Thermal Dynamics ULTRA-CUT 100 Operating Manual Download Page 1

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300

Operating Manual

PLASMA CUTTING SYSTEM

ULTRA-CUT

™

Rev. AG.01 Date:

July 10, 2007

Manual #

0-4819

Operating Features:

Art # A-04816

Summary of Contents for ULTRA-CUT 100

Page 1: ...300 Operating Manual PLASMA CUTTING SYSTEM ULTRA CUT Rev AG 01 Date July 10 2007 Manual 0 4819 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: ...oration All rights reserved Reproduction of this work in whole or in part without written permission 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 accident or any other cause Printed in the United States of America Licensed ...

Page 4: ...Thispageintentionallyblank ...

Page 5: ...ling System Requirements 3 1 C System Layout 3 2 D Cables Leads Identification 3 3 D Lift the Power Supply 3 4 E 1 Set Switches on the Command Control Module Type 1 Module 3 5 E 2 Set Switches on the Command Control Module Type 2 Module 3 7 F Remove the Connections Cover 3 9 G Connect Work Cable and Pilot and Negative Leads 3 10 H Check Adjust Input Voltage Configuration 3 11 I Connect Input Power...

Page 6: ...Right Side 6 12 Power Supply Replacement Parts Front Panel 6 13 Power Supply Replacement Parts Front Panel 6 14 Power Supply Replacement Parts Right Side 6 15 Power Supply Replacement Parts Rear Panel 6 16 Power Supply Replacement Parts Right Side 6 17 Power Supply Replacement Parts 6 18 Power Supply Replacement Parts Right Side 6 19 Power Supply Replacement Parts 6 20 Power Supply Replacement Par...

Page 7: ... Control Display Module PCB Layout A 6 APPENDIX 6 CCM CPU PCB Layout A 7 APPENDIX 7 CCM Input Output PCB Layout A 8 APPENDIX 8 CNC Control Module PCB Connections A 9 CNC functions A 10 CNC Input Output Descriptions A 11 Simplified CNC Circuit A 12 APPENDIX 9 Schematic 230 460V Power Supply A 14 APPENDIX 10 Schematic CCC 400V Power Supply A 16 APPENDIX 11 Schematic CE 400V Power Supply A 18 APPENDI...

Page 8: ...TABLE OF CONTENTS continued ...

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: ...r 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 EXPLOSION Fire and explosion can be caused by hot slag sparks or the...

Page 11: ...AND HEALTH IN ARC WELDING AND GAS WELDING AND CUTTING obtainable from the Super intendent of Documents U S Government Printing Office Washington D C 20402 4 ANSI Standard Z87 1 SAFE PRACTICES FOR OCCUPATION AND EDUCATIONAL EYE AND FACE PROTEC TION obtainable from American National Standards Institute 1430 Broadway New York NY 10018 5 ANSI Standard Z41 1 STANDARD FOR MEN S SAFETY TOE FOOTWEAR obtai...

Page 12: ... Welding Society Standard AWSF4 1 RECOMMENDED SAFE PRACTICES FOR THE PREPARATION FOR WELDING AND CUTTING OF CONTAINERS AND PIPING THAT HAVE HELD HAZARDOUS SUBSTANCES obtainable from the American Welding Society 550 N W LeJeune Rd Miami FL 33126 15 ANSI Standard Z88 2 PRACTICE FOR RESPIRATORY PROTECTION obtainable from American National Stan dards Institute 1430 Broadway New York NY 10018 ...

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: ... 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 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 ORACCE...

Page 15: ... for cutting operations The power supply also monitors system performance and cools and circulates the liquid coolant for the torch and leads 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 Gas Control Module This module allows remote sett...

Page 16: ... 50 60 74 206 260 3 0 230 50 60 72 181 230 2 0 400 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 Ultra Cut 300 Power Supply System Component Layout Primary power Work CNC Remote Arc Starter Art A 07234 Torch Coolant Supply Coolant Return Control Cable Coolant Supply Coola...

Page 17: ...Manual No 0 4819 2 3 SPECIFICATIONS 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 18: ...ant 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: ...uality Requirements Note 2 The tap water source 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...

Page 20: ... 6 SPECIFICATIONS 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 74 69 55 mm 1 57 39 96 mm 3 54 89 87 mm 6 30 160 10 mm Art A 04897 ...

