Tweco 100 Ultra-Cut Plasma Cutting System with Automated Gas Control - Manual (Page 197)

ULTRA-CUT 100 XT
Manual 0-5303 APPENDIX A-73
Troubleshooting:
1. First note whether the fault is an “E” meaning it’s currently low or an “L” meaning it was low but isn’t now.
Flow that remains low could indicate a failed component or a blockage such as clogged filter or pinched
hose. It also means you should be able to measure the flow to determine if it is really low or the sensor has
a problem.
2. First recycle power. If flow is still low or a component is defective the code should change to 404. Go to
that section for further troubleshooting.
3. If after recycling power there is no code, continue cutting to see if it occurs again. Take note of when it oc-
curs, for example if it’s with the torch at one end of the table, perhaps the leads get pinched there? In any
case go to code 404 section for more information.
403 Coolant overheated.
TS1 is a linear negative temperature coefficient (NTC) resistor sensor attached to the brass fitting at the exit of
the bypass valve. Here we determine the coolant being supplied to the torch is below the required temperature
which is currently 75 deg C (1�7F). The radiator is on the lower right side of the unit. The fan(s) are behind it
and blow out through the radiator. 100A & 200A units may either have 2 smaller fans or one larger one. The
300 & �00A units have one larger one.
Fans operate during cutting and for � minutes after last cut then shut off. Exception is AC 200 XT where the
fans are on whenever power is on. The external heat exchanger, HE�00, fan is thermostatically controlled so it
only comes on when coolant is over �0 deg C. It will shut off when the other fans shut off.
Possible reasons for coolant overheated:
Coolant fan(s) failed or defective fan control relay MC2.
• Radiator fins clogged with dirt.
• Duty cycle exceeded (ambient temperature above 40 deg C and operating at high duty cycle).
• Operating with an object placed in close proximity to the air outlet (right side of the unit) or the front
panel inlet openings.
• Operating for extended time with right lower side panel removed.
• Defective Relay board.
• Defective CCM.
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 HE�00XT heat exchanger, optional for 300A, standard for �00A, check for air blow-
ing out of it. Note that the HE�00XT fan, controlled by a thermal switch in the HE�00XT, only runs if
the coolant is over �0 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.