Thermal Dynamics AUTO-CUT 30 O2 Operating Manual Download

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Manual 0-4818 Auto-Cut 300

A-7

APPENDIX

APPENDIX 6: CNC - Control Module PCB Connections

C75

C79

C41

R149R1

R144

R148

R103R1

C11C

D34

U10

R88

R128R1

R39

R73

R118R1

R120

C16

R81

R11

U12

D8D

D10

TP6

SW6SW

R75R7

K5-E-STOPK5

-E

-S

R20R2

R1R1

R151

D37

U14

U5U

R139

U13

C56

C22

C50

U6U

R10

R14

D6D

D29D

D12D

R104R1

R125R1

D20D

R47

R82

J36

D18

R77

R72

TP7

SW13

J35

R131

R13

C53C

C78C

R62R6

C39

C77C

C87C

C33

R23R2

R132R1

U22

R145

C17

K1-PSR

D22D

R69R6

D21

TP9

R76

C26C

C58

R64R6

R117R1

R6R6

R79

R55

C40

C68C

C7C

R41R4

R44

R66R6

R121

D25D

D23

R31

R28R2

R45

R123R1

R102R1

R135R1

C2C

D14

C24

TP3

U18U

R67R6

R49

TP12

U23

C45

R57

R138

R127

C76C

C66C

R12

D26

C19

TP5

R38

D7D

R53R5

C18

D30

R27R2

C47

D17D

C30

SW11SW

R71R7

U20

R97

R99

C84

19X2174

D2D

R141

R15

REV

C TDC 2005

ALL SW OFF FOR 50:1 (DEFAULT)A

)

