Tweco 400 XT Ultra-Cut Plasma Cutting System With Automated Gas Control - Manual (Page 179)

ULTRA-CUT 400 XT
Manual 0-5306 APPENDIX A-55
• Cut current set too high for consumable parts being used.
• With DFC 3000 a faulty component would be expected to set a fault code in either the DPC or DMC. However, if a
wrong process is selected which doesn’t match the consumable type or if using a custom process where pressure
has been set too low or current too high that could cause 108 without setting any faults in the DFC 3000.
• A broken pilot wire in the torch lead making intermittent contact can allow piloting or sometimes the torch can transfer
using only HF (high frequency). This intermittent connection will upset the tip voltage measurement and can result in
the 108 code. Symptom is - it may cut for a short time then fault. Check for an open/broken torch lead pilot wire.
• Physically shorted torch body between anode (tip) and cathode (electrode).
The fault resulting in a 108 code is measured while cutting. It is more likely a shorted torch body, depending on the resistance
of the short, it will set code 208 (Unwanted Current) as that is measured prior to starting cut However, it must be considered
as a last resort.
109 Part Process not Configured.
This represents a status, not a fault. This is used with the DFC 3000 only. It means the operator hasn’t loaded the cutting
process from either the TSC 3000 or from the program embedded in the cutting table CNC controller. The solution is to load
a process. The code will continue to be displayed until the CNC Start is applied at which time the code will clear.
110 Not Used. This is one of the reserved codes from the earlier product.
Group 2 – Plasma Power Supply codes
General:
LEDS
Several LEDs are used as indicators on the different inverter module boards. RED LEDs indicate faults. Green LEDs should
be on for the most part. Green LEDs are: On the main board, D4-READY; On the Cap Bias Board, D6, -12V, D11 +12VP (pri-
mary referenced), D13, +12V; On the Control board D24, PWM will only be on when the inverter is enabled and its brightness
varies with the duty cycle of the PWM.
Signals:
General description of some Inverter Signals passed to the CCM that can generate fault codes in Group 2.
“Ready” also called AC IN FLT (D4, READY LED, green, on Main Inverter board)
On the inverter main board we measure the input voltage. The 3 phases are rectified and lightly filtered to achieve an average
voltage. Due to the light filtering a missing phase will also lower the average voltage so it will be detected. Voltage in the
correct range turns on the READY LED D4 (on the far left of the main boards, in the upper part of the “B” section or lower
part of the “A” section). Voltage outside the correct range or missing phase will turn D4 off.
An AC Input Fault by itself (no other faults occurring at the same time) will set codes in the 241-246 group depending on
which inverter sees the problem.
INV FLT (D1, INV FLT LED, red, on the Inverter Control and Fault board)
Several things can cause Inv Flt (Inverter Fault). Inverter fault is indicated by an LED, D1 on the Inverter Control and Fault
board. Inverter Fault, when it occurs, is latched on. The latch is reset next time the inverter is enabled unless it is still active
in which case it is immediately latched again. Inverter Fault will set the codes 247-252 unless it’s in conjunction with another
fault in which case that fault code may be set.
Things that can set the inverter fault:
• The local (to the inverter) + 12V & -12V bias supplies out of tolerance. There are LEDs on the Cap/Bias board that
light indicating these bias supplies are present but don’t verify they are in tolerance. It’s not likely this would happen.
More likely that fault related to the +/-12V the supply would be missing and it’s LED not on.
• Capacitor imbalance. In a cap imbalance condition D3, red Led on the main board (lower left corner of bottom or “A”
section and upper left corner of the upper or “B” section), will latch on.
• Primary over current. This is an over current condition in main switching transformer’s primary. This will latch on
but is cleared when the inverter is enabled unless it is still active in which case it is immediately latched again.
• Inverter over temperature sets the Fault signal and LED but has its own fault signal to the CCM. See OT Flt below.