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Manual No. 0-5056

4-3

OPERATION

4.03 Gas Control Module Operation

Functional Overview

The Gas Control Module provides all Plasma and Secondary gas selection and control instrumentation. There are
various controls and indicators used to set gas pressures and flows.

AMPERAGE

SET-UP

ENABLE

DISABLE

PLASMA
POWER
SUPPLY

SHIELD

FLOW

GAS

PRESSURE

MODE

GAS

GCM

2010

PLASMA

PREFLOW

O2 - AIR

O2 - O2

H35 - N2

F5 - N2

AIR - AIR

N2 - H20

N2 - N2

Art # A-04771

MODE

GAS

O2 - AIR

O2 - O2

H35 - N2

F5 - N2

AIR - AIR

N2 - H20

N2 - N2

ENABLE

DISABLE

PLASMA

POWER SUPPLY

FLOW

GAS

PRESSURE

AMPERAGE

SET-UP

9

9

H20

MIST

RUN

SET PREFLOW

SET PLASMA

& SHIELD

TEST

RUN

SET PREFLOW

SET PLASMA

& SHIELD

TEST

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Summary of Contents for 200 ULTRA-CUT

Page 1: ...PLASMA CUTTING SYSTEM 200 ULTRA CUT Operating Manual Rev AD Date February 5 2008 Manual 0 5056 OperatingFeatures Art A 04816 ...

Page 2: ...e please take the time to read the entire manual especially the Safety Precautions They will help you to avoid potential hazards that may exist when working with this product YOU ARE IN GOOD COMPANY The Brand of Choice for Contractors and Fabricators Worldwide Thermal Dynamics is a Global Brand of manual and automation Plasma Cutting Products for Thermadyne Industries Inc We distinguish ourselves ...

Page 3: ...tion All rights reserved Reproduction of this work in whole or in part without written per mission of the publisher is prohibited The publisher does not assume and hereby disclaims any liability to any party for any loss or damage caused by any error or omission in this Manual whether such error results from negligence acci dent or any other cause Printed in the United States of America Licensed u...

Page 4: ...Thispageintentionallyblank ...

Page 5: ...TALLATION 3 1 3 01 Installation Requirements 3 1 3 02 System Layout 3 2 3 03 Cables Leads Identification 3 3 3 04 Lift the Power Supply 3 4 3 05 Remove the Connections Cover 3 5 3 06 Ground Connections 3 10 3 07 Connect Work Cable and Pilot and Negative Leads 3 12 3 08 Connect Coolant Leads 3 13 3 09 Connect Control Cables for CNC Remote Arc Starter and GCM 3 14 3 10 Connect Fiber Optic Cable Type...

Page 6: ...Replacement Parts Right Side 6 11 6 09 Power Supply Replacement Parts Front Panel 6 12 6 10 Power Supply Replacement Parts Front Panel 6 13 6 11 Power Supply Replacement Parts Right Side 6 14 6 12 Power Supply Replacement Parts Rear Panel 6 15 6 13 Power Supply Replacement Parts Right Side 6 16 6 14 Power Supply Replacement Parts 6 17 6 15 Power Supply Replacement Parts Right Side 6 18 6 16 Power ...

Page 7: ...de Continued A 16 APPENDIX 10 Schematic 230 460V Unit w Resistor Pilot A 18 APPENDIX 10 Schematic 230 460V Unit w Resistor Pilot Continued A 20 APPENDIX 11 Schematic CCC 400V Unit w Chopper Pilot A 22 APPENDIX 11 Schematic CCC 400V Unit w Chopper Pilot Continued A 24 APPENDIX 12 Schematic CE 400V Unit w Chopper Pilot A 26 APPENDIX 12 Schematic CE 400V Unit w Chopper Pilot Continued A 28 APPENDIX 1...

Page 8: ......

Page 9: ...tronic health equipment Persons who work near plasma arc cutting applications should consult their medical health professional and the manufacturer of the health equipment to determine whether a hazard exists To prevent possible injury read understand and follow all warnings safety precautions and instructions before using the equipment Call 1 603 298 5711 or your local distributor if you have any...

Page 10: ...f from the work piece or other parts of the welding circuit Repair or replace all worn or damaged parts Extra care must be taken when the workplace is moist or damp Install and maintain equipment according to NEC code refer to item 9 in Subsection 1 03 Publications Disconnect power source before performing any service or repairs Read and follow all the instructions in the Operating Manual FIREAND ...

Page 11: ... Z49 1 Minimum Protective Suggested Arc Current Shade No Shade No Less Than 300 8 9 300 400 9 12 400 800 10 14 These values apply where the actual arc is clearly seen Experience has shown that lighter filters may be used when the arc is hidden by the workpiece 1 03 Publications Refer to the following standards or their latest revisions for more information 1 OSHA SAFETY AND HEALTH STANDARDS 29CFR ...

Page 12: ...s Association 1235 Jefferson Davis Highway Suite 501 Arlington VA 22202 12 CSA Standard W117 2 CODE FOR SAFETY IN WELDING AND CUTTING obtainable from the Canadian Standards Association Standards Sales 178 Rexdale Boulevard Rexdale Ontario Canada M9W 1R3 13 NWSA booklet WELDING SAFETY BIBLIOGRAPHY obtainable from the National Welding Supply Association 1900 Arch Street Philadelphia PA 19103 14 Amer...

Page 13: ...ment UL Underwriters Laboratory rating 94VO flammability testing for all printed circuit boards used ISO IEC 60974 1 BS 638 PT10 EN 60 974 1 EN50192 EN50078 applicable to plasma cutting equipment and associated accessories CENELEC EN50199 EMC Product Standard for Arc Welding Equipment For environments with increased hazard of electrical shock Power Supplies bearing the S mark conform to EN50192 wh...

Page 14: ...uch as the performance or breach thereof or from the manufacture sale delivery resale or use of any goods covered by or furnished by Thermal whether arising out of contract negligence strict tort or under any warranty or otherwise shall not except as expressly provided herein exceed the price of the goods upon which such liability is based THIS WARRANTYBECOMES INVALID IF REPLACEMENT PARTS ORACCESS...

Page 15: ...or cutting operations The power supply also monitors system performance and cools and circulates the liquid coolant for the torch and leads 2 03 Remote Arc Starter This unit produces a temporary HF pulse to start the pilot arc The pilot arc creates a path for the main arc to transfer to the work When the main arc is established the pilot arc shuts off 2 04 Gas Control Module This module allows rem...

Page 16: ...ge Type G G GC W Suggested Sizes See Note Line Voltages with Suggested Circuit Protection and Wire Sizes 1 Extra Hard Usage Type SO SOW SOO SOOW ST STW STO STOW STOO STOOW Based on National Electric Code and Canadian Electrical Code 2 07 System Component Layout Refer to section 3 11 for ground connections and ground cables Primary power Work CNC Remote Arc Starter Art A 07233_AB Torch Coolant Supp...

Page 17: ...Manual No 0 5056 2 3 SPECIFICATIONS 2 08 Power Supply Dimensions Art A 07182 37 75 inch 960 mm 27 5 inch 700 mm 33 inch 840 mm 27 inch 680 mm 41 25 inch 1050 mm 433 lb 196 kg ...

Page 18: ...olant Tank Coolant Filter Coolant Connections Input Power Terminals Pilot Pos Terminal Circuit Breaker Panel Terminal Cover AC Power Lamp Ground Terminals Gas Control Console Connector RETURN SUPPLY Art A 04794 CNC Connector Remote Arc Starter Connector Work Cable Terminal Torch Neg Terminal Leads Bracket ...

Page 19: ...ce does not need to be deionized but in water systems with extremely high mineral content a water softener is recommended Tap water with high levels of particulate matter must be filtered Note 1 The air source must be adequately filtered to remove all oil or grease Oil or grease contamination from compressed or bottled air can cause fires in conjunction with oxygen Note 3 Water Pressure Regulator ...

Page 20: ...IONS 2 12 XTTM 300 Torch Specifications A Torch Dimensions 2 25 57 15 mm 2 0 50 8 mm 2 39 60 81 mm 1 49 37 8 mm 19 00 482 68 mm 15 50 393 78 mm 2 63 66 8 mm 1 57 39 96 mm 3 98 101 1 mm 6 30 160 10 mm Art A 08301 Mounting Tube End Cap ...

Page 21: ...utor Shield Gas Distributor Shield Cap D Parts In Place PIP The torch is designed for use with a power supply which senses coolant return flow to confirm that torch parts are in place If coolant return flow to the power supply is absent or insufficient the power supply will not provide power to the torch Coolant leakage from the torch also indicates that torch parts are absent or installed imprope...

Page 22: ...0kV Current Up to 200 Amps DC Straight Polarity Plasma Gases Compressed Air Oxygen Nitrogen H35 Shield Gases Compressed Air Oxygen Nitrogen Water Operating Pressure 125 psi 10 psi 8 6 bar 0 7 bar Maximum Input Pressure 135 psi 9 3 bar Gas flow 10 300 scfh XTTM 300 Torch Ratings for use with Ultra Cut 200 Power Supply XTTM 300 Torch Gas Specifications G Plasma Power Supply Used With Thermal Dynamic...

