Tweco 400 XT Ultra-Cut Plasma Cutting System With Automated Gas Control - Manual (Page 173)

ULTRA-CUT 400 XT
Manual 0-5306 APPENDIX A-49
5. If D3 does light in the above step find the 40 pin ribbon cable plugged in to the top of the CCM. Confirm that it is
plugged in to both the CCM and the Relay board and the connector tabs are locked in place. Now using the spare
receptacle measure voltage between GND (TP1 on I/O) and the ribbon cable pin 12. It should be zero V. If not, if it’s
something like 10-15VDC, the ribbon cable is open or the Relay board is defective.
1
2
4
5
E-STOP
K?
GREEN
D13
(59)
12
15
13
16
J5
1A F20
16
14
13
15
J56
(57)
(56)
(58)
16
14
17
15
J55
GAS
CONTROL
CABLE
3
4
J26
AC24V GCM1 15
7
J10
AC24V Ret - GCM1
(114)
K1
PLASMA ENABLE
(112)
CCM I/O BOARD
RELAY BOARD
(103)
(110)
GCM 2010 GAS CONTROL
XT PLASMA SUPPLY
GCM 2010 CONTROL BOARD
GCM 2010 PLASMA ENABLE / E-STOP SIMPLIFIED CIRCUIT
Art # 12306
102 Pilot Ignition Failure
Code 102 is activated when there is no pilot current after 15 seconds of firing the Arc Starter. Pilot ignition requires the Pilot
board to be enabled, pilot switch (IGBT) turned on and high voltage pulses (HF) from the arc Starter (either the Remote Arc
Starter RAS 1000 XT or GCM 1000 XT or the arc starter built in to the AC 200 XT) applied between the tip and the electrode
of the torch.
Possible Causes for 102 code:
• No HF to the torch due to broken pilot wire connection in the torch leads.
• No HF to the torch due to defective Arc Starter.
• Arc Starter not receiving power.
• Pilot board not enabled.
• Pilot board defective.
• Relay board defective.
• Work lead current sensor defective.
• CCM defective.
Troubleshooting:
1. Determine if the problem is a lack of HF (Arc Starter) or if it’s due to the pilot circuit.
Auto-cut XT Arc Starter (inside main chassis for AC200 XT; in the GCM1000XT for AC300XT) has open spark gap. If the spark
gap is firing it is receiving power. A few early Ultra-Cut XT units were shipped with the RAS1000 Arc Starter. Troubleshoot
them the same as the GCM1000XT below. Most Ultra-Cut XT units now use the RAS1000XT Arc Starter which doesn’t use
a spark gap and is covered in the next section.