Thermal Dynamics VICTOR 200 AUTO-CUT Operating Manual Download Page 124

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Manual 0-4805 Auto-Cut 200

A-4

APPENDIX

APPENDIX 4: COMMAND-CONTROL PC BOARD LAYOUT (B)

C75

C79

C41

R149R1

R144

R148

R103R1

C11C

D34

U10

R88

R128R1

R39

R73

R118R1

R120

C16

R81

R11

U12

D8D

D10

TP6

SW6SW

R75R7

K5-E-STOPK5

-E

-S

R20R2

R1R1

R151

D37

U14

U5U

R139

U13

C56

C22

C50

U6U

R10

R14

D6D

D29D

D12D

R104R1

R125R1

D20D

R47

R82

J36

D18

R77

R72

TP7

SW13

J35

R131

R13

C53C

C78C

R62R6

C39

C77C

C87C

C33

R23R2

R132R1

U22

R145

C17

K1-PSR

D22D

R69R6

D21

TP9

R76

C26C

C58

R64R6

R117R1

R6R6

R79

R55

C40

C68C

C7C

R41R4

R44

R66R6

R121

D25D

D23

R31

R28R2

R45

R123R1

R102R1

R135R1

C2C

D14

C24

TP3

U18U

R67R6

R49

TP12

U23

C45

R57

R138

R127

C76C

C66C

R12

D26

C19

TP5

R38

D7D

R53R5

C18

D30

R27R2

C47

D17D

C30

SW11SW

R71R7

U20

R97

R99

C84

19X2174

D2D

R141

R15

REV

C TDC 2005

ALL SW OFF FOR 50:1 (DEFAULT)A

)

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

-1

U16

OK TO MOVE SELECTO

CONTACTS

DC VOLTS

C93

U17

R43

H10

H11

OK CNC

R46

PSR

CNC_E-STOP

CNC_START

HOLD_START

R115R1

CNC PREFLOW

GAS ONG

E-STOP_PSE-

C65C

C35C

U24

GND

+5V

R80

+15V

-15V

+15V

-15V

R87

+18V

GND

ISOLATED

PILOT

R56

DEMAND

CUT

DEMAND

ARC V-

R114

PILOT V

CC POT

TP8

R26R2

K7-GAS ONK7

-G

C34C

U19

C27C

R29R2

C83

R90

C69C

+ +

C52C

C48

R129R1

R50

C15

TB1

R59

C20C

R83R8

C82

C23

C55C

R147

C88

C95

K2-START

C46

R61

R109

D32

R143

C71

C49C

R91

R24R2

R60

R22R2

R142R1

R21R2

R108

R63

R40

R101

R37

C64C

C92C

T1T1

R30

R134R1

R119R1

R116R1

R89

R48R4

K3-E-STOP CNC

R78

D36

D31

R140

R107

C37

R65

R100

C28C

R84

U11

K4-OK

D1D

C73C

R25R2

R110

C54

D15

R133

R150

R122R1

R19R1

C31

TP11

D39

D38D

R86

R68

R42R4

D13

R126

R70R7

C80

R96

TB2

C21C

C85

R33R3

C70

D40

R17R1

C51C

R136R1

TP4

D28

R93

R52R5

C9C

TP14

D16

C61C

D35

C13C

R58

D5D

R85

R98

R94R9

C89

C62

C25

R74

R130

TP1

TP13

C91

R35R3

TP10

R18R1

C29C

C72

C42

C74

D19

R124R1

R95

C81

D11D

R54R5

C36C

D24

C12C

C86C

U21

U15

R16R1

TP2

C60

R32R3

R51R5

C32

C14C

D27D

R113

D33D

C38

R105

R34R3

R92

C59

R112

R106

R146

R111

R36R3

C10C

C57C

+29-41 VDC

C67

C63

C90

R223R2

C94C

R155

R158

D60D

R156

22
11

SW12SW

R154R1

R157

D61D

SW12-2 ON FOR 30:1SW

-2

SW12-3 ON FOR 40:1SW

-3

SW12-4 SPARESW

-4

R152R1

C44

R224

R225

C43

R227R2

R228R2

R226R2

AD+

Art # A-06901

TP14

TP7

TP6

SW6

SW12

J36

TB1

TB2

TP11

SW11

TP9

TP12

TP10

TP8

J35

TP4

TP3

TP2 SW13

TP5

TP1

TP13

Summary of Contents for VICTOR 200 AUTO-CUT

Page 1: ...on ___ 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 ope...

Page 2: ...Thispageintentionallyblank...

Page 3: ...Cutting System Cut out one strip and use as spine label in binder Discard extras Use next page as front cover insert in binder ManualNo 0 4805 Auto Cut 200 Plasma Cutting System Auto Cut 200 Plasma C...

Page 4: ...Thispageintentionallyblank...

Page 5: ...PLASMA CUTTING SYSTEM 200 AUTO CUT Rev AR Date January 8 2013 Manual 0 4805 OperatingFeatures Operating Manual...

