Tweco PAK 200i - Manual (Page 123)

PAK 200i
Manual 0-5335 APPENDIX A-43
The AC 200 XT and Pak 200 XT have the gas control and arc starter built into the main enclosure in the area that is
used for the top inverter module in other units of this family. The AC 300 XT has a separate gas control/Arc Starter
that sits on top of the main enclosure very similar to the GCM 1000 of our earlier Auto-Cut models. It is in fact called
a GCM 1000 XT. Both Auto-Cut XT models and the Pak 200 XT have an analog current control (Potentiometer).
On the front panel of the main unit for the AC �00 XT and Pak �00 XT and in the upper box, the GCM 1000 XT, for
the AC 300 XT version. In either case the amperage setting is displayed on the front panel digital display.
Both Auto-Cut models have the gas mode switch on the rear, for the AC 300 XT next to the gas inlets of the GCM
1000 XT. (The Pak 200 XT does not have this switch). On the AC 200 XT it’s near the connectors, fuses & circuit
breakers. The switch should be set according to the type of gas, AIR/O2 or N2, H35 or other non-oxidizing gas,
being used for the plasma.
In the AC 200 XT the Pilot board is mounted on the upper section of the second inverter module (IM#2) the ½ mod-
ule, in the place of the second or “B” section if it was a full module. The AC 300 XT and all Ultra-Cut XT models
have the Pilot board on the opposite side from the inverters, the “circuit breaker” side, in the upper rear behind
the CCM module. Refer to the Replacement Parts section of the manual for illustrations showing the locations.
Ultra-Cut XT units, 100, 200, 300 & 400A units all can use either the GCM 2010 “manual” Gas control or the DFC
3000 Auto Gas Control. These gas controls remain unchanged from earlier Ultra-Cut units.
Ultra-Cut XT units use the same flow switch, FS1, as the Auto-Cut XT units to detect and prevent operation when
coolant flow is below the minimum of 0.75 GPM (2.8 l/m) for PAK 200i the flow setting is 0.5 GPM (1.9 l/m). How-
ever, the Ultra-Cut XTs include a coolant flow sensor, FL1, which also measures the flow and can detect if there are
gas bubbles in the coolant which can reduce consumable part life. Detecting bubbles or low flow from FL1 will
NOT prevent cutting but will show a code as a warning that something is not right. The code is E406.
Ultra-Cut XTs have standard consumables for cutting currents lower than those used for Auto-Cut XT and PAK
200i, 15A vs. 55A as well as marking at lower currents. To improve operation at these lower currents an additional
output inductor, L1, is added in series with the 1st inverter section (IM#1A).
Status codes.
The codes for the power supply are displayed on the Display PCB 4 digit numerical display. Some codes refer to
the Gas Controls but more detailed Gas Control codes will be found on the individual gas controls. The gas con-
trols used with the XT family of plasma supplies have not changed. They have their own set of status codes which
should be covered in another section. This guide assumes you have first considered the Status Code Tables in the
Operation Section of the unit manual. Individual codes will point to different inverter sections while this guide
groups similar codes together. For example code E (or L) 249 indicates an inverter fault in Inverter 2A. This guide
covers codes 247-252 in one section as they are all the same, varying only by which inverter and section they refer to.
The codes are separated into 6 groups.
Group 1 Plasma Process -- Relating to pilot, transfer, torch voltages, etc.
Group � Plasma Power Supply -- Primarily the Inverter Sections
Group 3 Interface to Gas controls -- Mainly the DFC 3000
Group 4 Cooling System -- The liquid cooling system for the torch and inverters
Group 5 CCM -- Communications port to the gas controls
Group 6 CCM -- Status
For the XT units we are using a 3 digit code with group 1 codes in the 100’s, group 2 in the 200s etc. These cor-
respond to the older codes used in previous units, where 1-1 is now 101. For the most part the codes have the
same meaning. Where an older code no longer applies to the XT system we don’t use it over again and have left it
reserved to avoid confusion. For example the code 204 (2-4) which meant the inverter module wasn’t ready. We
now detect that error in a different way that has a somewhat different meaning so we have reserved the 204 Code.
While most of the codes indicate a fault has occurred, a few of them, such as 304 (formerly 3-4), simply refer to
the current status. 304 indicates either “priming” where the pump is filling the system with coolant or more often
“purging” where the gas is flowing to dry the consumables after replacing them or purging the gas lines when a
different gas type has been selected.