Thermal Dynamics Ultra-Cut 400 Operation Manual Download

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SPECIFICATIONS 2-4

Manual No. 0-5164

ULTRA-CUT 400

2.09 Power Supply Rear Panel Features

Art # A-09450

Coolant Tank

Coolant Filter

Coolant Connections

Input Power

Terminals

Pilot (Pos) Terminal

Circuit Breaker

Panel

Terminal Cover

AC Power Lamp

Ground Terminals

Gas Control

Console Connector

RETURN SUPPLY

CNC Connector

Remote Arc Starter

Connector

Torch (Neg) Terminal

Leads

Bracket

Terminal Cover

Support Panel

Work Cable Terminal

Heat Exchanger

Summary of Contents for Ultra-Cut 400

Page 1: ...ction ___ tab here sheet At Section 8 insert the torch information section Insert the assembled manual sections and tabs into the 3 ring binder Keep this manual with the power supply for installation...

Page 2: ...Blank...

Page 3: ...as spine label in binder Discard extras Cut out one strip and use as spine label in binder Discard extras Use next page as front cover insert in binder Use next page as front cover insert in binder Ma...

Page 4: ...Blank...

Page 5: ...Art A 09430 400 400 Operating Manual PLASMA CUTTING SYSTEM ULTRA CUT Rev AG Date April 10 2012 Manual 0 5164 Operating Features...

Page 6: ...Blank...

Page 7: ...Art A 09430 400 400 Operating Manual PLASMA CUTTING SYSTEM ULTRA CUT Rev AG Date April 10 2012 Manual 0 5164 Operating Features...

Page 8: ...e please take the time to read the entire manual especially the Safety Precautions They will help you to avoid potential hazards that may exist when working with this product YOU ARE IN GOOD COMPANY T...

Page 9: ...by Thermadyne 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 disclaim...

Page 10: ...This page intentionally blank...

Page 11: ...Insert Table of Con tents tab here Discard this sheet...

Page 12: ...This page intentionally blank...

Page 13: ...tions 2 7 SECTION 3 INSTALLATION 3 1 3 01 Installation Requirements 3 1 3 02 System Layout 3 2 3 03 Cables Leads Identification 3 3 3 04 Lift the Power Supply 3 4 3 05 Remove the Connections Cover 3 5...

Page 14: ...Right Side 6 16 6 07 Power Supply Replacement Parts Right Side 6 17 6 08 Power Supply Replacement Parts Right Side 6 18 6 09 Power Supply Replacement Parts Front Panel 6 19 6 10 Power Supply Replaceme...

Page 15: ...Layout A 8 APPENDIX 8 CNC Control Module PCB Connections A 9 APPENDIX 9 CNC A 11 CNC functions A 11 CNC Input Output Descriptions A 12 Simplified CNC Circuit A 13 CNC Connections A 14 APPENDIX 10 Sch...

Page 16: ...TABLE OF CONTENTS This Page Intentionally Blank...

Page 17: ...Barium Copper Selenium Beryllium Lead Silver Cadmium Manganese Vanadium Always read the Material Safety Data Sheets MSDS that should be supplied with the material you are using These MSDSs will give...

Page 18: ...ir latest revisions for more information 1 OSHA SAFETY AND HEALTH STANDARDS 29CFR 1910 obtainable from the Superintendent of Documents U S Government Printing Office Washington D C 20402 2 ANSI Standa...

Page 19: ...pas d liminer la fum e et les gaz Les sortes de gaz et de fum e provenant de l arc de plasma d pen dent du genre de m tal utilis des rev tements se trouvant sur le m tal et des diff rents proc d s Vou...

Page 20: ...ournissant des cabines ou des crans de protection Utilisez la nuance de lentille qui est sugg r e dans le recommenda tion qui suivent ANSI ASC Z49 1 Nuance Minimum Nuance Sugger e Courant Arc Protecti...

Page 21: ...70 de la NFPA CODE ELECTRIQUE NATIONAL disponible aupr s de la National Fire Protection Association Batterymarch Park Quincy MA 02269 10 Norme 51B de la NFPA LES PROC D S DE COUPE ET DE SOUD AGE dispo...

Page 22: ...y rating 94VO flammability testing for all printed circuit boards used CENELEC EN50199 EMC Product Standard for Arc Welding Equipment ISO IEC 60974 1 BS 638 PT10 EN 60 974 1 EN50192 EN50078 applicable...

Page 23: ...with such as the performance or breach thereof or from the manufacture sale delivery resale or use of any goods covered by or furnished by Thermal whether arising out of contract negligence strict tor...

