Thermal Dynamics ULTRA-CUT 200 XT Operating Manual Download

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ULTRA-CUT 200 XT

Manual 0-5304

APPENDIX

A-19

CCM I/O PCB
Test Points

TP1

GND

TP2

/COOLANT FANS ON

TP3

/TORCH PUMP ON

TP4

LOW COOLANT FLOW (SW)

TP5

COOLANT FLOW SIGNAL (PULSE)

TP6

+15V ISOLATED

TP7

-15V ISOLATED

TP8

+18V ISOLATED

TP9

ANALOG CURRENT CONTROL 0-3.3V

TP10

GND ISOLATED

TP11

/PILOT ENABLE

TP12 +5VDC

TP13 -15VDC

TP14 +15VDC

TP15 24VDC

TP18

+5V ISOLATED

TP19

WORK CURRENT

LED Reference

Green PLASMA ENABLE

Green E-STOP_PS

Green GAS ON

Green CNC START

Green HOLD START

D12

Green PREFLOW ON

D13

Green CSD

D18

Green MARK

D20

Green SPARE1

D25

Green EXP METAL

D33

Green OK TO MOVE

D37

Green PSR

D41

Green SPARE FIELD OUT 2

D43

Green SPARE FIELD OUT 1

J Connectors

J21

BASIC CNC

J22

EXTENDED CNC

J23

RELAY - INTERFACE BOARD

J24

ARC / TIP VOLTS

J25

TEST

J26

GAS BOX

J28

TO CPU

J29

TO CPU

Summary of Contents for ULTRA-CUT 200 XT

Page 1: ...Thermal Dynamics com 200 480V ULTRA CUT 200 XT PLASMA CUTTING SYSTEM AUTOMATED GAS CONTROL Operating Manual Revision AG Issue Date May 27 2015 Manual No 0 5304...

Page 2: ...ncern Therefore 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...

Page 3: ...omission in this Manual whether such error results from negligence accident or any other cause Original Publication Date May 1 2013 Revision Date May 27 2015 Record the following information for Warr...

Page 4: ...hereof contained in this manual and accompanying labels and or inserts when installed operated maintained and repaired in accordance with the instructions provided This equipment must be checked perio...

Page 5: ...nform ment la description contenue dans ce manuel les tiquettes d accompagnement et ou les feuillets d information si l quipement est install op r entretenu et r par selon les instructions fournies Vo...

Page 6: ...This Page Intentionally Blank...

Page 7: ...t Input Power and Ground Cables 3 5 3 07 Connect Work Cable and Pilot and Negative Leads 3 6 3 08 Ground Connections 3 7 3 09 Connect Coolant Leads 3 10 3 10 Connect Cables for CNC Remote Arc Starter...

Page 8: ...eplacement Power Supply 6 1 6 02 System Layout 6 1 6 03 Recommended Gas Supply Hose 6 1 6 04 Leads And Cables All Amperages 6 2 6 05 Power Supply External Replacement Parts 6 4 6 06 Power Supply Repla...

Page 9: ...A 15 APPENDIX 8 CCM CPU PCB LAYOUT A 16 APPENDIX 9 CCM I O PCB LAYOUT A 18 APPENDIX 10 PILOT PCB LAYOUT A 20 APPENDIX 11 RELAY AND INTERFACE PCB LAYOUT A 22 APPENDIX 12 DISPLAY PCB LAYOUT A 24 APPENDI...

Page 10: ...480V PG 2 A 44 APPENDIX 25 ADVANCED TROUBLESHOOTING A 46 APPENDIX 26 SL100 INTERCONNECTION A 90 APPENDIX 27 HE 400 XT CONNECTION A 92 APPENDIX 28 SL100 TORCH OPTION A 93 APPENDIX 29 PUBLICATION HISTOR...

Page 11: ...and collars should be kept buttoned and open pockets eliminated from the front of clothing 5 Protect other personnel from arc rays and hot sparks with a suitable non flammable partition or curtains 6...

Page 12: ...xposure to EMF may have other health effects which are unknown 3 Welders should use the following procedures to minimize exposure to EMF A Route the electrode and work cables together Secure them with...

Page 13: ...Do not perform any electrical work unless you are qualified to perform such work 2 Before performing any maintenance work inside a power source disconnect the power source from the incoming electrical...

Page 14: ...tion by solid objects or water Protection is provided against touch with a finger penetration of solid objects greater than 12mm and against spraying water up to 60 degrees from vertical Equipment mar...

Page 15: ...ULTRA CUT 200 XT Manual 0 5304 SAFETY INSTRUCTIONS 1 5 This Page Intentionally Blank...

Page 16: ...lier ininflammable afin de vous prot ger des tincelles et de la chaleur par rayonnement 4 Les tincelles et les projections de m tal incandescent risquent de se loger dans les manches retrouss es les r...

Page 17: ...ce restreint ou humide ne tenez vous pas directement sur le m tal ou sur la terre tenez vous sur des planches s ches ou une plate forme isol e et portez des chaussures semelles de caoutchouc 8 Avant d...

Page 18: ...u cylindre de la soupape ou du dispositif de surpression peut causer des blessures graves ou mortelles Par cons quent 1 Utilisez toujours le gaz pr vu pour une op ration et le d tendeur appropri con u...

Page 19: ...rc Welding 6 AWS C5 6 Recommended Practices for Gas Metal Arc Welding 7 AWS SP Safe Practices Reprint Welding Handbook 8 ANSI AWS F4 1 Recommended Safe Practices for Welding and Cutting of Containers...

Page 20: ...er s il est plac sur une surface dont la pente d passe 15 Vous pourriez vous blesser ou endommager l quipement de fa on importante 15 Art A 12726 Art A 12736 MISE EN GARDE Soulevez l aide de la m thod...

Page 21: ...ional The components are connected at installation 2 02 Plasma Power Supply The power supply provides the necessary current for cutting operations The power supply also monitors system performance and...

Page 22: ...olant and Forced Air Class F Ultra Cut 200 XT Power Supply Input Power Input Current Suggested Sizes See Note Voltage Freq 3 Ph 3 Ph Fuse Amps Wire AWG Wire mm2 Volts Hz kVA Amps 3 Ph 3 Ph 3 Ph 480 50...

Page 23: ...ULTRA CUT 200 XT Manual 0 5304 SPECIFICATIONS 2 3 2 07 Power Supply Dimensions Art A 11980 35 97 inch 914 mm 27 6 inch 701 mm 47 77 inch 1213 mm 200A 465 lb 211 kg...

