Thermal Dynamics ULTRA-CUT 100 User Manual

Manual No. 0-4819 4-14 OPERATION
Remote Arc Starter: Service Chart
Symptom Cause Check Remedy
Coolant has become conductiv
e
Use conductivity meter
Flush system,
replace coolant.
Pilot return wire not connected Visual inspection Connect Wire.
Spark gap set too close Check with feeler gauge Set to 0.063" ±0.002"
High Frequency cap (C4)
possibly open
Use capacitance meter Reconnect or replace.
Broken or missing ferrites Visual inspection Replace.
Short across in inductor (L1) Visual inspection
Remove short;
increase coil gaps.
Spark gap bus caps
(C1, C2, C3)
broken or defective
Capacitance meter Replace.
Negative supply not
connected correctly
Visual inspection Reconnect.
Spark gap set too large Check with feeler gauge Set to 0.063" ±0.002"
Faulty transformer Resistance measurement Replace.
No 120V supply Check input voltage at EMI filter
Make connections;
replace harness.
No/ loose connection
to spark gap
Visual inspection Reconnect.
Faulty EMI filter Voltage/ Resistor measurement Replace.
Loose fitting(s) Visual inspection Tighten fittings.
Failure to braze joints (L1) Visual inspection Replace HF Coil.
Damaged or punctured
coolant line(s).
Visual inspection Replace coolant line(s).
Supply & return hose reversed
Visual Inspection of color-coded
connections
Match coolant connection colors
to arc starter fitting colors.
Blockage in coil or
supply/return hoses
Loosen fitting slightly and check
for coolant flow
Flush system.
S
hield Drain
/
Torch lead inner
shield connector
missin
g
or loose.
Visual inspection of lead
attachment to Arc Starter
Reconnect / tighten
lead connectors.
Missing or loose
ground connection
Visual inspection of ground wire
to Arc Starter
Make or tighten
connections to
good ground.
Cap C5 not connected,
open or loose
Visual inspection / capacitor
measurement
Replace PCB.
Arc Starter Service Chart
Erratic System
Behavior
(EMI Interference)
No Pilot ignition:
Spark in Arc Starter
but no ignition
No Pilot ignition:
No Spark
in Arc Starter
No cooling or
insufficient cooling:
Leaks coolant
No cooling or
insufficient cooling:
No Coolant Flow

Thermal Dynamics ULTRA-CUT 100 Specifications

General

Brand	Thermal Dynamics
Model	ULTRA-CUT 100
Category	Welding System
Language	English