Page 21: ... 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 improperly ...

Page 22: ...0kV Current Up to 300 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 300 Power Supply XTTM 300 Torch Gas Specifications G Plasma Power Supply Used With Thermal Dynamic...

Page 23: ...ge 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 Poor cutting precision Reduced consumables life Oil or grease contamination from compressed or bottled air can cause fires in conjunction with oxygen B Cooling System Requirements Coolant must be added to the system on installation The amo...

Page 24: ...able Gas Control Module 300 A Power Supply Torch Valve Assembly Shield A B C D E P F I J K L H F1 F Q R S Ground Cable F Shield Plasma Gas Shield Gas Plasma Gas Shield Gas Preflow Gas Work Torch Positioning Tube Water Shield G T Pilot Return Pilot Return Negative Leads 2 Work Cables 2 25 7 6 m Maximum Length 125 38 1 m Maximum Length 175 53 3 m Maximum Length NOTE Installation requires two negativ...

Page 25: ...t 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 Start...

Page 26: ...r 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 with...

Page 27: ...fault 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 3 Gas Preflow Time 1 OFF 2 OFF 2 Seconds Factory default setting 1 ON 2 OFF ...

Page 28: ...o Move Contact closure 120VAC 1A Factory default setting or DC Volts 16 18vdc up to 100 ma SW11 Analog Current Control B from Gas Control Factory default setting or A from CNC Position A requires that SW 8 2 be ON SW12 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 07673 Only 1 on at a time SW11 SW13 SW6 SW12 SW13 TVA and XTL Switch...

Page 29: ...ed 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 30: ...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 TV...

Page 31: ...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 32: ... the illustration Connect the leads as shown Tighten securely Do not overtighten CAUTIONS The clear connections cover must remain in place There are two work cables and two negative leads to be connected PILOT WORK TORCH Connection Panel AC INPUT Torch Lead To Remote Arc Starter Work Torch Lead Connection Detail Connections Cover Support Panel Art A 07661 Connections Cover Pilot To Cutting Table L...

Page 33: ...board 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 jumpe...

Page 34: ...ck CAUTION The clear connections cover must remain in place 4 Pass a system ground cable through the leads bracket and through the same opening in the connections cover support panel as 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 ground ing PILOT WORK TOR...

Page 35: ...ound 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 c...

Page 36: ... for 230 VAC line CAUTION Remove all other connections from the ground rod during this test This test assumes the 115 or 230 VAC source neutral is connected to the utility earth ground Art A 07252 WARNING Use extreme caution This 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 remo...

Page 37: ...her control cables in parallel with the torch leads in power tracts 2 Keep torch leads clean Dirt and metal particles bleed off energy which causes difficult starting and increased chance of RF interference K Connect Coolant Leads 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 ...

Page 38: ...nect 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 at the CNC end of the cable Do not ground to the Plasma Power Supply RETURN SUPPLY Art A 04802 To CNC To Remote Arc Starter To Gas Control Module ...

Page 39: ... appropriate opening on the connections cover 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 power supply rear panel c Slide the strain relief assembly onto the connections cover fasten it in place with the strain relief securing nut Fasten the strain relief dome nut onto the strain relief do n...

Page 40: ... 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 str...

Page 41: ...ference 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 enter the module Louvers on the back panel of the module must also r...

Page 42: ...e Cover Removal N Fiber Optic Cable Installation 1 Install the through hole protector for the fiber optic cable in the hole in connection panel on the back of the Module 2 Pass the fiber optic cable connector through the hole in connection 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 t...

Page 43: ...ASMA OUT PREFLOW OUT J57 J56 SHIELD OUT H2O INPUTS TVA POWER SUPPLY H35 F5 AIR N2 O2 1 CO MM J57 J56 INP UTS TVA PO WE R SUPPLY H35 F5 AIR N2 O2 SHIELD PLASMA PREFLOW H2O SHIELD H2O 3 Insert the fiber optic cable connector into the receptacle on the vertically mounted circuit board as shown ...

Page 44: ...al No 0 4819 3 22 INSTALLATION 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 INP...

Page 46: ...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 07961 Installation The Remote Arc Starter must be installed in a suitable location near the torch head If the Arc Starter is mounted to a gantry or to any other support subject to motion or vibration fasten the Arc Starter to the support securely 1 L...

