enough voltage from
T1 to fire the gap.
�. Check for power to the high frequency (HF) transformer (T� in C �00 XT; T1 in GCM1000XT) during the 15
seconds following prefow (ignition phase). rc starter power comes through the rear panel circuit breaker
CB�, make sure it isn’t tripped.
a. For the GCM1000XT (C300XT) 1�0 VC from J59�7 & 9 on the power supply rear panel connects to
J58�7 & 9 on the GCM 1000XT. See diagram below. From J58 on the GCM1000XT it goes directly to the
line filter and passes through the filter to primary of T1. During the ignition phase, check for 1�0 VC
on the T1 side of the line filter.
b. For C�00XT the HF transformer T� has insulated Faston (also known as push on , stab�on, spade, etc.)
on its primary wires. Disconnect these and measure for 1�0 VC on the harness side during ignition
phase.
3. If 1�0 VC not present go to step �.
a. If 1�0 VC is present and still no spark, T1 (T� in C�00XT) may be bad. Remove power and measure
resistance of T1 (T� in C�00XT) primary and secondary. The primary should measure about 3�7 ohms.
The secondary about �5�35 K ohms. If either measurement not correct replace T1 (T� in C�00XT).
b. If T1 (T� in C�00XT) measures OK, check for shorted capacitors C1�C3 (very unlikely).
�. No 1�0 VC to T1 (T� in C�00XT) primary during the ignition phase (15 seconds following Preflow) check
for 1�0 VC into the line filter (GCM1000XT only). If it’s there replace the filter. If 1�0 VC isn’t present at
the line filter or if this is an C �00XT go to step 5 in section Either rc Starter below.