Victor ULTRA-CUT 200 Operating Manual Download Page 1

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t# A-08586_AC

PLASMA CUTTING SYSTEM
& AUTOMATED GAS CONTROL

200

ULTRA-CUT

™

Operating Manual

Rev. AK

Date:

March 13, 2013

Manual #

0-5133

Operating Features:

Summary of Contents for ULTRA-CUT 200

Page 1: ...Art A 08586_AC PLASMA CUTTING SYSTEM AUTOMATED GAS CONTROL 200 ULTRA CUT Operating Manual Rev AK Date March 13 2013 Manual 0 5133 OperatingFeatures...

Page 2: ...please take the time to read the entire manual especially the Safety Precautions They will help you to avoid potential hazards that may exist when working with this product YOU ARE IN GOOD COMPANY The...

Page 3: ...013 by Thermadyne Corporation 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 and hereby disc...

Page 4: ...Thispageintentionallyblank...

Page 5: ...s 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 3 0...

Page 6: ...ecommended Gas Supply Hose 6 2 6 04 Leads and Cables 6 3 6 05 Power Supply External Replacement Parts 6 10 6 06 Power Supply Replacement Parts Right Side 6 11 6 07 Power Supply Replacement Parts Right...

Page 7: ...put Output Descriptions A 9 A7 03 Simplified CNC Circuit A 10 A7 04 CNC Connections A 11 APPENDIX 8 SERIAL COMMUNICATIONS A 12 A8 01 Cables and Switch Settings for 2 and 4 Wire A 12 APPENDIX 9 Schemat...

Page 8: ...NOTE Section 8 Torch operation is provided separately...

Page 9: ...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 10: ...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 11: ...e 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 12: ...tes 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 pe...

Page 13: ...erican 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 SOUDA...

Page 14: ...4VO 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 to plasma...

Page 15: ...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 16: ...ULTRA CUT 200 1 8 Manual 0 5133...

Page 17: ...rent for cutting operations The power supply also monitors system performance and cools and circulates the liquid coolant for the torch and leads 2 03 Remote Arc Starter This unit produces a temporary...

Page 18: ...230 50 60 49 125 150 1 380 50 60 52 81 100 4 400 CE 50 60 52 77 90 4 460 50 60 59 75 90 4 600 50 60 52 51 60 6 Suggested wire size based on United States NFPA 70 National Electrical Code 2005 edition...

Page 19: ...rn Plasma Gas Shield Gas Work Cable DMC 3000 Gas Console Ultra Cut Power Supply DPC 3000 Gas Control Positioning Tube Plasma Gas Marking Shield Shield Gas Negative Pilot Return Control Cable 100 30 5...

Page 20: ...Manual No 0 5133 Ultra Cut 200 2 4 SPECIFICATIONS 2 08 Power Supply Dimensions Art A 07182 37 75 inch 960 mm 27 5 inch 700 mm 33 inch 840 mm 27 inch 680 mm 41 25 inch 1050 mm 433 lb 196 kg...

Page 21: ...nel 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 SU...

Page 22: ...ut 200 Power Supply Gas Pressures Flows and Quality Requirements Note 2 The tap water source does not need to be deionized but in water systems with extremely high mineral content a water softener is...

Page 23: ...IFICATIONS 2 12 XTTM 300 Torch Specifications A Torch Dimensions 2 25 57 15 mm 2 0 50 8 mm 2 39 60 81 mm 1 49 37 8 mm 19 00 482 68 mm 15 50 393 78 mm 2 63 66 8 mm 1 57 39 96 mm 3 98 101 1 mm 6 30 160...

Page 24: ...istributor Shield Gas Distributor Shield Cap D Parts In Place PIP The torch is designed for use with a power supply which senses coolant return flow to confirm that torch parts are in place If coolant...

Page 25: ...ltage Vpeak 500V Arc Striking Voltage 10kV Current Up to 200 Amps DC Straight Polarity Plasma Gases Compressed Air Oxygen Nitrogen H35 Shield Gases Compressed Air Oxygen Nitrogen Water Marking Gas Arg...

Page 26: ...Manual No 0 5133 Ultra Cut 200 2 10 SPECIFICATIONS This Page Intentionally Blank...

Page 27: ...up to 30 deg C Using wires of lower temperature rating or different insulation type may require larger wire size Derate for higher ambient temperature Wire sizes are suggestions only Always refer to...