SW12-1 ON FOR 16.7:1 (SC-11)SW

-1

U16

OK TO MOVE SELECTO

CONTACTS

DC VOLTS

C93

U17

R43

H10

H11

OK CNC

R46

PSR

CNC_E-STOP

CNC_START

HOLD_START

R115R1

CNC PREFLOW

GAS ONG

E-STOP_PSE-

C65C

C35C

U24

GND

+5V

R80

+15V

-15V

+15V

-15V

R87

+18V

GND

ISOLATED

PILOT

R56

DEMAND

CUT

DEMAND

ARC V-

R114

PILOT V

CC POT

TP8

R26R2

K7-GAS ONK7

-G

C34C

U19

C27C

R29R2

C83

R90

C69C

+ +

C52C

C48

R129R1

R50

C15

TB1

R59

C20C

R83R8

C82

C23

C55C

R147

C88

C95

K2-START

C46

R61

R109

D32

R143

C71

C49C

R91

R24R2

R60

R22R2

R142R1

R21R2

R108

R63

R40

R101

R37

C64C

C92C

T1T1

R30

R134R1

R119R1

R116R1

R89

R48R4

K3-E-STOP CNC

R78

D36

D31

R140

R107

C37

R65

R100

C28C

R84

U11

K4-OK

D1D

C73C

R25R2

R110

C54

D15

R133

R150

R122R1

R19R1

C31

TP11

D39

D38D

R86

R68

R42R4

D13

R126

R70R7

C80

R96

TB2

C21C

C85

R33R3

C70

D40

R17R1

C51C

R136R1

TP4

D28

R93

R52R5

C9C

TP14

D16

C61C

D35

C13C

R58

D5D

R85

R98

R94R9

C89

C62

C25

R74

R130

TP1

TP13

C91

R35R3

TP10

R18R1

C29C

C72

C42

C74

D19

R124R1

R95

C81

D11D

R54R5

C36C

D24

C12C

C86C

U21

U15

R16R1

TP2

C60

R32R3

R51R5

C32

C14C

D27D

R113

D33D

C38

R105

R34R3

R92

C59

R112

R106

R146

R111

R36R3

C10C

C57C

+29-41 VDC

C67

C63

C90

R223R2

C94C

R155

R158

D60D

R156

22
11

SW12SW

R154R1

R157

D61D

SW12-2 ON FOR 30:1SW

-2

SW12-3 ON FOR 40:1SW

-3

SW12-4 SPARESW

-4

R152R1

C44

R224

R225

C43

R227R2

R228R2

R226R2

AD+

Art # A-06901

TP14

TP7

TP6

SW6

SW12

J36

TB1

TB2

TP11

SW11

TP9

TP12

TP10

TP8

J35

TP4

TP3

TP2 SW13

TP5

TP1

TP13

Summary of Contents for AUTO-CUT 30 O2

Page 1: ...600 V 400 V 460 V 208 230 V 400 300 AMP 3 PHASE V CE Art A 08584 AUTO CUT PLASMA CUTTING SYSTEM Operating Manual Rev AL Issue Date July 6 2012 Manual No 0 4818 Operating Features 30O2...

Page 2: ...y w i l l h e l p y o u t o a v o i d p o t e n t i a l h a z a r d s t h a t m a y e x i s t w h e n w o r k i n g w i t h t h i s p r o d u c t YOU ARE IN GOOD COMPANY The Brand of Choice for Contr...

Page 3: ...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...

Page 4: ...Thispageintentionallyblank...

Page 5: ...plications 2 5 2 12 XTTM 301Torch Specifications 2 6 SECTION 3 INSTALLATION 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 Suppl...

Page 6: ...ght Side 6 6 6 06 Power Supply Replacement Parts Right Side 6 7 6 07 Power Supply Replacement Parts Front Panel 6 8 6 08 Power Supply Replacement Parts Right Side 6 9 6 09 Power Supply Replacement Par...

Page 7: ...7 APPENDIX 7 CNC Control Module PCB Connections A 9 CNC functions A 10 CNC Input Output Descriptions A 11 Simplified CNC Circuit A 12 APPENDIX 8 Schematic 230 460V Unit A 14 APPENDIX 8 Schematic 230 4...

Page 8: ...blank...

Page 9: ...Mercury Arsenic Cobalt Nickel Barium Copper Selenium Beryllium Lead Silver Cadmium Manganese Vanadium Always read the Material Safety Data Sheets MSDS that should be supplied with the material you ar...

Page 10: ...ter handling Wash hands after handling California Health Safety Code 25249 5 et seq 1 03 Publications Refer to the following standards or their latest revisions for more infor mation 1 OSHA SAFETY AND...

Page 11: ...des risques et des dangers de sant Eloignez toute fum e et gaz de votre zone de respiration Gardez votre t te hors de la plume de fum e provenant du chalumeau Utilisez un appareil respiratoire alimen...

Page 12: ...votre peau si vous ne vous prot gez pas correctement Pour prot ger vos yeux portez toujours un casque ou un cran de soudeur Portez toujours des lunettes de s curit munies de parois lat rales ou des l...

Page 13: ...adway New York NY 10018 6 Norme ANSI Z49 2 PR VENTION DES INCENDIES LORS DE L EMPLOI DE PROC D S DE COUPE ET DE SOUDAGE disponible aupr s de l American National Standards Institute 1430 Broadway New Y...

Page 14: ...tandards and technical requirements Among them are CSA Canadian Standards Association standard C22 2 number 60 for Arc welding equipment UL Underwriters Laboratory rating 94VO flammability testing for...

Page 15: ...ection therewith such 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 negligenc...

Page 16: ...of goods to Cigweld or our Nominated Accredited Distributor Accredited Service Provider are the responsibility of the consumer This warranty is given Cigweld Pty Ltd A B N 56007226815 71 Gower Street...

Page 17: ...ting 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...

Page 18: ...400 Incl CE 50 60 75 109 135 3 460 50 60 89 112 150 2 Line Voltages with Suggested Circuit Protection and Wire Sizes Based on National Electric Code and Canadian Electrical Code Auto Cut 30O2 Power S...

Page 19: ...Manual No 0 4818 Auto Cut 3002 2 3 SPECIFICATIONS 2 08 Power Supply Dimensions Art A 06939 33 inch 840 mm 27 inch 680 mm 37 75 inch 960 mm 52 25 inch 1030 mm 27 5 inch 700 mm 535 lb 243 kg...

Page 20: ...Access Wiring Coolant 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...