Page 23: ...e installation must conform to national and local codes for the type and method of wire being used Gas Supply The customer must supply all gases and pressure regulators Gases must be of high quality Pressure regulators must be double stage and installed as close as possible to the gas console Contaminated gas can cause one or more of the following problems Reduced cutting speed Poor cut quality Po...

Page 24: ...Cable Pilot Return Coolant Supply Coolant Return Plasma Gas Shield Gas Work Cable Fiber Optic Cable Control Cable Gas Control Module Power Supply Torch Valve Assembly Positioning Tube Plasma Gas Preflow Gas Water Shield Shield Shield Gas Negative Pilot Return Control Cable 100 30 5 m Maximum Length 125 38 1 m Maximum Length 175 53 3 m Maximum Length Shield H Q R T S A B C D E P K L O I J G 175 53 ...

Page 25: ...lot Return Power Supply to Arc Starter Negative Lead Power Supply to Arc Starter Control Cable Power Supply to Arc Starter Ground Cable Ground Cable Remote Arc Starter To Earth Ground O P Fiber Optic Cable Power Supply to Gas Control Module Control Cable Power Supply to Gas Control Module Green Red Coolant Return Lead Power Supply to Arc Starter 2 2 14 G Shielded Torch Lead Assembly Remote Arc Sta...

Page 26: ...ur lifting eyes when using lifting straps to lift the power supply Use a forklift crane or hoist to lift the unit off the shipping pallet as shown Keep the power supply steady and vertical Do not lift it any further than necessary to clear the shipping pallet Art A 04796 Set the power supply on a solid level surface The installer may fasten the power supply to the floor or a supporting fixture wit...

Page 27: ...e supplied by the end user and connected to the power supply Remove the connections cover on the rear of the Power Supply Use caution when removing the panel there is a ground wire connected to the inside of the panel Do not disconnect this wire Connections Cover Removed Connection Panel Art A 04797 ...

Page 28: ...oard The input voltage configuration is shown at the top of the board 2 If necessary disconnect the jumper at the top right corner of the board remove the board and re install it with the correct input voltage shown at the top of the board 3 Re connect the jumper Re install the power supply side panel Art A 04856 1 Disconnect jumper 2 Remove bolts 3 Invert board 4 Re install board 5 Connect jumper...

Page 29: ...ound terminal block CAUTION The clear connections cover must remain in place 4 If required pass a system ground cable F1 through the last opening in the connections cover support panel next to the input power cable Connect the cable to the ground terminal block on the power supply rear panel Refer to the Ground Connections Section for full details and procedures on proper system grounding PILOT WO...

Page 30: ...ntry 1 0 Work Cable Remote Arc Starter RAS 1000 1 0 Ground Cable F1 Star Ground on Cutting Table Star Ground on Cutting Table 1 0 Ground Cable Ultra Cut or Auto Cut O2 Note The gas control module can be mounted on top of the power supply If it is it should be grounded directly to the power supply with 4 AWG ground F This alternate location requires grounding the power supply to the Star ground wit...

Page 31: ...round Cable Customer Supplied 4 AWG Ground F Factory Installed GCM 1000 Gas Control Module Auto Cut Power Supply Star Ground Earth Ground Rod 1 0 Ground Cable F1 CNC Device Torch Cutting Table Cutting Machine Gantry 1 0 Work Cable Auto Cut Basic System Without RAS Art A 08254_AC ...

Page 32: ...round wire and the Gas Control Module should use minimum 4 AWG wire The connection point must be to clean bare metal rust and paint make poor connections For all components wires larger than the recommended minimum can be used and may improve noise protection 3 The cutting machine frame is then connected to the Star point using 1 0 AWG European 50 mm2 or larger wire 4 The plasma power supply work ...

Page 33: ...TRAL Earth Grounded HOT On 115V AC Line 3VAC 3 ohms 1VAC 1 ohm On 230V AC Line 1 5VAC 3 ohms 0 5VAC 1 ohm Ground Rod with other connections removed 100W Incandescent light bulb Can replace light bulb with a 100w resistor Use 100 ohm for 115VAC Use 500 ohm for 230VAC NEUTRAL PROBE VAC HOT PROBE Ground Testing 2 Increasing the ground rod length beyond 20 30 ft 6 1 9 1 m does not generally increase t...

Page 34: ...n the connections cover support panel 2 Refer to the illustration Connect the leads as shown Tighten securely Do not overtighten CAUTION The clear connections cover must remain in place PILOT WORK TORCH Connection Panel AC INPUT L1 L2 L3 Work Lead Torch Lead To Remote Arc Starter Work Torch Lead Connection Detail Connections Cover Support Panel Art A 07660_AB Connections Cover Pilot To Cutting Tab...

Page 35: ...Connect the color coded coolant hoses to the coolant connections on the power supply rear panel The supply line out is flagged green the return line in is flagged red Coolant Connections RETURN SUPPLY RETURN SUPPLY Art A 04800 To Remote Arc Starter COOLANT RED GREEN ...

Page 36: ... Starter and GCM 1 Connect one end of each cable to the power supply 2 Connect the other end of the CNC cable to the CNC device 3 The CNC cable shield must be attached to ground RETURN SUPPLY Art A 04802 To CNC To Remote Arc Starter To Gas Control Module Customer Wiring Access Hole ...

Page 37: ...wn a Remove the strain relief securing nut from the strain relief on the fiber optic cable s Loosen the strain relief dome nut from the strain relief b Pass the cable connector through the appropriate opening Slide the strain relief securing nut onto the cable Make a loop of the cable carefully press the cable connector into the appropriate receptacle on the internal control module c Tighten the s...

Page 38: ...led Factory default setting SW 1 2 Pilot Delay 2 OFF 3 OFF 4 OFF 0 Seconds Factory default setting SW 1 3 Pilot Delay 2 ON 3 OFF 4 OFF 0 1 Seconds SW 1 4 Pilot Delay 2 OFF 3 ON 4 OFF 0 2 Seconds 2 ON 3 ON 4 OFF 0 4 Seconds 2 OFF 3 OFF 4 ON 0 8 Seconds 2 ON 3 OFF 4 ON 1 0 Seconds 2 OFF 3 ON 4 ON 1 5 Seconds 2 ON 3 ON 4 ON 2 0 Seconds SW 4 Postflow Time 1 OFF 2 OFF 10 Seconds Factory default setting...

Page 39: ... closure 120VAC 1A Factory default setting or DC Volts 16 18vdc up to 100 ma SW 11 Analog Current Control B from Gas Control Factory default setting or A from CNC Position A requires that SW 8 2 be ON SW 12 1 2 3 4 Divided Arc signal All OFF 50 1 Factory default setting 1 ON 16 6 1 2 ON 30 1 3 ON 40 1 4 Not used Art A 06792 Only 1 on at a time SW11 SW13 SW6 SW12 No external connection cover SW13 T...

Page 40: ...equires connection to the full non divided arc voltage Also available on the terminal strip are 120VAC 120 0 and 24 VAC 24 0 Note that the two 0 s are not common The allowable current draw is 100ma 120VAC and 1Amp 24 VAC There is also a hole added in the rear panel above the J55 GCM receptacle for customer wiring This rather than the one in the CCM will be the preferred place for customer added wi...

Page 41: ... away as possible from the Arc Starter due to electromagnetic interference It is acceptable to locate the control cable in the same track as the cables from the Arc Starter The Module includes feet which lift the bottom panel off the mounting surface There are ventilation holes on the bottom panel the space between the bottom panel and the mounting surface must remain open for ventilating air to e...

Page 42: ... are not plumb incorrect flow indications may occur Preparation 1 Remove the screws securing the Cover Panel to the Module 2 Carefully remove the cover from the module noting the attached ground wire Remove the ground wire if needed Art A 06882 Gas Control Module Cover Do not remove Remove Ground Wire Cover Removal ...

Page 43: ...the back of the Module Pass enough of the cable into the Module to allow the cable to loop upward as shown CAUTION Avoid kinking twisting or bunching the fiber optic cable The cable can be damaged by being forced into tight radius turns 2 3 Circuit Board Art A 04772 Fiber Optic Cable COMM PLASMA OUT PREFLOW OUT J57 J56 SHIELD OUT H2O INPUTS TVA POWER SUPPLY H35 F5 AIR N2 O2 1 CO MM J57 J56 INP UTS...

Page 44: ... cable connector into the receptacle on the vertically mounted circuit board as shown Circuit Board Fiber Optic Cable Art A 04773 4 Tighten the through hole protector for the fiber optic cable 5 Reinstall the Cover Panel making sure the ground wire is attached ...

Page 45: ... Module to the mounting surface 5 Connect all gas water inputs to the rear panel of the module 6 Connect the appropriate control cables to terminals marked TVA torch valve assembly and power sup ply Gas Water Inputs Check Valves Connection Panel To Torch Valve Assembly To Torch Valve Assembly To Power Supply SHIELD PLASMA PREFLOW H O SHIELD 2 H O 2 AIR N2 O2 H35 F5 TVA POWER SUPPLY COMM J57 J56 IN...