Page 24: ...CB4 5A 120 VAC CB3 5A 24 VAC CB2 5A 120 VAC J55 GCM J15 CNC J59 RAS J70 HE J54 TSC COMM Art A 11842_AB AC Power Lamp Negative Return Coolant Filter C C M Circuit Breakers Input Power Ports Arc Starte...

Page 25: ...il or grease contamination from compressed or bottled air can cause fires in conjunction with oxygen For filtering a coalescing filter able to filter to 0 01 microns should be placed as close as possi...

Page 26: ...ions 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 Mounting Tube End Cap B Torch Leads Lengt...

Page 27: ...e power to the torch Coolant leakage from the torch also indicates that torch parts are absent or installed improperly E Type of Cooling Combination of gas stream through torch and liquid cooling F XT...

Page 28: ...ULTRA CUT 200 XT SPECIFICATIONS Manual 0 5304 This Page Intentionally Blank...

Page 29: ...er ambient These are suggestions only Always refer to your local and national codes that apply to your region for final determination of correct wire type and size Gas Supply The customer must supply...

Page 30: ...0 Gas Control Positioning Tube Plasma Gas Marking Shield Shield Gas Negative Pilot Return Control Cable 100 30 5 m Maximum Length Shield H Q R U S A B C D E P K L O I J G 175 53 3 m Maximum Length Pre...

Page 31: ...h Ground O P W 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 G Shielded Torch Lead A...

Page 32: ...e 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 Ensur...

Page 33: ...ttom of the panel There are 2 extra plates included at the cable entrance Discarding one or both allows changing the opening size for larger cable strain relief 3 Install stripped end of 3 phase wires...

Page 34: ...the two screws then lift up and pull away 2 Route the ends of the work cable pilot and negative torch leads upward through the leads strain relief at the bottom edge of the left rear panel 3 Refer to...

Page 35: ...ted with 1 0 AWG European 50 mm2 or larger wire to a good earth ground measuring less than 3 ohms an ideal ground measures 1 ohm or less Refer to paragraph C Creating An Earth Ground The ground rod mu...

Page 36: ...ds typically 10 ft 3 0 m long may be welded end to end for greater lengths Locate the rod as close as possible to the work table Install a ground wire 1 0 AWG European 50 mm2 or greater between the gr...

Page 37: ...0 VAC Ground Rod with other connections removed Art A 12710 5 Increasing the ground rod length beyond 20 30 ft 6 1 9 1 m does not generally increase the effectiveness of the ground rod A larger diamet...

Page 38: ...y rear panel The supply line out is flagged green the return line in is flagged red COOLANT RETURN SUPPLY Coolant Connections RED GREEN To RAS 1000 Arc Starter or HE 400 Heat Exchanger if used Art A 1...

Page 39: ...onnect 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 USER INPUT HEIGHT CONTROL F1 8A SB 230 VAC F2 8A SB 230 VAC CB4 5A 120 VAC CB3...

Page 40: ...ptics electrical signals are converted to light with a transmitter LED The light passes down the fiber where it is converted back to an electrical signal at the receiver end Any damage to the fiber fr...

Page 41: ...itself making a sharp bend where it exits the hose Art A 09417 2 Do not hook onto the fiber to pull on the cable Art A 09418 3 Once the fiber cable is installed in the CCM or gas control make sure th...

Page 42: ...g device leaving some slack in the fiber Keep the protective end covers on the fiber until you are ready to connect it to the PCB in the CCM or gas control Art A 09420 Correct installation in CCM or G...

Page 43: ...0 5304 INSTALLATION 3 15 Unplugging the fiber optic connector Do not pull on the fiber cable Art A 09423 For the CCM grip the fiber connector front and back squeezing the latch lever and remove from t...

Page 44: ...OLANT RETURN SUPPLY Art A 11991 USER INPUT HEIGHT CONTROL F1 8A SB 230 VAC F2 8A SB 230 VAC CB4 5A 120 VAC CB3 5A 24 VAC CB2 5A 120 VAC J55 GCM J15 CNC J59 RAS J70 HE J54 TSC COMM USER INPUT HEIGHT CO...

Page 45: ...d the Fiber Optic Cable plug and wires through the hole where the plastic plug was removed labeled GCM DMC and slide the thin nut back over the Fiber Optic Cable 4 Secure the thin nut on the through h...

Page 46: ...ds 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...

Page 47: ...Contact closure 120VAC 1A Factory default setting or DC Volts 16 18vdc up to 100 ma SW 11 Set B position up for default SW 11 Set A position down for remote analog current control SW 8 2 must be set...

Page 48: ...ll result in no communication with the device Art 12322 3 14 Height Control Connections The terminal strip provides connections to negative Arc Volts Torch or electrode Tip Volts Pilot and Work These...

Page 49: ...fasten the module to the support securely The Module should be located as far away as possible from the Arc Starter due to possible electromagnetic interference It is acceptable to locate the control...

Page 50: ...e tightening the hose fitting to it Art A 09141_AB NOTE Argon must be used for the Marking gas If replacing existing fittings in the base apply thread seal ant to the fitting threads according to manu...

Page 51: ...d bracket on the power supply where the provided 2 hose can reach to the DMC 3000 Mounting in another location is possible with a customer provided hose Below is typical customer added hose and instal...

Page 52: ...to locate the control cable in the same track as the cables from the Arc Starter and away from torch leads The Module includes feet which lift the bottom panel off the mounting surface Louvers on the...

Page 53: ...screws securing the Cover Panel to the Module Loosen or remove 2 screws Remove 2 Screws Art A 09144_AB 2 Carefully remove the cover from the module noting the attached wire harness that connects to J...

Page 54: ...ng any fittings already mounted in the unit by placing a wrench on it before tightening the hose fitting to it Do not connect Fiber Optic cable until later Art A 09146_AB 4 Connect hoses from the fron...

Page 55: ...ptic cable 1 Remove outer thin nut from through hole protector at the end of Fiber Optic Cable L that is connected to the CCM 2 Ensure that the cable is exposed beyond the through hole protector appro...

Page 56: ...on the through hole protector so both nut faces are tight against the sheet metal inside and out Art A 09149_AB 5 Plug the Fiber Optic Cable into the PCB as shown below Make sure the locking tabs are...

Page 57: ...ged by being forced into tight radius turns 2 Ensure that the outer protective hose cable is exposed beyond the through hole protector approximately 1 and secure by tightening the wide nut with the ro...