Page 21: ...rements Note 2 The tap water source does not need to be deionized but in water systems with high mineral content a water softener is recommended Tap water with high levels of particulate matter must b...

Page 22: ...IFICATIONS 2 12 XTTM 301 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...

Page 23: ...dge Art A 08304_AC This Art Is For Reference ONLY Cartridge Electrode Shield Shield Gas Distributor Tip Plasma Gas Distributor Shield Retainer Art A 07917_AC This Art Is For Reference ONLY D Parts In...

Page 24: ...Manual No 0 4818 Auto Cut 3002 2 8 SPECIFICATIONS This Page Intentionally Blank...

Page 25: ...ype of wire being used and method of installation Gas Supply The customer must supply all gases and pressure regulators Gases must be of high quality Pressure regulators must be double stage and insta...

Page 26: ...e Coolant Supply w Negative Coolant Return Control Cable Fiber Optic Cable Control Cable Gas Control Module 300 A Power Supply Torch Valve Assembly Shield A B C D E P I J K L H Q R S Shield Plasma Gas...

Page 27: ...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...

Page 28: ...all four 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 no...

Page 29: ...st be 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 th...

Page 30: ...ere is a voltage configuration board on each inverter module Power supplies with more than one inverter module require that all voltage configuration boards must be configured identically 2 If necessa...

Page 31: ...round 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 in...

Page 32: ...try 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 200Amp or less Ultra Cut or Auto Cut O2 Note The gas contr...

Page 33: ...1 0 Ground 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 C...

Page 34: ...es 1 0 earth ground 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...

Page 35: ...test uses live voltage NEUTRAL 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 bu...

Page 36: ...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 NOTE Negative Lead and Torch Lead are...

Page 37: ...ads 1 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...

Page 38: ...ne 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 at the CNC end of the cable Do not ground to the P...

Page 39: ...able 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 i...

Page 40: ...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...

Page 41: ...W 6 OK to Move Contact closure rated at 120VAC 1A Max 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 Po...

Page 42: ...quires 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 120...

Page 43: ...cceptable 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...

Page 44: ...INSTALLATION Preparation 1 Remove the screws securing the Cover Panel to the Module 2 Remove the Cover from the Module Remove the ground wire if needed Art A 06882 Gas Control Module Cover Do not remo...

Page 45: ...tion panel on 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...

Page 46: ...e fiber optic cable connector into the receptacle on the vertically mounted circuit board as shown Cable must snap into place Circuit Board Fiber Optic Cable Art A 04773 4 Tighten the through hole pro...

Page 47: ...5 Connect all gas water inputs to the rear panel of the module CAUTION When cutting with O2 oxygen plasma air must be connected to the Module 6 Connect the appropriate control cables to terminals mark...

Page 48: ...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...

Page 49: ...e cover to the Arc Starter Remove the upper screws securing the Cover Panel to the Arc Starter NOTE A wire grounds the cover to the Arc Starter base as shown below This wire must remain in place 2 Rem...

Page 50: ...Starter to the mounting surface Art A 09626 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...

Page 51: ...No 0 4818 Auto Cut 3002 3 27 INSTALLATION Coolant Return Red Coolant Supply Green Art A 09628 Green Red Art A 09629 Negative Cable from power supply Copper plate Negative Cable from Power Supply rear...

Page 52: ...t Return Cable from Power supply PILOT Return Cable from Power Supply rear panel NOTE The pilot return cable has a strain relief connector that must be installed in the rear panel of the remote arc st...

Page 53: ...rations Make the following output connections to the Arc Starter NOTE For newer leads with only black wire it must be connected to the pilot return There are no inner shield wires Pilot Lead Connectio...

Page 54: ...Red from Torch Coolant Supply Green to Torch 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...

Page 55: ...ce Torch Leads Use a clamp to secure the Torch Lead Shield brass ring to the port on the RemoteArc Starter as shown Art A 04759 Coolant and Pilot Leads to Torch Valve Assembly Torch Leads Shield Shiel...

