Tweco 400 Ultra-Cut(May 2014) - Manual (Page 210)

ULTRA-CUT 100 XT/200 XT/300 XT/400 XT
A-82 APPENDIX Manual 0-5302
Troubleshooting:
1. Check for air blowing out of the unit. Remember, except for the AC 200 XT, the fans only run when CNC START is applied
and for 4 minutes after cutting, you may have to apply start again to restart the 4 minute time. Fans may be forced on
by jumping TP2 on the CCM I/O board to TP1 (ground).
a. If using the external HE400XT heat exchanger, optional for 300A, standard for 400A, check for air blowing out of it.
Note that the HE400XT fan, controlled by a thermal switch in the HE400XT, only runs if the coolant is over 60 deg
C and the internal fans are operating. With the 100 & 200A if it has 2 fans make sure both fans are operating by
checking for air both top and bottom of the opening. The fans are difficult to see, perhaps you can use an inspection
mirror. Be careful not to get the mirror or your hands into the blades.
2. Fans are powered by 230 VAC. The 230 VAC for the fan(s) is switched by the MC2 control relay (except the AC 200 XT
where the fan(s) is powered directly from the T1 transformer at J13).
Art # 12311
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
J8
1
5
3
2
4
Fan Bias Control
K4
MC2
Fan Control
(160)
(161)
SA3
ARC_SUPPRESSOR
D24
24 VAC
Relay PCB
230 VAC from T1
MC2A
MC2B
To J70-2
To J70-3
(69)
(70)
(70)
(65A)
(70)
(69)
1
2
3
J73
(64A)
CHASSIS GND
1
2
3
J72 C4
FAN1
R
R
BK
BN
BL
1 2 3 4
J13
TP1 TP2
CCM I/O PCB
To test fan relay jump TP2 to TP1.
+24
J4-19
3. Check for 230 VAC at either of the fan connectors, J72 & J73. It may also be measured at the rear panel connector J70
for the HE400XT fan.
a. If the fans are not getting 230 VAC, measure for 24 VAC on the coil of MC2. If present and the relay contacts aren’t
closed the relay is defective. Note, the coil is rectified so you won’t measure continuity of even a good coil.
b. If 24 VAC is not on the MC2 coil check for D24 on the relay board being ON. If it’s on, the Relay board should be
providing the 24 VAC so if it’s not the Relay board must be defective.
c. If D24 is not on, measure on the CCM I/O board between TP2 and the common at TP1. It should be low, near zero
volts. If not the CCM is probably defective. Jumper TP2 (I/O board) to TP1. If the fans now come on replace the
CCM.
d. If jumping TP2 to TP1 does not turn the fans on then the Relay board or the 40 pin ribbon cable pin 19 is at fault.
404 Coolant System Not Ready
When power is applied to the system with External Plasma Enable satisfied and Plasma Power Supply Enabled (switch on
2010 or TSC 3000), assuming there is enough coolant in the tank, after some initial tests taking about 15-20 seconds (see
manual section 4 for details of the Start-Up Sequence) the pump will start. Coolant will be pumped through the system. Flow
is measured by the FS1 flow switch placed in the torch coolant return path just before the radiator (see plumbing diagram).
If the flow doesn’t reach at least 0.75 GPM (2.8 lpm) within 4 minutes it will set the 404 fault. The reason for the 4 minutes
is a new dry system especially one with long torch leads will take some time before the leads, hoses, radiator and cold plates
are full of coolant. More coolant may have to be added. On a system that has been run before it normally takes only a few
seconds to establish proper flow. In any case the pump will run for 4 minutes before setting the 404 fault.
First determine if the pump motor is running and if so is there any coolant flowing. With the right lower side panel removed
touch the pump and feel for vibration to indicate if the motor is running. Observe the clear coolant hoses to see if they are
full of coolant. There are two hose fittings on the back of the tank. The upper one is the coolant return. Remove the tank
filler cover. You should see a fairly strong stream of coolant from that fitting. The lower fitting is from the pump bypass