Thermal Dynamics Ultra-Cut 300 XT Operating Instructions Manual Download

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ULTRA-CUT 400 XT

Manual 0-5275

INSTALLATION

3-29

Output Connections

1. Refer to the illustrations. Make the following output connections to the 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 ground wire is not crimped between the cover and the base.

Art # A-12059

Lower screws

(2 per side)

Upper screws (2 per side)

Cover

Ground Wire

Summary of Contents for Ultra-Cut 300 XT

Page 1: ...Thermal Dynamics com ULTRA CUT 400 XT PLASMA CUTTING SYSTEM Operating Manual Revision AH Issue Date May 27 2015 Manual No 0 5275 8 480V...

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: ...ynamics Corporation 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 l...

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: ...3 04 Leads and Cables All Amperage 3 3 3 05 Lift the Power Supply 3 4 3 06 Connect Input Power and Ground Cables 3 5 3 07 Connect Work Cable and Pilot and Negative Leads 3 6 3 08 Ground Connections 3...

Page 8: ...ide 6 6 6 07 Power Supply Replacement Parts Lower Right Side 6 7 6 08 Power Supply Replacement Parts Rear Panel 6 8 6 09 Power Supply Replacement Parts Left Side 6 9 6 10 Gas Control Module GCM 2010 R...

Page 9: ...erter Bottom PCB Layout A 28 APPENDIX 15 Main Inverter Top PCB Layout A 30 APPENDIX 16 Control and Fault PCB Layout A 32 APPENDIX 17 Cap Bias Bottom PCB Layout A 34 APPENDIX 18 Cap Bias Top PCB Layout...

Page 10: ...TABLE OF CONTENTS This Page Intentionally Blank...

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 400 XT Manual 0 5275 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: ...hen the main arc is established the pilot arc shuts off 2 04 Gas Control Module This module allows remote setting of gas selection pressures and flows together with setting of cutting current 2 05 Pre...

Page 22: ...types rated for 75 deg C in ambient temperatures up to 30 deg C Using wires of lower temperature rating or different insulation type may require larger wire size De rate for higher ambient These are...

Page 23: ...AC 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 Star...

Page 24: ...ation 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 possible to the gas inlets...

Page 25: ...ons 5 12 7 mm 2 4 61 mm 2 50 8 mm 1 4 34 5 mm 70 4 3 109 1 mm 6 6 168 5 mm Art A 09534 2 25 57 15 mm 2 0 50 8 mm 2 4 61 mm 1 49 37 8 mm 19 482 7 mm 15 5 393 8 mm 2 7 69 6 mm 1 6 40 mm 3 98 101 1 mm 6...

Page 26: ...ply will not provide 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...

Page 27: ...her 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 28: ...Gas Shield Gas Preflow Gas Work Torch Positioning Tube Water Shield G T Work Cable 175 53 3 m Maximum Length Primary power Remote Arc Starter Coolant Supply 10 Coolant Return 10 Control Cable Pilot R...

Page 29: ...to Arc Starter Pilot Return Power Supply to Arc Starter Negative Lead Power Supply to Arc Starter Ground Cable Ground Cable Remote Arc Starter To Earth Ground O P Fiber Optic Cable Power Supply to Ga...

Page 30: ...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 31: ...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 32: ...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 33: ...ess Refer to paragraph C Creating An Earth Ground The ground rod must be placed as close as possible to the cutting table ideally less than 10 ft 3 0 m but no more than 20 ft 6 1 m from the cutting ta...

Page 34: ...uced EMI is a good low resistance earth ground rod There are several very expensive instruments to measure the ground but cost from several hundred to a few thousand dollars Below is a low cost altern...

Page 35: ...oil around the ground rod moist by continuously running a small amount of water into it will work Adding salt to the soil by soaking it in salt water may also reduce its resistance You may also try a...

Page 36: ...on the power supply rear panel The supply line out is flagged green the return line in is flagged red COOLANT RETURN SUPPLY Coolant Connections RED GREEN To HE 400 Heat Exchanger Art A 11992 USER INPU...

Page 37: ...ect 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 5A...

Page 38: ...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 39: ...n itself making a sharp bend where it exits the hose Art A 09417 2 Don t 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 40: ...Then secure the fiber connector to the pulling 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...

Page 41: ...onds 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 defau...