Page 56: ...Manual No 0 4818 Auto Cut 3002 3 32 INSTALLATION Art A 04801 RETURN SUPPLY RETURN SUPPLY Power Supply Rear Panel COOLANT Remote Arc Starter Input Connection Panel Remote Arc Starter...

Page 57: ...50 113 03 mm 261 Dia 6 63 mm Art A 08433 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 c...

Page 58: ...ma Gas Inlet Preflow Gas Inlet Shield Gas Inlet Water Shield Inlet Art A 06926 Torch Valve Inlet Side CAUTION Hold all fittings stationary while attaching hoses or leaks can be created Side pressure c...

Page 59: ...onnector Coolant Return Check Valve and Connector Plasma Lead Connector Pilot Lead Plasma Lead Art A 07324 Insulating Paper Insulating Paper 2 1 Positioning Tube O Ring O Ring Torch Leads End Cap Groo...

Page 60: ...tors stationary turn the leads fittings with a wrench to secure the leads to the Torch Head Do not overtighten CAUTION The gas and coolant leads include compression fittings Do not use sealant on thes...

Page 61: ...r E l 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 E...

Page 62: ...O Ring Torch Head Art A 08300_AB 0 063 0 083 1 6 2 1 mm Protrusion CAUTION Do not force the cartridge if it will not fully tighten Remove the cartridge and gently clean parts and apply oxygen compati...

Page 63: ...es 0 063 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 04...

Page 64: ...already done 3 Assemble B to C 4 Assemble A to B C CAUTION In C there is an insulating sleeve that must be in place on the Cartrudge before the Shield Cup is attached 7 Place the ohmic clip over the s...

Page 65: ...al Dynamics coolant The coolant level is visible through the translucent coolant tank The amount of coolant required varies with torch leads length Cat Number and Mixture Mixture Protects To 7 3580 Ex...

Page 66: ...ystem ON for the first time a Place the ON OFF Switch to ON b After about 30 seconds the system may shut down if the leads are not full of coolant c Place the ON OFF switch to OFF d After 10 seconds p...

Page 67: ...fill the reservoir and re install the filler cap 4 Purge coolant from the torch before firing the torch Ensure there are no leaks before use If leaks are evident consult the coolant leak trouble shoo...

Page 68: ...Manual No 0 4818 Auto Cut 3002 3 44 INSTALLATION Intentionally Blank...

Page 69: ...temperatures above normal limits Let the unit cool before continuing operation GAS Indicator The indicator blinks when the gas control is not ready Causes for not being ready are when purging Mode sw...

Page 70: ...t 5 seconds POWER ON OFF O I OFF O Art A 04812 3 Check the AC indicator If indicator is ON system is ready to operate pending fault checks by internal cir cuitry If indicator does not light after a fe...

Page 71: ...icators used to set gas pressures and flows ENABLE STATUS DISABLE PLASMA POWER SUPPLY SHIELD FLOW GAS PRESSURE MODE GAS GCM 2000 PLASMA PREFLOW Art A 06889 FLOW GAS PRESSURE AMPS PLASMA POWER SUPPLY E...

Page 72: ...operator to adjust pressure Gas automatically shuts off after 2 minutes if left in the SET PREFLOW position In the SET PLASMA SHIELD position selected cutting gases Plasma Shield flow to the torch to...

Page 73: ...tch is changed it initiates a purge of the new gas GAS PREFLOW H2O MIST PLASMA SHIELD PRESSURE PLASMA POWERSUPPL Y GAS FLOW ENABLE DISABLE MODE RUN SET PREFLOW SET PLASMA SHIELD TEST 9 9 Art A 06891_A...

Page 74: ...ssure Gauge Used to set preflow gas pressure MODE switch must be in SET PREFLOW position 6 PLASMA and SHIELD Control Knobs Pressure Gauges and Flow Meters Used to set plasma and shield gas pressures a...

Page 75: ...torch parts if necessary 4 Set the Gas Selection switch to the desired gas process 5 Apply AC power and set the Plasma Power Supply switch on the Gas Control Module to The Module performs purges of co...