Page 46: ...ions in the front of this manual to be sure that the location meets all safety requirements Interconnecting cables and hoses attach to the Arc Starter There must be adequate space around the Arc Starter for these connections without crimping Mounting Dimensions D 250 3 PLACES 6 35mm 8 00 203 20mm 12 00 304 80mm 2 00 50 80mm 1 49 37 77mm 10 50 266 70mm 7 51 190 83mm 50 12 70mm Arc Starter Box Art A...

Page 47: ... the support securely 1 Loosen but do not remove the lower screws securing the cover to the Arc Starter Remove the upper screws securing the Cover Panel to the Arc Starter NOTE A ground wire connects the cover to the Arc Starter base This wire must remain in place 2 Remove the Cover Panel from the Arc Starter Art A 07029 Lower screws Upper screws 4 per side Cover Ground Wire Cover Removal 3 Positi...

Page 48: ... Starter to the mounting surface Art A 04749 Minimum 2 Input Connections 1 Refer to the illustrations Make the following input connections to the Arc Starter Coolant Supply and Return Hoses from power supply Hoses and connectors are color coded Red for Return Green for Supply Coolant Supply and Return Hoses from power supply Art A 04750 ...

Page 49: ...anual No 0 5056 3 27 INSTALLATION Coolant Return Red Coolant Supply Green Art A 04751 Coolant Return Red Red Green Art A 04752 Negative Cable from power supply Negative Cable from Power Supply rear panel ...

Page 50: ...Manual No 0 5056 3 28 INSTALLATION Art A 04753 Pilot Return Cable from Power supply PILOT Return Cable from Power Supply rear panel Art A 04755 Control Cable from Power Supply rear panel ...

Page 51: ...tions 1 Refer to the illustrations Make the following output connections to the Arc Starter Pilot Lead Connection Detail Inner Shield Connection Detail Inner Shield Lead Pilot Lead Art A 04933 Pilot Return Cable and Inner Shield Lead from Torch Leads ...

Page 52: ...Green Coolant Return Fitting Tagged with Red Coolant Supply and Return Hoses from Torch Reinstall the Arc Starter Cover Ensure that the ground wire is not crimped between the cover and the base Art A 07029 Lower screws Upper screws 4 per side Cover Ground Wire The Arc Starter must be grounded the grounding terminal is marked Refer to the previous section for grounding details ...

Page 53: ... Art A 04758 1 Nut and 1 Washer Remain in Place Torch Leads Use a clamp to secure the Torch Lead Shield braid to the port on the Remote Arc Starter as shown Art A 04759 Coolant and Pilot Leads to Torch Valve Assembly Torch Leads Shield Shield Clamp ...

Page 54: ...ON Connect Control Cable 1 Connect the Remote Arc Starter cable to the Remote Arc Starter receptacle Art A 04801 RETURN SUPPLY RETURN SUPPLY Power Supply Rear Panel COOLANT Remote Arc Starter Input Connection Panel Remote Arc Starter ...

Page 55: ... mm 261 Dia 6 63 mm Art A 07648 1 Mount the Valve Kit as close as possible to the Torch The valve kit can be mounted in any convenient position provided the outlet side with two fittings is closer to the torch than the inlet side with three fittings and a control cable connector 2 Connect the Valve Kit outlets to the torch leads as shown XTL shown Art A 07645 Do not remove brass plugs Front and si...

Page 56: ...ary while attaching the gas lines XTL shown Control Cable Plasma Gas Inlet Shield Gas Inlet Preflow Gas Inlet Water Inlet Art A 07646 Exhaust Muffler CAUTION Hold all fittings stationary while attaching hoses or leaks can be created Side pressure can break the check valves or weaken their connection to the torch valve assembly All fittings must be checked for leaks after assembly ...

Page 57: ...nd Cap stationary Pull approximately 18 0 5 m of leads through the End Cap 3 Remove and discard the protective end caps from the Mounting Tube 4 Install the O ring in the groove at the upper end of the Mounting Tube 5 Install the Mounting Tube as follows a Position the Mounting Tube at the end of the leads assemblies as shown b Slide the Mounting Tube upward onto the leads assemblies c Press the u...

Page 58: ...h installation 7 Connect the pilot lead to the Torch Head Press the two ends of the connector firmly together Thread the plastic lead cover connector onto the mating Torch Head connector 8 Press the Torch Head Assembly upward to connect to the Mounting Tube Pull the leads back as needed to ensure a proper fit through the MountingTube andTorch Leads End Cap Hold theTorch Head Assembly stationary ro...

Page 59: ... e c t r o d e C a r t r i d g e Art A 08303 A B C 1 Assemble A 200 A only 2 Assemble B 3 Assemble B to C 4 Assemble A to B C assembly 4 Insert the stack of consumable parts into the cartridge Ensure that the large O ring on the torch tip fits completely into the cartridge If any part of the O ring protrudes from the cartridge the parts are not seated properly 5 Use the cartridge tool to hold the ...

Page 60: ... 38 INSTALLATION Torch Head O Ring Torch Head Art A 08300_AB 0 063 0 083 1 6 2 1 mm Protrusion Installing Assembled Cartridge Onto Torch Head 6 Slide the ohmic clip over the shield cup if using ohmic torch height sensing ...

Page 61: ...63 0 083 1 6 2 1 mm Electrode Plasma Gas Distributor Tip Shield Gas Distributor Shield Cap O Ring on Tip 1 Stack Parts 2 Press Cartridge onto Stacked Parts 4 Check Shield Cap Protrusion Art A 04873 No Gaps Between Parts 3 Thread Shield Cup onto Cartridge Shield Cap Shield Cup Installing Assembled Cartridge Onto Torch Head ...

Page 62: ...the wire lead from the height finder to the ohmic clip if using ohmic torch height sensing A 03393 Ohmic Clip NOTE Ohmic height sensing is not recommended with water shield Water on the plate interferes electrically with the ohmic sensing circuit ...

Page 63: ...coolant required varies with torch leads length Cat Number and Mixture Mixture Protects To 7 3580 Extra CoolTM 25 75 10 F 12 C 7 3581 Ultra CoolTM 50 50 27 F 33 C 7 3582 Extreme CoolTM Concentrate 65 F 51 C Coolant Capabilities For mixing with D I CoolTM 7 3583 RETURN SUPPLY RETURN SUPPLY Art A 04803 COOLANT Fill Range Coolant Tank 2 After the complete system has been installed check that the cool...

Page 64: ...b through d until the system no longer shuts down Depending on the length of the torch leads this sequence may need to be done three to five times f After the system stays operational allow the pump to operate for ten minutes to properly purge any air from the coolant lines before using the system 3 Re fill the reservoir and re install the filler cap 4 Purge coolant from the torch before firing th...

Page 65: ...ndicator Normally OFF Indicator will come ON when the internal temperature sensors detect temperatures above normal limits Let the unit cool before continuing operation GAS Indicator Normally ON Indicates adequate gas pressure for operation in the system DC Indicator Indicates the power supply is generating output DC voltage Status Indicator Show system status The number of flashes indicates the s...

Page 66: ...ower 2 Turn ON OFF switch to ON up position AC Indicator turns ON POWER ON OFF O I OFF O Art A 04812 3 Check the AC indicator If indicator does not light reverse two phases of primary input power cable If indicator is ON system is ready to operate pending fault checks by internal circuitry ...

Page 67: ...ors used to set gas pressures and flows AMPERAGE SET UP ENABLE DISABLE PLASMA POWER SUPPLY SHIELD FLOW GAS PRESSURE MODE GAS GCM 2010 PLASMA PREFLOW O2 AIR O2 O2 H35 N2 F5 N2 AIR AIR N2 H20 N2 N2 Art A 04771 MODE GAS O2 AIR O2 O2 H35 N2 F5 N2 AIR AIR N2 H20 N2 N2 ENABLE DISABLE PLASMA POWER SUPPLY FLOW GAS PRESSURE AMPERAGE SET UP 9 9 H20 MIST RUN SET PREFLOW SET PLASMA SHIELD TEST RUN SET PREFLOW...

Page 68: ...Art A 04765 9 9 GCM 2010 Normally in the RUN position during torch operation In the SET PREFLOW position Air or N2 travels to the torch The Preflow valve remains open for 2 minutes to allow the operator to adjust flow pressure In the SET PLASMA SHIELD position gases travel to the torch The Preflow valve at the torch remains open for 2 minutes to allow the operator to adjust flow pressures and rate...

Page 69: ...S O2 AIR O2 O2 H35 N2 F5 N2 AIR AIR N2 H2O N2 N2 PREFLOW H2O MIST PLASMA SHIELD PRESSURE PLASMA POWERSUPPL Y GAS FLOW AMPERAGE SET UP High Precision Plasma Cutting System ENABLE DISABLE GAS MODE RUN SET PREFLOW SET PLASMA SHIELD TEST O2 AIR O2 O2 H35 N2 F5 N2 AIR AIR N2 H2O N2 N2 9 9 Art A 04766 GCM 2010 ...

