Tweco 100 Ultra-Cut Plasma Cutting System with Automated Gas Control - Manual (Page 188)

ULTRA-CUT 100 XT
A-64 APPENDIX Manual 0-5303
238 System Bias voltage identification is invalid.
At power up the System Bias board measures the input voltage and sends signals to the CCM indicating which
range of voltage it has detected. See section 231-23� for details. If one of the 3 voltage ranges, 20�-230V, 3�0-
�15V or ��0V isn’t identified then both ID signals are high resulting in an invalid signal.
Possible causes:
• Unit is connected to voltage below the 208-230V range or above the 480V range. (unlikely unless there is
a problem with the incoming voltage.)
• Defective System Bias board
• Bad connection between System Bias output J62 and CCM input J27 on the I/O board.
• Defective CCM
Troubleshooting:
1. Measure all 3 phases of the input voltage and confirm they are within the tolerance specified in the unit
manual.
2. Refer to section 231-236 Inverter VAC Mismatch and perform troubleshooting in step 1.b. If the 2 signals
don’t match the incoming voltage, if both are high, then the System Bias is defective.
3. If step 2 was OK make the same measurement at J27 on the CCM I/O PCB. If OK here the CCM is defec-
tive. Otherwise inspect the connections at J62 and J27.
239 AC Voltage High
Voltage OK -- At power up the System Bias board measures the input voltage and determined if it is within the
range of voltage set by the J1� jumper. See section 231-23� Inverter VAC Mismatch Troubleshooting step 1.a
for details of the jumper. Normally when the input voltage is OK the System Bias board turns on a relay K1
on the left die of the board to apply power to the T1 Auxiliary transformer. D��, a green “Transformer ON”
LED, will light when K1 is energized. T1 provides power to the gas controls and the TSC 3000 as well as the
pumps and fans.
Voltage High -- If the AC voltage is determined to be too high it lights D�, ACV HIGH, a red LED on the System
Bias board, and sets the signal “AC V HIGH b” on J�2-� to a “high” about 2�VDC (normal for a “low” here is
10-1�VDC). To prevent the possibility of excessive voltage applied to several items (gas controls, pumps, fans
etc.) K1 is opened removing power from T1 and D�� goes off. If it’s more than a momentary glitch the gas
controls and the TSC 3000 (if used) will reset. Communication with the cutting table may be interrupted. With
the DFC 3000 Auto Gas Control and perhaps the cutting table control, the process will have to be reloaded.
D� is on and the signal “AC V HIGH b” is high only while the voltage is actually high. The signal “AC V HIGH
b” does not latch on.
If the fault is E239 that means it is currently active, that is, currently detected as being too high. If it’s L239 that
means the voltage too high previously but it is not too high now. Applying START will clear the fault unless
it becomes active again.
The voltage that triggers an AC Voltage High fault is above 550V for ��0VAC line; above �70V for a 3�0, �00 or
�15V nominal line; above 270V for a 20� or 230VAC line.
Possible causes:
• Incoming voltage is or was too high.
• Bad connection at J62 or J27
• Bad connection at J61 jumper
• System Bias board defective
• CCM defective.