Page 76: ...only the pressure is specified set the Shield Gas switch to Pressure c Set the Shield Pressure using the Shield regulator knob and pressure gauge If required set the Shield flow using the Shield Flow...

Page 77: ...ngle between the surface of the cut edge and a plane perpendicular 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...

Page 78: ...m of the plate Failure to follow this recommendation could result in poor cut quality and short consumable parts life Ohmic Height Sensing Ohmic Height Sensing is not recommended with water shield wat...

Page 79: ...ith air shield A good clean welding grade nitrogen should be used B Shield Gases 1 Compressed Air Shield Air shield is normally used when operating with air or oxygen plasma Improves cut quality on so...

Page 80: ...p 4 After a 1 2 second delay the indicator blinks 3 times the condition code is 4 3 indicating that the coolant is overheating After a 4 second delay the indicator repeats the sequence until the condi...

Page 81: ...oo high shorted torch body consumable parts worn out 2 1 Missing Phase Blown fuse Broken or loose connection on power cable Inverter s not configured correctly for input voltage Poor power quality bro...

Page 82: ...compatibility 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 C...

Page 83: ...not locked 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...

Page 84: ...on Reconnect 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...

Page 85: ...Manual No 0 4818 Auto Cut 3002 4 17 OPERATION 4 08 Remote Arc Starter Spark Gap Adjustment Art A 04857 0 063 0 002 1 6 0 05 mm...

Page 86: ...Intentionally Blank...

Page 87: ...s Clean or replace external coolant filter Clean coolant tank Vacuum out any dust buildup inside power supply Check internal coolant filter 5 02 External Coolant Filter Cleaning Procedure Periodic cle...

Page 88: ...In Line 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 fittin...

Page 89: ...230V 3 9115 1 Auto Cut 30O2 Power Supply 460V 3 9115 2 Auto Cut 30O2 Power Supply 400V 3 9115 3 Auto Cut 30O2 Power Supply 400V CE 3 9115 4 Auto Cut 30O2 Power Supply 600V CSA 3 9115 5 Gas Control Mod...

Page 90: ...Optic Cable Control Cable Gas Control Module 300 A Power Supply Torch Valve Assembly Shield A B C D E P I J K L H Q R S Shield Plasma Gas Shield Gas Plasma Gas Shield Gas Preflow Gas Work Torch Positi...

Page 91: ...4909 9 4900 9 9302 9 8312 30 9 1 m 4 3066 35 10 6 m 4 3050 9 9427 4 3078 4 3051 9 9332 9 9335 9 9303 50 15 2 m 4 3031 9 4800 9 4926 9 4934 4 3079 4 3038 9 4910 9 4901 9 9304 9 8313 75 22 9 m 4 3032 9...

Page 92: ...c 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 Con...

Page 93: ...talog 1 1 Power Supply Front Panel N A 2 1 Power Supply Rear Panel N A 3 1 Power Supply Top Panel 9 0445G 9 0455B 4 1 Power Supply Right Side 9 0500G 9 0500B 5 1 Power Supply Left Side 9 0501G 9 0501B...

Page 94: ...ual No 0 4818 Auto Cut 3002 6 6 Parts List 6 05 Power Supply Replacement Parts Right Side Item Qty Description Ref Des Catalog 1 1 Heat Exchanger Fan FAN1 FAN2 9 9338 2 1 Radiator 9 9339 1 2 Art A 082...

Page 95: ...er 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 R...

Page 96: ...0 4818 Auto Cut 3002 6 8 Parts List 6 07 Power Supply Replacement Parts Front Panel Item Qty Description Ref Des Catalog 7 1 Main Power Switch Circuit Protector CP1 9 9344 for 230 460 VAC units 7 Art...

Page 97: ...l No 0 4818 Auto Cut 3002 6 9 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 07064_AB...

Page 98: ...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...

Page 99: ...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...

Page 100: ...o Cut 3002 6 12 Parts List 6 11 Power Supply Replacement Parts Item Qty Description Catalog 3 Inverter Module 208 230V 9 9360D 3 Inverter Module 400V CE and 400V Non CE 9 9482D 3 Inverter Module 600V...