Page 58: ...tic Cable into the PCB as shown below for the DMC 3000 Make sure the locking tabs are engaged Plug Fiber Optic cable to from DPC 3000 here Art A 09154 6 Plug the Fiber Optic Cable into the PCB as show...

Page 59: ...n meets all safety requirements The TSC 3000 mounting brackets allow for mounting on or under a horizontal surface as well as left or right of a vertical surface Choose which ever works best for prote...

Page 60: ...p is on and the coolant temperature is above a predetermined level It may come on anytime while the main pump is operating WARNING Do not disassemble the Cooler with the power applied or the coolant f...

Page 61: ...it will strip the fitting threads and will cause a leak Do not start the Ultra Cut XT without coolant in the reservoir An additional gallon 3 78l of coolant is required to compensate for the HE400XT b...

Page 62: ...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 fo...

Page 63: ...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...

Page 64: ...ing input connections to the Arc Starter Coolant Supply and Return Hoses from HE 400 Heat Exchanger Hoses and connectors are color coded Red for Return Green for Supply Coolant Supply and Return Hoses...

Page 65: ...sher on each NOTE Slave and Master refer to only those set ups using two power supplies in parrallel Slave is not used in single system operations Negative Master Torch Lead Pilot Art A 12063_AB Negat...

Page 66: ...e Arc Starter Pilot Lead Art A 12065 Green Red Coolant Return Red Coolant Supply Green Pilot Return Cable Coolant Supply and Return Hoses from Torch 2 Reinstall the Arc Starter Cover Ensure that the g...

Page 67: ...r to the previous section for grounding details Ground Cable Art A 04758 1 Nut and 1 Washer Remain in Place Torch Leads 4 Use a clamp to secure the Torch Lead Shield braid brass ring to the port on th...

Page 68: ...Control Cable 1 Connect the Remote Arc Starter cable to the Remote Arc Starter receptacle USER INPUT HEIGHT CONTROL F1 8A SB 230 VAC F2 8A SB 230 VAC CB4 5A 120 VAC CB3 5A 24 VAC CB2 5A 120 VAC J55 G...

Page 69: ...ll 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 upper end of the Mountin...

Page 70: ...to connect to the Mounting Tube Pull the leads back as needed to ensure a proper fit through the Mounting Tube and Torch Leads End Cap Hold the Torch Head Assembly stationary rotate the Mounting Tube...

Page 71: ...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 car...

Page 72: ...water shield Water on the plate interferes electrically with the ohmic sensing circuit 30 100 Amp Parts Assembly Cartridge Covers O Ring on Torch Tip Shield Cap Protrudes 0 063 0 083 1 6 2 1 mm Elect...

Page 73: ...panel near the rear of the power supply Predrilled holes for mounting the iHT V D board as well as another popular height control are provided CAUTION If using another board that doesn t align with t...

Page 74: ...end of the torch and the metal or plate being cut A wire usually a single highly flexible wire that withstands the reflective heat from the arc is connected between the V D board and the torch shield...

Page 75: ...ng on the length of the torch leads the system may require more coolant after turning the system ON for the first time a Place the ON OFF Switch to ON b After about 4 minutes the system may shut down...

Page 76: ...ULTRA CUT 200 XT INSTALLATION Manual 0 5304 This Page Intentionally Blank...

Page 77: ...g output DC voltage A Status Indicator Shows CCM code version on start up followed by the Current Control setting and system status Refer to Section 4 05 and Status Code Section for details Rear Panel...

Page 78: ...is disabled Plasma Enable shut off the pump doesn t start and display alternates between status code E101 and 0 Assuming the unit is not disabled as soon as adequate coolant flow is detected usually...

Page 79: ...LE DISPLAYS SYSTEM STATUS IN ALL SCREENS BACKBUTTON REVERSES TO THE PREVIOUS PAGE INCREMENTS DECREMENTS THE SELECTED VALUE OK NEXT BUTTON ACCEPTS ENTRIES AND MOVES TO THE NEXT PAGE PAGE HEADER SELECTI...

Page 80: ...Enter XT lead DPC to Torch only 4 currently allowed Enter DFC 3000 lead length DMC to DPC Utility Screen 2 is for information only Displays Device and Cutchart IDs setting of options switches etc Uti...

Page 81: ...installed in the torch Go to THC CNC settings for cutting 5 Select new standard process by material thickness amperage 1 or enter process using pop up number pad 2 5 PROCESS MONITOR Now you are ready...

Page 82: ...dy to start cutting Displayed Amps Demand is the output current setting not the actual current As soon as Start is applied Process Monitor shows output voltage gas pressures status of Start OK to Move...

Page 83: ...ues if you change too far it may cause faults You may also change the values displayed on THC CNC Settings screen THC CNC settings on the TSC 3000 at this time are for information only They do not con...

Page 84: ...ttons If the custom process requires different setting speed arc voltage etc edit it here Editing the THC CNC SETTING is for reference only does not change the actual THC or CNC setting That must be d...

Page 85: ...USB Flash drive Backing Up Custom Process 1 For the remotely mounted DSC 3000 insert the flash drive in the USB connector on the back If using the TSC 3000 mounted in the plasma supply front panel the...

Page 86: ...assword 00000 unless you ve changed it 3 Press the Restore Custom USB Art A 09235_AB 4 Shortly almost instantly if only a few files you should see at the bottom Status Copy to Files Custom Complete th...

Page 87: ...nfirmed as operational 1 Before Applying power a Ensure that the required gasses are connected to the DMC 3000 inlet and gasses are turned on and set for required inlet pressure b Ensure you have a to...

Page 88: ...g process selection you will come to the Torch Consumables screen At this point if you have not installed correct consumables and Plasma is not already disabled shut off disable the Plasma Enable SW I...

Page 89: ...types With Plasma Disable the system remembers what was used last and does only the amount of purge necessary possibly saving time 11 Use Plasma Disable a You may use the Plasma Disable when removing...

Page 90: ...ldup on cut surface nitride buildup 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 ste...

Page 91: ...le parts life and premature torch failure A cartridge type particulate water filter may help achieve optimum cutting performance 4 11 CCM Status Codes NOTE See the Appendix for Advanced Troubleshootin...

Page 92: ...remained in contact with work in excess of 15 seconds Pak200i 108 Tip to Electrode voltage fault Tip voltage too close to electrode voltage Torch consumable parts worn out Wrong consumables installed...

Page 93: ...ibbon cable If problem persists replace Inverter Module 2 218 Inverter 1A Output Current High Plasma work current high during cutting and attributed to Inverter Module 1 Section A output high If probl...