Page 24: ...ULTRA CUT 400 GENERAL INFORMATION 1 8 Manual 0 5164 This Page Intentionally Blank...

Page 25: ...ULTRA CUT 400 Manual 0 5164 1 9 GENERAL INFORMATION Insert Section 2 tab here Discard this sheet...

Page 26: ...ULTRA CUT 400 GENERAL INFORMATION 1 10 Manual 0 5164...

Page 27: ...mporary HF pulse to start the pilot arc The pilot arc creates a path for the main arc to transfer to the work When the main arc is established the pilot arc shuts off 2 04 Gas Control Module This modu...

Page 28: ...temperature rating or different insula tion type may require larger wire size Derate for higher ambient These are suggestions only Always refer to your local and national codes that apply to your reg...

Page 29: ...Manual No 0 5164 2 3 SPECIFICATIONS ULTRA CUT 400 2 08 Power Supply Dimensions Art A 09449 33 inch 840 mm 27 inch 680 mm 37 75 inch 960 mm 53 inch 1350 mm 27 5 inch 700 mm 627 lb 285 kg...

Page 30: ...Filter Coolant Connections Input Power Terminals Pilot Pos Terminal Circuit Breaker Panel Terminal Cover AC Power Lamp Ground Terminals Gas Control Console Connector RETURN SUPPLY CNC Connector Remot...

Page 31: ...ended 120 psi 8 3 bar 827 kPa 200 scfh 5700 l h H17 17 5 Hydrogen 32 5 Argon 50 Nitrogen 99 995 Purity gas recommended 120 psi 8 3 bar 827 kPa 200 scfh 5700 l h Ar Argon 99 995 Purity gas recommended...

Page 32: ...Air Air N2 N2 H20 N2 N2 H20 50A Cut Air O2 Air Air Air Air Air Air Air N2 N2 H20 N2 N2 H20 70A Cut Air O2 Air Air Air Air Air Air Air N2 N2 H20 N2 N2 H20 100A Cut Air O2 Air N2 H35 N2 N2 H35 N2 N2 N2...

Page 33: ...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 34: ...tributor Shield Cap D Parts In Place PIP The torch is designed for use with a power supply which senses coolant return flow to confirm that torch parts are in place If coolant return flow to the power...

Page 35: ...imum Current 400 Amps Voltage Vpeak 500V Arc Striking Voltage 10kV Current Up to 400 Amps DC Straight Polarity XT Torch Gas Specifications Plasma Gases Compressed Air Oxygen Nitrogen H35 H17 Shield Ga...

Page 36: ...SPECIFICATIONS 2 10 Manual No 0 5164 ULTRA CUT 400 This Page Intentionally Blank...

Page 37: ...Manual No 0 5164 2 11 SPECIFICATIONS ULTRA CUT 400 Insert Sec 3 tab here discard this sheet...

Page 38: ......

Page 39: ...erature rating or differ ent insulation type may require larger wire size Derate for higher ambient These are suggestions only Always refer to your local and national codes that apply to your region f...

Page 40: ...ntrol Module Torch Valve Assembly P I J K L H Q R S Plasma Gas Shield Gas Plasma Gas Shield Gas Preflow Gas Work Torch Positioning Tube Water Shield G T Work Cable 175 53 3 m Maximum Length Primary po...

Page 41: ...er 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 Gas Control Module Control Cable Power Supply to Gas Con...

Page 42: ...ing lifting straps to lift the power supply Use a forklift crane or hoist to lift the unit off the shipping pallet as shown Keep the power supply steady and verti cal Do not lift it any further than n...

Page 43: ...must be supplied by the end user and connected to the power supply Remove the connections cover on the rear of the Power Supply Use caution when removing the panel there is a ground wire connected to...

Page 44: ...one on the right side See NOTE 2 If necessary disconnect the jumper at the top right corner of the board remove the board and reinstall it with the correct input voltage shown at the top of the board...

Page 45: ...nnect the individual cables as shown Connect the power cable ground cord to the ground terminal block CAUTION The clear connections cover must remain in place 4 If required pass a system ground cable...

Page 46: ...the illustration Connect the leads as shown Tighten securely Do not overtighten CAUTION The clear connections cover must remain in place PILOT WORK TORCH Connection Panel AC INPUT L1 L2 L3 Work Lead...

Page 47: ...ngle point usually on the cutting table is connected 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 parag...

Page 48: ...the ground rod and interference is experienced it may help to install a second earth ground rod next to the plasma power supply The plasma power supply chassis would then be connected to this ground...

Page 49: ...ground rod A larger diameter rod which has more surface area may help Sometimes keeping the soil around the ground rod moist by continuously running a small amount of water into it will work Adding s...