Page 6: ...Thispageintentionallyblank...

Page 7: ...Rev AR Date January 8 2013 Manual 0 4805 OperatingFeatures PLASMA CUTTING SYSTEM 200 AUTO CUT Operating Manual...

Page 8: ...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 Th...

Page 9: ...9 2010 2011 2012 2013 by Victor Technologies All rights reserved Reproduction of this work in whole or in part without written per mission of the publisher is prohibited The publisher does not assume...

Page 10: ...Thispageintentionallyblank...

Page 11: ...INSERT TABLE OF CONTENTS TAB HERE DISCARD THIS SHEET...

Page 12: ...Thispageintentionallyblank...

Page 13: ...anel Features 2 4 2 09 Gas Requirements 2 5 2 10 Gas Applications 2 5 2 11 XTTM 301Torch Specifications 2 6 SECTION 3 INSTALLATION 3 1 3 01 Installation Requirements 3 1 3 02 Cables and Leads Identifi...

Page 14: ...ower Supply Replacement Parts Right Side 6 7 6 08 Power Supply Replacement Parts Front Panel 6 8 6 09 Power Supply Replacement Parts Front Panel 6 9 6 10 Power Supply Replacement Parts Right Side 6 10...

Page 15: ...opper Pilot Cont A 16 Appendix 8 Power Supply Schematic 230 460V Resistor Pilot A 18 Appendix 8 Power Supply Schematic 230 460V Resistor Pilot Cont A 20 Appendix 9 Power Supply Schematic CCC 400V Chop...

Page 16: ...TABLE OF CONTENTS...

Page 17: ...Insert Section 1 tab here Discard this sheet...

Page 18: ......

Page 19: ...y Arsenic Cobalt Nickel Barium Copper Selenium Beryllium Lead Silver Cadmium Manganese Vanadium Always read the Material Safety Data Sheets MSDS that should be supplied with the material you are using...

Page 20: ...fety Code 25249 5 et seq 1 03 Publications Refer to the following standards or their latest revisions for more infor mation 1 OSHA SAFETY AND HEALTH STANDARDS 29CFR 1910 obtainable from the Superinten...

Page 21: ...zone de respiration Gardez votre t te hors de la plume de fum e provenant du chalumeau Utilisez un appareil respiratoire alimentation en air si l a ration fournie ne permet pas d liminer la fum e et...

Page 22: ...es de s curit munies de parois lat rales ou des lunettes de protection ou une autre sorte de protec tion oculaire Portez des gants de soudeur et un v tement protecteur appropri pour prot ger votre pea...

Page 23: ...rican Welding Society 550 N W LeJeune Rd Miami FL 33126 8 Norme 51 de l Association Am ricaine pour la Protection contre les Incendies NFPA LES SYSTEMES GAZ AVEC ALIMENTATION EN OXYGENE POUR LE SOUDAG...

Page 24: ...Underwriters Laboratory 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 EN5...

Page 25: ...therewith such as the performance or breach thereof or from the manufacture sale delivery resale or use of any goods covered by or furnished by Thermal whether arising out of contract negligence stric...

Page 26: ...of goods to Cigweld or our Nominated Accredited Distributor Accredited Service Provider are the responsibility of the consumer This warranty is given Cigweld Pty Ltd A B N 56007226815 71 Gower Street...

Page 27: ...Insert Section 2 tab here Discard this sheet...

Page 28: ......

Page 29: ...liquid coolant for the torch and leads 2 03 Gas Control Module Arc Starter This module mounts to the top of the power supply This module enables the operator to select gas set pressures and flows and...

Page 30: ...Freq 3 Ph 3 Ph Fuse Amps Wire AWG Volts Hz kVA Amps 3 Ph 3 Ph 208 60 47 130 160 22 230 60 49 125 150 22 400 50 54 77 100 21 400 CE 50 54 77 100 21 460 60 59 75 90 21 Auto Cut 200 Power Supply 2 Extra...

Page 31: ...ual No 0 4805 Auto Cut 200 2 3 SPECIFICATIONS Art A 04822 33 inch 840 mm 27 inch 680 mm 37 75 inch 960 mm 41 25 inch 1050 mm 27 5 inch 700 mm 48 75 inch 1238 mm 397 lb 180 kg 2 07 Power Supply Dimensi...

Page 32: ...Coolant Connections Input Power Terminals Pilot Pos Terminal Circuit Breaker Panel Terminal Cover AC Power Lamp Ground Terminals Gas Control Connector RETURN SUPPLY Art A 04823 CNC Connection Arc Star...

Page 33: ...5 Argon Hydrogen H35 35 Hydrogen 65 Argon 99 995 Purity gas recommended 120 psi 8 3 bar 827 kPa 200 scfh 5664 l h H2O Water See Note 2 50 psi 3 5 bar 10 gph 38 lph Auto Cut 200 BASIC Power Supply Gas...