Page 94: ...verter Module 3 installed Defective Inverter module 237 Too Few Inverters Found Two or more Inverter Sections required to operate Ribbon cable from CCM to Inverter Section damaged or disconnected 238...

Page 95: ...ed radiator Defective fan If problem persists replace inverter module 254 Inverter 1B Over Temp Inverter Module 1 Section B is over temperature Operating with side panels re moved Check for restricted...

Page 96: ...tactor or CB4 tripped Inverter section input not connected Defective Inverter 270 Inverter 3B No Input Power Inverter section may have no input power Contactor W2 not closed Defective con tactor or CB...

Page 97: ...y temperature exceeded 75 degrees Celcius 167F Operating with side panel loose or removed Air flow blocked at air inlet or exit of power supply Coolant fan failed radiator fins clogged with dirt 404 C...

Page 98: ...Fault Unable to create Log file on USB Flash drive last firmware update attempt Use dif ferent USB Flash Drive or Reformat 614 No USF File File VTCCMFW USF missing from Flash Drive Add proper files t...

Page 99: ...flash program firmware revision number in a 2 digit code as explained below Following the revision code 2 Green indicator On steady OK communication established Blinking no communication established...

Page 100: ...n available Contact customer service Group 3 CCM Communication Port 3 1 CCM Acknowledge error Check DMC to CCM fiber optic cable and connections Dirty or defective fiber optic Replace DMC Control PCB...

Page 101: ...place solenoid Shorted wire harness Defective DMC Control PCB Communication faults shown on the DMC can be caused by the device on the other end of the communication line Before assuming the DMC is at...

Page 102: ...re too high Valve at minimun setting Restriction in plasma hose torch DPC manifold defective control valve V5 defective pressure sensor PS6 DPC Control PCB Group 6 Plasma Low Proportional Valve V4 6 1...

Page 103: ...ield H2O Proportional Valve V2 9 1 Valve open Check for open connection Replace valve 9 2 DPC inlet Supply pressure low Raise plasma inlet pressure check for DMC valve not open restriction in gas supp...

Page 104: ...or 120 VAC at the plasma supply s rear panel connector J59 7 9 during ignition time 120V present open control cable 120V not present fault in plasma power supply Faulty Electronic Ignition module Chec...

Page 105: ...ace as needed Clean water filter if using H2 O Mist Six Months Clean or replace coolant filter Clean coolant tank Vacuum out any dust buildup inside power supply 5 02 External Coolant Filter Cleaning...

Page 106: ...to drain then apply a maximum of 5psi to clear the lines CAUTION Applying more than 5 psi air pressure to the cooling system will result in damage Extra cau tion must be used when performing this task...

Page 107: ...Coolant Return Control Cable Pilot Return Coolant Supply Coolant Return Plasma Gas Shield Gas Work Cable DMC 3000 Gas Console Ultra Cut Power Supply DPC 3000 Gas Control Positioning Tube Plasma Gas M...

Page 108: ...th Ground O P W 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 G Shielded Torch Lead...

Page 109: ...9 4908 9 4909 9 9332 9 4910 9 4911 9 4912 9 4913 9 4914 O Work Cable 9 7350 9 7351 9 7352 9 7353 P Control Cable CNC to PS 9 7368 9 7369 9 7370 9 7371 9 7372 H L Q R S T U Auto Gas Lead Set Note 2 4 3...

Page 110: ...ernal Replacement Parts Item Qty Description Catalog 1 1 Power and Leads Cable Cover 9 7346 2 1 Top Panel 9 7300 3 1 Upper Side Covers 9 7301 4 1 Lower Left Side Panel 9 7304 5 1 Lower Right Side 100A...

Page 111: ...s PCB 9 9253 2 1 Pilot PCB 9 9250 3 1 CCM Assembly 9 7335 4 1 Relays Pump Fan MC3 MC2 9 7314 5 1 Relay Inrush Control K1 9 7336 6 1 Relay Inrush MC1 9 7337 7 1 Resistor Inrush R2 9 7376 8 1 Display PC...

Page 112: ...nsor Coolant level 9 7307 4 1 Pump Coolant Assembly with motor 9 7309 1 Pump Coolant Assembly no motor 9 7423 5 1 Motor Pump motor only 9 7424 6 1 Heat Exchanger Fan 9 7312 7 1 Radiator 9 7311 8 1 Flo...

Page 113: ...scription Breaker Rating Circuit Rating Ref Des Catalog 1 1 Coolant Filter Assy 9 7320 2 1 Coolant Filter 9 7321 3 1 Fuse 8A SB 500 VAC 9 7377 Art A 11549_AC 1 2 3 USER INPUT HEIGHT CONTROL F1 8A SB 5...

Page 114: ...04 6 09 Power Supply Replacement Parts Left Side Item Qty Description Ref Des Catalog 1 1 AC Suppresion PCB 9 9254 2 1 Main Contactor W1 9 7318 3 1 Inverter Module Partial 480 VAC 9 7331 4 1 Inverter...

Page 115: ...REPLACEMENT PARTS 6 9 6 10 DFC 3000 Automated Gas Control System Replacement Components Item Qty Description Catalog 1 1 Assy DMC 3000 Demo 9 9491D 2 1 Assy DPC 3000 Demo 9 9443D 3 1 Assy TSC 3000 Rem...

Page 116: ...4 3 1 Manifold subassembly includes 15 of item 2 9 7546 4 1 SMPS PCB 9 8263 5 1 Control PCB 9 7291 Not shown 6 1 WMS Water Softener Kit includes the following items 9 1068 7 1 WMS Replacement Filter C...

Page 117: ...em Qty Description Catalog 1 1 Assy DPC 3000 Demo 9 9443D 2 1 DPC PCB 9 8262 3 1 SMPS PCB 9 8263 4 1 Shield Gas P Valve 9 8267 5 1 Sensor Pressure 1 8mnpt six total 9 8269 6 1 Solenoid 9 8264 7 1 Plas...

Page 118: ...mote and Internal Replacement Parts Item Qty Description Catalog 1 1 Assy TSC 3000 Remote Demo 9 9490D 2 1 Touch Panel Computer 9 7543 3 1 Switch Rocker SPST 9 1042 4 1 Ribbon Cable HMI to Interface P...

Page 119: ...ARTS 6 13 6 14 Remote Arc Starter RAS 1000 Replacement Parts Item Qty Description Catalog 1 1 Complete RAS 1000 XT Assembly 3 9130E 2 1 Pilot Cap Assembly 9 9423 3 1 Electronic Ignition Module 9 7342...

