Tweco 400 Ultra-Cut(May 2014) - Manual (Page 187)

ULTRA-CUT 100 XT/200 XT/300 XT/400 XT
Manual 0-5302 APPENDIX A-59
Troubleshooting:
1. If both D2 and D3 are on and you still have 101 fault replace the CCM. Otherwise go to step 2 except if it’s an AC 200
XT skip to step 4.
2. If D3 is not on and there is a TSC 3000 in use remove its cable from J54. K7 on the Relay board will de-energize and
satisfy the Plasma Enable to K1. If D3 is now on problem was in the TSC 3000 or its cable. Otherwise reconnect the
cable.
3. For an Ultra-Cut with DFC 3000 or GCM 2010 or an Auto-Cut 300 with a GCM 1000 XT remove the cable from J55
the gas control connector and jumper pins 1 & 2. If D3 is on now problem is in the Gas Control or its cable. If D3
still not on replace the Gas Control cable.
4. If neither of the above steps works, on the CCM I/O board, jumper J26-7 to GND (TP1 on I/O). If D2 is on and D3
still does not light then replace the CCM.
5. If D3 does light in the above step find the 40 pin ribbon cable plugged in to the top of the CCM. Confirm that it is
plugged in to both the CCM and the Relay board and the connector tabs are locked in place. Now using the spare
receptacle measure voltage between GND (TP1 on I/O) and the ribbon cable pin 12. It should be zero V. If not, if it’s
something like 10-15VDC, the ribbon cable is open or the Relay board is defective.
1
2
4
5
E-STOP
K?
GREEN
D13
(59)
12
15
13
16
J5
1A F20
16
14
13
15
J56
(57)
(56)
(58)
16
14
17
15
J55
GAS
CONTROL
CABLE
3
4
J26
AC24V GCM1 15
7
J10
AC24V Ret - GCM1
(114)
K1
PLASMA ENABLE
(112)
CCM I/O BOARD
RELAY BOARD
(103)
(110)
GCM 2010 GAS CONTROL
XT PLASMA SUPPLY
GCM 2010 CONTROL BOARD
GCM 2010 PLASMA ENABLE / E-STOP SIMPLIFIED CIRCUIT
Art # 12306
102 Pilot Ignition Failure
Code 102 is activated when there is no pilot current after 15 seconds of firing the Arc 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 Arc
Starter RAS 1000 XT or GCM 1000 XT or the arc starter built in to the AC 200 XT) applied between the tip and the electrode
of the torch.
Possible Causes for 102 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.