Page 47: ... mounting surface 4 Use pre drilled holes in at least two of the feet on the bottom of the Arc Starter to secure the Arc 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 ...

Page 48: ...Manual No 0 4819 3 26 INSTALLATION Coolant Supply and Return Hoses from power supply Art A 04750 Coolant Return Red Coolant Supply Green Art A 04751 Coolant Return Red Red Green ...

Page 49: ...Manual No 0 4819 3 27 INSTALLATION Art A 04752 Negative Cable from power supply Art A 04754 Negative Cable for 150 Amps Negative Cables from Power Supply rear panel ...

Page 50: ...Manual No 0 4819 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: ...etail Inner Shield Connection Detail Inner Shield Lead Pilot Lead Art A 04933 Pilot Return Cable and Inner Shield Lead from Torch Leads Art A 04757 Coolant Return Red from Torch Coolant Supply Green to Torch Some items are removed for clarity Coolant Supply Fitting Tagged with Green Coolant Return Fitting Tagged with Red Coolant Supply and Return Hoses from Torch ...

Page 52: ... cover grounding area is arranged as shown 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 Ground Cable Art A 04758 1 Nut and 1 Washer Remain in Place Torch Leads ...

Page 53: ... 4819 3 31 INSTALLATION 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: ...m 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 side...

Page 56: ...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 R Connecting Torch Connect the Torch as f...

Page 57: ...ds assemblies as shown b Slide the Mounting Tube upward onto the leads assemblies c Press the upper end of the Mounting Tube into the lower end of theTorch Leads End Cap Ensure that the O Ring on the Tube engages the mating groove inside the Torch Leads End Cap d Ensure that the Mounting Tube is free to rotate within the Torch Leads End Cap 6 Connect the gas and coolant leads to the Torch Head a C...

Page 58: ... Install Consumable Torch Parts 1 Install the consumable parts as follows to ensure proper operation These steps will help ensure that parts are seated correctly Art A 03887 WARNINGS Do not install consumables into the Cartridge while the Cartridge is attached to the Torch Head Keep foreign materials out of the consumables and Cartridge Handle all parts carefully to avoid damage which may affect t...

Page 59: ...TION CAUTION Do not force the cartridge if it will not fully tighten Remove the cartridge and gently clean the threads on the torch head body with a wire brush Apply oxygen compatible lubricant supplied with the torch to the threads ...

Page 60: ...otrudes 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 3 Thread Shield Cup onto Cartridge Shield Cap Shield Cup ...

Page 61: ...o Torch Head 6 Slide the ohmic clip over the shield cup if using ohmic torch height sensing A 03393 Ohmic Clip 7 Connect the wire lead from the height finder to the ohmic clip if using ohmic torch height sensing NOTE Ohmic height sensing is not recommended with water shield Water on the plate interferes electrically with ohmic sensing circuits ...

Page 62: ...ries 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 coolant has been pumped...

Page 63: ...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...

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Page 65: ...EMP Indicator Normally OFF Indicator turns ON when the internal 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 Shows system status The number of flashes indicates the status Refe...

Page 66: ...er 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: ...s 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 S...

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: ...s 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 Used to set plasma and shield gas pressures and flows MODE switch must be...

Page 71: ...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 wi...

Page 72: ...tween 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 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 pla...

Page 73: ...uld move counterclockwise around the circle To keep the square edge along an outside diameter cut the torch should travel in a clockwise direction Underwater Cutting Cutting on a water table either underwater or with the water touching the plate or with a water muffler system is not recommended If a water table is used the water level must be a minimum of 4 inches from the bottom of the plate Fail...

Page 74: ... Provides faster cutting speeds Provides very smooth finishes and minimizes nitride build up on cut surface nitride build up can cause difficulties in producing high quality welds if not removed 4 Nitrogen N2 Plasma Provides better cut quality on nonferrous materials such as stainless steel and aluminum Can be used in place of air plasma with air shield or carbon dioxide CO2 Provides much better p...