Page 34: ...ONS 2 11 XTTM 301 Torch Specifications A Torch Dimensions 2 25 57 15 mm 2 0 50 8 mm 2 39 60 81 mm 1 49 37 8 mm 19 00 482 68 mm 15 50 393 78 mm 2 74 69 55 mm 1 57 39 96 mm 3 54 89 87 mm 6 30 160 10 mm...

Page 35: ...ode Tip Plasma Gas Distributor Shield Gas Distributor Shield Cap D Parts In Place PIP The torch is designed for use with a power supply which senses coolant return flow to confirm that torch parts are...

Page 36: ...0 Amps Voltage Vpeak 500V Arc Striking Voltage 10kV Current Up to 200 Amps DC Straight Polarity See Note Plasma Gases Compressed Air Oxygen Nitrogen H35 F5 Shield Gases Compressed Air Oxygen Nitrogen...

Page 37: ...Manual No 0 4805 Auto Cut 200 2 9 SPECIFICATIONS Insert Sec 3 tab here Discard this sheet...

Page 38: ......

Page 39: ...reference only The installation must conform to national and local codes for the type and method of wire being used Gas Supply The customer must supply all gases and pressure regulators Gases must be...

Page 40: ...power Control Cable Ground Cable Work Art A 07231_AB Torch Work Cable Auto Cut Power Supply Arc Starter Gas Control Module GCM 1000 Pilot Return Negative Coolant Supply Coolant Return Control Cable CN...

Page 41: ...Leads Power Supply to Arc Starter 1 0 50 mm Cable Pilot Return Power Supply to Arc Starter Negative Lead Power Supply to Arc Starter Control Cable Power Supply to Arc Starter Ground Cable Ground Cabl...

Page 42: ...and equipment damage Use all four lifting eyes when using lifting straps to lift the power supply Useaforklift crane orhoisttolifttheunitofftheshippingpalletasshown Keepthepowersupplysteadyandvertica...

Page 43: ...cted to the power supply Refer to local and national electrical codes for suggested cable and fuse sizes Remove the connections cover on the rear of the Power Supply Use caution when removing the pane...

Page 44: ...The input voltage configuration is shown at the top of the board 2 If necessary disconnect the jumper from the top right corner of the board remove the board and re install with the correct input volt...

Page 45: ...ound terminal block CAUTION The clear connections cover must remain in place 4 If required pass a system ground cable F1 through the last opening in the connections cover support panel next to the inp...

Page 46: ...0 Ground Cable CNC Device Torch Cutting Table Cutting Machine Gantry 1 0 Work Cable Remote Arc Starter RAS 1000 1 0 Ground Cable Star Ground on Cutting Table Auto Cut W RAS Star Ground on Cutting Tab...

Page 47: ...6 m Maximum 1 0 Ground Cable 4 AWG Ground Factory Installed GCM 1000 Gas Control Module Auto Cut Power Supply Star Ground Earth Ground Rod 1 0 Ground Cable F1 CNC Device Torch Cutting Table Cutting Ma...

Page 48: ...ground wire and the Gas Control Module should use minimum 4 AWG wire The connection point must be to clean bare metal rust and paint make poor connections For all components wires larger than the rec...

Page 49: ...his test assumes the 115 or 230 VAC source neutral is connected to the utility earth ground Art A 07252 WARNING Use extreme caution This test uses live voltage NEUTRAL Earth Grounded HOT On 115V AC Li...

Page 50: ...ork Cable 1 Pass the end of the work cable upward through the leads bracket at the bottom of the power supply rear panel then up through the opening in the connections cover support panel 2 Refer to t...

Page 51: ...805 Auto Cut 200 3 13 INSTALLATION 3 08 Connect Gas Supply Lines 1 Connect the gas supply lines to the appropriate input ports as shown RETURN SUPPLY RETURN SUPPLY Art A 04844 Plasma Gas In Shield Gas...

Page 52: ...09 Connect CNC Cable 1 Connect one end of the CNC cable to the power supply receptacle marked CNC 2 Connect the other end of the cable to the CNC device 3 The CNC cable shield must be attached to grou...

Page 53: ...0 1 Seconds SW 1 4 Pilot Delay 2 OFF 3 ON 4 OFF 0 2 Seconds 2 ON 3 ON 4 OFF 0 4 Seconds 2 OFF 3 OFF 4 ON 0 8 Seconds 2 ON 3 OFF 4 ON 1 0 Seconds 2 OFF 3 ON 4 ON 1 5 Seconds 2 ON 3 ON 4 ON 2 0 Seconds...

Page 54: ...0VAC 1A Factory default setting or DC Volts 16 18vdc up to 100 ma SW 11 Analog Current Control B from Gas Control Factory default setting or A from CNC Position A requires that SW 8 2 be ON SW 12 1 2...

Page 55: ...tion 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 120VAC and 1Amp...

Page 56: ...kink or bend the leads 3 Inside the module slide the leads clamp over the leads 4 Connect the leads to the module in the sequence shown Coolant leads and connectors are color tagged red for coolant r...