Page 42: ...ontact 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 to...

Page 43: ...on divided arc voltage Also available on the terminal strip are 120VAC and 24 VAC The allowable current draw is 100ma 120VAC and 1Amp 24 VAC Art A 11900 24 VAC 1A TB4 1 2 3 4 5 6 7 120 VAC 100 ma Work...

Page 44: ...cceptable to locate the control cable in the same track as the cables from the Arc Starter The Module includes feet which lift the bottom panel off the mounting surface There are ventilation holes on...

Page 45: ...ion 1 Remove the screws securing the Cover Panel to the Module 2 Carefully remove the cover from the module noting the attached ground wire Remove the ground wire if needed Art A 06882 Gas Control Mod...

Page 46: ...on the back of the Module Pass enough of the cable into the Module to allow the cable to loop upward as shown CAUTION Avoid kinking twisting or bunching the fiber optic cable The cable can be damaged...

Page 47: ...into the receptacle on the vertically mounted circuit board as shown Cable must snap into place Circuit Board Fiber Optic Cable Art A 04773 4 Tighten the through hole protector for the fiber optic ca...

Page 48: ...the 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 suppl...

Page 49: ...n 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 flowing...

Page 50: ...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 bein...

Page 51: ...ns 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...

Page 52: ...ver 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 Cov...

Page 53: ...owing 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 Hos...

Page 54: ...r on each NOTE Slave and Master refer to only those set ups using two power sup plies in parrallel Slave is not used in single system operations Negative Master Torch Lead Pilot Art A 12063_AB Negativ...

Page 55: ...the 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 th...

Page 56: ...o 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 the R...

Page 57: ...ect 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 J5...

Page 58: ...03 mm 261 Dia 6 63 mm Art A 07648 1 Mount the Valve Kit as close as possible to the Torch The valve kit can be mounted in any convenient position provided the outlet side with two fittings is closer t...

Page 59: ...lves stationary while attaching the gas lines Control Cable Plasma Gas Inlet Shield Gas Inlet Preflow Gas Inlet WMS Inlet Art A 07646 Exhaust Muffler CAUTION Hold all fittings stationary while attachi...

Page 60: ...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 Mounting...

Page 61: ...set screw in any of the threaded holes to secure the Torch Head Assembly to the Mounting Tube 10 Install the appropriate consumable parts as shown on the following pages The torch manual includes dia...

Page 62: ...shield retainer Without this protrusion the shield cup is not properly tightened onto the cartridge assembly 6 Take the cartridge tool off the cartridge Fit the cartridge assembly onto the torch head...

Page 63: ...es 0 063 0 083 1 6 2 1 mm Electrode Plasma Gas Distributor Tip Shield Gas Distributor Shield Cap O Ring on Tip 1 Stack Parts 2 Press Cartridge onto Stacked Parts 4 Check Shield Cap Protrusion Art A 04...

Page 64: ...e then every precaution must be taken to keep metal filings from being deposited inside the power supply Install the V D Board 1 Locate the V D Board which should be with the iCNC 2 Inside the Power S...

Page 65: ...in the shield cup allowing easy removal for parts change The Ohmic wire can be connected to this clip with a female push on terminal Significant amounts of high frequency HF energy causing electromag...

Page 66: ...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 if...

Page 67: ...ill come ON when the internal temperature sensors detect temperatures above normal limits Let the unit cool before continuing operation GAS Lamp Flashing during start up gas purge pump priming then st...

Page 68: ...d the 4 status display digits illuminate all segments as a test Then for about 6 seconds the display shows the letter C code followed by the CCM code version Example C1 2 0 During this time various in...

Page 69: ...r distance above the work piece 6 Apply START Gas indicator lights Gas pre flow starts During gas pre flow power supply is enabled DC lamp turns ON 7 Pilot Arc At the end of pre flow ignition occurs a...

Page 70: ...le parts life and premature torch failure A cartridge type particulate water filter may help achieve optimum cutting performance 4 03 Gas Selection A Plasma Gases 1 Air Plasma Most often used on ferro...

Page 71: ...ity Alternative to H35 Plasma Yields slightly higher cut speeds and similar cut quality When using H17 the gas should be supplied to the gas supply port marked H35 Poor cut quality on ferrous material...

Page 72: ...indicators used to set gas pressures and flows 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_A...

