Tweco 400 Ultra-Cut(May 2014) - Manual (Page 182)

ULTRA-CUT 100 XT/200 XT/300 XT/400 XT
A-54 APPENDIX Manual 0-5302
Appendix 29: Advanced Troubleshooting
System Overview
The Auto-Cut 200 & 300 XT & Ultra-Cut 100, 200, 300 & 400 XT
power supplies include one, two or three inverter modules (IM).
Each IM may have either 1 or 2 inverter sections designated A or B
sections. The IMs are mounted one over the other numbered from
bottom to top. The sections are also designated from bottom to top
with section A being on the bottom of each module. An IM with one
section is considered to be a ½ or “partial” module with the upper
or “B” section missing. ½ modules are used with the 200A & 300A
power supplies and will always be in the middle position. IMs with
2 sections are considered to be “full” modules.
Each inverter section can supply up to 67A but does not do so in
all configurations:
A 400A unit uses 6 sections. 400A / 6 = 66.67A per section.
A 300A unit uses 5 sections. 300A / 5 = 60A per section.
A 200A unit uses 3 sections. 200/3 = 66.67A per section.
A 100A unit uses 2 sections. 100/2=50A per section.
Unit configurations.
With the exception of the AC 200 XT all other units have the same
chassis with room for up to 3 IMs. The unused areas have blank
panels filling the empty locations which are required for proper air
flow. A 100A system uses 1 full IM; 200A uses 1 and ½ modules
with a full module in the bottom location and a ½ module in the
middle position. A 300A unit has full modules top and bottom with
the ½ module in the middle location. The AC 200 XT has only the
bottom and middle locations for IMs. An internal Arc Starter and
Gas Control are located in the place of the 3rd or upper IM.
Inverter module cooling.
The power semiconductors of the inverter modules are liquid cooled
allowing us to get more power in a smaller area and at lower cost.
Each IM has a liquid cooled heatsink or “cold plate” shared by the
2 inverter sections. The magnetic components, transformers and
inductors, are air cooled and mounted on the back side of the IMs
where they are exposed to high volumes of air flow from the cool-
ing fans whose air also cools liquid coolant in the radiator or heat
exchanger. It is important that lower right side panel be in place or
the air flow will not be proper for cooling the magnetics.
Inverter control.
The inverter sections are operated as separate inverters whose
outputs are connected in parallel. They are controlled independently
from the Command and Control Module (CCM) which is the “brains”
of the system. Each inverter section has a separate ribbon cable
connected to it coming from the CCM which has 6 connectors,
J31 – J36 corresponding to the inverter sections 1A through 3B.
The ribbon cables are labeled on the inverter ends as INV with the
number and section (INV 1A, INV 1B, etc.). A 100A unit will only
have ribbon cables in J31 & J32; a 200A will have J31-J33 filled with
the others empty. 300A will have J34 missing with the others filled.
Art # 12299
Art # 12300