Page 101: ...Manual No 0 4818 Auto Cut 3002 6 13 Parts List 6 12 Power Supply Replacement Parts Right Side Item Qty Description Ref Des Catalog 30 1 Sensor Thermistor TH1 9 9361 30 Art A 04787...

Page 102: ...arts List 6 13 Power Supply Replacement Parts Left Side 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 P...

Page 103: ...Parts List 6 14 Power Supply Replacement Parts Left Side Item Qty Description Ref Des Catalog 1 1 PCBoard 230 460 and 400VAC PCB1 9 9362 1 1 PCBoard 600 VAC PCB1 9 9491 2 1 Magnetic Contactor MC1 MC3...

Page 104: ...6 16 Parts List 6 15 Power Supply Replacement Parts Right Side Item Qty Description Ref Des Catalog 1 1 Relay PC Board PCB7 9 9366 2 1 24 VDC Power Supply DCS1 9 9493 3 1 Internal Control PC Board PC...

Page 105: ...Qty Description Ref Des Catalog 1 1 Inline filter 8 3460 2 1 Sensor Coolant Flow FL1 9 9359 3 1 Pump Check Valve Bypass ValveAssembly 9 9380 4 1 Bypass Valve part of assembly Call 5 1 Motor MOT1 9 93...

Page 106: ...18 Parts List 6 17 Command Control Module Type 2 Replacement Parts Item Qty Description Catalog 1 1 Assembly CCM Auto Cut 9 9418 2 1 Plate CCM Face 9 9419 3 1 Panel CCM Mount Call 4 1 Harness CCM I O...

Page 107: ...Manual No 0 4818 Auto Cut 3002 6 19 Parts List This page is blank intentionally...

Page 108: ...Mode Selection Switch Assembly 9 9406 5 2 Flowmeter 0 150 8 6801 Not shown Valve Assembly 9 9382 Tube 9 9383 Knob 9 9384 6 1 Switching PCBAssembly Current control 9 9481 7 1 Pressure Transducer 100 P...

Page 109: ...A POWERSUPPL Y GAS FLOW ENABLE DISABLE GAS MODE RUN SET PREFLOW SET PLASMA SHIELD TEST 9 9 GCM 2000 AMPS Automated Plasma Cutting System Thermal Dynamics O2 AIR H35 N2 AIR AIR N2 H2O 15 5 5 COMM J57 J...

Page 110: ...lve Assembly Replacement Parts Item Qty Description Catalog 1 1 Torch ValveAssembly 9 9436 2 1 Control Cable Harness 9 9479 3 1 Fuel B Fitting Call 4 1 Check Valve 9 7006 5 1 Fitting Call 6 1 Fitting...

Page 111: ...1 1 Harness Internal Not Shown 9 4956 2 1 Pilot Cap Assembly 9 9423 3 1 EMI Filter 9 1023 4 1 HF Water Cooled Coil Assembly 9 4958 5 1 HF TransformerAssembly Arc Starter 9 4959 6 1 Enclosure Arc Star...

Page 112: ...nt Parts Item Qty Description Catalog 1 1 Retainer ABS Wall 9 4964 2 1 Outer Torch Lead GroundAssembly 9 4955 3 1 Bracket Bulkhead Holder 9 4963 4 1 Cover Arc Starter 9 4962 5 1 Strain Relief large 9...

Page 113: ...Turn the Shield Cup to remove it from the Cartridge Assembly Assembled Cartridge Cartridge Tool Shield Cup Art A 04344_AB 2 Take the Cartridge tool off the back of the CartridgeAssembly Use the cartr...

Page 114: ...and slide the locking ring downward for access to the O Ring under the locking ring O Ring Cat No 9 3029 Inner O Ring Cat No 9 3030 Location Under Locking Ring O Ring Cat No 9 3028 Art A 07087_AD 300...

Page 115: ...7 03 Parts Wear Replace the Gas Distributor if it is charred or cracked Replace the Gas Distributor if the flange is damaged in any way Replace the tip and or electrode if they are worn Good Electrod...

Page 116: ...d Consumables 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 C...