Page 73: ...utting gases Plasma Shield flow to the torch to allow operator to set the pressure regulator gauge and flow knob at top of flowmeter Gases automatically shut off after 2 min utes if left in the SET PL...

Page 74: ...SMA SHIELD TEST O2 AIR O2 O2 H35 N2 F5 N2 AIR AIR N2 H2O N2 N2 9 9 Art A 04766_AB GCM 2010 3 LCD Display LED display shows Gas Control Status such as Waiting for Communication Plasma Power Supply Disa...

Page 75: ...o normal operation under control of the CNC device 6 PREFLOW Control Knob and Pressure Gauge Used to set preflow gas pressure and flow MODE switch must be in SET PREFLOW position 7 PLASMA and SHIELD C...

Page 76: ...tion 1 Set the Plasma Power Supply Enable Disable switch to Disable DANGER Always shut off input power to the system before changing or inspecting torch parts a Change the torch parts if necessary b S...

Page 77: ...als and thicknesses Right Side Cut Angle Left Side Cut Angle A 00512 Kerf Width Cut Surface Bevel Angle Top Edge Rounding Cut Surface Drag Lines Dross Build Up Top Spatter A 00007 Cut Surface The cond...

Page 78: ...ong an inside diameter of a circle the torch should move counterclockwise around the circle To keep the square edge along an outside diameter cut the torch should travel in a clockwise direction Under...

Page 79: ...ds Torch consumable parts worn Ensure correct process selected or manual setting including current control setting matches consumables Plasma pressure too high Defective Arc Starter Defective Pilot PC...

Page 80: ...er 1B Output Current Low Plasma work current low during cutting and attributed to Inverter Module 1 Sec tion B output low Inverter output disconnected Possible defective ribbon cable If problem persis...

Page 81: ...age rating Bad ribbon cable connection CCM J31 to Inverter Module 1 Section A Wrong voltage Inverter Module 1 installed Defective Inverter module 232 Inverter 1B VAC Mismatch Inverter AC Voltage ratin...

Page 82: ...nverter Section Defective Inverter module 246 Inverter 3B Input Volt age Error Inverter Input Voltage fault voltage out of range or missing phase at AC Input of In verter Module 3 Section B Poor AC Po...

Page 83: ...ly cause is ambient greater than 40 deg C Reduce power supply cutting Duty Cycle Reduce ambient air temperature Add auxiliary cooler 264 Inverter 3B Over Temp Ambient Inverter circuitry is over temper...

Page 84: ...nts Group 4 Torch Coolant System 401 Coolant Level low Check coolant level add as needed Defective or disconnected level sensor 402 Low coolant flow Coolant flow as measured by flow switch FS1 is less...

Page 85: ...e CCM Firmware file specified in VTCCMFW USF not found Add proper files to Flash Drive for Firmware updating 616 DPC Update Fault Fault occurred attempting to update DPC firmware Add proper files to U...

Page 86: ...In the 1 Torch module K201 should energize when W5 does Either it failed to energize or the pressure switch PS2 is failed closed 704 Contact Start pressure fault Pressure switch PS2 detects less than...

Page 87: ...for 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 Ch...

Page 88: ...ULTRA CUT 400 XT OPERATION Manual 0 5275 This Page Intentionally Blank...

Page 89: ...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 90: ...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 caution must be used when performing this task...

Page 91: ...3 8120 2 Ultra Cut 400 XT Power Supply 480V 10 15 with SL100 interface 3 8120 2T Gas Control Module GCM 2010 with XTL Torch Valve Assembly 3 9131 Gas Control Module GCM 2010 Only 7 4000 Original Torc...

Page 92: ...ld G T Work Cable 175 53 3 m Maximum Length Primary power Remote Arc Starter Coolant Supply 10 Coolant Return 10 Control Cable Pilot Return Coolant Supply Coolant Return Ultra Cut XT Power Supply Shie...

Page 93: ...Lead 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...

Page 94: ...938 G Assembly Torch Lead 4 5200 4 5201 4 5202 4 5203 4 5204 4 5205 4 5206 4 5207 4 3016 I Plasma Lead 9 3333 J Shield Lead 9 3334 K Control Cable PS to GCM 9 4907 9 4908 9 4909 9 9332 9 4910 9 4911 9...

Page 95: ...xternal 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 Pa...