Page 70: ...rc at the torch while the operator selects and adjusts gases or changes torch parts The DISABLE position also stops coolant and gas flow In the ENABLE position allows normal operation under control of the CNC device 5 PREFLOW Control Knob and Pressure Gauge Used to set preflow gas pressure MODE switch must be in PREFLOW position 6 PLASMA and SHIELD Control Knobs Pressure Gauges and Flow Meters Use...

Page 71: ...se the PLASMA and SHIELD control knobs pressure gauges and flow meters to set plasma and shield gas pressures and flows Refer to the torch manual for pressure settings c In installations using water shield use the H2 O MIST control knob and flow meter to set water flow rate Refer to the torch manual for flow rates 5 Use the AMPERAGE SET UP control knob to set the desired amperage output The module...

Page 72: ...dicular to the surface of the plate A perfectly perpendicular cut would result in a 0 bevel angle Top Edge Rounding Rounding on the top edge of a cut due to wearing from the initial contact of the plasma arc on the workpiece Dross Build up and Top Spatter Dross is molten material which is not blown out of the cut area and re solidifies on the plate Top spatter is dross which accumulates on the top...

Page 73: ...from the bottom of the plate Failure to follow this recommendation could result in poor cut quality and short consumable parts life Ohmic Sensing Ohmic sensing is not recommended with water shield Water on the plate interferes electrically with the ohmic sensing circuit 4 05 Gas Selection A Plasma Gases 1 Air Plasma Most often used on ferrous or carbon base materials for good quality at faster cut...

Page 74: ...ke and heat input to the workpiece Effective up to 1 2 inch 12 7 mm maximum material thickness Tap water provides low operating expense 4 06 Power Supply Status Codes On start up and during operation the power supply control circuitry performs various tests If the circuitry detects a condition requiring operator attention the status indicator on the control panel flashes a 2 part code to indicate ...

Page 75: ...e Broken or loose connection on power cable Inverter s not configured correctly for input voltage Poor power quality brownouts dropouts Input power capacity wiring too small causing voltage drop broken or loose power cable connections 2 3 Inverter or Pilot Regulator Over Temperature Failed fan Ambient above 40 deg C 104 F Blocked airflow 2 4 Power Supply not Ready Defective inverter 2 5 DC Output ...

Page 76: ...ibility 3 7 Gas Control returns wrong command sequence Check firmware compatibility 3 8 CCM and Gas Control type Autocut Ultracut mismatch Install correct CCM or Gas Control for system 3 9 Gas Control Communication reply fault Reply not compatible with request Check firmware compatibility 3 10 Warning Gas Control Systemwill function but control may not be optimized for best 4 1 Coolant Level low f...

Page 77: ...ocked into connector sharp bends in fiber fiber defective CANBUS hardware error CCM or Gas Control PCB 6 1 CCM Analog Voltage Error Replace CCM 6 2 CCM ADC or DAC error Replace CCM Torch coolant tube broken or missing CCM fault replace CCM 6 4 CCM Data Memory error Replace CCM Status Code Key cond Message Cause Remedy 5 2 Dirt on fiber ends or in connectors blow out with clean dry air fiber not lo...

Page 78: ...onnect Faulty EMI filter Voltage Resistor measurement Replace Loose fitting s Visual inspection Tighten fittings Failure to braze joints L1 Visual inspection Replace HF Coil Damaged or punctured coolant line s Visual inspection Replace coolant line s Supply return hose reversed Visual Inspection of color coded connections Match coolant connection colors to arc starter fitting colors Blockage in co...

Page 79: ...Manual No 0 5056 4 15 OPERATION 4 08 Remote Arc Starter Spark Gap Adjustment Art A 04857 0 063 0 002 1 6 0 05 mm ...

Page 80: ...Manual No 0 5056 4 16 OPERATION This page intentionally blank ...

Page 81: ...replace external coolant filter Clean coolant tank Vacuum out any dust buildup inside power supply Check internal coolant filter 5 02External Coolant Filter Cleaning Procedure Periodic cleaning of the coolant filter ensures maximum coolant flow efficiency Poor coolant flow causes ineffi cient torch parts cooling with consequent faster consumable wear Clean the coolant filter as follows 1 Disconnec...

Page 82: ...ne FilterAssembly 5 04 Coolant Replacement Procedure Replace coolant as follows 1 Disconnect the system from main input power At the bottom of the coolant tank disconnect the coolant line fitting and collect coolant in a disposable container 2 Connect the system to main input power and turn it on to allow the pump to empty the tank The pump will run approximately for 20 seconds before the flow swi...

Page 83: ...8 230V 3 9119 1 Ultra Cut 200 Power Supply 460V 3 9119 2 Ultra Cut 200 Power Supply 400V 3 9119 3 Ultra Cut 200 Power Supply 400V CE 3 9119 4 Gas Control Module GCM 2010 with Torch Valve Assembly 3 9131 Gas Control Module GCM 2010 Only 7 4000 Original Torch Valve Assembly Only 4 3049 XTL Torch Valve Assembly Only 4 3054 Remote Arc Starter RAS 1000 3 9130 OPTIONAL EQUIPMENT Wheel Kit 9 9379 ...

Page 84: ...as Shield Gas Work Cable Fiber Optic Cable Control Cable Gas Control Module Power Supply Torch Valve Assembly Positioning Tube Plasma Gas Preflow Gas Water Shield Shield Shield Gas Negative Pilot Return Control Cable 100 30 5 m Maximum Length 125 38 1 m Maximum Length 175 53 3 m Maximum Length Shield H Q R T S A B C D E P K L O I J G 175 53 3 m Maximum Length Refer to section 3 05 for ground conne...

Page 85: ...Arc Starter Control Cable Power Supply to Arc Starter Ground Cable Ground Cable Remote Arc Starter To Earth Ground O P Fiber Optic Cable Power Supply to Gas Control Module Control Cable Power Supply to Gas Control Module Green Red Coolant Return Lead Power Supply to Arc Starter 2 2 14 G Shielded Torch Lead Assembly Remote Arc Starter to Torch Plasma Gas Lead Torch Valve to Torch Shield Gas Lead To...

Page 86: ...ilot Return Cable only 50 15 2 m 9 4792 A Pilot Return Cable only 75 22 8 m 9 4793 A Pilot Return Cable only 100 30 5 m 9 4794 A Pilot Return Cable only 125 38 1m 9 4796 B Negative Cable only 3 1 m 9 4892 B Negative Cable only 10 3 05 m 9 4897 B Negative Cable only 15 4 5 m 9 4798 B Negative Cable only 25 7 6 m 9 4799 B Negative Cable only 35 10 6 m 9 9427 B Negative Cable only 50 15 2 m 9 4800 B ...

Page 87: ...Control Cable only Power Supply to Arc Starter 75 22 9 m 9 4943 E Control Cable only Power Supply to Arc Starter 100 30 5 m 9 4944 E Control Cable only Power Supply to Arc Starter 125 38 1 m 9 4922 F Ground Wire Power Supply to Gas Control Module 3 1 m 9 4923 F Ground Wire Power Supply to Gas Control Module 15 4 5 m 9 4924 F Ground Wire Power Supply to Gas Control Module 25 7 6 m 9 4925 F Ground W...

Page 88: ...e 2 4 3041 H Q R S T Gas Lead Set 150 45 7 m See Note 2 4 3042 H Q R S T Gas Lead Set 175 53 3 m See Note 2 4 3043 I Plasma Lead 4 1 22 m Torch Valve Assembly to Torch 9 3333 J Shield Lead 4 1 22 m Torch Valve Assembly to Torch 9 3334 L Control Cable Fiber Optic 3 1 m 9 4898 L Control Cable Fiber Optic 15 4 5 m 9 4899 L Control Cable Fiber Optic 25 7 6 m 9 4900 L Control Cable Fiber Optic 35 10 6 ...

Page 89: ...e 150 45 7 m 9 4914 O Work Cable 10 3 05 m 9 9300 O Work Cable 15 4 5 m 9 9301 O Work Cable 25 7 6 m 9 9302 O Work Cable 35 10 6 m 9 9303 O Work Cable 50 15 2 m 9 9304 O Work Cable 75 22 9 m 9 9305 O Work Cable 100 30 5 m 9 9306 O Work Cable 125 38 1 m 9 9307 P Control Cable CNC to Power Supply 25 7 6 m 9 8312 P Control Cable CNC to Power Supply 50 15 2 m 9 8313 P Control Cable CNC to Power Supply...

Page 90: ...9 9380 1 Power Supply Rear Panel 9 9381 1 Power Supply Top Panel 9 9382 1 Power Supply Right Side Panel 9 9383 1 Power Supply Left Side Panel 9 9384 1 Louver Panel 9 9385 1 Power Supply Connections Cover 9 9386 1 Lifting Eye 9 9373 1 Touch Up Paint Not Shown 9 9388 9 9380 9 9382 9 9384 9 9373 9 9386 9 9383 Art A 04931 9 9381 9 9385 9 9385 9 9385 ...