Page 50: ...s 1 Connect the color coded coolant hoses to the coolant connections on the power supply rear panel The supply line out is flagged green the return line in is flagged red To HE 400 Heat Exchanger COOL...

Page 51: ...0 1 Connect one end of each cable to the power supply 2 Connect the other end of the CNC cable to the CNC device 3 The CNC cable shield must be attached to ground RETURN SUPPLY Art A 09454 RETURN SUPP...

Page 52: ...ransmit ter 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 from sharp bends or pulling that stretches the fiber can...

Page 53: ...t pull out of it like this Art A 09419 Sharp Bend Hose not secured in the Strain Relief Correct installation Correct way to pull the cable is to use a snake or a wire or another cable and attach it se...

Page 54: ...ber so there is no stress on the fiber where it exits the connector or the hose Art A 09421 No sharp bends CCM No Sharp Bends Art A 09422 DMC 3000 part of DFC 3000 gas control uses 2 fiber optic cable...

Page 55: ...7 INSTALLATION ULTRA CUT 400 Unplugging the fiber optic connector Do not pull on the fiber Art A 09423 For the CCM grip the fiber connector front and back squeezing the latch lever and remove from the...

Page 56: ...00 For the Gas controls where you can t grip the back of the connector press in on the latch lever and push away from the sockets Or grip the sides of the connector with thumb and finger while using i...

Page 57: ...ain relief on the fiber optic cable s Loosen the strain relief dome nut from the strain relief b Pass the cable connector through the appropriate opening Slide the strain relief securing nut onto the...

Page 58: ...nds Factory default setting SW 1 3 Pilot Delay 2 ON 3 OFF 4 OFF 0 1 Seconds SW 1 4 Pilot Delay 2 OFF 3 ON 4 OFF 0 2 Seconds 2 ON 3 ON 4 OFF 0 4 Seconds 2 OFF 3 OFF 4 ON 0 8 Seconds 2 ON 3 OFF 4 ON 1 0...

Page 59: ...tact closure 120VAC 1A Factory default setting or DC Volts 16 18vdc up to 100 ma SW 11 Analog Current Control B from Gas Control Factory default setting or A Remote Analog Source Position A requires t...

Page 60: ...uires connection to the full non divided arc voltage Also available on the terminal strip are 120VAC 120 0 and 24 VAC 24 0 Note that the two 0 s are not common The allowable current draw is 100ma 120V...

Page 61: ...acceptable to locate the control cable in the same track as the cables from the Arc Starter The Module includes feet which lift the bottom panel off the mounting surface There are ventilation holes o...

Page 62: ...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 63: ...el 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 damag...

Page 64: ...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 65: ...ure 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 su...

Page 66: ...UltraCut pump and fans therefore it can start at any time WARNING Do not disassemble the Cooler with the power applied or the coolant flowing Dangerous 220 AC voltages and high pressure liquid are pr...

Page 67: ...hreads and will cause a leak Do not start the Ultracut without coolant in the reservoir An additional gallon 3 78l of coolant is required to compensate for the HE400 being attached to the system Monit...

Page 68: ...his manual to be sure that the location meets all safety requirements Interconnecting cables and hoses attach to the Arc Starter There must be adequate space around the Arc Starter for these connectio...

Page 69: ...bration fasten the Arc Starter to the support securely 1 Loosen but do not remove the lower screws securing the cover to the Arc Starter Remove the upper screws securing the Cover Panel to the Arc Sta...

Page 70: ...m of the Arc Starter to secure the Arc Starter to the mounting surface Input Connections 1 Refer to the illustrations Make the following input connections to the Arc Starter Coolant Supply and Return...

Page 71: ...No 0 5164 3 33 INSTALLATION ULTRA CUT 400 Coolant Return Red Coolant Supply Green Art A 09628 Green Red Art A 09629 Negative Cable from power supply Copper plate Negative Cables from Power Supply rear...

Page 72: ...INSTALLATION 3 34 Manual No 0 5164 ULTRA CUT 400 Art A 09630 Pilot Return Cable from Power supply PILOT Return Cable from Power Supply rear panel Art A 09631 Control Cable from Power Supply rear panel...

Page 73: ...tions Make the following output connections to the Arc Starter NOTE For newer leads with only one black wire it must be connected to the pilot return There are no inner shield wires Pilot Lead Connect...

Page 74: ...Green Coolant Return Fitting Tagged with Red Coolant Return Red from Torch Coolant Supply Green to Torch Coolant Supply and Return Hoses from Torch Reinstall the Arc Starter Cover Ensure that the grou...