Page 96: ...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 PCB...

Page 97: ...ant Tank 9 7306 3 1 Sensor Coolant level 9 7307 4 1 Pump Coolant Assembly with motor 9 7309 1 Pump Coolant Assembly no motor 9 7422 5 1 Motor Pump motor only 9 7424 6 1 Heat Exchanger Fan 9 7348 7 1 R...

Page 98: ...ription 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 500...

Page 99: ...ACEMENT PARTS 6 9 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 2 total W1 W2 9 7318 3 1 Inverter Module Full 480 V...

Page 100: ...id Logic PC Board 9 9409 10 1 Cover 9 9410 11 3 Gauge 0 160 psi 8 6800 12 1 Regulator 8 3223 13 1 Pressure Transducer and wire harness 100 PSI 9 9407 14 2 Pressure Transducer and wire harness 250 PSI...

Page 101: ...gauge 2 diameter 8 6800 5 1 Pressure gauge 2 diameter 8 4313 6 1 Flow Meter 8 6801 Not shown Valve Assembly 9 9382 Tube 9 9383 Knob 9 9384 7 1 Protective Display Lens only 9 9395 PREFLOW H2O MIST PLA...

Page 102: ...5275 6 12 Remote Arc Starter RAS 1000 XT 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 4...

Page 103: ...MENT PARTS 6 13 6 13 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 Therma...

Page 104: ...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 Torch Valve Assembly 4 3054 2 1 Torch Valve Assembly Harness 9 9413 3 1 Plug 14...

Page 105: ...NOTE The XTL Torch Valve Assembly requires Firmware versions 3 2 or higher for the C C M and 3 1 or higher for the GCM 2010 It also requires the resetting of DIP switches in the C C M Item Qty Descri...

Page 106: ...ULTRA CUT 400 XT REPLACEMENT PARTS Manual 0 5275 This Page Intentionally Blank...

Page 107: ...1 SECTION 7 TORCH MAINTENANCE 7 01 Consumable Removal 1 Use the removal tool to hold the Shield Cup Cartridge Assembly stationary Turn the Shield Cup to remove it from the Cartridge Assembly Assembled...

Page 108: ...with O Ring Lubricant supplied Remove the snap ring on the cartridge assembly and slide the locking ring downward for access to the O Ring under the locking ring O Ring Cat No 9 3029 Inner O Ring Cat...

Page 109: ...3 7 03 Parts Wear Replace the Gas Distributor if it is charred or cracked Replace the Gas Distributor if the flange is damaged in any way Replace the tip and or electrode if they are worn Good Electro...

Page 110: ...rudes 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...

Page 111: ...atible 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...

Page 112: ...mbly 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 r...

Page 113: ...rode 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 N2 0 08 2 150 O2 0 06 1 5 H35 0 08 2 N2 0 08 2 2...

Page 114: ...ULTRA CUT 400 XT TORCH INFORMATION Manual 0 5275 This Page Intentionally Blank...

Page 115: ...oprietary 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...

Page 116: ...T GCM 2010 GAS CONTROL POWER SUPPLY PLASMA SHIELD PREFLOW FERRITE CORE Safety Gnd low freq RF Gnd Shield ENABLE PS3 PS4 Shield Flow Shield Press Plasma Precharge Bypass H2O Shield FIBER OPTIC To CCM U...

Page 117: ...DER w SW A B F1 0 125A SOL1 F2 0 125A SOL2 F3 0 125A SOL3 F4 0 125A SOL4 F5 0 125A SOL5 F6 0 125A SOL6 F7 0 125A SOL7 F8 0 125A SOL8 F9 0 125A SOL9 F10 0 125A SOL10 F11 0 125A SOL11 F12 0 125A SOL12 F...

Page 118: ...SOL10 SOL6 SOL7 SOL11 SOL12 SOL13 GAS MANIFOLD SOL5 SHIELD PLASMA PREFLOW TVA XTL TVA WATER H2O Pressure Sensor SOL4 SOL17 SOL14 SOL15 SOL16 New Plasma Inlet Pressure Sensor New Shield Inlet Pressure...

Page 119: ...PPENDIX 4 Gas Control Module PCB Layout J13 Art A 07621 J1 J13 F12 F11 F8 F15 F17 F7 F16 F9 F13 F14 F10 J12 TP10 TP9 TP8 F5 F3 F1 F2 F4 F6 TP1 J6 J7 J11 TP11 TP12 TP13 TP15 TP14 TP16 J8 J10 TP18 TP19...