Page 91: ...Manual No 0 5056 6 9 Power Supply Parts List 6 06 Power Supply Replacement Parts Right Side Item Qty Description Ref Des Catalog 1 1 Heat Exchanger Fan FAN1 9 9338 2 1 Radiator 9 9339 1 2 Art A 08308 ...

Page 92: ...ower Supply Replacement Parts Right Side Item Qty Description Ref Des Catalog 1 1 Output Filter PC PCB8 9 9341 2 1 Sensor HCT2 9 9368 3 1 Magnetic Contactor pilot MC2 9 9343 4 1 Resistor R6 9 9340 5 1 Resistor R9 6 1 Capacitor C2 1 2 Art A 08309 4 5 6 3 ...

Page 93: ...nual No 0 5056 6 11 Power Supply Parts List 6 08 Power Supply Replacement Parts Right Side Item Qty Description Ref Des Catalog 1 Chopper Module 9 9389 1 Sensor HCT1 9 9342 Chopper Module Art A 08311 HCT1 ...

Page 94: ...0 5056 6 12 Power Supply Parts List 6 09 Power Supply Replacement Parts Front Panel Item Qty Description Ref Des Catalog 7 1 Main Power Switch Circuit Protector CP1 9 9344 for 230 400 460 VAC units 7 Art A 08312 ...

Page 95: ...rts List 6 10 Power Supply Replacement Parts Front Panel Item Qty Description Ref Des Catalog 1 PC Board PCB3 9 9365 1 PC Board 230 460VAC PCB4 9 9370 1 PC Board 600VAC PCB4 9 9492 1 Display PC Board PCB6 9 9347 PCB3 PCB4 PCB6 Art A 08313 ...

Page 96: ... Supply Parts List 6 11 Power Supply Replacement Parts Right Side Item Qty Description Ref Des Catalog 1 1 PCBoard 230 400 460VAC PCB1 9 9362 1 1 PCBoard 600VAC PCB1 9 9491 2 1 Magnetic Contactor MC1 MC3 9 9364 Art A 08314 1 2 2 ...

Page 97: ...aker AGC 125V 2 5A 120VAC 1A CP5 9 9348 16 1 Circuit Breaker AGC 125V 2 5A 15VDC 1A CP6 9 9348 17 1 Circuit Breaker Pump 250V 10A 200VAC 3A CP7 9 9351 18 1 Circuit Breaker Fan 125V 3 15A 24VDC 1A CP8 9 9349 1 Coolant Tank 9 5948 1 Tank Cap 8 5142 1 Filter Coolant 8 4276 RETURN SUPPLY Art A 04932_AB COOLANT Coolant Tank Tank Cap Filter RAS 125V 2 5A CCM 125V3 15A GCM 125V 10A GCM 125V2 5A GCM 125V2...

Page 98: ...3 Power Supply Replacement Parts Right Side Item Qty Description Ref Des Catalog 1 1 Resistor R7 9 9363 2 1 Rectifier Diode D1 9 9345 3 1 Transformer T1 9 9355 for 230 460 VAC units 4 1 Diode D2 9 9486 5 1 Terminal Strip TB3 N A Art A 08310 1 2 3 4 5 ...

Page 99: ...17 Power Supply Parts List 6 14 Power Supply Replacement Parts Item Qty Description Catalog 29 2 Inverter Module 208 230V 9 9360D 2 Inverter Module 400V CE and 400V Non CE9 9482D 2 Inverter Module 600V 9 9485D Art A 04786 ...

Page 100: ...Manual No 0 5056 6 18 Power Supply Parts List 6 15 Power Supply Replacement Parts Right Side Item Qty Description Ref Des Catalog 30 1 Sensor Thermistor TH1 9 9361 ...

Page 101: ...9 Power Supply Parts List 6 16 Power Supply Replacement Parts Item Qty Description Ref Des Catalog 1 1 Relay PC Board PCB7 9 9366 2 1 24 VDC Power Supply N A N A 3 1 Internal Control PC Board PCB5 9 9346 Art A 08315 1 2 3 ...

Page 102: ...y Description Ref Des Catalog 22 1 Sensor Level Switch LSW1 9 9354 24 1 Motor M 9 9381 25 1 Pump Check Valve Bypass Valve Assembly 9 9380 26 1 Bypass Valve part of assembly 27 1 Pump part of assembly 28 1 Sensor Flow Indicator F1 9 9359 Illustration is for Reference ONLY 27 22 25 24 26 28 Art A 08236 ...

Page 103: ...id Logic PC Board 9 9409 10 1 Cover 9 9410 11 3 Gauge 0 160 psi 8 6800 12 1 Regulator 8 3223 13 3 Pressure Transducer and wire harness 100 PSI 9 9509 14 2 Pressure Transducer and wire harness 250 PSI 9 9508 NOT SHOWN 1 Torch Valve Assembly Wire Harness J13 to J57 9 9399 1 Power Supply Connection Wire Harness J3 J5 to J56 9 9400 1 LCD Interface PC Board Wire Harness 9 9401 1 Rotary Encoder Switch W...

Page 104: ...auge 2 diameter 8 6800 5 1 Pressure gauge 2 diameter 8 4313 6 1 Flow Meter 8 6801 Not shown Valve Assembly 9 9382 Tube 9 9383 Knob 9 9384 7 1 Protective Display Lens only 9 9395 PREFLOW H2O MIST PLASMA SHIELD PRESSURE PLASMA POWERSUPPL Y GAS FLOW AMPERAGE SET UP High Precision Plasma Cutting System ENABLE DISABLE GAS MODE RUN SET PREFLOW SET PLASMA SHIELD TEST O2 AIR O2 O2 H35 N2 F5 N2 AIR AIR N2 ...

Page 105: ...1 1 Harness Internal Not Shown 9 4956 2 1 Pilot Cap Assembly 9 4960 3 1 EMI Filter 9 1023 4 1 HF Water Cooled Coil Assembly 9 4958 5 1 HF Coil Assembly Arc Starter 9 4959 6 1 Enclosure Arc Starter Base 9 4961 7 1 Spark Gap Cap Assembly HF 9 4957 8 1 Ferrite Bead 2 Long 9 4965 Art A 04898 3 5 4 6 7 8 8 2 To Torch Valve Assembly ...

Page 106: ... Arc Starter RAS 1000 Replacement Parts Item Qty Description Catalog 1 1 Retainer ABS Wall 9 4964 2 1 Outer Torch Lead Ground Assembly 9 4955 3 1 Bracket Bulkhead Holder 9 4963 4 1 Cover Arc Starter 9 4962 Art A 04899 3 4 1 2 1 Coolant Leads from Power Supply ...

Page 107: ...alog 1 1 Assembly CCM Ultra Cut 9 9417 2 1 Plate CCM Face 9 9419 3 1 Panel CCM Mount Not Available 4 1 Harness CCM I O Board 9 9421 3 4 2 1 Art A 06867 NOTE This page covers parts for Command Control module without an external connections cover See previous page for Command Control module with an external connections cover ...

Page 108: ... or higher for the GCM 2010 It also requires the resetting of DIP switches in the C C M Item QtyDescription Catalog 1 1 Torch Valve Assembly 4 3054 2 1 Torch Valve Assembly Harness 9 9413 3 1 Plug 14 Circuit 9 3294 4 1 Check Valve 8 4512 5 3 Check Valve 9 7006 6 1 1 8 NPT STR TEE Fitting 8 0352 7 1 Street Elbow Bushing 8 3369 8 1 Top Cover 9 3324 9 1 Front Cover 9 3323 1 Art A 07650 3 7 5 4 2 6 8 ...

Page 109: ...TE The XTL Torch Valve Assembly requires Firmware versions 3 2 or higher for the C C M and 3 1 or higher for the GCM 2010 It also requires the resetting of DIP switches in the C C M Item Qty Description Catalog 1 1 Exhaust Muffler 9 3321 2 2 Solenoid 9 3319 3 3 Solenoid 9 9392 Art A 07651 SOL18 SOL19 1 2 3 ...

Page 110: ...Manual No 0 5056 6 28 Power Supply Parts List Intentionally Blank ...

Page 111: ...up Cartridge Assembly stationary Turn the Shield Cup to re move it from the Cartridge Assembly Assembled Cartridge Cartridge Tool Shield Cup Art A 04344 2 Take the Removal Tool off the back of the Cartridge Assembly Use the removal tool to push the consumable parts out of the Cartridge Cartridge Tool Cartridge Assembly Art A 04345 ...

Page 112: ... Ring O Ring Cat No 8 0540 Snap Ring Cartridge Assembly Art A 07087 Cartridge Retaining Ring 9 9489 O Rings Art A 04066 Cat No 8 0539 Cat No 8 3487 Cat No 8 0530 Torch Head Cat No 9 9041 CAUTION Use only Thermal Dynamics No 9 4893 O Ring Lubricant Christo Lube MCG 129 with this torch part Use of other lubricants may cause irreparable damage to the torch 7 03 Parts Wear Replace the Gas Distributor ...

