Tweco Troubleshooting Power Supply - Manual

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Troubleshooting Ultracut & Autocut Systems from Status Codes
This is work in progress, do not assume correct or complete
The power supply for these systems is made by another company to TDCs
specifications. The rest of the system, the Communications & Control Module (CCM),
Remote Arc Starter (RAS), and various gas controls (GCM 1000, GCM 2000, GCM
2010) were designed and are manufactured by TDC.
Because the CCM, which is the “brains” of the system, is mounted into the rear panel
of the power supply one might consider it to be part of the power supply however, for this
discussion, is it considered a separate part. References to “power supply” or “power
supply boards” do not include the CCM.
On start-up and during operation, the power supply control circuitry, along with the
CCM, performs various tests. If the circuitry detects a condition requiring operator
attention, the CCM causes the Status Indicator on the front panel to flash a 2-part code.
First part of the code indicates a code, the second part a particular condition within that
group. After 4 seconds the sequence repeats.
Example: Indicator flashes 4 times; the condition is in group 4. After 1.2 seconds
delay, the indicator blinks 3 times; the condition code is 4-3, indicating the coolant is
overheating or has overheated. After a 4 second delay, the indicator repeats the sequence
until the condition is corrected.
The code groups are:
Group 1
Process Codes
Group 2 Power Supply Codes
Group 3 Gas Control Codes
Group 4 Coolant System Codes
Group 5 CANBus Code
Group 6 CCM Fault Codes
Some conditions can be active indefinitely, while others are momentary. Some
momentary conditions can shut down the system then they are gone. The power supply
and the CCM latch and hold the codes that are set by momentary faults so you can see
why the code was set. Most latched codes are cleared by reapplying CNC Start. A few
require shutting the power supply off to reset it.
The status indicator may show multiple conditions in sequence; it is important to
recognize all possible conditions that may be displayed.
Troubleshooting (General)
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. I suggest making a couple probes. Use steel wire copper
buss wire that is small enough isn’t stiff enough, it just folds over. One idea is take a
socket from an Amp mat-n-loc or similar connector into which your meter probe will fit