Page 120: ...Layout 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 20...

Page 121: ...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 122: ...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 123: ...op Ret 4 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 An...

Page 124: ...ect analog voltage to maintain at least 5A output To use Analog Current Control on the I O PCB set SW 11 to down position and on the CPU PCB set SW8 2 ON up Hold Start input Normally open close to hol...

Page 125: ...cutting machine motion as soon as pilot established 5 OK to Move2 Provides a second set of N O contacts that close when arc transfer is detected Contacts are rated for maximum of 24 VAC DC 1A Simplif...

Page 126: ...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 127: ...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 13...

Page 128: ...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 129: ...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 130: ...ULTRA CUT 400 XT APPENDIX Manual 0 5275 APPENDIX 8 CCM CPU PCB Layout Test Point Test Point Art A 11675_AB...

Page 131: ...0V TP3 24V TP4 3 3V TP5ISO GND TP6 5 0V TP7TOTAL 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 Re...

Page 132: ...ULTRA CUT 400 XT APPENDIX Manual 0 5275 APPENDIX 9 CCM I O PCB Layout Test Point Test Point Art A 11676_AC...

Page 133: ...P12 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 D12Green PRE...

Page 134: ...ULTRA CUT 400 XT APPENDIX Manual 0 5275 APPENDIX 10 Pilot PCB Layout Art A 11677 Test Point Test Point...

Page 135: ...ULTRA CUT 400 XT Manual 0 5275 APPENDIX A 21 Pilot PCB Test Points TP1GND TP2PILOT GATE TP3 5V TP4TIP LED Reference D2 Green PILOT ENABLE D11 Green 5V...

Page 136: ...ULTRA CUT 400 XT APPENDIX Manual 0 5275 APPENDIX 11 Relay and Interface PCB Layout Test Point Test Point Art A 11678_AB...

Page 137: ...5V 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 D12Green WORK CURRENT DETECTED D22Green CONTACTORS ON D23Green...

Page 138: ...ULTRA CUT 400 XT APPENDIX Manual 0 5275 APPENDIX 12 Display PCB Layout Test Point Test Point Art A 11679...

Page 139: ...ULTRA CUT 400 XT Manual 0 5275 APPENDIX A 25 Display PCB Test Points TP1GND TP2 5VDC TP3 24VDC...

Page 140: ...ULTRA CUT 400 XT APPENDIX Manual 0 5275 APPENDIX 13 System Bias PCB Layout Test Point Test Point Art A 11680...

Page 141: ...224VDC TP3DC INPUT POSITIVE TP4Vcc1 TP5Vcc2 TP6GATE TP7PRIMARY GND TP8 12V PRIMARY TP9P_ISOL_GND TP10 DC SENSE POSITIVE LED Reference D3 Red MISSING PHASE D4 Red AC V HIGH D14Red AC V LOW D15Green VAC...

Page 142: ...ULTRA CUT 400 XT APPENDIX Manual 0 5275 APPENDIX 14 Main Inverter Bottom PCB Layout Test Point Test Point Art A11681_AB...

Page 143: ...r Bottom PCB Test Points TP1GND TP2GATE 2A TP3GATE 1A TP4GATE 3A TP5GATE 4A TP6GATE 2B TP7GATE 1B TP8GATE 4B TP9GATE 3B TP10 12VP TP11 12VDC TP12 THERMISTOR SIDE A TP13 THERMISTOR SIDE B TP14 5VDC TP1...

Page 144: ...ULTRA CUT 400 XT APPENDIX Manual 0 5275 APPENDIX 15 Main Inverter Top PCB Layout Test Point Test Point Art A11682_AB...

Page 145: ...ter Top PCB Test Points TP1GND TP2GATE 2A TP3GATE 1A TP4GATE 3A TP5GATE 4A TP6GATE 2B TP7GATE 1B TP8GATE 4B TP9GATE 3B TP10 12VP TP11 12VDC TP12 THERMISTOR SIDE A TP13 THERMISTOR SIDE B TP14 5VDC TP15...

Page 146: ...ULTRA CUT 400 XT APPENDIX Manual 0 5275 APPENDIX 16 Control and Fault PCB Layout Test Point Test Point Art A11683_AB...

