Tweco 400 XT Ultra-Cut Plasma Cutting System With Automated Gas Control - Manual (Page 171)

ULTRA-CUT 400 XT
Manual 0-5306 APPENDIX A-47
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 correspond 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.
Troubleshooting (General)
In many cases where the cause may be listed as a cable or wire disconnected but also includes loose or broken.
All Ribbon cables have an extra receptacle near one end for measuring signals on the cable.
A number of the measurements will require probing of some small connectors or measuring signal on ribbon cables. For probing
the small connectors, standard meter probes are usually too big. We suggest making a couple probes using steel wire. Copper
buss wire isn’t stiff enough. A paper clip is a little too big. One idea is take a socket from an Amp mate-n-loc or similar connector
into which your meter probe will fit and crimp a small piece of steel wire, (0.020 to 0.025” dia.; (0.5-0.6 mm) works best), into
where wire would normally be crimped. The wire should be soldered and crimped. The steel wire may be found in hobby stores
that cater to model building.
Art # 12302 Art # 12303
Insulate all but the end of the wire and slide these onto your meter probe. If your meter has alligator clip adaptors you could hold
the wire in these as well, be sure they don’t short together.
Problems that do not set Status or Fault codes:
1. At power on GAS LED blinks continuously, no code set. Real problem is no or low coolant flow but it takes 4 minutes
before code is set and people don’t wait that long.
Power Supply Status Codes
Group 1, Process Codes
101 Plasma Enable Is Disabled
Code 101 is activated by either an open circuit between TB1-1 & 2 on CCM I/O PCB or Plasma Enable switched off on the
GCM 2010 or on the TSC 3000. TB1-1 & 2 comes from the factory with a jumper installed. An installer may remove the
jumper and connect a separate Plasma Enable switch or use the Plasma Enable wires included in the 37 pin CNC cable used
with the Ultra-Cut XT & Auto-Cut 300XT. The Auto-Cut 200XT which uses a 14 pin CNC does not have the Plasma Enable
in the cable. These may be used to connect to the cutting table E-Stop switch. In either case the jumper would be removed
from TB1-1 & 2. 101 is not a latched code, it clears as soon as the condition is fixed.
Causes for 101 code other than one of the Enable switches being off (see detailed descriptions below):
• Gas Control Cable from J55 to gas control not connected.
• Ribbon cable from Relay board to I/O board not connected.
• CNC cable not connected (if using a Plasma Enable switch or output from the cutting table or robot).
• Defective Relay PCB
• Defective CCM I/O PCB
Special case: Display alternates between E101 and ----. This happens when there is both a missing phase and Plasma enable
is off. It is probably a bug in the code, it should be showing E101 & E201 (missing phase code). We will likely fix this in a
later code release but be aware of it for now.