Page 113: ...all parts carefully to avoid damage which may affect torch performance 1 Install the consumables as follows Cartridge Covers Upper O Ring on Torch Tip Shield Cap Protrudes 0 063 0 083 1 6 2 1 mm Electrode Plasma Gas Distributor Tip Shield Gas Distributor Shield Cap Upper O Ring on Tip 1 Stack Parts 2 Press Cartridge onto Stacked Parts 4 Check Shield Cap Protrusion Art A 04716 No Gaps Between Parts...

Page 114: ...orch head with a wire brush Apply oxygen compatible lubricant supplied with the torch to the threads Torch Head O Ring Torch Head Art A 08300_AB 0 063 0 083 1 6 2 1 mm Protrusion Installing Assembled Cartridge Onto Torch Head 3 Slide the ohmic clip over the shield cup if using ohmic torch height control sensing A 03393 Ohmic Clip 4 Connect the wire lead from the height finder to the ohmic clip NOT...

Page 115: ...umables Re assemble Torch Still leaks The parts probably are worn out See chart for approximate life expectancy The torch may be damaged See page to determine if head damage has occurred Order Coolant Tube Replacement Kit Leaking from Coolant Supply or Coolant Return Yes Yes Yes No Return Supply Used Order Coolant Check Valve Kit 9 4846 New Torch leaks Torch Electrodes Are Torch Consumable Parts I...

Page 116: ...TORCH INFORMATION 7 6 Manual 0 5056 This page is blank intentionally ...

Page 117: ...ARK 2 WEST LEBANON NH 03784 603 298 5711 Tuesday November 01 2005 14 47 17 of Information Proprietary to THERMAL DYNAMICS CORPORATION TITLE of TITLE 8X290 NEG HF to Torch 8X291 DAT 9 21 04 RAS 1000 ARC STARTER POWER SUPPLY ARC STARTER TORCH Jumper in Cable to ID Arc Starter Connected Water Cooled Inductor L1 T1 Assembly TORCH LEAD INNER SHIELD AB ECO 101810 RS 11 01 05 14 PIN J59 RAS 14 PIN 1 2 3 ...

Page 118: ...2010 GAS CONTROL POWER SUPPLY PLASMA SHIELD PREFLOW FERRITE CORE Safety Gnd low freq RF Gnd Shield ENABLE PS3 PS4 Shield Flow Shield Press Plasma Precharge Bypass H2O Shield FIBER OPTIC To CCM U36 U35 F20 1A F20 1A J11 10 PIN J11 10 PIN 1 2 3 4 5 6 7 8 9 10 SOL5 SOL5 J5 16 PIN J5 16 PIN 1 2 3 4 5 6 7 8 9 10 11 12 13 14 16 15 J55 J55 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25...

Page 119: ... A B F1 0 125A SOL1 F2 0 125A SOL2 F3 0 125A SOL3 F4 0 125A SOL4 F5 0 125A SOL5 F6 0 125A SOL6 F7 0 125A SOL7 F8 0 125A SOL8 F9 0 125A SOL9 F10 0 125A SOL10 F11 0 125A SOL11 F12 0 125A SOL12 F13 0 125A SOL13 F14 0 250A SOL14 F15 0 250A SOL15 F16 0 125A SOL16 F17 0 125A SOL17 F18 1 6A 120 VAC to Solenoids F19 1A 120 VAC to Low Voltage Power Supply F20 1A to E Stop Relay 19X2219_AG and earlier F14 1...

Page 120: ...7 SOL11 SOL12 SOL13 GAS MANIFOLD SOL5 SHIELD PLASMA PREFLOW TVA XTL TVA WATER H2O Pressure Sensor SOL4 SOL17 SOL14 SOL15 SOL16 New Plasma Inlet Pressure Sensor New Shield Inlet Pressure Sensor SOL18 SOL19 PLASMA SHIELD Atmosphere SOL 18 19 normally open Operate in parallel with normally closed SOL 14 15 SOL 18 19 in XTL TVA only ...

Page 121: ...X 4 Gas Control Module PCB Layout J13 Art A 07621 J1 J13 F12 F11 F8 F15 F17 F7 F16 F9 F13 F14 F10 J12 TP10 TP9 TP8 F5 F3 F1 F2 F4 F6 TP1 J6 J7 J11 TP11 TP12 TP13 TP15 TP14 TP16 J8 J10 TP18 TP19 J3 F19 F18 TP4 TP2 TP3 F20 J5 JP1 TP6 TP5 ...

Page 122: ...out R21 D17 R8 R12 19X2220 REV R7 R16 R18 D11 R20 R9 R13 R5 D5 R15 C1 D4 D18 R4 D1 R6 R19 D12 D2 R3 D10 R22 R17 D6 D3 D19 R2 R14 D13 R11 D7 D20 R10 68 69 D21 1 33 D15 R23 J1 D22 LCD INTERFACE C 2005 TDC D23 D14 70 D24 R24 D25 D9 D26 D16 R1 C2 16 34 2 1 72 D8 AB Art A 06904 J1 ...

Page 123: ... R79 C2 U5 R91 D11 R51 C25 R89 R18 R8 C51 D3 D13 U28 1 C8 R31 R40 C34 R85 R38 C48 D7 R92 R57 R7 R4 C1 R36 1 2 1 SW4 C9 R3 R62 R63 U17 R13 160 U14 1 40 120 80 R27 C31 R59 R55 R32 U13 1 C45 C39 L1 R44 R84 R61 R20 R58 R78 U29 C14 D2 R33 C7 U22 C52 R76 C46 R21 U11 1 R37 R16 C10 R41 D4 R83 R49 U15 R93 R39 C53 C59 C47 U23 1 U19 1 C24 C29 R94 D5 R48 R60 D14 C28 R75 R12 C11 U10 C44 R53 C23 L6 1 U21 C37 D1...

Page 124: ...PILOT PILOT R56 R56 DEMAND DEMAND CUT CUT DEMAND DEMAND ARC V ARC V R114 R114 PILOT V PILOT V CC POT CC POT D3 D3 TP8 TP8 R26 R26 K7 GAS ON K7 GAS ON C34 C34 U19 U19 L2 L2 C27 C27 R29 R29 C83 C83 R90 R90 C69 C69 C52 C52 U2 U2 1 1 C48 C48 U9 U9 1 1 R129 R129 R50 R50 C15 C15 TB1 TB1 R59 R59 C20 C20 R83 R83 C82 C82 D9 D9 C4 C4 C23 C23 C55 C55 R147 R147 C88 C88 C95 C95 K2 START K2 START C46 C46 R61 R6...

Page 125: ...e Analog Current Control 0 10V TB1 11 TB1 12 TB2 1 Hold Start TB2 2 Hold Start TB2 3 Preflow On TB2 4 Preflow On TB2 5 TB2 6 Pilot On Relay Contacts NO TB2 7 TB2 8 Pilot On Relay Contacts NO TB2 9 TB2 10 OK to Move Contacts or DC Volts TB2 11 TB2 12 OK to Move Contacts or DC Volts TB2 TB1 Sustained Start Stop TB1 5 TB1 6 Momentary Start Stop TB1 4 TB1 5 TB1 6 Stop Start Start Stop Circuit Configur...

Page 126: ...ionsareonlyavailableonTB1 2 2 SW6 on CCM I O PCB selects OK to Move for isolated contact closure or DC Volts 15 18V at 100ma When set for contacts OK to Move circuit is rated for 120 VAC 28 VDC 1A Internal CNC connections TB1 TB2 on CCM module Connections are provided on the CCM module TB1 TB2 terminal blocks including most of the rear panel functions plus some additional features All these signal...

Page 127: ... ON up Hold Start input Normally open close to hold start Circuit rating 10 ma 20VDC Delays pilot ignition gas preflow continues Used for synchronizing starts when multiple plasma supplies are used on same cutting table User supplies circuit to keep Hold Start inputs active until all torches have found height Preflow On input Normally open close to start preflow prior to normal START signal Circui...

Page 128: ...ON 30 1 SW12 3 ON 40 1 SW12 4 ON ARC V 2 1 3 5 4 6 SW6 Active LOW Logic Input 16 to 18 VDC isolated PSR OK to Move ARC V Active LOW Logic Input 100K 3 6 SW12 3 4 5 SW12 4 1 8 SW12 1 2 7 SW12 2 2 1 3 SW11 100K 1 8 7 6 2 U37A LT1013 Input Circuit Common isolated OK to MOVE STOP NC PREFLOW ON START STOP OR START LATCH START STOP Ret PILOT ON output Contacts OK TO MOVE output contacts or DC Volts Remo...

Page 129: ...Manual 0 5056 A 13 APPENDIX This page intentionally blank ...

Page 130: ...30 230 208 230 460 VAC 3 Phase CN6 100A INVERTER MODULE 2 bottom same as 1 D2 Sht 2 RIBBON CABLE SIGNALS CN6 16 Ckt Ribbon Cable 2 4 I_REF Scaled Cut Demand 5 PS_START Start 6 REDUNDANT_START Start2 8 INV_READY 9 PS_START disabled by Input_NG 12 OCR 13 PS_START disabled by OCR 14 TEMP_ERR 15 PS_START disabled by Temp _Err CN32 CN32 1 2 3 4 LED3 INPUT NG LED3 INPUT NG N2 N2 TB2 TB2 P1 P1 TB1 TB1 S ...