Page 28: ...76 F 60 C Coolant Capabilities For mixing with D I CoolTM 7 3583 Primary power Work CNC Remote Arc Starter Art A 09124_AC Torch Coolant Supply Coolant Return Control Cable Pilot Return Coolant Supply...

Page 29: ...Lead Power Supply to Arc Starter Control Cable Power Supply to Arc Starter Ground Cable Ground Cable Remote Arc Starter To Earth Ground O P W Fiber Optic Cable Power Supply to DMC 3000 Control Cable...

Page 30: ...sing lifting straps to lift the power supply Use a forklift crane or hoist to lift the unit off the shipping pallet as shown Keep the power supply steady and vertical Do not lift it any further than n...

Page 31: ...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 32: ...the voltage configuration board The input voltage configuration is shown at the top of the board 2 If necessary disconnect the jumper at the top right corner of the board remove the board and re insta...

Page 33: ...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 F1 through the last opening in the co...

Page 34: ...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 T...

Page 35: ...ually on the cutting table is connected with 1 0 AWG European 50 mm2 or larger wire to a good earth ground measuring leass than 3 ohms an ideal ground measures 1 ohm or less Refer to paragraph C Creat...

Page 36: ...perienced 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 rod NOTE It is recommended that the Pl...

Page 37: ...h 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 salt to the soil by soaking it in salt...

Page 38: ...ads 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 Coolant Connections RETURN...

Page 39: ...e Arc Starter and DMC 3000 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 SUPPL...

Page 40: ...Supply labelled GCM DCM RETURN SUPPLY Art A 09134 To TSC 3000 Fiber Optic To DMC 3000 CAUTION Avoid kinking twisting or bunching the fiber optic cable The cable can be damaged by being forced into tig...

Page 41: ...nut on the through hole protector so both nut faces are tight against the sheet metal inside and out 5 Plug the Fiber Optic Cable into the PCB as shown below Make sure the locking tabs are engaged Th...

Page 42: ...tting SW 1 3 Pilot Delay 2 ON 3 OFF 4 OFF 0 1 Seconds SW 1 4 Pilot Delay 2 OFF 3 ON 4 OFF 0 2 Seconds 2 ON 3 ON 4 OFF 0 4 Seconds 2 OFF 3 OFF 4 ON 0 8 Seconds 2 ON 3 OFF 4 ON 1 0 Seconds 2 OFF 3 ON 4...

Page 43: ...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 44: ...to height controls etc 3 13 DMC 3000 Gas Manifold Control Installation The DMC 3000 Gas Control must be installed in a suitable location where it is easily accessible to the system operator The unit m...

Page 45: ...5 00 in 127 0 mm 7 08 in 179 8 mm 12 18 in 309 4 mm 11 44 in 290 6 mm 30 in 7 62 mm DMC 3000 Top 13 60 in 345 6 mm DMC 3000 Pro le Art A 09138 Preparation 1 Remove the screws securing the Cover Panel...

Page 46: ...00 except the Fiber Optic cable which will be covered a little later Avoid turning any fittings already mounted in the unit by placing a wrench on it before tightening the hose fitting to it Art A 091...

Page 47: ...e 1 4 and the air fitting is 3 8 4 Connect the ground cable to rear of DMC 3000 shown in previous illustration 5 Connect Control cable from the Power Supply to J56 on the front of the DMC 3000 as show...

Page 48: ...the cables from the Arc Starter The Module includes feet which lift the bottom panel off the mounting surface There are ventilation holes on the bottom panel the space between the bottom panel and th...

Page 49: ...ws securing the Cover Panel to the Module Loosen or remove 2 screws Remove 2 Screws Art A 09144 2 Carefully remove the cover from the module noting the attached wire harness that connects to J4 Remove...

Page 50: ...er Avoid turning any fittings already mounted in the unit by placing a wrench on it before tightening the hose fitting to it Do not connect Fiber Optic cable until later Art A 09146 4 Connect hoses fr...

Page 51: ...Avoid kinking twisting or bunching the fiber optic cable The cable can be damaged by being forced into tight radius turns 2 Ensure that the cable is exposed beyond the through hole protector approxim...

Page 52: ...tector so both nut faces are tight against the sheet metal inside and out Art A 09149 5 Plug the Fiber Optic Cable into the PCB as shown below Make sure the locking tabs are engaged Fiber Optic Cable...