Page 147: ...GND 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 READ...

Page 148: ...ULTRA CUT 400 XT APPENDIX Manual 0 5275 APPENDIX 17 Cap Bias Bottom PCB Layout Art A 11685_AB...

Page 149: ...ULTRA CUT 400 XT Manual 0 5275 APPENDIX A 35 APPENDIX 18 Cap Bias Top PCB Layout Art A 11686_AB...

Page 150: ...ULTRA CUT 400 XT APPENDIX Manual 0 5275 APPENDIX 19 Suppressor PCB Layout Art A 11684_AB...

Page 151: ...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 152: ...ATORS Rear Panel Internal 019X502700 019X502000 019X502000 019X502700 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 F...

Page 153: ...6 1TORCH PRESS OK 7 FLOW SENSOR pulses 8 LOW COOLANT FLOW 9 COOLANT 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...

Page 154: ...IGH b VAC_IDA a VAC_IDA b VAC_IDB a VAC_IDB b 43 T1 57 58 59 56 64A 65B 66 67 69 70 64B 69 70 71 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_...

Page 155: ...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 Remote CC analog 29 Remote CC Pot High 31 R...

Page 156: ...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 157: ...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 158: ...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 159: ...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 160: ...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 161: ...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 162: ...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 163: ...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 164: ...C200XT may be bad Remove power and measure resistance of T1 T2 in AC200XT primary and secondary The primary should measure about 3 7 ohms The secondary about 25 35 K ohms If either measurement not cor...

Page 165: ...n and there is not 120 VAC at J8 3 11 then the Relay board is bad Either Arc Starter 5 RAS ON signal not on CCM sends active low signal RAS ON over the 40 pin ribbon cable on pin 16 to the Relay Inter...

Page 166: ...EEN D23 RF ON 1 5 3 4 K2 RAS CONTROL 120 VAC 120 VAC to RAS 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 J8 120 VAC RET 120 VAC_1 From J9 1 120 VAC_RET From J9 7 CCM I O Board Relay Interface Board 1 2 3 4...

Page 167: ...elay board is on if work current is detected If D12 is not on skip to step 5 otherwise disconnect J1 the work sensor connector If D12 is still on the Relay board is defective 5 If D12 goes out when J1...

Page 168: ...ts in zero cut demand o If system is Auto Cut XT current control is an analog voltage from the GCM 1000 XT or the AC 200 XT front panel pot The current control setting will be shown on the front panel...

Page 169: ...rrent and gas type flow rate and consumable design Once the arc is transferred the pilot switch opens leaving the tip basically floating The voltage then is deter mined by how much of a cold gas barri...

Page 170: ...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 t...

Page 171: ...l and 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 repo...

Page 172: ...led and CCM measures the 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 o...

Page 173: ...be 0V 0 04VDC If greater than 0 04VDC with no work lead current the sensor is defective If the signal voltage is within the limits and D12 is on then the Relay board is defective If D12 is not on and...

Page 174: ...l high check the Relay board Relay Board or CCM If D11 on the Relay PCB is still on after the previous tests measure the output to the CCM on the 40 pin ribbon cable Relay J4 to CCM J23 between pins 2...

Page 175: ...f 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 high see section on code 207 f...

Page 176: ...other end If still gives 224 Inverter 1 not found fault it s a bad CCM Oth erwise it s the ribbon cable 225 230 Inverter Revision and CCM incompatible If sometime in the future we should make a chang...

Page 177: ...ard at J62 measure relative to TP1 or J62 8 24VDC_RET to J62 12 for signal VAC_IDAb and J62 14 for signal VAC_IDBb The 2 signals should read according to this table 0 10 12V 1 24V signal 230V 400V 480...

Page 178: ...input J27 on the I O board Defective CCM Troubleshooting 1 Measure all 3 phases of the input voltage and confirm they are within the tolerance specified in the unit manual 2 Refer to section 231 236 I...

Page 179: ...ignal AC V HIGH b on J62 6 is high about 24VDC relative to TP1 or J62 8 the System Bias board is defective b If D4 is not on and the signal AC V HIGH b on J62 6 is low about 10 14VDC relative to TP1 o...

Page 180: ...Error The System Bias board checks for input voltage high low or missing a phase from the power coming in from the power cord It is unlikely but not impossible that a problem with the incoming power...