Page 120: ...l 0 5304 6 15 Optional HE400XT Heat Exchanger Replacement Parts Item Qty Description Catalog 1 1 Assembly HE400XT Heat Exchanger 9 9416 2 1 Fan 9 7348 3 1 Radiator 9 7349 4 1 Capacitor 9 1059 5 1 Ther...

Page 121: ...eld Cup Cartridge Assembly stationary Turn the Shield Cup to remove it from the Cartridge Assembly Assembled Cartridge Cartridge Tool Shield Cup Art A 04344_AB 2 Take the Removal Tool off the back of...

Page 122: ...ion Under Locking Ring O Ring Cat No 9 3028 Art A 04071_AC Snap Ring Cartridge Assembly Art A 04066_AC O Rings Cat No 9 3027 Cat No 9 3026 Cat No 9 3025 Torch Head Cat No 9 9041 CAUTION Use only Therm...

Page 123: ...Handle 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...

Page 124: ...e 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...

Page 125: ...sembly fully and re assemble the Torch Properly See Installation Manual Replace Torch Head Is the Torch Damaged Replace Consumable Cartridge and Shield Cup Torch still leaks Remove and Lubricate all O...

Page 126: ...age Plasma Gas Recommended Wear Depth for Electrode Replacement Inch mm 30 O2 0 04 1 Air 0 04 1 N2 0 04 1 50 O2 0 04 1 Air 0 08 2 N2 0 04 1 70 O2 0 04 1 Air 0 08 2 N2 0 04 1 100 O2 0 04 1 H35 0 08 2 N...

Page 127: ...e Plasma Marking Corner Current Reduction Expanded Metal Spare 1 Output Normally Open Contacts Spare 2 Output Normally Open Contacts Hold Start CNC Plasma Enable LV OK To Move 2 Preflow On Start Stop...

Page 128: ...R W GN OR Data Data The multicolor wires are twisted pairs CCM to TSC 3000 is RS 485 2 wire OR W Orange wire with White stripe W OR W GN GN W BL W RS 422 wiring 4 wire half duplex also called RS 485 4...

Page 129: ...ple CCMs 120 120 Signal GND also required but not shown SW14 OFF SW14 OFF SW14 ON TSC 3000 HMI or CNC using 2 wire RS 485 CCM 1 CCM 2 CCM last in line Data Data Art A 09483 RS 422 4 wire half duplex T...

Page 130: ...ect is set for voltage Rear Panel CNC Connector J15 37 Circuit Amp CPC Remote Standard These are also duplicated on TB1 TB2 TB3 use one or the other not both Chassis gnd for SC 11 cable shield 1 Start...

Page 131: ...op Ret4 TB1 6 TB1 5 comm or Start Latched NO 4 TB1 6 TB1 5 comm used with Stop Latched Divided Arc Voltage TB1 8 TB1 7 comm Remote Analog Current Control TB1 9 Analog Comm or 10K CC Pot low TB1 10 Ana...

Page 132: ...until height is found Remove HOLD to ignite pilot initiate arc transfer Preflow On input Normally open close to start preflow prior to normal START signal Circuit rating 10 ma 20VDC Torch Height Contr...

Page 133: ...ng that the cutting speed is being reduced to navigate a corner or small radius the cutting current is reduced at a fixed rate to a predetermined level to provide an improved cut at the lower speed Cu...

Page 134: ...Start Plasma M arki ng Plasma M arki ng Corner Current Reducti on Corner Current Reducti on Cut Expanded M etal Cut Expanded M etal Spare 2 NO Spare 2 NC Spare 1b NO 1 2 3 4 5 6 7 8 9 10 11 12 TB2 1...

Page 135: ...CNC Plasma Enable 26 CNC Plasma Enable 32 Stop SW momentary 33 Stop SW Ret 34 Pilot is ON a 35 Pilot is ON b 36 Spare OUT 1 a 37 Spare OUT 1 b 132 133 137 132 133 C hassi s 136 134 135 139 138 134 135...

Page 136: ...for CNC cable Do not connect wire 1 to anything Cable Shield drain wire must be connected to ground at cutting machine Art A 11901 SW6 DC 18 19 17 15 16 23 24 22 20 21 28 29 27 25 26 33 34 32 30 31 37...

Page 137: ...BLACK OK TO MOVE 14 BLUE OK TO MOVE 16 WHITE BROWN YELLOW HOLD START 17 WHITE BROWN GREEN HOLD START 21 WHITE BLACK ORANGE PLASMA MARK 22 WHITE BLACK RED PLASMA MARK 23 WHITE BROWN ORANGE CUT EXPANDE...

Page 138: ...ULTRA CUT 200 XT APPENDIX Manual 0 5304 APPENDIX 4 DMC 3000 Control PCB Layout J1 J9 TP6 J5 J6 SW2 J8 TP5 J2 TP3 TP2 TP4 J3 J4 SW1 TP7 TP1 Art A 09188_AB LED D1 D 17 LED D_E1 D_E15 D21 D22...

Page 139: ...200 XT Manual 0 5304 APPENDIX A 13 APPENDIX 5 DPC 3000 Control PCB Layout TP6 J5 J6 SW2 TP5 TP3 TP2 TP4 SW1 TP8 TP1 Art A 09189_AB J1 J2 J3 J4 J9 J8 TP7 TP9 TP10 TP11 J10 D7 D12 D11 D10 D5 D4 D3 D2 D1...

Page 140: ...ULTRA CUT 200 XT APPENDIX Manual 0 5304 APPENDIX 6 DMC 3000 DPC 3000 Power Supply PCB Layout F2 J2 D7 D6 TP1 TP6 D5 D9 TP7 D16 TP8 J1 F1 TP4 TP5 TP2 TP3 Art A 09597...

Page 141: ...ULTRA CUT 200 XT Manual 0 5304 APPENDIX A 15 APPENDIX 7 TSC 3000 PCB Layout TP4 TP1 TP3 J1 J2 J3 TP2 J4 J5 Art A 09190_AB D1 D11 D13 D14 D15...

Page 142: ...ULTRA CUT 200 XT APPENDIX Manual 0 5304 APPENDIX 8 CCM CPU PCB Layout Test Point Test Point Art A 11675_AB...

Page 143: ...0V TP3 24V TP4 3 3V TP5 ISO GND TP6 5 0V TP7 TOTAL DEMAND 3 3V 400A TP9 WR TP10 RD TP11 CPU TEMP SENSE TP12 3 3VA TP13 15VDAC TP14 PC2 TP15 15VDAC TP16 CLKO TP18 OSC_CLOCK LED Reference D2 Red RXD D3...