Page 75: ...r to the previous section for grounding details Ground Cable Art A 04758 1 Nut and 1 Washer Remain in Place Torch Leads Use a clamp to secure the Torch Lead Shield braid brass ring to the port on the...

Page 76: ...INSTALLATION 3 38 Manual No 0 5164 ULTRA CUT 400 Connect Control Cable 1 Connect the Remote Arc Starter cable to the Remote Arc Starter receptacle COOLANT RETURN SUPPLY RETURN SUPPLY Art A 09558...

Page 77: ...mm 261 Dia 6 63 mm Art A 07648 1 Mount the Valve Kit as close as possible to the Torch The valve kit can be mounted in any convenient position provided the outlet side with two fittings is closer to t...

Page 78: ...stationary while attaching the gas lines XTL shown Control Cable Plasma Gas Inlet Shield Gas Inlet Preflow Gas Inlet WMS Inlet Art A 07646 Exhaust Muffler CAUTION Hold all fittings stationary while at...

Page 79: ...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 80: ...ting tube Leads must lie as shown in the installation sketch 9 The lower end of the Mounting Tube includes four threaded holes Install an Allen set screw in any of the threaded holes to secure the Tor...

Page 81: ...hold the cartridge assembly while turning the shield cup and shield retainer for 200 Amp parts onto the cartridge assembly For 300 Amp parts turn the shield retainer onto the shield cup now When this...

Page 82: ...tributor Tip Shield Gas Distributor Shield Cap O Ring on Tip 1 Stack Parts 2 Press Cartridge onto Stacked Parts 4 Check Shield Cap Protrusion Art A 04873 No Gaps Between Parts 3 Thread Shield Cup onto...

Page 83: ...No 0 5164 3 45 INSTALLATION ULTRA CUT 400 Ohmic Clip Art A 03393_AB NOTE Ohmic height sensing is not recommended with water shield Water on the plate interferes electri cally with the ohmic sensing c...

Page 84: ...nt of coolant required varies with torch leads length Coolant Capabilities Cat Number and Mixture Mixture Protects To 7 3580 Extra CoolTM 25 75 10 F 12 C 7 3581 Ultra CoolTM 50 50 27 F 33 C 7 3582 Ext...

Page 85: ...the ON OFF switch to ON again e Repeat steps b through d until the system no longer shuts down Depending on the length of the torch leads this sequence may need to be repeated f After the system stay...

Page 86: ...INSTALLATION 3 48 Manual No 0 5164 ULTRA CUT 400 This Page Intentionally Blank...

Page 87: ...Manual No 0 5164 3 49 INSTALLATION ULTRA CUT 400 COPY CENTER Insert Sec 4 tab here discard this sheet...

Page 88: ...Blank...

Page 89: ...l temperature sensors detect tempera tures above normal limits Let the unit cool before continuing operation GAS Indicator Normally ON Indicates gas control is ready for operation The indicator blinks...

Page 90: ...er modules are correctly configured for the input voltage and the switch is ON then voltage has been applied to the inverter modules input contactors are ON If the indicator does not light after a few...

Page 91: ...s controls and 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 N...

Page 92: ...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 minutes if left in the SET PLASMA SH...

Page 93: ...PLASMA SHIELD TEST O2 AIR O2 O2 H35 N2 F5 N2 AIR AIR N2 H2O N2 N2 9 9 Art A 04766 GCM 2010 3 LCD Display LED display shows Gas Control Status such as Waiting for Communication Plasma Power Supply Dis...

Page 94: ...n 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 Control Knobs Pres...

Page 95: ...ontrol or it s main PC Board is replaced 4 05 Sequence Of Operation For first time operation see previous steps First Time Operation 1 Set the Plasma Power Supply Enable Disable switch to Disable DANG...

Page 96: ...ontrol module or the piece being cut Cut Quality Cut quality requirements differ depending on application For instance nitride build up and bevel angle may be major factors when the surface will be we...

Page 97: ...82 Workpiece Scrap Swirl Effect on Side Characteristics Of Cut To make a square edged cut along an inside diameter of a circle the torch should move counterclockwise around the circle To keep the squa...

Page 98: ...gher cost A 65 argon 35 hydrogen mixture should be used 3 Oxygen O2 Plasma Oxygen is recommended for cutting ferrous materials Provides faster cutting speeds Provides very smooth finishes and minimize...

Page 99: ...shield is used with Ar H2 H35 plasma Provides smooth finishes on nonferrous materials May reduce smoke when used with Ar H2 plasma 3 Water Shield Water shield should be used only in mechanized applic...

Page 100: ...C Input Phase Plasma Enable Off External E Stop Activated or CCM TB1 1 2 jumper miss ing Missing AC Phase No power to GCM 2000 or 2010 Gas Control check GCM control cable connected reset CP4 or CP5 ci...