Page 53: ...Manual No 0 5133 3 27 INSTALLATION ULTRA CUT 200 Art A 09151 After...

Page 54: ...ching the fiber optic cable The cable can be damaged by being forced into tight radius turns 2 Ensure that the cable is exposed beyond the through hole protector approximately 1 and secure by hand tig...

Page 55: ...as shown below for the DMC 3000 Make sure the locking tabs are engaged Plug Fiber Optic cable to from DPC 3000 here Art A 09154 6 Plug the Fiber Optic Cable into the PCB as shown below for the DPC 30...

Page 56: ...cautions in the front of this manual to be sure that the location meets all safety requirements The TSC 3000 mounting brackets allow for mounting on or under a horizontal surface as well as left or ri...

Page 57: ...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 for these...

Page 58: ...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 Starter NOTE A ground wire connects...

Page 59: ...Starter to the mounting surface Art A 09626 Minimum 2 Input Connections 1 Refer to the illustrations Make the following input connections to the Arc Starter Coolant Supply and Return Hoses from power...

Page 60: ...LATION 3 34 Manual No 0 5133 ULTRA CUT 200 Coolant Return Red Coolant Supply Green Art A 09628 Green Red Art A 09629 Negative Cable from power supply Copper plate Negative Cable from Power Supply rear...

Page 61: ...Manual No 0 5133 3 35 INSTALLATION ULTRA CUT 200 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 62: ...he illustrations 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 L...

Page 63: ...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 64: ...Refer 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 to the port on the Remote...

Page 65: ...CUT 200 Connect Control Cable 1 Connect the Remote Arc Starter cable to the Remote Arc Starter receptacle Art A 04801 RETURN SUPPLY RETURN SUPPLY Power Supply Rear Panel COOLANT Remote Arc Starter In...

Page 66: ...eads End Cap stationary Pull approximately 18 0 5 m of leads through the End Cap 3 Remove and discard the protective end caps from the Mounting Tube 4 Install the O ring in the groove at the upper end...

Page 67: ...the excess wire in a serpentine shape and tuck inside cover Thread the plastic lead cover connector onto the matingTorch Head connector 8 Press the Torch Head Assembly upward to connect to the Mountin...

Page 68: ...from the cartridge the parts are not seated properly 4 Use the cartridge tool to hold the cartridge assembly while turning the shield cup or shield retainer for onto the cartridge assembly When this g...

Page 69: ...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 70: ...ct the wire lead from the height finder to the ohmic clip if using ohmic torch height sensing Ohmic Clip Art A 03393_AB NOTE Ohmic height sensing is not recommended with water shield Water on the plat...

Page 71: ...level is visible through the translucent coolant tank The amount of coolant required varies with torch leads length Cat Number and Mixture Mixture Protects To 7 3580 Extra CoolTM 25 75 10 F 12 C 7 358...

Page 72: ...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 this sequence may need to be done thre...

Page 73: ...ure sensors detect tempera tures above normal limits Let the unit cool before continuing operation GAS Indicator Normally ON when gas is flowing The indicator blinks when the gas control is not ready...

Page 74: ...after a few seconds disconnect power and check that each inverter is correctly configured for the input voltage and all 3 phases are present Check Status Indicator for any codes that can help Once it...

Page 75: ...1 Enter Initial default PASSWORD 00000 2 HOME Enter XT lead DPC to Torch only 4 current allowed Enter DFC 3000 lead length DMC to DPC Utility Screen 2 is for information only Displays Device and Cutc...

Page 76: ...nstalled in the torch Go to THC CNC settings for cutting 5 Select new standard process by material thickness amperage 1 or enter process using pop up number pad 2 5 PROCESS MONITOR Now you are ready t...

Page 77: ...ready to start cutting Displayed Amps Demand is the output current setting not the actual current As soon as Start is applied Process Monitor shows output voltage gas pressures status of Start OK to...

Page 78: ...ues if you change too far it may cause faults You may also change the values displayed on THC CNC Settings screen THC CNC settings on the TSC 3000 at this time are for information only They do not con...

Page 79: ...buttons If the custom process requires different setting speed arc voltage etc edit it here Editing the THC CNC SETTING is for reference only does not change the actual THC or CNC setting That must be...

Page 80: ...USB Flash drive Backing Up Custom Process 1 For the remotely mounted DSC 3000 insert the flash drive in the USB connector on the back If using the TSC 3000 mounted in the plasma supply front panel th...