Page 75: ...tem s Firmware is a prior version contact your distributor for updates Error Code Error Remedy Comments 1 1 System not Enabled or Missing AC Input Phase Plasma Enable Off External E Stop Activated or CCM TB1 1 2 jumper missing Missing AC Phase No power to GCM 2000 or 2010 Gas Control check GCM control cable connected reset CP4 or CP5 circuit breaker in power supply blown fuse F19 in GCM 1 2 Pilot ...

Page 76: ... not locked into connector sharp bends in fiber fiber defective Gas Control PCB defective replace CCM defective replace 3 2 Gas Control Communication reply fault connection was established but CCM did receive a reply to a process request Gas Control did not reply to signal from CCM in allowed time Dirt on fiber ends or in connectors blow out with clean dry air fiber not locked into connector sharp...

Page 77: ...ng detected low coolant level does not stop cut Add coolant as required 5 1 CANBUS Failure to Acknowledge fault If GCM 1000 Basic ID signal missing Other gas controls Fiber disconnected or broken Transceiver what fiber plugs into fault replace Gas control PCB or CCM 5 2 CANBUS Off due to excessive data errors Dirt on fiber ends or in connectors blow out with clean dry air fiber not locked into con...

Page 78: ...ect 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 coil ...

Page 79: ...Manual No 0 4819 4 15 OPERATION Remote Arc Starter Spark Gap Adjustment Art A 04857 0 063 0 002 1 6 0 05 mm ...

Page 80: ...Manual No 0 4819 4 16 OPERATION This page intentionally blank ...

Page 81: ...external coolant filter Clean coolant tank Vacuum out any dust buildup inside power supply Check internal coolant filter External 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 Disconnect the system...

Page 82: ...ne FilterAssembly 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 switch c...

Page 83: ... Ultra Cut 300 Power Supply 400V CE 3 9118 4 Gas Control Module GCM 2010 with XTL Torch Valve Assembly 3 9131 Requires Firmware version 3 2 or higher for C C M Gas Control Module GCM 2010 Only 7 4000 Original Torch Valve Assembly Repair Part Only 4 3049 XTL Torch Valve Assembly Only 4 3054 Requires C C M Firmware version 3 2 or higher and GCM 2010 Firmware version 3 1 or higher Remote Arc Starter ...

Page 84: ...ol Cable Gas Control Module 300 A Power Supply Torch Valve Assembly Shield A B C D E P F I J K L H F1 F Q R S Ground Cable F Shield Plasma Gas Shield Gas Plasma Gas Shield Gas Preflow Gas Work Torch Positioning Tube Water Shield G T Pilot Return Pilot Return Negative Leads 2 Work Cables 2 25 7 6 m Maximum Length 125 38 1 m Maximum Length 175 53 3 m Maximum Length NOTE Installation requires two neg...

Page 85: ... 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 Starte...

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: ...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 m 9 9335 L Control Cable Fiber Opt...

Page 89: ...0 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 75 22 9 m 9 8315 P Control Cable ...

Page 90: ... Inert B LH 9 9012 9 9013 9 9014 9 9015 JIC 9 6985 9 6986 9 6988 9 6996 9 6992 9 6993 9 6994 HOSE FITTINGS Catalog number ID CATALOG NUT NUT NIPPLE NUT NUT NIPPLE JIC CLAMP per foot Inert B LH Inert B RH Inert FUEL B LH O2 B RH 1 4 9 3743 9 3556 9 2776 9 2775 8 5518 8 5015 8 0327 8 0266 8 0384 3 8 9 3616 8 6473 20x962 N A N A 8 6617 N A 8 0271 8 0384 1 2 9 2551 8 6470 20x884 N A 8 0267 9 3831 ADAP...

Page 91: ... Catalog 1 Power Supply Front Panel 1 Power Supply Rear Panel 1 Power Supply Top Panel 9 9382 1 Power Supply Right Side Panel 1 Power Supply Left Side Panel 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 9382 9 9373 9 9386 Art A 06888 ...

Page 92: ...Manual No 0 4819 6 10 Power Supply Parts List 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 ...

Page 93: ...anual No 0 4819 6 11 Power Supply Parts List Power Supply Replacement Parts Right Side Item Qty Description Ref Des Catalog 3 1 Resistor R6 9 9340 4 1 Output Filter PCB PCB8 9 9341 5 1 Sensor HCT1 9 9342 ...