Page 181: ...ndition it activates the signal OVERTEMP_FLT going to the CCM over the inverter sections ribbon cable Inverters semiconductors transistors and diodes are liquid cooled Anything that increases the cool...

Page 182: ...or it s hard to see them to confirm they are turning but perhaps you can use an inspection mirror Be careful not to get the mirror or your hands into the blades 100 200A units have 2 smaller fans 300...

Page 183: ...r operation as it pulls in when the contactor is energized b Check for CB2 on the rear panel being tripped The white button marked 5 indicating it s 5 amps will pop out if tripped Reset it and if it p...

Page 184: ...not connected or broken Defective control board or power supply in the Gas Control Defective CCM Troubleshooting 1 Check that the fiber optic cable is fully plugged in to both sockets Clean the cable...

Page 185: ...during a disable should be 101 Circuits on the I O PCB detect the Plasma Enable is disabled and send signal to the microcontroller in the CCM If a fault in the CCM prevents that signal from getting s...

Page 186: ...tarter coolant goes to the water cooled HF high frequency coil and then to the torch supply lead attached to the internal torch connection bulkhead Coolant from the Torch returns to the RAS and on to...

Page 187: ...ed on and enabled and fails to achieve proper coolant flow after 4 minutes code 404 will be set Getting code 402 means it initially had enough flow but something has caused the flow to be re duced Lis...

Page 188: ...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 appl...

Page 189: ...tor is running and if so is there any coolant flowing With the right lower side panel removed touch the pump and feel for vibration to indicate if the motor is running Observe the clear coolant hoses...

Page 190: ...er TP3 I O board to TP1 If the pump comes on now replace the CCM d If jumping TP3 to TP1 does not turn the fans on then the Relay board or the 40 pin ribbon cable pin 13 is at fault Art 12313 MC3A MC3...

Page 191: ...detect it due to defective components Defective or disconnected FS1 flow switch Relay board CCM Flow Switch FS1 disconnected FS1 comes with wire about 1 ft long and a connector that connects to a 3 wi...

Page 192: ...n Ajumper in the gas control connector J56 pins 8 9 gives the signal Basic ID telling the CCM not to expect any CANBUS If somewhere this circuit is open in the Gas Control cable connector pins connect...

Page 193: ...usly for a while You can unplug the fiber from the CCM and should see the transmitter red LED on the CCM PCB blinking It may stop after a while so recycle power before deciding it isn t working If no...

Page 194: ...g 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 USB Log File Creation Fault When updating the CCM DMC and D...

Page 195: ...D Q2 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 T...

Page 196: ...e 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 ATC...

Page 197: ...h on 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 sys...

Page 198: ...ard If pin 20 is low less than 2VDC then the CCM is likely at fault If pin 20 is high with J84 removed the Relay board is bad 3 W5 is energized Before disassembling the 1Torch Module to inspect W5 loo...

Page 199: ...ecks that K201 is functioning and the pressure switch PS2 is normally open If either of these is not correct you get the 703 fault All this happens very quickly so it is nearly impossible to measure w...

Page 200: ...to the solenoid coil First set up for measurement of 24 VAC between pins 13 14 on J11 of the Relay Board Press the 1Torch trigger If no voltage the Relay Board may be bad d If there was 24VAC in the...

Page 201: ...ULTRA CUT 400 XT Manual 0 5275 APPENDIX A 87 This Page Intentionally Blank...

Page 202: ...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 203: ...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 204: ...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 205: ...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 206: ...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 207: ...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 208: ...ontrol is used to set the air pressure Pull the torch trigger momentarily to start gas flow To adjust the pressure pull the knob out and push in to lock 1 Ensure source meets requirements Inlet Pressu...

Page 209: ...the filter hose 3 Connect the air line to the Filter The illustration shows typical fittings as an example NOTE For a secure seal apply thread sealant to the fitting threads according to the maker s...

Page 210: ...75 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 211: ...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 212: ...Ground rod tester info ECO B2676 Update Sect 6 Pilot cap part ECO B2677 Remove DoC ECO B2680 Add Sect 6 Current transducer ECO B2681 Updated Sect 6 Radiator art ECO B2689 Jan 30 2015 AG In the Appdx a...

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Page 214: ...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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