Page 101: ...to ground 2 10 Reserved No information available Contact customer service 2 11 Reserved No information available Contact customer service 3 1 Gas Control Communication fault Cannot establish Communica...

Page 102: ...eal Clogged coolant filter Damaged torch coolant tube Defective pump assembly 4 5 Low Coolant Level Warning Low coolant level during cut does not stop cut Add coolant as required 5 1 CANBUS Acknowledg...

Page 103: ...Manual No 0 5164 4 15 OPERATION ULTRA CUT 400 4 08 Remote Arc Starter Spark Gap Adjustment Art A 04857 0 063 0 002 1 6 0 05 mm...

Page 104: ...OPERATION 4 16 Manual No 0 5164 ULTRA CUT 400 This page intentionally blank...

Page 105: ...Manual No 0 5164 4 17 OPERATION ULTRA CUT 400 COPY CENTER Insert Sec 5 tab here Discard this sheet...

Page 106: ...This page intentionally blank...

Page 107: ...d Six Months Clean or replace external coolant filter Clean coolant tank Vacuum out any dust buildup inside power supply Check internal coolant filter 5 02 External Coolant Filter Cleaning Procedure P...

Page 108: ...n Line Filter Assembly 5 04 Coolant Replacement Procedure Replace coolant as follows 1 Disconnect the system from main input power At the bottom of the coolant tank disconnect the coolant line fitting...

Page 109: ...supply Check input voltage at EMI filter Make connections replace harness No loose connection to spark gap Visual inspection Reconnect Faulty EMI filter Voltage Resistor measurement Replace No coolin...

Page 110: ...MAINTENANCE 5 4 Manual 0 5164 ULTRA CUT 400 This Page Intentionally Blank...

Page 111: ...Manual No 0 5164 5 5 MAINTENANCE ULTRA CUT 400 Insert Sec 6 tab here Discard this sheet...

Page 112: ...MAINTENANCE 5 6 Manual 0 5164 ULTRA CUT 400 This page is blank intentionally...

Page 113: ...upply 400V CCC 3 9120 3 Ultra Cut 400 Power Supply 400V CE 3 9120 4 Gas Control Module GCM 2010 with XTL Torch Valve Assembly 3 9131 Requires Firmware version 3 2 or higher for C C M Gas Control Modul...

Page 114: ...5 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 Power Supply Shield Negative Cable Pilot...

Page 115: ...er 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 Gas Control Module Control Cable Power Supply to Gas Con...

Page 116: ...nly 35 10 6 m 9 9426 A Pilot Return Cable only 50 15 2 m 9 4792 A Pilot Return Cable only 75 22 8 m 9 4793 A Pilot Return Cable only 100 30 5 m 9 4794 A Pilot Return Cable only 125 38 1m 9 4796 B Nega...

Page 117: ...942 E Control Cable only Power Supply to Arc Starter 75 22 9 m 9 4943 E Control Cable only Power Supply to Arc Starter 100 30 5 m 9 4944 E Control Cable only Power Supply to Arc Starter 125 38 1 m 9 4...

Page 118: ...Torch Valve Assembly to Torch 9 3333 J Shield Lead 4 1 22 m Torch Valve Assembly to Torch 9 3334 K Control Cable Power Supply to Gas Control Module 3 1 m 9 4907 K Control Cable Power Supply to Gas Co...

Page 119: ...P Control Cable CNC to Power Supply 75 22 9 m 9 8315 P Control Cable CNC to Power Supply 100 30 5 m 9 8316 P Control Cable CNC to Power Supply 125 38 1 m 9 8317 Q Shield Gas Hose 10 3 05 m 9 7277 Q Sh...

Page 120: ...l Cable 35 10 6 m 9 4757 S Control Cable 50 15 2 m 9 4759 S Control Cable 75 22 9 m 9 4760 S Control Cable 100 30 5 m 9 4761 S Control Cable 125 38 1 m 9 4879 T Water Shield 10 3 05 m 9 6985 T Water S...

Page 121: ...cription Catalog 1 1 Power Supply Front Panel N A 2 1 Power Supply Rear Panel N A 3 1 Power Supply Top Panel Blue 9 0445B 4 1 Power Supply Right Side Blue 9 0500B 5 1 Power Supply Left Side Blue 9 050...

Page 122: ...6 06 Power Supply Replacement Parts Right Side Item Qty Description Ref Des Catalog 1 2 Heat Exchanger Fan used with radiator FAN1 2 9 9338 2 2 Radiator 9 9339 NOTE Heat Exchanger Fan is the same fan...