Page 144: ...ULTRA CUT 200 XT APPENDIX Manual 0 5304 APPENDIX 9 CCM I O PCB Layout Test Point Test Point Art A 11676_AC...

Page 145: ...5VDC TP13 15VDC TP14 15VDC TP15 24VDC TP18 5V ISOLATED TP19 WORK CURRENT LED Reference D2 Green PLASMA ENABLE D3 Green E STOP_PS D4 Green GAS ON D6 Green CNC START D8 Green HOLD START D12 Green PREFL...

Page 146: ...ULTRA CUT 200 XT APPENDIX Manual 0 5304 APPENDIX 10 Pilot PCB Layout Art A 11677 Test Point Test Point...

Page 147: ...ULTRA CUT 200 XT Manual 0 5304 APPENDIX A 21 Pilot PCB Test Points TP1 GND TP2 PILOT GATE TP3 5V TP4 TIP LED Reference D2 Green PILOT ENABLE D11 Green 5V...

Page 148: ...ULTRA CUT 200 XT APPENDIX Manual 0 5304 APPENDIX 11 Relay and Interface PCB Layout Test Point Test Point Art A 11678_AB...

Page 149: ...TP3 5VDC TP4 12V TP5 24V TP6 15V TP7 5VDC LED Reference D2 Green 1 TORCH GAS ON D7 Green PILOT ENABLE D11 Green PILOT CURRENT DETECTED D12 Green WORK CURRENT DETECTED D22 Green CONTACTORS ON D23 Green...

Page 150: ...ULTRA CUT 200 XT APPENDIX Manual 0 5304 APPENDIX 12 Display PCB Layout Test Point Test Point Art A 11679...

Page 151: ...ULTRA CUT 200 XT Manual 0 5304 APPENDIX A 25 Display PCB Test Points TP1 GND TP2 5VDC TP3 24VDC...

Page 152: ...ULTRA CUT 200 XT APPENDIX Manual 0 5304 APPENDIX 13 System Bias PCB Layout Test Point Test Point Art A 11680...

Page 153: ...C TP3 DC INPUT POSITIVE TP4 Vcc1 TP5 Vcc2 TP6 GATE TP7 PRIMARY GND TP8 12V PRIMARY TP9 P_ISOL_GND TP10 DC SENSE POSITIVE LED Reference D3 Red MISSING PHASE D4 Red AC V HIGH D14 Red AC V LOW D15 Green...

Page 154: ...ULTRA CUT 200 XT APPENDIX Manual 0 5304 APPENDIX 14 Main Inverter Bottom PCB Layout Test Point Test Point Art A11681_AB...

Page 155: ...ttom PCB Test Points TP1 GND TP2 GATE 2A TP3 GATE 1A TP4 GATE 3A TP5 GATE 4A TP6 GATE 2B TP7 GATE 1B TP8 GATE 4B TP9 GATE 3B TP10 12VP TP11 12VDC TP12 THERMISTOR SIDE A TP13 THERMISTOR SIDE B TP14 5VD...

Page 156: ...ULTRA CUT 200 XT APPENDIX Manual 0 5304 APPENDIX 15 Main Inverter Top PCB Layout Test Point Test Point Art A11682_AB...

Page 157: ...op PCB Test Points TP1 GND TP2 GATE 2A TP3 GATE 1A TP4 GATE 3A TP5 GATE 4A TP6 GATE 2B TP7 GATE 1B TP8 GATE 4B TP9 GATE 3B TP10 12VP TP11 12VDC TP12 THERMISTOR SIDE A TP13 THERMISTOR SIDE B TP14 5VDC...

Page 158: ...ULTRA CUT 200 XT APPENDIX Manual 0 5304 APPENDIX 16 Control and Fault PCB Layout Test Point Test Point Art A11683_AB...

Page 159: ...ND TP22 12VDC TP23 5VDC TP24 GATE 1 TP25 A_OUT1 TP26 B_OUT1 TP27 GATE 1 TP28 I_SNS1 TP29 GATE 2 TP30 I_DMD1 0 5V 6 7V TP31 GATE 2 TP32 12VDC TP33 START 2 TP34 SHDN TP35 ENABLE TP36 READY IN TP37 READY...

Page 160: ...ULTRA CUT 200 XT APPENDIX Manual 0 5304 APPENDIX 17 Cap Bias Bottom PCB Layout Art A 11685_AB...

Page 161: ...ULTRA CUT 200 XT Manual 0 5304 APPENDIX A 35 APPENDIX 18 Cap Bias Top PCB Layout Art A 11686_AB...

Page 162: ...ULTRA CUT 200 XT APPENDIX Manual 0 5304 APPENDIX 19 Suppressor PCB Layout Art A 11684_AB...

Page 163: ...le Sensor Level Switch HE400 Torch Coolant Supply Torch Coolant Return Cold Plate 1 Cold Plate 2 Cold Plate 3 Radiator Pump Coolant tank Filter 1 Over Flow Supply RAS 1000 XT 300 FOR 400 AMP SYSTEMS C...

Page 164: ...prietary to Victor Technologies Title Not for release reproduction or distribution without written consent 7 30 2013 Date Printed Date Revised 7 30 2013 AA ECO B2487 RWH 07 30 2013 1 2 3 4 5 6 7 8 9 1...

Page 165: ...ULTRA CUT 200 XT Manual 0 5304 APPENDIX A 39 This Page Intentionally Blank...

Page 166: ...ROUNDING SCREW TSC 3000 19X2200 HMI CONTROL COMMUNICATIONS 4W 2W SW14 NOTE DMC solenoids are 18 VDC Coils are about 46 ohms 24 VDC is applied for 1 second then reduced by pulse width modulation to an...

Page 167: ...D1 PLASMA_PWM D2 PLASMA_VENT_PWM D3 SHIELD_H20_PWM D4 SHIELD_GAS_PWM D5 MARKING_PWM D6 PLASMA_PILOT_PWM D7 5VDC D8 DPC STATUS D9 SHIELD_H20_FLOW D10 PLASMA_CUT_PWM D11 PLASMA_LOW_PWM D12 CANBUS COMMUN...

Page 168: ...ents LT1 LT2 INPUT POWER NEON INDICATORS Rear Panel Internal 019X502000 019X502700 019X502000 Sht 2 A1 Sht 2 E3 D3 RED CAP IMBALANCE D4 GREEN READY D6 GREEN 12V D11 GREEN 12VP D13 GREEN 12V D1 RED INV...