Page 131: ...esday October 03 2006 08 11 44 Thermal Dynamics D RAS PCB 8 WK 5687 RC RF CAPS HALL SENSOR HALL SENSOR PILOT REG CHOPPER PCB1 WK 5750 BIAS POWER PILOT REGULATOR CHOPPER OVER_TEMP P_DEM P_Iref P_Enable P_ena PILOT REG CHOPPER PCB2 WK 5754 I_DET I_SE PILOT CURRENT SIGNAL WORK CURRENT SIGNAL PILOT ENABLE PILOT DEMAND C1 Capacitor 0 1 uf 1250 VDC D2 Sht 2 C2 Capacitor 2 uf 430VAC A9 Sht 1 C P1 Circuit...

Page 132: ... D2 E STOP_PS D2 E STOP_PS V GND SIG FL1 FLOW_TURBINE_PULSE V GND SIG FL1 FLOW_TURBINE_PULSE R B G T1 T1 460 220 0 13 0 100 0 200 0 110 0 120 0_ 24 0__ 24_ 0___ 120 0___ TP10 TP10 1 2 CN10 CN10 1 2 3 TB1 TB1 D15 PSR D15 PSR R7 1K 30W R7 1K 30W D12 STATUS CODE D12 STATUS CODE TP9 TP9 C P5 C P5 1 2 3 CN7 CN7 1 2 3 4 TP14 TP14 CN6 CN6 1 2 3 4 CN8 CN8 1 2 3 4 MC2 MC2 D1 GAS_ON D1 GAS_ON TP7 TP7 CN1 CN...

Page 133: ... 298 5711 150 200 Amp Power Supply 208 230 460V Chopper Tuesday October 03 2006 08 11 44 Thermal Dynamics D KEY PLUG CN11 34 CKT CN10 26 CKT J36 34 CKT J35 26 CKT RIBBON CABLE TEST SOCKET RIBBON CABLE TEST SOCKET E2 E2 E4 F4 POWER SUPPLY REAR PANEL TB1 TB2 DIVIDED ARC V DIVIDED ARC V REMOTE ANALOG CURRENT CONTROL REMOTE ANALOG CURRENT CONTROL E STOP E STOP PILOT ON OUTPUT HOLD START HOLD START PRE...

Page 134: ...2 bottom same as 1 D2 Sht 2 RIBBON CABLE SIGNALS CN6 16 Ckt Ribbon Cable 2 4 I_REF Scaled Cut Demand 5 PS_START Start 6 REDUNDANT_START Start2 8 INV_READY 9 PS_START disabled by Input_NG 12 OCR 13 PS_START disabled by OCR 14 TEMP_ERR 15 PS_START disabled by Temp _Err CN32 CN32 1 2 3 4 LED3 INPUT NG LED3 INPUT NG N2 N2 TB2 TB2 P1 P1 TB1 TB1 S S MC3 C MC3 C 1 2 3 4 CN1 CN1 1 5 8 CN7 CN7 1 2 3 4 5 LE...

Page 135: ...CAPS HALL SENSOR HALL SENSOR PILOT REG CHOPPER PCB1 WK 5750 BIAS POWER PILOT REGULATOR CHOPPER OVER_TEMP P_DEM P_Iref P_Enable P_ena PILOT REG CHOPPER PCB2 WK 5754 I_DET I_SE PILOT CURRENT SIGNAL WORK CURRENT SIGNAL PILOT ENABLE PILOT DEMAND C1 Capacitor 0 1 uf 1250 VDC D2 Sht 2 C2 Capacitor 2 uf 430VAC A9 Sht 1 C P1 Circuit protector ON OFF SW B2 Sht 1 15A 460V 3P C P2 Circuit protector 2 5A 125V...

Page 136: ... 2 TP4 TP4 CN20 CN20 1 2 3 CN3 CN3 1 2 3 D2 E STOP_PS D2 E STOP_PS V GND SIG FL1 FLOW_TURBINE_PULSE V GND SIG FL1 FLOW_TURBINE_PULSE R B G T1 T1 460 220 0 13 0 100 0 200 0 110 0 120 0_ 24 0__ 24_ 0___ 120 0___ TP10 TP10 1 2 CN10 CN10 1 2 3 TB1 TB1 D15 PSR D15 PSR R7 1K 30W R7 1K 30W RY2 RELCOL_0 RY2 RELCOL_0 D12 STATUS CODE D12 STATUS CODE TP9 TP9 C P5 C P5 1 2 3 CN7 CN7 1 2 3 4 TP14 TP14 CN6 CN6 ...

Page 137: ...y 208 230 460V Resistor Tuesday October 03 2006 08 11 44 Thermal Dynamics D KEY PLUG CN11 34 CKT CN10 26 CKT J36 34 CKT J35 26 CKT RIBBON CABLE TEST SOCKET RIBBON CABLE TEST SOCKET E2 E2 E4 F4 POWER SUPPLY REAR PANEL TB1 TB2 DIVIDED ARC V DIVIDED ARC V REMOTE ANALOG CURRENT CONTROL REMOTE ANALOG CURRENT CONTROL E STOP E STOP PILOT ON OUTPUT HOLD START HOLD START PREFLOW ON PREFLOW ON OK to MOVE OK...

Page 138: ...00 VAC 3 Phase CN6 100A INVERTER MODULE 2 bottom same as 1 D2 Sht 2 RIBBON CABLE SIGNALS CN6 16 Ckt Ribbon Cable 2 4 I_REF Scaled Cut Demand 5 PS_START Start 6 REDUNDANT_START Start2 8 INV_READY 9 PS_START disabled by Input_NG 12 OCR 13 PS_START disabled by OCR 14 TEMP_ERR 15 PS_START disabled by Temp _Err CN32 CN32 1 2 3 4 LED3 INPUT NG LED3 INPUT NG N2 N2 TB2 TB2 P1 P1 TB1 TB1 S S MC3 C MC3 C 1 ...

Page 139: ...er 03 2006 08 11 44 Thermal Dynamics D RAS PCB 8 WK 5687 RC RF CAPS HALL SENSOR HALL SENSOR PILOT REG CHOPPER PCB1 WK 5750 BIAS POWER PILOT REGULATOR CHOPPER OVER_TEMP P_DEM P_Iref P_Enable P_ena PILOT REG CHOPPER PCB2 WK 5754 I_DET I_SE PILOT CURRENT SIGNAL WORK CURRENT SIGNAL PILOT ENABLE PILOT DEMAND C1 Capacitor 0 1 uf 1250 VDC D2 Sht 2 C2 Capacitor 2 uf 430VAC A9 Sht 1 C P1 Circuit protector ...

Page 140: ...TP4 TP4 CN20 CN20 1 2 3 CN3 CN3 1 2 3 C P4 C P4 D2 E STOP_PS D2 E STOP_PS V GND SIG FL1 FLOW_TURBINE_PULSE V GND SIG FL1 FLOW_TURBINE_PULSE R B G T1 TX1P8S T1 TX1P8S 400 200 0 13 0 100 0 200 0 110 0 120 0_ 24 0__ 24_ 0___ 120 0___ TP10 TP10 1 2 CN10 CN10 1 2 3 TB1 TB1 D15 PSR D15 PSR R7 1K 30W R7 1K 30W D12 STATUS CODE D12 STATUS CODE TP9 TP9 RY2 RELCOL_0 RY2 RELCOL_0 C P6 C P6 C P3 C P3 1 2 3 CN7...

Page 141: ... 150 200 A Power Supply 400V CCC Chopper Tuesday October 03 2006 08 11 44 Thermal Dynamics D KEY PLUG CN11 34 CKT CN10 26 CKT J36 34 CKT J35 26 CKT RIBBON CABLE TEST SOCKET RIBBON CABLE TEST SOCKET E2 E2 E4 F4 POWER SUPPLY REAR PANEL TB1 TB2 DIVIDED ARC V DIVIDED ARC V REMOTE ANALOG CURRENT CONTROL REMOTE ANALOG CURRENT CONTROL E STOP E STOP PILOT ON OUTPUT HOLD START HOLD START PREFLOW ON PREFLOW...

Page 142: ...SIGNALS CN6 16 Ckt Ribbon Cable 2 4 I_REF Scaled Cut Demand 5 PS_START Start 6 REDUNDANT_START Start2 8 INV_READY 9 PS_START disabled by Input_NG 12 OCR 13 PS_START disabled by OCR 14 TEMP_ERR 15 PS_START disabled by Temp _Err CN32 CN32 1 2 3 4 LED3 INPUT NG LED3 INPUT NG N2 N2 TB2 TB2 P1 P1 TB1 TB1 S S L7 L7 MC3 C MC3 C 1 2 3 4 CN1 CN1 1 5 8 CN7 CN7 1 2 3 4 5 LED5 ERROR LED5 ERROR P P CN18 CN18 1...