Page 123: ...Description Ref Des Catalog 1 1 Output Filter PC PCB8 9 9341 2 1 Sensor Work HCT2 9 9368 3 1 Magnetic Contactor pilot MC2 9 9343 4 1 Resistor R6 9 9340 5 1 Resistor R9 9 8170 6 1 Sensor Pilot HCT1 9 9...

Page 124: ...RA CUT 400 6 08 Power Supply Replacement Parts Right Side Item Qty Description Ref Des Catalog 1 1 PC Board 230 460VAC PCB4 9 9370 2 1 PC Board PCB3 9 9365 3 1 Internal Control PC Board PCB5 9 8169 4...

Page 125: ...Supply Replacement Parts Front Panel Item Qty Description Ref Des Catalog 1 1 Main Power Switch Circuit Protector for 230 400 460 VAC units CP1 9 9344 1 for 600 VAC units CP1 9 9514 2 1 Relay 110 120...

Page 126: ...Power Supply Parts List 6 20 Manual No 0 5164 ULTRA CUT 400 6 10 Power Supply Replacement Parts Front Panel Item Qty Description Ref Des Catalog 1 Display PC Board PCB6 9 9347 PCB6 Art A 09644...

Page 127: ...er Supply Parts List ULTRA CUT 400 6 11 Power Supply Replacement Parts Right Side Item Qty Description Ref Des Catalog 1 1 PCBoard 230 400 460VAC PCB1 9 9362 2 1 Magnetic Contactor MC1 MC3 MC4 MC5 9 9...

Page 128: ...ker AGC 125V 2 5A 120VAC 1A CP5 9 9348 16 1 Circuit Breaker AGC 125V 2 5A 15VDC 1A CP6 9 9348 17 1 Circuit Breaker Pump HE 250V 8A 230VAC 5A CP7 9 8165 18 1 Circuit Breaker Fan 125V 3 15A 24VDC 1A CP8...

Page 129: ...pply Replacement Parts Right Side Item Qty Description Ref Des Catalog 1 1 Resistor R7 9 9363 2 1 Rectifier Diode D1 9 9345 3 1 Transformer T2 9 4 1 Transformer for 230 460 VAC units T1 9 9355 1 for 4...

Page 130: ...Replacement Parts Item Qty Description Catalog 29 3 Inverter Module 208 230V 460V 9 9360D 3 Inverter Module 400V CE and 400V Non CE 9 9482D Not Shown 3 Inverter Cooling Fan 9 9338 NOTE The Inverter Co...

Page 131: ...Manual No 0 5164 6 25 Power Supply Parts List ULTRA CUT 400 6 15 Power Supply Replacement Parts Right Side Item Qty Description Ref Des Catalog 1 1 Thermistor Coolant TH1 9 9361 1 Art A 09463...

Page 132: ...e Item Qty Description Ref Des Catalog 1 1 Inline filter 8 3460 2 1 Sensor Coolant Flow FL1 9 9359 3 1 Pump Check Valve Bypass Valve Assembly 4 1 Bypass Valve part of assembly BYPV 9 8168 5 1 Motor MO...

Page 133: ...Solenoid Logic PC Board 9 9409 10 1 Cover 9 9410 11 3 Gauge 0 160 psi 8 6800 12 1 Regulator 8 3223 13 3 Pressure Transducer and wire harness 100 PSI 9 9407 14 2 Pressure Transducer and wire harness 25...

Page 134: ...sure 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...

Page 135: ...atalog 1 1 Harness Internal Not Shown 9 4956 2 1 Pilot Cap Assembly 9 9423 3 1 EMI Filter 9 1023 4 1 HF Water Cooled Coil Assembly 9 4958 5 1 HF Transformer Assembly Arc Starter 9 4959 6 1 Enclosure A...

Page 136: ...lacement Parts Item Qty Description Catalog 1 1 Retainer ABS Wall 9 4964 2 1 Outer Torch Lead Ground Assembly 9 4955 3 1 Bracket Bulkhead Holder 9 4963 4 1 Cover Arc Starter 9 4962 5 1 Strain Relief l...

Page 137: ...st ULTRA CUT 400 6 21 Command Control Module Replacement Parts Item Qty Description Catalog 1 1 Assembly CCM Ultra Cut 9 9417D 2 1 Plate CCM Face 9 9419 3 1 Panel CCM Mount Not Available 4 1 Harness C...

Page 138: ...5164 ULTRA CUT 400 6 22 HE 400 Heat Exchanger Replacement Parts Item Qty Description Catalog 1 1 Assembly HE 400 Heat Exchanger 9 9416 2 1 Fan 8 6312 3 1 Radiator 8 1347 4 1 Capacitor 8 3263 5 1 Ther...