Page 57: ...onnection Tagged Red Art A 04832 Plasma Gas Connection Shield Gas Connection Torch Leads 5 Fold the end of the leads outer jacket back over the connection ring inside the module Slide the leads clamp...

Page 58: ...Manual No 0 4805 Auto Cut 200 3 20 INSTALLATION Clamp 5 Art A 04935_AB Inner Shield Connection for OLDER LEADS ONLY...

Page 59: ...mounting tube Slide the torch mounting tube onto the leads far enough to expose the fittings on the ends of the leads 4 Connect the Torch Head to the torch leads Follow the sequence shown Do not let t...

Page 60: ...o the Torch Speed Charts to select the correct parts for the application The application will deter mine which torch parts must be used Refer to the speed charts for the proper torch parts to install...

Page 61: ...ap Protrudes 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 Protrusio...

Page 62: ...ield Cup Art A 04344 InstallingShieldCupOntoCartridge 6 Take the removal tool off the cartridge Fit the cartridge assembly onto the torch head The cartridge should seal to the large O ring on the torc...

Page 63: ...Protrusion 8 Slide the ohmic clip over the shield cup if using ohmic torch height sensing NOTE Ohmic height sensing is not recommended with water shield Water on the plate interferes electrically with...

Page 64: ...rch leads length 2 Replace the cap on the tank Cat Number and Mixture Mixture Protects To 7 3580 Extra CoolTM 25 75 10 F 12 C 7 3581 Ultra CoolTM 50 50 27 F 33 C 7 3582 Extreme CoolTM Concentrate 65 F...

Page 65: ...lant c Place the ON OFF switch to OFF d After 10 seconds place 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...

Page 66: ...This Page Intentionally Blank...

Page 67: ...Insert Sec 4 tab here Discard this sheet...

Page 68: ......

Page 69: ...power on TEMP Lamp Normally OFF Lamp will come ON when the internal temperature sensors detect tempera tures above normal limits Let the unit cool before continuing operation GAS Lamp Normally ON Indi...

Page 70: ...eter and Control Knob GCM 1000 A CUT OUT Run Set Selector Use SET position to adjust plasma and shield pressures and flows Once these are set switch to RUN position for operation Plasma and Shield Gas...

Page 71: ...or plug unit in to supply primary power to the system D Work Cable Connection Check for a solid and clean work cable connection to the workpiece or cutting table The connection area must be free from...

Page 72: ...rn the knob to adjust gas pressure d Push the knob back in to lock the pressure setting 3 To set the Shield Gas pressure Set the Shield Mode Selector switch to the GAS or H2 O MIST position For Gas Sh...

Page 73: ...angle between the surface of the cut edge and a plane perpendicular to the surface of the plate A perfectly perpendicular cut would result in a 0 bevel angle Top Edge Rounding Rounding on the top edge...

Page 74: ...cut along 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...

Page 75: ...O Art A 04842 3 Check the AC lamp If lamp is ON AC input power is present in the power supply Circuitry in the power supply monitors the status of various conditions If the circuitry detects a situati...

Page 76: ...Pilot arc is established 9 Move Torch within transfer distance of workpiece a Main arc transfers to the workpiece Pilot arc shuts off 10 Complete cutting operation 11 Stop the torch a Main arc stops...

Page 77: ...te the pilot arc any longer than necessary 3 Use care in handling torch leads and protect them from damage 4 When using water as the shield note the following Use clean drinking quality tap water to h...

Page 78: ...ctive during ramping and cutting Possible double arc 1 8 Shorted Torch Electrode to tip voltage 50v w inverter on 2 1 Missing Phase 1 of 3 input AC phases missing 2 2 Input voltage out of tolerance Te...

Page 79: ...k add as needed 4 3 Coolant Overheated over 158 F 70 C Coolant temperature must drop by 9 F 5 C to clear overtemp condition 4 4 Cooling System Not Ready Pump has run 30 sec w o reaching minimum flow r...

Page 80: ......

Page 81: ...Insert sec 5 tab here discard this sheet...

Page 82: ......

Page 83: ...racks or abrasion Replace as needed Clean water filter if using H2O Mist Six Months Replace coolant filter Clean coolant tank Vacuum out any dust buildup inside power supply 5 02 Coolant Filter Cleani...

Page 84: ...ield Clean the filter as follows 1 Disconnect system from main input power 2 Unscrew and remove the filter bowl by hand Be sure to keep the gasket 3 Remove and clean the filter Re install the bowl tig...

Page 85: ...input power and turn it on to allow the pump to empty the tank The pump will run approximately for 20 seconds before the flow switch causes an interlock This procedure may be repeated a few times unt...

Page 86: ...nnect Faulty EMI filter Voltage Resistor measurement Replace Loose fitting s Visual inspection Tighten fittings Failure to braze joints L1 Visual inspection Replace HF Coil Damaged or punctured coolan...

Page 87: ...05 Auto Cut 200 5 5 MAINTENANCE 5 06 Arc Starter Spark Gap Adjustment 1 Shut off input power Remove the top console cover 2 Adjust the spark gap as shown Re install the top cover 0 063 0 002 1 6 0 05...