Page 94: ...Manual No 0 4819 6 12 Power Supply Parts List Power Supply Replacement Parts Right Side Item Qty Description Ref Des Catalog 5 1 Sensor HCT1 9 9342 6 1 Contactor MC2 9 9343 ...

Page 95: ...Manual No 0 4819 6 13 Power Supply Parts List Power Supply Replacement Parts Front Panel Item Qty Description Ref Des Catalog 7 1 Main Power Switch Circuit Protector CP1 9 9344 ...

Page 96: ...Manual No 0 4819 6 14 Power Supply Parts List Power Supply Replacement Parts Front Panel Item Qty Description Ref Des Catalog 11 1 Display PC Board PCB6 9 9347 ...

Page 97: ...4819 6 15 Power Supply Parts List Power Supply Replacement Parts Right Side Item Qty Description Ref Des Catalog 19 1 Resistor R1 5 9 9353 20 1 Resistor R1 5 9 9353 21 1 Resistor R1 5 9 9353 1 Chopper Module 9 9389 ...

Page 98: ...1 Circuit Breaker AGC 120V 2 5A CP5 9 9348 16 1 Circuit Breaker AGC 15V 2 5A CP6 9 9348 17 1 Circuit Breaker Pump 200V 5A CP7 9 9351 18 1 Circuit Breaker Fan 24V 15A CP8 9 9352 1 Coolant Tank 9 5948 1 Tank Cap 8 5142 RETURN SUPPLY Art A 04932 COOLANT Coolant Tank Tank Cap RAS 120V 5A CCM 24V3 15A GCM 24V 10A GCM 120V2 5A GCM 15V2 5A PUMP 200V 5A FAN 24V 15A CIRCUIT BREAKERS J55 J59 J15 G C M C N C...

Page 99: ...Manual No 0 4819 6 17 Power Supply Parts List Power Supply Replacement Parts Right Side Item Qty Description Ref Des Catalog 23 1 Transformer T1 9 9355 ...

Page 100: ...6 18 Power Supply Parts List Power Supply Replacement Parts Item Qty Description Catalog 29 3 Inverter Module 208 230V 9 9360D 3 Inverter Module 400V CE and 400V Non CE 9 9482D 3 Inverter Module 600V 9 9485D Art A 04786 ...

Page 101: ...Manual No 0 4819 6 19 Power Supply Parts List Power Supply Replacement Parts Right Side Item Qty Description Ref Des Catalog 30 1 Sensor Thermistor TH1 9 9361 ...

Page 102: ...9 6 20 Power Supply Parts List Power Supply Replacement Parts Item Qty Description Ref Des Catalog 31 1 Filter PC Board PCB1 9 9362 32 1 Resistor R7 9 9363 33 1 Magnetic Contactor MC1 9 9364 34 1 PC Board PCB3 9 9365 ...

Page 103: ... Supply Parts List Power Supply Replacement Parts Right Side Item Qty Description Ref Des Catalog 8 1 Rectifier Diode D1 9 9345 10 1 Internal Control PC Board PCB5 9 9346 23 1 Transformer T1 9 9355 35 1 Relay PC Board PCB7 9 9366 ...

Page 104: ...Replacement Parts Right Side Item Qty Description Ref Des Catalog 22 1 Sensor Level Switch LSW1 9 9354 24 1 Pump Motor Assembly M 9 9356 25 1 Check Valve 26 1 Bypass Valve Relief Valve 9 9357 27 1 Pump part of Motor Assembly 28 1 Sensor Flow Indicator F1 9 9359 ...

Page 105: ... Gauge 0 160 psi 8 6800 13 1 Regulator 8 3223 14 1 Pressure Transducer and wire harness 9 9407 15 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 Wire Harness 9 9402 1 Gas Selection Switch Wire Harness ...

Page 106: ...PDT 9 3426 4 1 Pressure gauge 2 diameter 8 6800 5 1 Pressure gauge 2 diameter 8 4313 6 1 Flow Meter 8 6801 7 1 Protective Display Lens only 9 9395 PREFLOW H2O MIST PLASMA SHIELD PRESSURE PLASMA POWERSUPPLY 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 GCM 2010 Art A 048...