Page 139: ...Insert Sec 7 tab here Discard this sheet...

Page 140: ...Blank...

Page 141: ...ld Cup CartridgeAssembly 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 th...

Page 142: ...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 143: ...le all parts carefully to avoid damage which may affect tor ch per formance 1 Install the consumables as follows Cartridge Covers Upper O Ring on Torch Tip Shield Cap Protrudes 0 063 0 083 1 6 2 1 mm...

Page 144: ...he 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 145: ...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 146: ...acement 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 85 Air 0 08 2 100 O2 0 04 1 H35 0 08 2 N2 0 08 2 150 O2 0 06 1 5 H35 0 08 2 N2 0 0...

Page 147: ...Manual 0 5164 7 7 TORCH INFORMATION ULTRA CUT 400 Insert Section 8 and Section 8 tab here Discard this sheet...

Page 148: ......

Page 149: ...EBANON NH 03784 603 298 5711 Tuesday November 01 2005 14 47 17 of Information Proprietary to THERMAL DYNAMICS CORPORATION TITLE of TITLE 8X290 NEG HF to Torch 8X291 DAT 9 21 04 RAS 1000 ARC STARTER PO...

Page 150: ...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 151: ...R 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 F13...

Page 152: ...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 153: ...ENDIX 4 Gas Control Module PCB Layout J13 Art A 07621 J1 J13 F12 F11 F8 F15 F17 F7 F16 F9 F13 F14 F10 J12 TP10 TP9 TP8 F5 F3 F1 F2 F4 F6 TP1 J6 J7 J11 TP11 TP12 TP13 TP15 TP14 TP16 J8 J10 TP18 TP19 J3...

Page 154: ...B 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 2...

Page 155: ...ULTRA CUT 400 APPENDIX 6 CCM Input Output PCB Layout Art A 09187_AB TP7 TP6 J1 SW6 SW12 J36 TB1 TB2 J4 J9 TP11 J5 J6 J7 SW11 TP9 J8 TP12 J2 TP10 TP8 J35 TP4 TP3 TP2 SW13 TP5 TP1 TP13 J3 TP15 D1 D2 D4...

Page 156: ...P3 TP4 TP5 TP6 TP7 TP8 J2 J3 J1 TP9 TP10 TP13 TP12 TP14 TP15 Switches O N O N 1 2 1 SW3 1 2 1 SW9 1 2 1 SW5 PRE FLOW POST FLOW FUNC SYS CONT AUTO PILOT OKTO MOVE D 1 2 1 SW4 3 2 1 1 SW1 4 3 2 1 1 SW8...

Page 157: ...ol 0 10V TB1 11 10V 10ma For Remote CC POT TB1 12 OK 2 Contacts 24V Max TB2 1 Hold Start TB2 2 Hold Start TB2 3 Preflow On TB2 4 Preflow On TB2 5 TB2 6 Pilot On Relay Contacts NO TB2 7 TB2 8 Pilot On...

Page 158: ...APPENDIX A 10 Manual 0 5164 ULTRA CUT 400 This Page Intentionally Blank...

Page 159: ...ot both Additional functions are only available on TB1 2 2 SW6 on CCM I O PCB selects OK to Move for isolated contact closure or DC Volts 15 18V at 100ma When set for contacts OK to Move circuit is ra...

Page 160: ...Circuit rating 10 ma 20VDC Delays pilot ignition gas preflow continues Used for synchronizing starts when multiple plasma supplies are used on same cutting table User supplies circuit to keep Hold Sta...

Page 161: ...gic Input Active LOW Logic Input All I O except Plasma Marking is isolated from plasma power supply circuits TB3 is not isolated Activate with relay or switch isolated from other circuits MOMENTARY ST...

Page 162: ...Source 16 VDC 10 ma Divided Arc V Arc V through 100K Arc V through 100K 10 11 10 11 Divided Arc V Remote Analog Current Control Remote Analog Current Control Relay DCV Contact or 1A DCV 120 VAC 15 18...

Page 163: ...Manual 0 5164 A 15 APPENDIX ULTRA CUT 400...

Page 164: ...0 230 208 230 460 VAC 3 Phase 100A INVERTER MODULE 3 bottom same as 1 100A INVERTER MODULE 4 right side same as 1 CN103 16 CKT CN6 CN6 CN6 B6 C3 STATUS LEDS LED1 ON INV OVER TEMP LED2 ON OCR FAULT LED...