Page 88: ...Manual No 0 4805 Auto Cut 200 5 6 MAINTENANCE This page is blank intentionally...

Page 89: ...Manual No 0 4805 Auto Cut 200 5 7 MAINTENANCE Insert Sec 6 tab here discard this sheet...

Page 90: ......

Page 91: ...01 Replacement Power Supply Complete Unit Component Catalog Numbers Catalog Number Auto Cut 200 Power Supply 208 230V 3 9112 1 Auto Cut 200 Power Supply 460V 3 9112 2 Auto Cut 200 Power Supply 400V 3...

Page 92: ...lot Return Cable only 4 ft 1 2 m 9 4890 B Negative Cable only 9 4892 C Hose Coolant Supply only 9 4886 D Hose Coolant Return only 9 4888 E Control Cable only Power Supply to Arc Starter 4 ft 1 2 m 9 4...

Page 93: ...lot Return Power Supply to Arc Starter Negative Lead Power Supply to Arc Starter Control Cable Power Supply to Arc Starter Ground Cable Ground Cable Arc Starter To Earth Ground O P Control Cable Power...

Page 94: ...alog 1 1 Power Supply Front Panel N A 2 1 Power Supply Rear Panel N A 3 1 Power Supply Top Panel 9 0445G 9 0445B 4 1 Power Supply Right Side 9 0442G 9 0442B 5 1 Power Supply Left Side 9 0443G 9 0443B...

Page 95: ...Manual No 0 4805 Auto Cut 200 6 5 Parts List 6 05 Power Supply Replacement Parts Right Side Item Qty Description Ref Des Catalog 1 1 Heat Exchanger Fan FAN1 9 9338 2 1 Radiator 9 9339 1 2 Art A 08308...

Page 96: ...wer Supply Replacement Parts Right Side Item Qty Description Ref Des Catalog 1 1 Output Filter PC PCB8 9 9341 2 1 Sensor HCT2 9 9368 3 1 Magnetic Contactor pilot MC2 9 9343 4 1 Resistor R6 9 9340 5 1...

Page 97: ...ual No 0 4805 Auto Cut 200 6 7 Parts List 6 07 Power Supply Replacement Parts Right Side Item Qty Description Ref Des Catalog 1 Chopper Module 9 9389 1 Sensor HCT1 9 9342 Chopper Module Art A 08311 HC...

Page 98: ...0 4805 Auto Cut 200 6 8 Parts List 6 08 Power Supply Replacement Parts Front Panel Item Qty Description Ref Des Catalog 7 1 Main Power Switch Circuit Protector CP1 9 9344 for 230 400 460 VAC units 7 A...

Page 99: ...ts List 6 09 Power Supply Replacement Parts Front Panel Item Qty Description Ref Des Catalog 1 PC Board PCB3 9 9365 1 PC Board 230 460VAC PCB4 9 9370 1 PC Board 600VAC PCB4 9 9492 1 Display PC Board P...

Page 100: ...0 6 10 Parts List 6 10 Power Supply Replacement Parts Right Side Item Qty Description Ref Des Catalog 1 1 PCBoard 230 400 460VAC PCB1 9 9362 1 1 PCBoard 600VAC PCB1 9 9491 2 1 Magnetic Contactor MC1 M...

Page 101: ...Circuit Breaker AGC 125V 2 5A 120VAC 1A CP5 9 9348 16 1 Circuit Breaker AGC 125V 2 5A 15VDC 1A CP6 9 9348 17 1 Circuit Breaker Pump 250V 10A 200VAC 3A CP7 9 9351 18 1 Circuit Breaker Fan 125V 3 15A 24...

Page 102: ...Power Supply Replacement Parts Right Side Item Qty Description Ref Des Catalog 1 1 Resistor R7 9 9363 2 1 Rectifier Diode D1 9 9345 3 1 Transformer T1 9 9355 for 230 460 VAC units 4 1 Diode D2 9 9486...

Page 103: ...Cut 200 6 13 Parts List 6 13 Power Supply Replacement Parts Item Qty Description Catalog 29 2 Inverter Module 208 230V 9 9360D 2 Inverter Module 400V CE and 400V Non CE 9 9482D 2 Inverter Module 600V...

Page 104: ...Manual No 0 4805 Auto Cut 200 6 14 Parts List 6 14 Power Supply Replacement Parts Right Side Item Qty Description Ref Des Catalog 30 1 Sensor Thermistor TH1 9 9361 30 Art A 04787...

Page 105: ...Cut 200 6 15 Parts List 6 15 Power Supply Replacement Parts Item Qty Description Ref Des Catalog 1 1 Relay PC Board PCB7 9 9366 2 1 24 VDC Power Supply N A N A 3 1 Internal Control PC Board PCB5 9 93...

