Tweco Troubleshooting Power Supply Manuel d'utilisateur

1 Troubleshooting Ultracut & Autocut Systems from Status Codes This is work in progress, do not assume correct or complete The

101-5 Off the Plate (software not currently implemented) Off the Plate feature, when activated (CCM CPU board’s SW5-2 on), detects rapid rise in vo

11• Blown fuse in wall fuse/disconnect box or phase missing from power distribution. • Loose connection on power cord. • C.P1 (On/Off SW) defectiv

12 measure resistance between terminals marked R2 and +. Should measure be hundreds or thousands of ohms. A short will read less than 100 ohms.

13 When a phase is not missing the optoisolator, PHC2, output transistor is off or open so voltage across CN7-1 & 2 is +15 VDC. When a phase is

14 2-2 Input voltage out of range. The Power supply contains circuits that monitor the AC input voltage. This works as wrong voltage detection

15If code set just after arc transfer: • Unit pilots OK and can perhaps cut at lower currents but higher current will set 2-2 shortly after transfer

16Input_NGLED2D3 & 4CCMINPUTNGMISSINGPHASEMC1RY1D5 & 6VOLTAGE SELECT PCBCN26123CP1TP0CN1 (CN2)1234R11CN26123CN712345MISSING PHASEPCB7R1INPUT

17 INPUT_NG is derived from VACIN which comes from PCB1 where the 3 phase input is rectified and divided (See section on Voltage Selection &

18 2-3 Power Supply Overheated. Inverter module(s) and pilot regulator (chopper) module have sensors monitoring their temperature. An over

19 If no or reduced flow, suspect failed fan. Fans can be inspected / replaced without removing inverters. At the rear of the unit there are remo

2and crimp a small piece of steel wire, 0.020 to 0.025” dia. (0.5-0.6 mm) works best, into where wire would normally be crimped. A paper clip is a l

20 Power Supply PCB PCB5, WK-5602A, takes the signal /TEMP_ERR from the inverters on CN6-14, combines it with signal CHOPPER_TEMP_ERR (units afte

21 Ribbon Cable disconnected or open. Even though INV_READY is open collector, normally high, the ribbon cable must be connected to CN6 on PCB5

22 Measure for 110 VAC on contactor coil. If present and contactor is not energized then contactor is defective. If 110 VAC is not present, eith

23Inverter The active low signal /READY TO OPERATE comes from PCB5 and is sent to the CCM on J36-13 (34 ckt ribbon cable). Signal INV_RE

24 Code 2-5 remains set (latched) after Start is removed to indicate why unit stopped. Code is cleared next time Start is applied (if fault has be

25difficult to detect on a meter as it is only low for about 150 ms. If J35-6 does not go low even momentarily but remains high at about +10 VDC, CCM

26Cut Demand from CCM may be measured at TP13 on CCM I/O PCB (TP1 common) or J35-2. Before CNC START, Cut Demand is set to zero, if it is other tha

27as I_REF. I_REF is sent to the inverter module(s) on CN6-2 (16 ckt ribbon cable). I_REF should be 80% of Cut Demand if unit is 100, 200 or 300A

28defective. Signal Inverter OCR is sent to CCM on J36-16. If CN6-12 is not low and J36-16 is low PCB5 is defective or the 34 ckt ribbon cable is s

29 For troubleshooting code 2-7 with software prior to version 2.1 got to Troubleshooting Unwanted Current Faults and start the beginning. For troub

3 Digi-Key Part Number 922576-20-NDManufacturer Part Number 922576-20-I Price Break1 Unit Price 14.84000 Price 14.84 Digi-Key Part Number 922576-40-

30• Short between power supply negative output and earth ground. • Defective or incorrectly installed user supplied equipment such as torch height

31considered outside the supply. If it still sets code 2-7, 2-8 or 2-9 problem is inside power supply or in user installed equipment. Shorts outsi

32the J6 connector. You cannot test this by disconnecting J6 or the black and blue wires as this will set the 2-5, DC Output Low code which gets set

33Group 3, Gas Control Codes. Also refer to Gas Control Status Codes at the end of this section. 3-1 Gas Control Communication Fault No signal dete

34 3-6 Invalid Current Control level from Gas Control Whe ncCM requests the output current setting Gas Control it returned a value outside the range

35 When there is a communication error it will be displayed but once it has recovered the display will show what the error was by displaying: ^E4 –

36is pin 5 of the ribbon cable. Common is also available on at TP0 on PCB5 or TP1 on CCM I/O PCB. No flow, either actual or failure to sense fl

37 Coolant not overheated but code 4-3 still set: • Coolant temperature sensor circuit open • PCB5 • CCM Failed fan – Check for 24 VDC at fan con

38Coolant actually flows (for 30 sec. until pump shut off due to not sensing flow): • Flow sensor disconnected or failed, see sect. code 4-2 for des

39Sensor disconnected – flow sensor comes with wire about 1 ft. long and a connector that connects to a 3 wire harness. This could be disconnected or

4External E-Stop E-Stop input is on CCM module TB1-1&2. This circuit must be closed for normal operation; open activates E-Stop, generating 1

40 5-1 CANBUS Failure to Acknowledge fault. • Gas control is GCM 1000 with Basic ID problem • CANBUS / Fiber optic problem GCM 1000 (also ca

41The codes are as follows: "6-1" = CCM Analog Voltage Error "6-2" = CCM Analog to Digital Converter (ADC) or Digit

5D2100uF63V18345627K61N4004150123456J9Jumper in HMI24 VAC Powerto HMI24 VAC24 VAC RETE-STOP to Power SupplyE-STOP to GAS Control24 VACTo CPU E-Stop

6• If T1 measures OK, check for shorted capacitors C1-C3. 3. No 120 VAC to T1 primary during the ignition phase (15 seconds following Preflow) c

7 For resistor pilot units where the pilot current is controlled by the main inverter, Pilot Enable causes PCB5 to connect Pilot Demand to the inve

8charges a capacitor. If using a meter with a diode scale, expect to see continuity one way (diode forward biased) and open with probes reversed. A

9Causes for 1-4 code: • Cut demand set much lower than recommended for torch parts, i.e. 100A consumables in torch but cut current set for 30 or 50A