Page 117: ...L DYNAMICS INDUSTRIAL PARK 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...

Page 118: ...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 F...

Page 119: ...OTHERWISE SPECIFIED 1 RESISTOR VALUES ARE EXPRESSED IN OHMS 1 4W 5 2 CAPACITOR VALUES ARE EXPRESSED IN MICROFARADS uF Chk App TITLE Last Modified Size SCHEMATIC 42X1224 Tuesday January 30 2007 1 1 Org...

Page 120: ...SOL10 SOL6 SOL7 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...

Page 121: ...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 T...

Page 122: ...R70 R2 U27 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 C3...

Page 123: ...ISOLATED 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...

Page 124: ...Manual 0 4818 Auto Cut 3002 A 8 APPENDIX This page intentionally blank...

Page 125: ...Remote 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...

Page 126: ...onal functions are only available onTB1 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...

Page 127: ...nal isolation module will have to be used It was not specifically designed to be used to remote a potentiometer but it could work if the pot high is connected to an accurate external 10 VDC whose comm...

Page 128: ...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...

Page 129: ...Manual 0 4818 Auto Cut 3002 A 13 APPENDIX This page intentionally blank...

Page 130: ...2 middle same as 1 D3 Sht 2 CN6 100A INVERTER MODULE 3 bottom same as 1 D3 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 IN...

Page 131: ...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 CURR...

Page 132: ...TOP_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 C P3 C P3 1 2 CN10 CN10...

Page 133: ...NH 03784 603 298 5711 300 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 RIB...

Page 134: ...1 D3 Sht 2 CN6 100A INVERTER MODULE 3 bottom same as 1 D3 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_STA...

Page 135: ...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...

Page 136: ...TOP_PS D2 E STOP_PS V GND SIG FL1 FLOW_TURBINE_PULSE V GND SIG FL1 FLOW_TURBINE_PULSE R B G T1 T1 400 200 0 13 0 100 0 200 0 110 0 120 0_ 24 0__ 24_ 0___ 120 0___ TP10 TP10 1 2 C P3 C P3 1 2 CN10 CN10...

Page 137: ...H 03784 603 298 5711 300 Amp 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 CA...

Page 138: ...MODULE 2 middle same as 1 D3 Sht 2 CN6 100A INVERTER MODULE 3 bottom same as 1 D3 Sht 2 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...

Page 139: ...Pilot B8 Sht 1 HCT2 Hall Current Sensor Work C9 Sht 1 L1 9 11 Toroid Core input common mode filter A2 B2 C2 Sht 1 L2 7 Toroid Core common mode filter B1 C1 Sht 1 L8 10 12 Toroid Core output common mo...

Page 140: ...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 400 200 0 13 0 100 0 200 0 110 0 120 0_ 24 0__ 24_ 0___ 120 0___ TP10 TP10 1...

Page 141: ...5711 300 Amp 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 E...

Page 142: ...2 CN6 100A INVERTER MODULE 3 bottom same as 1 D3 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 disable...

Page 143: ...ILOT 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 P...

Page 144: ...NC_PREFLOW 1 2 RY3 RY3 MC4 MC4 1 2 D26 HOLD_START D26 HOLD_START RY2 RELCOL_0 RY2 RELCOL_0 FAN2 FAN2 CN14 CN14 1 2 D12 STATUS CODE D12 STATUS CODE CN4 CN4 1 2 3 RY4 RY4 1 2 AC AC D3 AC AC D3 D23 CNC_S...

Page 145: ...11 300 Amp 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...

Page 146: ...July 24 2008 AF Per ECOB1007 update negative cable connection for the RAS section 3 Nov 11 2008 AG Updated section 3 per ECOB1163 to show new single shielded leads Also up dated some sheetmetal repair...

Page 147: ...This Page Intentionally Blank...

Page 148: ...g Indonesia Customer Care Ph 6221 8990 6095 Fax 6221 8990 6096 Rawang Malaysia Customer Care Ph 603 6092 2988 Fax 603 6092 1085 Melbourne Australia Australia Customer Care Ph 1300 654 674 tollfree Ph...

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