Page 143: ...CHOPPER PCB1 WK 5750 BIAS POWER PILOT REGULATOR CHOPPER OVER_TEMP P_DEM P_Iref P_Enable P_ena PILOT REG CHOPPER PCB2 WK 5754 I_DET I_SE PILOT CURRENT SIGNAL WORK CURRENT SIGNAL PILOT ENABLE PILOT DEMAND C1 Capacitor 0 1 uf 1250 VDC D2 Sht 2 C2 Capacitor 2 uf 430VAC A9 Sht 1 C P1 Circuit protector ON OFF SW B2 Sht 1 15A 460V 3P C P2 Circuit protector 2 5A 125V D2 Sht 1 C P3 Circuit protector 3 15A ...

Page 144: ...TP4 TP4 CN20 CN20 1 2 3 CN3 CN3 1 2 3 C P4 C P4 D2 E STOP_PS D2 E STOP_PS V GND SIG FL1 FLOW_TURBINE_PULSE V GND SIG FL1 FLOW_TURBINE_PULSE R B G T1 TX1P8S T1 TX1P8S 400 200 0 13 0 100 0 200 0 110 0 120 0_ 24 0__ 24_ 0___ 120 0___ TP10 TP10 1 2 CN10 CN10 1 2 3 TB1 TB1 D15 PSR D15 PSR R7 1K 30W R7 1K 30W D12 STATUS CODE D12 STATUS CODE TP9 TP9 C P6 C P6 C P3 C P3 1 2 3 CN7 CN7 1 2 3 4 TP14 TP14 CN6...

Page 145: ...150 200A Power Supply 400V CE Chopper Tuesday October 03 2006 08 11 44 Thermal Dynamics D KEY PLUG CN11 34 CKT CN10 26 CKT J36 34 CKT J35 26 CKT RIBBON CABLE TEST SOCKET RIBBON CABLE TEST SOCKET E2 E2 E4 F4 POWER SUPPLY REAR PANEL TB1 TB2 DIVIDED ARC V DIVIDED ARC V REMOTE ANALOG CURRENT CONTROL REMOTE ANALOG CURRENT CONTROL E STOP E STOP PILOT ON OUTPUT HOLD START HOLD START PREFLOW ON PREFLOW ON...

Page 146: ...SIGNALS CN6 16 Ckt Ribbon Cable 2 4 I_REF Scaled Cut Demand 5 PS_START Start 6 REDUNDANT_START Start2 8 INV_READY 9 PS_START disabled by Input_NG 12 OCR 13 PS_START disabled by OCR 14 TEMP_ERR 15 PS_START disabled by Temp _Err S S TB1 TB1 P1 P1 TB2 TB2 N2 N2 LED3 INPUT NG LED3 INPUT NG CN32 CN32 1 2 3 4 CN18 CN18 1 2 3 P P LED5 ERROR LED5 ERROR CN7 CN7 1 2 3 4 5 CN1 CN1 1 5 8 1 2 3 4 MC3 C MC3 C L...

Page 147: ..._ena PILOT REG CHOPPER PCB2 WK 5754 I_DET I_SE PILOT CURRENT SIGNAL WORK CURRENT SIGNAL PILOT ENABLE PILOT DEMAND HCT1 Hall Current Sensor Pilot B8 Sht 1 HCT2 Hall Current Sensor Work C9 Sht 1 L1 L9 Toroid Core input common mode filter A2 B2 Sht 1 L2 7 Toroid Core common mode filter B1 C1 Sht 1 L8 L10 Toroid Core output common mode filter A6 C6 Sht 1 LSW1 Level SW coolant NC B5 Sht 2 MC1 Contactor...

Page 148: ...W D28 CNC_PREFLOW 1 2 RY3 RY3 1 2 D26 HOLD_START D26 HOLD_START C P7 C P7 CN14 CN14 1 2 D12 STATUS CODE D12 STATUS CODE C P4 C P4 CN20 CN20 1 2 3 RY4 RY4 C P2 C P2 D23 CNC_START D23 CNC_START CN8 CN8 1 2 3 4 T1 TX1P8S T1 TX1P8S 400 200 0 13 0 100 0 200 0 110 0 120 0_ 24 0__ 24_ 0___ 120 0___ C P3 C P3 V GND SIG FL1 FLOW_TURBINE_PULSE V GND SIG FL1 FLOW_TURBINE_PULSE R B G TP4 TP4 TP13 TP13 TP7 TP7...

Page 149: ...CE Resistor Tuesday October 03 2006 08 11 44 Thermal Dynamics D KEY PLUG CN11 34 CKT CN10 26 CKT J36 34 CKT J35 26 CKT RIBBON CABLE TEST SOCKET RIBBON CABLE TEST SOCKET E2 E2 E4 F4 POWER SUPPLY REAR PANEL TB1 TB2 DIVIDED ARC V DIVIDED ARC V REMOTE ANALOG CURRENT CONTROL REMOTE ANALOG CURRENT CONTROL E STOP E STOP PILOT ON OUTPUT HOLD START HOLD START PREFLOW ON PREFLOW ON OK to MOVE OK to MOVE MOM...

Page 150: ...0 600 VAC 3 Phase CN6 100A INVERTER MODULE 2 bottom same as 1 D2 Sht 2 RIBBON CABLE SIGNALS CN6 16 Ckt Ribbon Cable 2 4 I_REF Scaled Cut Demand 5 PS_START Start 6 REDUNDANT_START Start2 8 INV_READY 9 PS_START disabled by Input_NG 12 OCR 13 PS_START disabled by OCR 14 TEMP_ERR 15 PS_START disabled by Temp _Err CN32 CN32 1 2 3 4 LED3 INPUT NG LED3 INPUT NG N2 N2 TB2 TB2 P1 P1 TB1 TB1 S S MC3 C MC3 C...

Page 151: ...RAS PCB 8 WK 5687 RC RF CAPS HALL SENSOR HALL SENSOR PILOT REG CHOPPER PCB1 WK 5750 BIAS POWER PILOT REGULATOR CHOPPER OVER_TEMP P_DEM P_Iref P_Enable P_ena PILOT REG CHOPPER PCB2 WK 5754 I_DET I_SE PILOT CURRENT SIGNAL WORK CURRENT SIGNAL PILOT ENABLE PILOT DEMAND C1 Capacitor 0 1 uf 1250 VDC D2 Sht 2 C2 Capacitor 2 uf 430VAC A9 Sht 1 C3 Capacitor 47 uf 400V C1 Sht 2 C P1 Circuit protector ON OFF...

Page 152: ... 2 TP4 TP4 CN20 CN20 1 2 3 CN3 CN3 1 2 3 C P4 C P4 D2 E STOP_PS D2 E STOP_PS V GND SIG FL1 FLOW_TURBINE_PULSE V GND SIG FL1 FLOW_TURBINE_PULSE R B G T1 T1 600 220 0 13 0 100 0 200 0 110 0 120 0_ 24 0__ 24_ 0___ 120 0___ TP10 TP10 1 2 CN10 CN10 1 2 3 TB1 TB1 D15 PSR D15 PSR R7 1K 30W R7 1K 30W D12 STATUS CODE D12 STATUS CODE TP9 TP9 C P6 C P6 C P3 C P3 1 2 3 CN7 CN7 1 2 3 4 TP14 TP14 AC AC D3 AC AC...

Page 153: ... 150 200 A Power Supply 600V CSA Chopper Tuesday October 03 2006 08 11 44 Thermal Dynamics D KEY PLUG CN11 34 CKT CN10 26 CKT J36 34 CKT J35 26 CKT RIBBON CABLE TEST SOCKET RIBBON CABLE TEST SOCKET E2 E2 E4 F4 POWER SUPPLY REAR PANEL TB1 TB2 DIVIDED ARC V DIVIDED ARC V REMOTE ANALOG CURRENT CONTROL REMOTE ANALOG CURRENT CONTROL E STOP E STOP PILOT ON OUTPUT HOLD START HOLD START PREFLOW ON PREFLOW...

Page 154: ...over Date Rev Change s Jan 7 2008 AA First issue Jan 14 2008 AB Added flow meter replacement parts per ECOB704 Jan 28 2008 AC Per ECOB738 updated GCM plumbing diagram in Appendix Feb 5 2008 AD Per ECOB646 added input terminal strip information to sections 3 and 6 ...

Page 155: ...257 224800 Thermadyne China RM 102A 685 Ding Xi Rd Chang Ning District Shanghai PR 200052 Telephone 86 21 69171135 Fax 86 21 69171139 Thermadyne Asia Sdn Bhd Lot 151 Jalan Industri 3 5A Rawang Integrated Industrial Park Jln Batu Arang 48000 Rawang Selangor Darul Ehsan West Malaysia Telephone 603 6092 2988 Fax 603 6092 1085 Cigweld Australia 71 Gower Street Preston Victoria Australia 3072 Telephone...

Page 156: ...Corporate Headquarters 16052 Swingley Ridge Road Suite 300 St Louis MO 63017 Telephone 636 728 3000 Email TDCSales Thermadyne com www thermadyne com ...

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