Page 107: ... 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 108: ...c 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 109: ...2 1 Plate CCM Face 9 4947 3 1 Panel CCM Mount Not available 4 1 Bracket CCM Strain Relief 9 4949 5 1 Cover CCM Strain Relief 9 4950 6 1 Assembly CCM Ultra Cut 9 4953 3 5 4 1 2 6 Art A 04850 NOTE This page covers parts for Command Control module with an external connections cover See next page for Command Control module without an external connections cover ...

Page 110: ...og 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 111: ...ent Parts Item Qty Description Catalog 1 1 Torch Valve Assembly 4 3049 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 Art A 07031 3 5 4 1 2 6 7 ...

Page 112: ...0 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 9 ...

Page 113: ...embly 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 114: ...This page intentionally blank ...

Page 115: ...p 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 116: ...on Under Locking Ring O Ring Cat No 8 0540 Art A 04071 Snap Ring Cartridge Assembly O Rings Art A 04066 Cat No 8 0539 Cat No 8 0534 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 C Parts Wear Replace the Gas Distributor if it is charred or...

Page 117: ...ll 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 118: ...torch head with a wire brush Apply oxygen compatible lubricant supplied with the torch to the threads Torch Head O Ring Torch Head Art A 07202 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 NOTE Ohmic height sensing is not recommended with water shield Water on the plate interfe...

Page 119: ...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 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 Tips Are Torch Consumable Parts I...

Page 120: ...TORCH INFORMATION 7 6 Manual 0 4819 This page is blank intentionally ...

Page 121: ...MICS 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 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 101916 RS 11 01 05 14 PIN J59 ...

Page 122: ...INTERMEDIATE GAS CONTROL POWER SUPPLY PLASMA SHIELD PREFLOW FERRITE CORE Safety Gnd low freq RF Gnd Shield F20 1A F20 1A SOL5 SOL5 1 2 3 4 5 6 7 8 9 10 J11 10 PIN J11 10 PIN 1 2 3 4 5 6 7 8 9 10 11 12 13 14 17 16 15 19 20 18 J12 18 PIN J12 18 PIN 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 26 27 28 29 30 31 32 33 34 35 36 37 J55 J55 1 2 3 4 5 6 7 8 9 10 11 12 13 14 16 15 J5 1...

Page 123: ...uF Chk App TITLE Last Modified Size SCHEMATIC 42X1202 Friday June 10 2005 1 1 Ultracut Intermediate Gas Control TVA Wednesday January 26 2005 13 57 13 D LCD DISPLAY CONNECTOR CURRENT CONTROL Thumbwheel optional ENCODER IN CIRCUIT SERIAL PROGRAMMING LCD DISPLAY ENCODER w SW A B F1 SOL1 F2 SOL2 F3 SOL3 F4 SOL4 F5 SOL5 F6 SOL6 F7 SOL7 F8 SOL8 F9 SOL9 F10 SOL10 F11 SOL11 F12 SOL12 F13 SOL13 F14 SOL14 ...

Page 124: ...77 AIR N2 O2 H35 F5 SOL1 SOL2 SOL3 SOL8 SOL9 SOL10 SOL6 SOL7 SOL11 SOL12 SOL13 GAS MANIFOLD SOL5 SHIELD PLASMA PREFLOW TVA WATER H2O Pressure Sensor 100 PSI SOL4 SOL17 SOL14 SOL15 SOL16 New Plasma Inlet Pressure Sensor 250 PSI New Shield Inlet Pressure Sensor 250 PSI ...

Page 125: ...DIX 4 Gas Control Module PCB Layout J1 J13 J3 J12 J6 J7 J11 TP11 TP12 TP13 TP15 TP14 TP16 J8 J10 F12 F11 F8 F15 F17 F7 F16 F9 F13 F14 F10 F19 F18 TP4 TP2 TP3 F20 J5 JP1 TP6 TP5 TP10 TP9 TP8 F5 F3 F1 F2 F4 F6 Art A 07621 TP18 TP19 TP1 ...

Page 126: ...ut 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 127: ... 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 128: ...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 129: ...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 130: ...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 131: ... 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 132: ...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 133: ...Manual 0 4819 A 13 APPENDIX This page intentionally blank ...