Page 169: ...LEVEL OK 10 COMMON 11 NA 12 PLASMA ENABLE HMI 13 COOLANT PUMP ON 14 COMMON 15 PILOT ENABLE 16 RAS ON 17 CONTACTORS ON 18 COMMON 19 COOLANT FANS ON 20 1TORCH CONTACTOR ON 21 PLASMA ENABLE RELAY 22 COMM...

Page 170: ...72 73 74 75 76 77 78 79 53 51 55 83 84 89 90 93 92 94 95 1 2 J74 65A 65A 230V 400V 480V ERR J62 12 VAC_IDAb 0 1 0 1 J62 14 VAC_IDBb 0 0 1 1 Measure relative to TP1 24VDC_RET 0 10 12V 1 24V 70 69 1 2 3...

Page 171: ...3 104 106 108 109 110 111 101 102 108 109 113 121 Tx GND GND Tx Rx Rx 120 119 118 117 116 115 4 CNC Start 6 Divided Arc V 5 Divided Arc V 12 OK to Move 14 OK to Move 7 Preflow ON 9 Preflow ON 30 Remot...

Page 172: ...h are required for proper air flow A 100A system uses 1 full IM 200A uses 1 and modules with a full module in the bottom location and a module in the middle position A 300A unit has full modules top a...

Page 173: ...tes the flow rate and can detect the presence of gas bubbles in the coolant All these signals pass to the CCM via a 40 conductor ribbon cable going to the CCM I O board The Display Board Has LEDs for...

Page 174: ...is used for the top inverter module in other units of this family The AC 300 XT has a separate gas control Arc Starter that sits on top of the main enclosure very similar to the GCM 1000 of our earli...

Page 175: ...inverter sections while this guide groups similar codes together For example code E or L 249 indicates an inverter fault in Inverter 2A This guide covers codes 247 252 in one section as they are all t...

Page 176: ...set Status or Fault codes Coolant Problems 1 Blinking Gas Indicator At power on the GAS indicator on the front panel blinks continuously No code is showing The actual Real problem is no or low coolan...

Page 177: ...or output from the cutting table or robot Defective Relay PCB Defective CCM I O PCB Special case Display alternates between E101 and This happens when there is both a missing phase and Plasma enable...

Page 178: ...ected 24 VAC through a jumper in the TSC 3000 energizes K7 opening its NC contacts and now GND connects through the TDC 3000 Plasma Enable switch The GND obtained by either path passes through the GCM...

Page 179: ...XT Automation Torch ONLY No HF to the torch due to broken pilot wire connection in the torch leads No HF to the torch due to defective Arc Starter Arc Starter not receiving power XT Torch or 1Torch o...

Page 180: ...conds following Preflow check for 120 VAC into the line filter GCM1000XT only If it s there replace the filter If 120 VAC isn t present at the line filter or if this is an AC 200XT go to step 5 in sec...

Page 181: ...the Relay board Pilot LED D11 is still on it s due to a fault in the detection circuits 7 Faulty detection circuit There isn t any pilot current but a fault in the circuits measuring pilot current is...

Page 182: ...0 group instructions to bypass the W4 contactor 3 If D11 on the Pilot board is not on check if the 10 pin ribbon cable is connected between the Pilot board J42 and the Relay board J3 Measure for 24 VD...

Page 183: ...tor or the DPC 3000 and the torch Check for leaks Coolant flow goes too low while cutting causing the unit to shut the arc off This normally should set 402 fault but for reasons currently unknown some...

Page 184: ...a level that the tip can handle for a while Fault occurs with the Pak200i torch if the tip has contacted the work longer than 15 seconds The 1Torch with the current reduced by the tip saver circuit is...

Page 185: ...t This is used with the DFC 3000 only It means the operator hasn t loaded the cutting process from either the TSC 3000 or from the program embedded in the cutting table CNC control ler The solution is...

Page 186: ...nd Fault board Inverter over temperature lights LED D14 on the Inverter Control and Fault board and will latch the fault signal and it s LED but also has its own separate fault so that will be reporte...

Page 187: ...power supply output voltage between negative Torch to positive Work at the output terminals If this is less than a set value during preflow or if at any time during piloting or cutting it drops to be...

Page 188: ...code is still active either the Relay board or the CCM is defective CCM or ribbon cable The work current signal leaving the relay board is on the 40 pin ribbon cable Relay J4 to CCM J23 pins 27 28 If...

Page 189: ...nd 25 It should be less than 0 1V If not the Relay board is bad If voltage is zero then the CCM is defective 2 208 code comes on during preflow IM 1 and the Pilot board are enabled near the end of pre...

Page 190: ...sconnect work lead from back of unit Check for continuity to chassis there should be none Inspect for incorrectly connected user equipment 2 If no shorts were found or if fault was current signal too...

Page 191: ...connection or defective ribbon cable o Check ribbon cable connections at both ends of INV1Ato CCM J31 1A cable Make sure it is plugged into J31 the top connector on the CCM o Plug a different inverter...

Page 192: ...s board defective Troubleshooting 1 If System Bias board has either the wrong jumper or is defective it will call out the first inverter section code 231 because all the inverters won t match the inco...

Page 193: ...the ribbon cables back in their original positions Now swap suspect ribbon cables on the CCM If the fault now changes it s the ribbon cable If it remains the same it is the CCM c If there are 2 or mor...

Page 194: ...at is currently detected as being too high If it s L239 that means the voltage too high previously but it is not too high now Applying START will clear the fault unless it becomes active again The vol...

Page 195: ...l problem may be due to incoming voltage dips or sags voltage drops lasting from cycle to as much as a minute Usually if the plasma is at fault the problem will be present all the time After ruling ou...

Page 196: ...would more likely trigger a different fault If it s the incoming power it would be likely not always be the same inverter 2 Phase missing or intermittent to a specific inverter the fault would always...

Page 197: ...r enters the louvers on the left side of the front panel If an inverter goes over temperature and we have determined that the ambient exceeds 40 deg C we will get one or more of the high ambient codes...

Page 198: ...is no power into the section or something is wrong with that inverter section s bias power Possible causes The 3 input phases J103 105 to that inverter section not connected The circuit breaker CB2 p...

Page 199: ...sections try disconnecting one section at a time and cut at lower current See if you find one that causes the problem and if so replace that ribbon cable Group 3 codes relate to the GAS Controls Statu...