Page 165: ...2 Power Supply Rear Panel DAT RIBBON CABLE SIGNALS CN6 16 Ckt Ribbon Cable 2 4 I_REF Scaled Cut Demand 5 PS_START Start 6 REDUNDANT_START Start2 8 INV_READY 9 PS_START disabled by Input_NG 12 OCR 13...

Page 166: ...D28 CNC_PREFLOW D28 CNC_PREFLOW TP9 TP9 D17 RS485 TXD D17 RS485 TXD PUMP MOT1 PUMP MOT1 V GND SIG FL1 FLOW_TURBINE_PULSE V GND SIG FL1 FLOW_TURBINE_PULSE R B G T2 T2 600_ 460_ 0 230 400__ 220__ 200__...

Page 167: ...or 4 WIRE uses TX TX RX RX J35 26 CKT J14 J14 2W SW14 SW14 LINE TERMINATION normally on refer to manual RIBBON CABLE 5 9 8 7 6 1 2 3 4 SW10 ADDRESS normally 0 refer to manual 0 TEST SOCKET UNDIVIDED A...

Page 168: ...TER MODULE 1 top PCB 5 WK 6276A partial INTERFACE PCB MISSING PHASE pulses CN101 16 CKT P_GND VAC_IN PCB3 WK 5694 PCB4 WK 5604 BIAS SUPPLY FOR PCB5 Not used on 400A Supply 100A INVERTER MODULE 3 botto...

Page 169: ...Contactor pilot Coil B3 Sht 2 Contacts B9 Sht 1 MC4 5 Contactor 3P Inv 2 input Coil B2 Sht 2 Contacts B3 C3 Sht 1 Aux Contact B3 Sht 2 MC6 Contactor 3P Inv 3 input Coil B2 Sht 2 Contacts C8 Sht 1 Aux...

Page 170: ...00_ 460_ 0 230 400__ 220__ 200__ 0___ TB5 TB5 D13 5V D13 5V TP7 TP7 MC4 MC4 CN13 CN13 1 2 3 D11 INITIALIZING PROGRAMMING D11 INITIALIZING PROGRAMMING RY2 RY2 RY3 RY3 1 2 3 1 2 3 C P8 C P8 D12 STATUS C...

Page 171: ...WIRE uses TX TX RX RX J35 26 CKT J14 J14 2W SW14 SW14 LINE TERMINATION normally on refer to manual RIBBON CABLE 5 9 8 7 6 1 2 3 4 SW10 ADDRESS normally 0 refer to manual 0 TEST SOCKET UNDIVIDED ARC VO...

Page 172: ...1 ON INV OVER TEMP LED2 ON OCR FAULT LED3 ON INV NOT READY MAY BE ON DIM WHEN PLASMA DISABLED OR IN E STOP STATUS LEDS S S TB1 TB1 P1 P1 TB2 TB2 N2 N2 CN32 CN32 1 2 3 4 CN18 CN18 1 2 3 T T P P L1 L1 C...

Page 173: ...ntacts B9 Sht 1 MC4 5 Contactor 3P Inv 2 input Coil B2 Sht 2 Contacts B3 C3 Sht 1 Aux Contact B3 Sht 2 MC6 Contactor 3P Inv 3 input Coil B2 Sht 2 Contacts C8 Sht 1 Aux Contact B3 Sht 2 MOT1 Motor Pump...

Page 174: ...GND SIG FL1 FLOW_TURBINE_PULSE V GND SIG FL1 FLOW_TURBINE_PULSE R B G C P5 C P5 t TH1 t TH1 TP5 TP5 TP14 TP14 C P6 C P6 D23 CNC_START D23 CNC_START 1 2 CN14 CN14 1 2 TB4 TB4 MC3 MC3 D18 RS485 RXD CN2...

Page 175: ...MPER IN REMOTE HMI RS 485 422 on CPU board 19X2554 only KEY PLUG Was 7 pin changed to 14 pin in 2009 CN11 34 CKT CN10 26 CKT Iso J36 34 CKT PCB6 DISPLAY WK 5603 JUMPER for 2 WIRE RS485 only wire to A...

Page 176: ...0 part numbers per ECOB1844 Jan 13 2011 AC Corrected part numbers for S cables in section 6 per ECOB1889 June 1 2011 AD Updated flow chart for gas requirements on pg 2 5 per ECOB1901 Jan 25 2012 AE Up...

Page 177: ...This Page Intentionally Blank...

Page 178: ...mer Care Ph 6221 8990 6095 Fax 6221 8990 6096 Rawang Malaysia Customer Care Ph 603 6092 2988 Fax 603 6092 1085 Melbourne Australia Australia Customer Care Ph 1300 654 674 tollfree Ph 61 3 9474 7400 Fa...

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