Page 81: ...older on a USB flash drive and plug it into the USB port on the TDC 3000 1 For the remotely mounted DSC 3000 insert the flash drive in the USB connector on the back If using the TSC 3000 mounted in th...

Page 82: ...sses saved Art A 09236 2 Use Windows Rename to change the file name to whatever you want Do not change the file extension cus or the file number in the brackets Suggest not making the name too long as...

Page 83: ...0 to Enabled 2 Turn on 3 phase power at the main disconnect Plasma Enable on TSC 3000 on Turn on the power supply ON Off switch on the front panel a The AC indicator on the front panel will come on an...

Page 84: ...cooling system The Gas indicator on the front panel blinks until correct coolant flow is detected Normally only a few seconds See step 2 d for full details 7 The next screen following Torch Consumabl...

Page 85: ...ly saving time 11 Use Plasma Disable a You may use the Plasma Disable when removing the torch cartridge to change or inspect consumables Plasma disable stops coolant pump shuts off all gas solenoids r...

Page 86: ...igher 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 minimiz...

Page 87: ...N2 Shield Nitrogen 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 i...

Page 88: ...tion Failure Pilot did not start within 15 seconds Ensure process loaded agrees with torch parts installed Torch consumable parts worn Defective Arc Starter Defective chopper 100 300A unit Defective 2...

Page 89: ...below process setting Measure current of each inverter only one low likely defective inverter All low likely defective PCB5 CCM 3 1 Gas Control Communication fault Cannot establish Communication with...

Page 90: ...S Acknowledge fault Message sent over CANBUS Fiber optic was not acknowledged as received by DMC CCM to DMC Fiber optic cable not properly connected dirty or defective DMC power supply or Control PCB...

Page 91: ...upply fault such as 1 3 in the DMC could prevent communicating with the DPM so the DPC would flash one it s group 2 codes You have to consider the codes in all the modules CCM DMC DPC before determini...

Page 92: ...for dirty or defective fiber optic to DPC See DPC status code 4 5 Reserved No information available Contact customer service 4 6 Reserved No information available Contact customer service 5 1 Sol 1 H3...

Page 93: ...defective pressure sensor PS2 4 1 Plasma High V5 shorted Check for shorted wire harness Replace valve 4 2 Plasma Low V4 shorted Check for shorted wire harness Replace valve 4 3 Pilot V3 shorted Check...

Page 94: ...ly pressure low Raise plasma inlet pressure check for DMC valve not open restriction in gas supply hoses 8 3 Outlet pressure too low Valve full open but pressure still too low Leak in plasma hose to t...

Page 95: ...ths 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 Periodic c...

Page 96: ...in the In Line FilterAssembly 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...

Page 97: ...nspection Reconnect 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 pu...

Page 98: ...Manual No 0 5133 Ultra Cut 200 5 4 MAINTENANCE ULTRA CUT 200 5 06 Remote Arc Starter Spark Gap Adjustment Art A 04857 0 063 0 002 1 6 0 05 mm...

Page 99: ...em Replacement Complete Unit Component Catalog Number Ultra Cut 200 Power Supply 208 230V 3 9119 1 Ultra Cut 200 Power Supply 460V 3 9119 2 Ultra Cut 200 Power Supply 400V 3 9119 3 Ultra Cut 200 Power...

Page 100: ...hield Shield Gas Negative Pilot Return Control Cable 100 30 5 m Maximum Length Shield H Q R U S A B C D E P K L O I J G 175 53 3 m Maximum Length Preflow Fiber Optic L Water Shield T F 125 38 1 m Maxi...

Page 101: ...egative Lead Power Supply to Arc Starter Control Cable Power Supply to Arc Starter Ground Cable Ground Cable Remote Arc Starter To Earth Ground O P W Fiber Optic Cable Power Supply to DMC 3000 Control...

Page 102: ...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 Negative Cable...

Page 103: ...2 m 9 4942 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...

Page 104: ...15 2 m See Note 2 4 3090 H L Q R S T U Auto Gas Lead Set 75 22 9 m See Note 2 4 3091 H L Q R S T U Auto Gas Lead Set 100 30 5 m See Note 2 4 3092 H L Q R S T U Auto Gas Lead Set 125 38 1 m See Note 2...