Page 106: ...ment Parts Right Side Item Qty Description Ref Des Catalog 22 1 Sensor Level Switch LSW1 9 9354 24 1 Motor M 9 9381 25 1 Pump Check Valve Bypass Valve Assembly 9 9380 26 1 Bypass Valve part of assembl...

Page 107: ...Catalog 1 1 Assembly CCM Auto Cut 9 9418 2 1 Plate CCM Face 9 9419 3 1 Panel CCM Mount Not Available 4 1 Harness CCM I O Board 9 9421 NOTE This page covers parts for Command Control module without an...

Page 108: ...ox Arc Starter 9 4989 12 1 Mount Neg Lead Attach 9 4990 13 1 Bracket Gas Box Arc Starter 9 4991 14 1 Bracket Filter Water Mist 9 4992 15 1 Hose Package 9 4993 16 1 Harness Gas Controls 9 4994 17 1 Har...

Page 109: ...Manual No 0 4805 Auto Cut 200 6 19 Parts List Art A 04852_AC Right Side Left Side 9 5 6 7 8 10 13 15 14 11 12 3 17 16 20 19 21 26 27 23 24 25 22 28 29...

Page 110: ...Manual No 0 4805 Auto Cut 200 6 20 Parts List This Page Intentionally Blank...

Page 111: ...Manual No 0 4805 Auto Cut 200 6 21 Parts List Insert Sec 7 tab here discard this sheet...

Page 112: ......

Page 113: ...d Cup Cartridge Assembly stationary Turn the Shield Cup to re move it from the Cartridge Assembly Assembled Cartridge Cartridge Tool Shield Cup Art A 04344_AB 2 Take the Removal Tool off the back of t...

Page 114: ...r the locking ring 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 Thermal Dynamics No 9 4893 O Ring Lubricant Christo Lube MCG 129 with this...

Page 115: ...he consumables and Cartridge Handle all parts carefully to avoid damage which may affect torch performance NOTE For 200 Amp consumables when replacing the shield retainer or the shield cup assemble th...

Page 116: ...Cap Protrudes 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 Protrusi...

Page 117: ...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 118: ...New or Used Are Parts fully assembled into the Torch Unsure Disassembly fully and re assemble the Torch Properly See Installation Manual Replace Torch Head Is the Torch Damaged Replace Consumable Car...

Page 119: ...Manual 0 4805 Auto Cut 200 7 7 TORCH MAINTENANCE Insert sec 8 tab here discard this sheet...

Page 120: ......

Page 121: ...25 23 Jumper to 15 28 22 26 24 Sol 1 29 27 30 31 32 36 37 POWER SUPPLY J55 Art A 04848 ARC STARTER GAS CONTROL MODULE J56 1 Jumper to 2 2 Jumper to 1 15 Jumper to 23 14 Run Set Sw 16 17 33 Ground 34 3...

Page 122: ...Power Supply J59 to Arc Starter Gas Control Console J58 3 9 120 VAC RET 5 1 Jumpered to 4 6 7 120 VAC 8 10 13 14 11 12 Art A 04849 2 Ground POWER SUPPLY J59 ARC STARTER GAS CONTROL MODULE J58 3 5 4 1...

Page 123: ...15 R70 R2 U27 R79 C2 U5 R91 D11 R51 C25 R89 R18 R8 C51 D3 D13 U28 1 C8 R31 R40 C34 R85 R38 C48 D7 R92 R57 R7 R4 C1 R36 1 2 1 SW4 C9 R3 R62 R63 U17 R13 160 U14 1 40 120 80 R27 C31 R59 R55 R32 U13 1 C45...

Page 124: ...SOLATED PILOT PILOT R56 R56 DEMAND DEMAND CUT CUT DEMAND DEMAND ARC V ARC V R114 R114 PILOT V PILOT V CC POT CC POT D3 D3 TP8 TP8 R26 R26 K7 GAS ON K7 GAS ON C34 C34 U19 U19 L2 L2 C27 C27 R29 R29 C83...

Page 125: ...Manual 0 4805 Auto Cut 200 A 5 APPENDIX This page is blank intentionally...

Page 126: ...10 Remote Analog Current Control 0 10V TB1 11 TB1 12 TB2 1 Hold Start TB2 2 Hold Start TB2 3 Preflow On TB2 4 Preflow On TB2 5 TB2 6 Pilot On Relay Contacts NO TB2 7 TB2 8 Pilot On Relay Contacts NO T...

Page 127: ...functionsareonlyavailableonTB1 2 2 SW6 on CCM I O PCB selects OK to Move for isolated contact closure or DC Volts 15 18V at 100ma When set for contacts OK to Move circuit is rated for 120 VAC 28 VDC 1...

Page 128: ...W8 2 ON up Hold Start input Normally open close to hold start Circuit rating 10 ma 20VDC Delays pilot ignition gas preflow continues Used for synchronizing starts when multiple plasma supplies are use...

Page 129: ...12 2 ON 30 1 SW12 3 ON 40 1 SW12 4 ON ARC V 2 1 3 5 4 6 SW6 Active LOW Logic Input 16 to 18 VDC isolated PSR OK to Move ARC V Active LOW Logic Input 100K 3 6 SW12 3 4 5 SW12 4 1 8 SW12 1 2 7 SW12 2 2...

