Tweco 400 XT Ultra-Cut Plasma Cutting System With Automated Gas Control - Manual (Page 191)

ULTRA-CUT 400 XT
Manual 0-5306 APPENDIX A-67
Troubleshooting:
1. Check that the input power cables are connected to the inverters.
2. Check if the contactor for that section (W1 for 1A, 1B, 2A; W2 for 2B, 3A, 3B) is energized.
a. There is a rectangular section in the middle of each contactor top that can be used to attach auxiliary contacts. This
can also be an indicator of contactor operation as it pulls in when the contactor is energized.
b. Check for CB2 on the rear panel being tripped. The white button marked “5” indicating it’s 5 amps, will pop out if
tripped. Reset it and if it pops out again something (contactor coil?) may be shorted.
c. Measure for 120 VAC on the contactor coil. If present, but the contactor isn’t pulled in, it’s probably a defective
contactor.
3. On the Relay board D22, CONTACTOR ON LED (green) next to relay K1 lights if K1 is being told to energize.
a. If it’s on check for 120 VAC between J8-1 and J8-9. If present the relay board is OK.
b. If D22 is on but 120 VAC is not present at J8-1 and J8-9 (make sure meter is set for ACV) then the relay board is
defective.
c. D22 is not on, go to the 40 pin ribbon cable test connector and measure voltage on pin 17 (relative to TP1 on either
the Relay board or the CCM I/O Board). It should be low, less than 1 volt. If it is the relay board is likely bad. If it’s
high, about 24VDC then the CCM may be bad, not telling the contactor to turn on.
4. The inverter section may be defective with a bad bias supply. Swap the inverter end of the ribbon cable with one next to
it.
a. If it now reports a different code, that of the inverter that was swapped with, then the original section is bad.
b. If it still reports the same section even though the ribbon cable was swapped then the CCM is bad.
271 Inverter ID Reading Fault.
Refer to section for codes 225-230 for a description of the ID signals. If this code appears it means one of these ID signals
has gone false some time after power up.
Possible causes:
• An intermittent ribbon cable or one not fully latched in place.
• EMI interference.
Troubleshooting:
1. First recycle power to see if the fault is still there. It may now show up as one of the 225-230 codes which will indicate
which inverter.
2. Determine when the code shows up. If it is EMI it may not happen every time but if, when it happens, it is always at the
beginning of piloting, it may be EMI interference. Check the system ground cables and if an AC200XT check the torch
shield connection to the unit rear panel.
3. If it happens intermittently during cutting or idling it might be an intermittent ribbon cable. This code does not say which
inverter section so you have to check each ribbon cable for proper connection on each end. It’s highly unlikely for a rib-
bon cable to be intermittent but if you have more than 2 sections try disconnecting one section at a time and cut at lower
current. See if you find one that causes the problem and if so replace that ribbon cable.
Group 3 codes relate to the GAS Controls Status and Communication Protocol
Also refer to GCM 2010 Status Codes at the end of this Group 3 codes section.
301 Gas Control Communication Fault
No signal detected over the fiber-optic link from the gas control. In the case where there are additional devices other than
Gas Control connected to the CANBUS this code would indicate the Gas Control is having communication problems while
the other CANBUS devices are OK. We don’t currently have any other devices on the CANBUS so it is more likely that code
501 will be what is set. In any case troubleshooting is the same as for 501.