Page 105: ...7 6 m 9 4909 K Control Cable Power Supply to Gas Control Module 35 10 6 m 9 9332 K Control Cable Power Supply to Gas Control Module 50 15 2 m 9 4910 K Control Cable Power Supply to Gas Control Module...

Page 106: ...re FlowHose 15 4 5 m 9 6957 R Pilot Gas Pre Flow Hose 25 7 6 m 9 6959 R Pilot Gas Pre FlowHose 35 10 6 m 9 6961 R Pilot Gas Pre Flow Hose 50 15 2 m 9 6963 R Pilot Gas Pre Flow Hose 75 22 9 m 9 6964 R...

Page 107: ...se 125 38 1 m 9 7077 U Marking Gas Hose 150 45 7 m 9 7078 U Marking Gas Hose 175 53 3 m 9 7079 V Cable Remote TSC to CCM 10 3 05 m 9 9230 V Cable Remote TSC to CCM 15 4 5 m 9 9231 V Cable Remote TSC t...

Page 108: ...Description Catalog 1 1 Power Supply Front Panel N A 2 1 Power Supply Rear Panel N A 3 1 Power Supply Top Panel 9 0445B 9 0445G 4 1 Power Supply Right Side 9 0442B 9 0442G 5 1 Power Supply Left Side 9...

Page 109: ...ly Parts List ULTRA CUT 200 6 06 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 NOTE Heat Exchanger Fan is the sa...

Page 110: ...UT 200 6 07 Power 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...

Page 111: ...Ultra Cut 200 6 13 Power Supply Parts List ULTRA CUT 200 6 08 Power Supply Replacement Parts Right Side Item Qty Description Ref Des Catalog 1 Chopper Module 9 9389 1 Sensor HCT1 9 9342 Chopper Module...

Page 112: ...t 200 6 14 Power Supply Parts List ULTRA CUT 200 6 09 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...

Page 113: ...ts List ULTRA CUT 200 6 10 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 Disp...

Page 114: ...Supply Parts List ULTRA CUT 200 6 11 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 C...

Page 115: ...1 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...

Page 116: ...A CUT 200 6 13 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 D...

Page 117: ...lacement 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 9 9485D Not Shown 2 Inverter Cooling Fan 9 93...

Page 118: ...ual No 0 5133 Ultra Cut 200 6 20 Power Supply Parts List ULTRA CUT 200 6 15 Power Supply Replacement Parts Right Side Item Qty Description Ref Des Catalog 30 1 Sensor Thermistor TH1 9 9361 30 Art A 04...

Page 119: ...Power Supply Parts List ULTRA CUT 200 6 16 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 B...

Page 120: ...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 assembly 27 1 Pump part...

Page 121: ...200 6 18 DFC 3000 Automated Gas Control System Replacement Componants Item Qty Description Catalog 1 1 Assy DMC 3000 Demo 9 9491D 2 1 Assy DPC 3000 Demo 9 9443D 3 1 Assy TSC 3000 Fixed Mounting Demo N...

Page 122: ...0 6 19 DMC 3000 Gas Control Module Replacement Parts Item Qty Description Catalog 1 1 DMC 3000 assembly 9 9491D 2 1 Solenoid 9 8264 3 1 Manifold subassembly includes 15 or item 2 9 7546 4 1 SMPS PCB 9...

Page 123: ...y DPC 3000 Demo 9 9443D 2 1 Flow Sensor 9 7659 3 1 DPC PCB 9 8262 4 1 SMPS PCB 9 8263 5 1 Shield Gas P Valve 9 8267 6 1 Sensor Pressure 1 8mnpt six total 9 8269 7 1 Water Shield P Valve 9 8265 8 1 Sol...

Page 124: ...and Internal Replacement Parts Item Qty Description Catalog 1 1 Assy TSC 3000 Remote Demo 9 9490D 1 1 Assy TSC 3000 Internal Demo 9 944 2 1 Touch Panel Computer 9 7543 3 1 Switch Rocker SPST 9 1042 4...

Page 125: ...ption Catalog 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 Encl...

Page 126: ...000 Replacement Parts Item Qty Description Catalog 1 1 Retainer ABS Wall 9 4964 2 1 Outer Torch Lead Ground Assembly 9 4955 3 1 Bracket Bulkhead Holder 9 4963 4 1 Cover Arc Starter 9 4962 5 1 Strain R...