Page 130: ...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 VDC or 28 VDC up...

Page 131: ...Manual 0 4805 Auto Cut 200 A 11 APPENDIX This Page Intentionally Blank...

Page 132: ...12 12 13 13 14 14 WORK WORK WORK WORK T1 T1 11X16 11X16 T1 T1 11X16 11X16 1 2 3 4 J55 J55 J55 J55 1 2 3 4 5 6 7 8 9 10 10 11 11 12 12 13 13 14 14 15 15 16 16 17 17 18 18 19 19 20 20 21 21 22 22 23 23...

Page 133: ...Thursday February 03 2005 C DWG No DWG No Sheet Sheet of of Supersedes Supersedes Scale Scale Date Date Drawn Drawn References References Date Date By By Revisions Revisions Rev Rev PCB No PCB No Ass...

Page 134: ...60 230 230 208 230 460 VAC 3 Phase CN6 100A INVERTER MODULE 2 bottom same as 1 D2 Sht 2 RIBBON CABLE SIGNALS CN6 16 Ckt Ribbon Cable 2 4 I_REF Scaled Cut Demand 5 PS_START Start 6 REDUNDANT_START Star...

Page 135: ...er Tuesday October 03 2006 08 11 44 Thermal Dynamics D RAS PCB 8 WK 5687 RC RF CAPS HALL SENSOR HALL SENSOR PILOT REG CHOPPER PCB1 WK 5750 BIAS POWER PILOT REGULATOR CHOPPER OVER_TEMP P_DEM P_Iref P_E...

Page 136: ...ELCOL_0 CN12 CN12 1 2 CN2 CN2 1 2 TP4 TP4 CN20 CN20 1 2 3 CN3 CN3 1 2 3 D2 E STOP_PS D2 E STOP_PS V GND SIG FL1 FLOW_TURBINE_PULSE V GND SIG FL1 FLOW_TURBINE_PULSE R B G T1 T1 460 220 0 13 0 100 0 200...

Page 137: ...4 603 298 5711 150 200 Amp Power Supply 208 230 460V Chopper Tuesday October 03 2006 08 11 44 Thermal Dynamics D KEY PLUG CN11 34 CKT CN10 26 CKT J36 34 CKT J35 26 CKT RIBBON CABLE TEST SOCKET RIBBON...

Page 138: ...460 230 230 208 230 460 VAC 3 Phase CN6 100A INVERTER MODULE 2 bottom same as 1 D2 Sht 2 RIBBON CABLE SIGNALS CN6 16 Ckt Ribbon Cable 2 4 I_REF Scaled Cut Demand 5 PS_START Start 6 REDUNDANT_START Sta...

Page 139: ...RC RF CAPS HALL SENSOR HALL SENSOR PILOT REG CHOPPER PCB1 WK 5750 BIAS POWER PILOT REGULATOR CHOPPER OVER_TEMP P_DEM P_Iref P_Enable P_ena PILOT REG CHOPPER PCB2 WK 5754 I_DET I_SE PILOT CURRENT SIGNA...

Page 140: ...CN2 1 2 TP4 TP4 CN20 CN20 1 2 3 CN3 CN3 1 2 3 D2 E STOP_PS D2 E STOP_PS V GND SIG FL1 FLOW_TURBINE_PULSE V GND SIG FL1 FLOW_TURBINE_PULSE R B G T1 T1 460 220 0 13 0 100 0 200 0 110 0 120 0_ 24 0__ 24...

Page 141: ...Supply 208 230 460V Resistor Tuesday October 03 2006 08 11 44 Thermal Dynamics D KEY PLUG CN11 34 CKT CN10 26 CKT J36 34 CKT J35 26 CKT RIBBON CABLE TEST SOCKET RIBBON CABLE TEST SOCKET E2 E2 E4 F4 P...

Page 142: ...CB 400 400 VAC 3 Phase CN6 100A INVERTER MODULE 2 bottom same as 1 D2 Sht 2 RIBBON CABLE SIGNALS CN6 16 Ckt Ribbon Cable 2 4 I_REF Scaled Cut Demand 5 PS_START Start 6 REDUNDANT_START Start2 8 INV_REA...

Page 143: ...October 03 2006 08 11 44 Thermal Dynamics D RAS PCB 8 WK 5687 RC RF CAPS HALL SENSOR HALL SENSOR PILOT REG CHOPPER PCB1 WK 5750 BIAS POWER PILOT REGULATOR CHOPPER OVER_TEMP P_DEM P_Iref P_Enable P_en...

Page 144: ...2 1 2 TP4 TP4 CN20 CN20 1 2 3 CN3 CN3 1 2 3 C P4 C P4 D2 E STOP_PS D2 E STOP_PS V GND SIG FL1 FLOW_TURBINE_PULSE V GND SIG FL1 FLOW_TURBINE_PULSE R B G T1 TX1P8S T1 TX1P8S 400 200 0 13 0 100 0 200 0 1...

