Tweco 400 Ultra-Cut(May 2014) - Manual (Page 208)

ULTRA-CUT 100 XT/200 XT/300 XT/400 XT
A-80 APPENDIX Manual 0-5302
When there is a communication error it will be displayed but once it has recovered the display will show what the error was
by displaying:
^E4 – Low level CAN bus error where the CCM did not acknowledge receiving a message from the Gas Control.
^E5 – Low level CAN bus error where the bus is off.
^E6 – CAN bus communication (the fiber-optic) has timed out.
Group 4 codes relate to the Liquid Cooling System
Cooling system description. System includes a reservoir, a pump, one or more heat exchangers, flow switch, level switch
and flow sensor on some models. Also included are a filter and various fittings and hoses. New coolant is installed into the
reservoir or “tank” from an opening in the unit’s front panel where there is a visual level indicator. Coolant flows to the pump
inlet from the bottom of the tank, is pumped through a pressure relief or “bypass” valve which limits MAX pressure to 150
PSI bypassing excess flow back into the reservoir. The coolant temperature sensor, TS1, a linear NTC sensor, is mounted
on the bypass valve.
From the bypass valve in most systems coolant is plumbed to the rear panel coolant supply fitting where it goes to the torch
via the RAS 1000 XT, the remote arc starter, The UC 400 XT had an additional external heat exchanger, the HE 400XT in the
supply line between the power supply and the remote arc starter. In the AC 200 XT with built in arc starter coolant goes to the
water cooled HF (high frequency) coil and then to the torch supply lead attached to the internal torch connection bulkhead.
Coolant from the Torch returns to the RAS and on to the return fitting on the rear of the power supply. For the AC 200 XT
return is to the torch bulkhead built in to the unit. Coolant returning from the torch is routed through the rear panel filter
then through the radiator (internal heat exchanger) and through the flow switch. Ultra-Cut models also have a flow sensor in
series the flow switch that can detect bubbles in the coolant. Upon leaving the radiator, coolant goes into the bottom inverter
“cold plate” or liquid cooled heat sink. It flows through the inverters in series and returns to the tank. detect bubbles in the
coolant. Upon leaving the radiator, coolant goes into the bottom inverter “cold plate” or liquid cooled heat sink. It flows
through the inverters in series and returns to the tank.
401 Coolant Level Low
The coolant reservoir (tank) has a normally open (tank dry) float type level switch, LS1. When the coolant level in the tank
is below about ½ full this fault will signal the need to add coolant. It will not stop the process during a cut but will instead
show the 405 fault as a warning. As soon as the cut stops it will not allow another to start until the issue is corrected.
Possible causes:
• Coolant is low
• Level switch defective, disconnected or installed upside down.
• Relay board defective or J7 disconnected.
• CCM defective.
Troubleshooting:
1. Confirm visually that the level switch float is below the coolant, if not add more coolant to the tank.
2. Check J7 on the Relay board.
a. If properly connected remove J7 and check continuity between pins 2 and 4 (pins 2 & 3 of J71 on the switch itself).
b. If no continuity at J71 on the switch, if it is still open, replace the switch.
3. If there was continuity at J7 plug it back in and measure voltage on pin 9 of the 40 pin ribbon cable (Relay board J4 to
CCM J23). Common is TP1 on either the Relay or the I/O board.
a. Pin 9 should be high, about +10 to +15V. If it’s not the relay board is bad or the ribbon cable is shorted.
b. To test the ribbon cable remove both ends, J4 on the Relay board and J23 on the I/O board and measure from pin
9 of the ribbon cable to both pin 8 and pin 10 of the cable. Both should be open. If not replace the ribbon cable.
Otherwise it’s the Relay board.
4. If pin 9 of the 40 pin ribbon cable was high in step 3.a the CCM is defective.