Page 127: ...arts List ULTRA CUT 200 6 24 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 Ha...

Page 128: ...Manual No 0 5133 Ultra Cut 200 6 30 Power Supply Parts List ULTRA CUT 200 Intentionally Blank...

Page 129: ...e Shield 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 ba...

Page 130: ...g O Ring Cat No 9 3028 Art A 07087_AD 300 Amp and Less Snap Ring Cartridge Assembly Cartridge Retaining Ring Cat No 9 9489 Art A 04066_AC O Rings Cat No 9 3027 Cat No 9 3026 Cat No 9 3025 Torch Head C...

Page 131: ...ridge Handle all parts carefully to avoid damage which may affect torch performance 1 Install the consumables as follows Cartridge Covers Upper O Ring on Torch Tip Shield Cap Protrudes 0 063 0 083 1 6...

Page 132: ...on the 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 08300_AB 0 063 0 083 1 6 2 1 mm Protrusion Installing A...

Page 133: ...idge and Consumables Re assemble Torch Still leaks The parts probably are worn out See chart for approximate life expectancy The torch may be damaged See page to determine if head damage has occurred...

Page 134: ...TORCH INFORMATION 7 6 Manual 0 5056 Ultra Cut 200 ULTRA CUT 200 This page is blank intentionally...

Page 135: ...RIAL PARK 2 WEST LEBANON NH 03784 603 298 5711 Tuesday November 01 2005 14 47 17 of Information Proprietary to THERMAL DYNAMICS CORPORATION TITLE of TITLE 8X290 NEG HF to Torch 8X291 DAT 9 21 04 RAS 1...

Page 136: ...APPENDIX A 2 Manual 0 5133 ULTRA CUT 200 APPENDIX 2 DMC 3000 PCB Layout J1 J9 TP6 J5 J6 SW2 J8 TP5 J2 TP3 TP2 TP4 J3 J4 SW1 TP7 TP1 Art A 09188_AB LED D1 D 17 LED D_E1 D_E15 D21 D22...

Page 137: ...al 0 5133 A 3 APPENDIX ULTRA CUT 200 APPENDIX 3 DPC 3000 PCB Layout TP6 J5 J6 SW2 TP5 TP3 TP2 TP4 SW1 TP8 TP1 Art A 09189_AB J1 J2 J3 J4 J9 J8 TP7 TP9 TP10 TP11 J10 D7 D12 D11 D10 D5 D4 D3 D2 D1 D9 D8...

Page 138: ...APPENDIX A 4 Manual 0 5133 ULTRA CUT 200 APPENDIX 4 TSC 3000 PCB Layout TP4 TP1 TP3 J1 J2 J3 TP2 J4 J5 Art A 09190_AB D1 D11 D13 D14 D15...

Page 139: ...ULTRA CUT 200 APPENDIX 5 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 140: ...Layout TP11 TP2 TP1 TP3 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...

Page 141: ...a 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 Relay Contacts NO TB2 9...

Page 142: ...unctionsareonlyavailableonTB1 2 2 SW6 on CCM I O PCB selects OK to Move for isolated contact closure or DC Volts 15 18V at 100ma When set for contacts OK to Move circuit is rated for 120 VAC 28 VDC 1A...

Page 143: ...rating 10 ma 20VDC Delays pilot ignition gas preflow continues Used for synchronizing starts when multiple plasma supplies are used on same cutting table User supplies circuit to keep Hold Start inpu...

Page 144: ...Logic 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...

Page 145: ...NC 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...

Page 146: ...manual KEY PLUG PLASMA ENABLE TSC 3000 J54 1 2 3 4 5 6 7 8 9 10 11 12 13 14 REMOTE TSC to CCM CABLE V OR W W BL J61 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 BK R W GN OR Data Data The multicolor wires...

Page 147: ...CCM has a line termination switch SW14 whose default position is ON For CCMs that are not at the end of the line like CCM 1 2 below switch off SW14 RS 485 with multiple CCMs 120 120 Signal GND also r...

Page 148: ...TER PCB 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_S...

Page 149: ...687 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 S...

Page 150: ...CN14 CN14 1 2 TB4 TB4 TB2 TB2 CN2 CN2 1 2 CN12 CN12 1 2 3 RY1 RY1 MC1 MC1 RY10 RY10 TP9 TP9 PUMP MOT1 PUMP MOT1 TP15 TP15 1 2 3 T1 T1 460 220 0 13 0 100 0 200 0 110 0 120 0_ 24 0__ 24_ 0___ 120 0___...