Page 145: ...5711 150 200 A Power Supply 400V CCC Chopper Tuesday October 03 2006 08 11 44 Thermal Dynamics D KEY PLUG CN11 34 CKT CN10 26 CKT J36 34 CKT J35 26 CKT RIBBON CABLE TEST SOCKET RIBBON CABLE TEST SOCK...

Page 146: ...N 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 PS_START disabled by OCR 14 TEMP_ERR...

Page 147: ...REG CHOPPER PCB1 WK 5750 BIAS POWER PILOT REGULATOR CHOPPER OVER_TEMP P_DEM P_Iref P_Enable P_ena PILOT REG CHOPPER PCB2 WK 5754 I_DET I_SE PILOT CURRENT SIGNAL WORK CURRENT SIGNAL PILOT ENABLE PILOT...

Page 148: ...2 1 2 TP4 TP4 CN20 CN20 1 2 3 CN3 CN3 1 2 3 C P4 C P4 D2 E STOP_PS D2 E STOP_PS V GND SIG FL1 FLOW_TURBINE_PULSE V GND SIG FL1 FLOW_TURBINE_PULSE R B G T1 TX1P8S T1 TX1P8S 400 200 0 13 0 100 0 200 0 1...

Page 149: ...5711 150 200A Power Supply 400V CE Chopper Tuesday October 03 2006 08 11 44 Thermal Dynamics D KEY PLUG CN11 34 CKT CN10 26 CKT J36 34 CKT J35 26 CKT RIBBON CABLE TEST SOCKET RIBBON CABLE TEST SOCKET...

Page 150: ...ON 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 PS_START disabled by OCR 14 TEMP_ER...

Page 151: ...able P_ena PILOT REG CHOPPER PCB2 WK 5754 I_DET I_SE PILOT CURRENT SIGNAL WORK CURRENT SIGNAL PILOT ENABLE PILOT DEMAND HCT1 Hall Current Sensor Pilot B8 Sht 1 HCT2 Hall Current Sensor Work C9 Sht 1 L...

Page 152: ...PREFLOW D28 CNC_PREFLOW 1 2 RY3 RY3 1 2 D26 HOLD_START D26 HOLD_START C P7 C P7 CN14 CN14 1 2 D12 STATUS CODE D12 STATUS CODE C P4 C P4 CN20 CN20 1 2 3 RY4 RY4 C P2 C P2 D23 CNC_START D23 CNC_START CN...

Page 153: ...400V CE Resistor Tuesday October 03 2006 08 11 44 Thermal Dynamics D KEY PLUG CN11 34 CKT CN10 26 CKT J36 34 CKT J35 26 CKT RIBBON CABLE TEST SOCKET RIBBON CABLE TEST SOCKET E2 E2 E4 F4 POWER SUPPLY...

Page 154: ...ER PCB 600 600 VAC 3 Phase CN6 100A INVERTER MODULE 2 bottom same as 1 D2 Sht 2 RIBBON CABLE SIGNALS CN6 16 Ckt Ribbon Cable 2 4 I_REF Scaled Cut Demand 5 PS_START Start 6 REDUNDANT_START Start2 8 INV...

Page 155: ...cs D RAS PCB 8 WK 5687 RC RF CAPS HALL SENSOR HALL SENSOR PILOT REG CHOPPER PCB1 WK 5750 BIAS POWER PILOT REGULATOR CHOPPER OVER_TEMP P_DEM P_Iref P_Enable P_ena PILOT REG CHOPPER PCB2 WK 5754 I_DET I...

Page 156: ...CN2 1 2 TP4 TP4 CN20 CN20 1 2 3 CN3 CN3 1 2 3 C P4 C P4 D2 E STOP_PS D2 E STOP_PS V GND SIG FL1 FLOW_TURBINE_PULSE V GND SIG FL1 FLOW_TURBINE_PULSE R B G T1 T1 600 220 0 13 0 100 0 200 0 110 0 120 0_...

Page 157: ...5711 150 200 A Power Supply 600V CSA Chopper Tuesday October 03 2006 08 11 44 Thermal Dynamics D KEY PLUG CN11 34 CKT CN10 26 CKT J36 34 CKT J35 26 CKT RIBBON CABLE TEST SOCKET RIBBON CABLE TEST SOCK...

Page 158: ...sion control starting with AA 01 Oct 10 2006 AB 01 Added inverter module part numbers for 400V 400V CE and 600V Jan 10 2007 AC 01 Updated Error codes in section 4 and added notice to update to Firmwar...

Page 159: ...This Page Intentionally Blank...

Page 160: ...Indonesia Customer Care Ph 6221 8990 6095 Fax 6221 8990 6096 Rawang Malaysia Customer Care Ph 603 6092 2988 Fax 603 6092 1085 Melbourne Australia Australia Customer Care Ph 1300 654 674 tollfree Ph 61...

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