Page 134: ...ons Rev PCB No Assy No Information Proprietary to THERMAL DYNAMICS CORPORATION Not For Release Reproduction or Distribution without Written Consent NOTE Chk App TITLE Last Modified Size INDUSTRIAL PARK No 2 WEST LEBANON NH 03784 603 298 5711 THERMAL DYNAMICS DWG No Sheet of Supersedes Scale Date Drawn References Date By Revisions Rev PCB No Assy No Information Proprietary to THERMAL DYNAMICS CORPO...

Page 135: ... Information Proprietary to THERMAL DYNAMICS CORPORATION Not For Release Reproduction or Distribution without Written Consent NOTE Chk App TITLE Last Modified Size INDUSTRIAL PARK No 2 WEST LEBANON NH 03784 603 298 5711 THERMAL DYNAMICS DWG No Sheet of Supersedes Scale Date Drawn References Date By Revisions Rev PCB No Assy No Information Proprietary to THERMAL DYNAMICS CORPORATION Not For Release...

Page 136: ...ons Rev PCB No Assy No Information Proprietary to THERMAL DYNAMICS CORPORATION Not For Release Reproduction or Distribution without Written Consent NOTE Chk App TITLE Last Modified Size INDUSTRIAL PARK No 2 WEST LEBANON NH 03784 603 298 5711 THERMAL DYNAMICS DWG No Sheet of Supersedes Scale Date Drawn References Date By Revisions Rev PCB No Assy No Information Proprietary to THERMAL DYNAMICS CORPO...

Page 137: ... Information Proprietary to THERMAL DYNAMICS CORPORATION Not For Release Reproduction or Distribution without Written Consent NOTE Chk App TITLE Last Modified Size INDUSTRIAL PARK No 2 WEST LEBANON NH 03784 603 298 5711 THERMAL DYNAMICS DWG No Sheet of Supersedes Scale Date Drawn References Date By Revisions Rev PCB No Assy No Information Proprietary to THERMAL DYNAMICS CORPORATION Not For Release...

Page 138: ...ons Rev PCB No Assy No Information Proprietary to THERMAL DYNAMICS CORPORATION Not For Release Reproduction or Distribution without Written Consent NOTE Chk App TITLE Last Modified Size INDUSTRIAL PARK No 2 WEST LEBANON NH 03784 603 298 5711 THERMAL DYNAMICS DWG No Sheet of Supersedes Scale Date Drawn References Date By Revisions Rev PCB No Assy No Information Proprietary to THERMAL DYNAMICS CORPO...

Page 139: ...o Information Proprietary to THERMAL DYNAMICS CORPORATION Not For Release Reproduction or Distribution without Written Consent NOTE Chk App TITLE Last Modified Size INDUSTRIAL PARK No 2 WEST LEBANON NH 03784 603 298 5711 THERMAL DYNAMICS DWG No Sheet of Supersedes Scale Date Drawn References Date By Revisions Rev PCB No Assy No Information Proprietary to THERMAL DYNAMICS CORPORATION Not For Releas...

Page 140: ...ons Rev PCB No Assy No Information Proprietary to THERMAL DYNAMICS CORPORATION Not For Release Reproduction or Distribution without Written Consent NOTE Chk App TITLE Last Modified Size INDUSTRIAL PARK No 2 WEST LEBANON NH 03784 603 298 5711 THERMAL DYNAMICS DWG No Sheet of Supersedes Scale Date Drawn References Date By Revisions Rev PCB No Assy No Information Proprietary to THERMAL DYNAMICS CORPO...

Page 141: ... Information Proprietary to THERMAL DYNAMICS CORPORATION Not For Release Reproduction or Distribution without Written Consent NOTE Chk App TITLE Last Modified Size INDUSTRIAL PARK No 2 WEST LEBANON NH 03784 603 298 5711 THERMAL DYNAMICS DWG No Sheet of Supersedes Scale Date Drawn References Date By Revisions Rev PCB No Assy No Information Proprietary to THERMAL DYNAMICS CORPORATION Not For Release...

Page 142: ...fault Contact TDC for resolution CCM software V2 3 1 Started using new cover styles Ref ECO B 122 August 25 2006 AA 01 Added leads lengths C and D as part of ECO B122 missed earlier Corrected artpages 2 2 3 2 3 3 6 2 and 6 3 adding callout letters on system layout diagramsadded G art and removed S art from cables and leads diagram Removed referenceand art for Coolant Deionizer Bag and Basket Inser...

Page 143: ...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 144: ...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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