Tweco 400 XT Ultra-Cut Plasma Cutting System With Automated Gas Control - Manual (Page 192)

ULTRA-CUT 400 XT
A-68 APPENDIX Manual 0-5306
Possible cause:
• Most likely cause is dirty or defective fiber-optic cable or connector.
• Cable to GCM 2010, DMC or DPC not connected or broken.
• Defective control board or power supply in the Gas Control
• Defective CCM
Troubleshooting:
1. Check that the fiber-optic cable is fully plugged in to both sockets. Clean the cable ends with a soft cloth and blow out
the sockets with air.
2. Check gas control cables. If any of the gas control cables are not connected there will be no communication as there
will be no power to the control. This may show up as a 301 or 501 code. Also if the cable is broken or defective such
that the gas control is not enabled it may have power but in the case of the DMC or DPC its fault light will blink error 101
while the CCM will only detect that there is no communication and it will show 301 or possibly 501.
302 Gas Control communications reply fault
Communication has been established but Gas Control did not reply to a request from the CCM in the time allowed. Likely
cause is Fiber-optic problems (see code 501) or if problem persists defective Gas Control main PCB.
303 Gas Pressure fault
Gas pressure faults only show up when you try to start the torch, not during purging or setting flows .
With the Auto-Cut 200 XT and the Auto-Cut 300 XT (GCM 1000 XT), the gas pressure sensor is only on the plasma gas and
is in series with Run/Set switch. A 303 code here indicates either plasma gas missing or very low pressure, less than 50
PSI, or RUN/SET switch is in SET position.
Starting with GCM2010 revision AG we measure inlet pressure of both plasma and shield gas at the inlet of the gas selection
manifold. If pressure is either too low or too high it sets 303 code. Earlier revision should not display 303 code. GCM2010
will display which gas is the problem and its actual pressure. The pressure at the point where it is measured should be in the
range of 100-135 PSI. Exception is for shield gas if the Gas switch is set to Pressure then the min pressure can be 85 PSI.
In the GCM 2010 Gas Control, on the main PCB, measure between test points TP1 (ground) and TP18 (shield) and TP19
(plasma) to measure the output of the pressure sensors. Voltage should be between 2.6V to 3.5V for 100-135 PSI. With
shield switch set to pressure low limit is 2.1V. Whichever gas is outside those limits will be the one causing the fault. Re-
member the pressure may drop during operation, set the code, then recover displaying L303 when you are measuring it.
• To test for faulty pressure sensor or inadequate gas supply with too much restriction. On the GCM 2010 place the Mode
switch to SET Plasma & Shield, turn the mechanical pressure regulators to max pressure and compare mechanical
gauges with the pressure display. If the pressure display doesn’t approximately match the gauge the sensor is likely
defective. If the gauge and the pressure display both show low pressure the supply to the gas control has too much
restriction. Perhaps the hose is too long or too small.
304 Gas Control not ready
This is the normal code when the gas control is conducting a purge at start up or when the process is loaded or changed
or when the plasma system has been disabled and is returned to “Enable”. If it is a GCM 2010 the Mode switch may not be
set to the RUN mode.
Code 304 combined with 204 & 402 when the Plasma Enable on the GCM 2010 gas control is set to disable can indicate a
fault in the CCM I/O PCB. When switching back to Enabled the pump will not restart so continues to display 4-2 indicating
no coolant flowing.
Normally the code during a disable should be 101. Circuits on the I/O PCB detect the Plasma Enable is disabled and send
signal to the microcontroller in the CCM. If a fault in the CCM prevents that signal from getting sent to the microcontroller
it doesn’t know the system is disabled so it sets these other 3 codes.
305 Gas Control Protocol Error
Application error or firmware incompatibility fault. Consult factory for latest firmware update. Possible electromagnetic
interference from the Arc Starter; inspect grounding, bonding, and isolation.