Page 200: ...re and compare mechanical gauges with the pressure display If the pressure display doesn t approximately match the gauge the sensor is likely defective If the gauge and the pressure display both show...

Page 201: ...excess flow back into the reservoir The coolant temperature sensor TS1 a linear NTC sensor is mounted on the bypass valve From the bypass valve in most systems coolant is plumbed to the rear panel coo...

Page 202: ...normally open flow switch requires 0 7 GPM 2 65 liter min about 10 to close PAK 200i uses a different flow SW set for 0 25 GPM 0 95 65 liter min When the system is turned on and enabled and fails to a...

Page 203: ...d Defective CCM Troubleshooting 1 Check for air blowing out of the unit Remember except for the AC 200 XT the fans only run when CNC START is applied and for 4 minutes after cutting you may have to ap...

Page 204: ...e reason for the 4 minutes is a new dry system especially one with long torch leads will take some time before the leads hoses radiator and cold plates are full of coolant More coolant may have to be...

Page 205: ...404 fault code is displayed measure for 230 VAC at the motor connector J16 pin 1 to pin 3 a If the pump motor is not getting 230 VAC measure for 24 VAC on the coil of MC3 If present and the relay con...

Page 206: ...m With the unit switched off remove the return hose from the back of the power supply Place it in a container of a known volume Turn the unit on and let the pump run exactly 30 seconds It should pump...

Page 207: ...tic link No signal has been detected Communication with the DPC which is relayed through the DMC sets a different code 301 if there is a problem with it Possible causes Gas control is GCM 1000 XT Auto...

Page 208: ...in response to a request from the CCM The black end of the fiber cable is inserted into the transmitter which is the gray housing on the PCB The other end of the transmitting fiber is blue and goes in...

Page 209: ...or some other device that draws too much current exceeding the limits of the USB power supply Try another flash drive or if you know this one is OK it works with a computer then replace the CCM 613 US...

Page 210: ...2 220C 220D 52A 2 52B 1 52B 2 W5 L1 L2 L4 L3 T2 T1 T4 T3 To NEG OUTPUT BUSS BAR 49 12 AWG 10 AWG 10 AWG 219A 219B 219C 224B 223A 223B 223C WO R K 1 Torch ATC 220A 220B RELAY PCB J85 J11 J84 J86 1 TORC...

Page 211: ...the tip by the gas flow Interlock measurements during XT Automation torch operation 1 Regardless of whether a 1Torch is plugged into the ATC 15 V is applied via K201 to the 1Torch electrode circuit AT...

Page 212: ...n pin 20 of the 40 pin ribbon cable J23 J4 It should be low less than 2VDC If it is the Relay Board is faulty If pin 20 is not low the CCM is likely the cause 3 W4 Contactor does not close when system...

Page 213: ...ced current 2 W5 is not energized or stuck a The Relay board LED D40 should be on when W5 is OK If it is not on remove J84 from the Relay board If D40 still does not come on the Relay board is defecti...

Page 214: ...ring across its coil pin 7 to pin 8 Should be zero but if it s 24 VDC then the Relay Board is defective c If voltage was OK at K201 5 measure from TP1 to K201 1 If not there K201 s NC contact is open...

Page 215: ...hould be low less than 2VDC when pressing the 1Torch trigger If it does not go low the CCM or the ribbon cable is faulty If pin 4 is low or goes low when the torch trigger is pressed but D2 on the Rel...

Page 216: ...ified Contactor Enable 1 Torch Gas Sol ON 1 Torch GBU404 D 1 2 3 J85 D38 GREEN D35 1 2 3 4 5 J84 D41 GREEN D40 1 TORCH CONTACTOR OK 10K R 1 2 J41 52A 1 W4 A W4 B WORK 1 2 3 4 5 J40 INVERTER Automation...

Page 217: ...TRODE TIP 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 J86 24 VAC Ret 24 VAC Ret W4 W5 AUX SOL4 14 AWG 24 VAC Ret TIP ELECTRODE 1 Torch Press OK Ret Common 12 AWG 10 AWG 10 AWG W4 energized when...

Page 218: ...Suite 300 St Louis Missouri 63017 USA Drawn Date Sheet of Size Drawing Number SCHEMATIC HE400XT The information contained herein is proprietary to Victor Technologies Title Not for release reproducti...

Page 219: ...ling power supply torch parts or torch and leads assemblies Torch Connections If necessary connect the torch to the Power Supply Connect only the Thermal Dynamics model SL100 Manual Torch to this powe...

Page 220: ...utting at reduced current Parts In Place PIP The torch includes a Parts In Place PIP circuit When the shield cup is properly installed it closes a switch The torch will not operate if this switch is o...

Page 221: ...air line filter is to be installed 1 Connect the air line to the inlet port The illustration shows typical fittings as an example NOTE For a secure seal apply thread sealant to the fitting threads acc...

Page 222: ...pply ON 3 For cutting adjust output air pressure from 70 85 psi 4 8 5 9 bar Refer to the chart for pressure setting details Gas Pressure Settings Leads Length SL100 Hand Torch Up to 25 7 6 m 70 psi 4...

Page 223: ...ULTRA CUT 200 XT Manual 0 5304 APPENDIX A 97 Art A 12760 1 4 NPT to 1 4 6mm Fitting Regulator Filter Assembly Inlet Port Hose Clamp Gas Supply Hose Single Stage Air Filter Attachment...

Page 224: ...04 Replacement parts 2 5 4 6 1 3 Description BOM ID Qty Name 9 6319 2 1 Solenoid Assy Description BOM ID Qty Name 9 7379 1 1 Contactor 8 6800 4 1 Pressure Gauge 9 9509 5 1 Regulator 9 7380 6 2 Relay 9...

Page 225: ...ired pressure to the SL100 module torch The Filter Element can be removed from its housing dried and reused Allow 24 hours for Element to dry Refer to Section 6 Parts List for replacement filter eleme...

Page 226: ...Update Sect 6 Pilot cap part ECO B2677 Update Sect 3 various text Updated codes ECO B2679 Remove DoC ECO B2680 Add Sect 6 Current transducer ECO B2681 Updated Sect 6 Radiator fan art ECO B2689 Jan 30...

Page 227: ......

Page 228: ...omer Care Ph 1 905 827 4515 Fax 1 800 588 1714 tollfree EUROPE Chorley United Kingdom Customer Care Ph 44 1257 261755 Fax 44 1257 224800 Milan Italy Customer Care Ph 39 0236546801 Fax 39 0236546840 AS...

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