Page 151: ...al GND Isolated from Plasma Supply INTERNAL TERMINAL STRIP TB3 KEY PLUG TB1 TB2 C9 sht 1 RS 485 2 wire uses Tx Tx only used for TSC 3000 Signal Basic ID Used to identify GCM 1000 present RIBBON CABLE...

Page 152: ...CB FILTER PCB 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 Start...

Page 153: ...CB 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_SE PILOT...

Page 154: ...8 C P8 FAN1 FAN1 TB5 TB5 TP15 TP15 D15 PSR D15 PSR CN8 CN8 1 2 3 4 CN12 CN12 1 2 C P3 C P3 D9 GAS_ON D9 GAS_ON D21 CNC_E STOP D21 CNC_E STOP LSW1 1 SW_LIQUID_LEVEL_NC LSW1 1 SW_LIQUID_LEVEL_NC CN4 CN4...

Page 155: ...ated from Plasma Supply INTERNAL TERMINAL STRIP TB3 KEY PLUG TB1 TB2 C9 sht 1 RS 485 2 wire uses Tx Tx only used for TSC 3000 Signal Basic ID Used to identify GCM 1000 present RIBBON CABLE TEST SOCKET...

Page 156: ...LE 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 15 P...

Page 157: ...PER 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 OVERTEMP PILOT ENABLE PILOT DEMAND C1 Capacitor 0 1 uf 1250 VDC D2 Sht 2 C2...

Page 158: ...PUMP MOT1 CN14 CN14 1 2 TP18 TP18 CN6 CN6 1 2 3 4 CN5 CN5 1 2 3 4 5 6 MC2 MC2 1 2 RY10 RY10 CN9 CN9 1 2 3 D23 CNC_START D23 CNC_START TP10 TP10 1 2 C P6 C P6 C P2 C P2 CN3 CN3 1 2 3 R8 1K 30W R8 1K 30...

Page 159: ...d from Plasma Supply INTERNAL TERMINAL STRIP TB3 KEY PLUG TB1 TB2 C9 sht 1 RS 485 2 wire uses Tx Tx only used for TSC 3000 Signal Basic ID Used to identify GCM 1000 present RIBBON CABLE TEST SOCKET RS...

Page 160: ...CB INTERFACE PCB FILTER 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 REDUNDA...

Page 161: ...T 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 OVERTEMP PILOT EN...

Page 162: ...3 T1 T1 460 220 0 13 0 100 0 200 0 110 0 120 0_ 24 0__ 24_ 0___ 120 0___ TB3 TB3 CN7 CN7 1 2 3 4 1 2 3 TP7 TP7 RY11 RY11 TP8 TP8 C P8 C P8 FAN1 FAN1 TB5 TB5 TP15 TP15 D15 PSR D15 PSR CN8 CN8 1 2 3 4...

Page 163: ...ated from Plasma Supply INTERNAL TERMINAL STRIP TB3 KEY PLUG TB1 TB2 C9 sht 1 RS 485 2 wire uses Tx Tx only used for TSC 3000 Signal Basic ID Used to identify GCM 1000 present RIBBON CABLE TEST SOCKET...

Page 164: ...RS232 Configured for RS485 TPC 660E TOUCH SCREEN PANEL J63 HARNESS NOT INSTALLED for future use with Height Control GROUNDING SCREW TSC 3000 19X2200 HMI CONTROL COMMUNICATIONS 4W 2W SW14 NOTE DMC sole...

Page 165: ...SE OPTION SWITCHES LEDs Listed Below DPC FiberOptic Port DPC3000 Control PCB LEDs D1 PLASMA_PWM D2 PLASMA_VENT_PWM D3 SHIELD_H20_PWM D4 SHIELD_GAS_PWM D5 MARKING_PWM D6 PLASMA_PILOT_PWM D7 5VDC D8 DPC...

Page 166: ...orrected chart on pg 4 21 to show all information in group 6 per ECOB1598 Apr 16 2010 AE Updated the appendix with serial communication information Appdx 8 per ECOB1706 Aug 26 2010 AF Updated sections...

Page 167: ...This Page Intentionally Blank...

Page 168: ...0 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 Fax 61 3 9474 7391 Int...

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