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Congratulations on your new Thermal Dynamics product. We are

proud to have you as our customer and will strive to provide you

with the best service and reliability in the industry. This product is

backed by our extensive warranty and world-wide service net-

work. To locate your nearest distributor or service agency call 1-

800-426-1888, or visit us on the web

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This Operating Manual has been designed to instruct you on the

correct use and operation of your Thermal Dynamics product.

Your satisfaction with this product and its safe operation is our

ultimate concern. Therefore please take the time to read the en-

tire manual, especially the Safety Precautions. They will help you

to avoid potential hazards that may exist when working with this

product.

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The Brand of Choice for Contractors and Fabricators Worldwide.

Thermal Dynamics is a Global Brand of manual and automation

Plasma Cutting Products for Thermadyne Industries Inc.

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Содержание AUTO-CUT 30 O2

Страница 1: ...600 V 400 V 460 V 208 230 V 400 300 AMP 3 PHASE V CE Art A 08584 AUTO CUT PLASMA CUTTING SYSTEM Operating Manual Rev AL Issue Date July 6 2012 Manual No 0 4818 Operating Features 30O2...

Страница 2: ...y w i l l h e l p y o u t o a v o i d p o t e n t i a l h a z a r d s t h a t m a y e x i s t w h e n w o r k i n g w i t h t h i s p r o d u c t YOU ARE IN GOOD COMPANY The Brand of Choice for Contr...

Страница 3: ...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 disclaims any liability to any party...

Страница 4: ...Thispageintentionallyblank...

Страница 5: ...plications 2 5 2 12 XTTM 301Torch Specifications 2 6 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 Suppl...

Страница 6: ...ght Side 6 6 6 06 Power Supply Replacement Parts Right Side 6 7 6 07 Power Supply Replacement Parts Front Panel 6 8 6 08 Power Supply Replacement Parts Right Side 6 9 6 09 Power Supply Replacement Par...

Страница 7: ...7 APPENDIX 7 CNC Control Module PCB Connections A 9 CNC functions A 10 CNC Input Output Descriptions A 11 Simplified CNC Circuit A 12 APPENDIX 8 Schematic 230 460V Unit A 14 APPENDIX 8 Schematic 230 4...

Страница 8: ...blank...

Страница 9: ...Mercury 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 ar...

Страница 10: ...ter handling Wash hands after handling California Health Safety 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...

Страница 11: ...des risques et des dangers de sant Eloignez toute fum e et gaz de votre zone de respiration Gardez votre t te hors de la plume de fum e provenant du chalumeau Utilisez un appareil respiratoire alimen...

Страница 12: ...votre peau si vous ne vous prot gez pas correctement Pour prot ger vos yeux portez toujours un casque ou un cran de soudeur Portez toujours des lunettes de s curit munies de parois lat rales ou des l...

Страница 13: ...adway New York NY 10018 6 Norme ANSI Z49 2 PR VENTION DES INCENDIES LORS DE L EMPLOI DE PROC D S DE COUPE ET DE SOUDAGE disponible aupr s de l American National Standards Institute 1430 Broadway New Y...

Страница 14: ...tandards and technical requirements Among them are CSA Canadian Standards Association standard C22 2 number 60 for Arc welding equipment UL Underwriters Laboratory rating 94VO flammability testing for...

Страница 15: ...ection 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 negligenc...

Страница 16: ...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...

Страница 17: ...ting 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 HF pulse to...

Страница 18: ...400 Incl CE 50 60 75 109 135 3 460 50 60 89 112 150 2 Line Voltages with Suggested Circuit Protection and Wire Sizes Based on National Electric Code and Canadian Electrical Code Auto Cut 30O2 Power S...

Страница 19: ...Manual No 0 4818 Auto Cut 3002 2 3 SPECIFICATIONS 2 08 Power Supply Dimensions Art A 06939 33 inch 840 mm 27 inch 680 mm 37 75 inch 960 mm 52 25 inch 1030 mm 27 5 inch 700 mm 535 lb 243 kg...

Страница 20: ...Access Wiring 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...

Страница 21: ...rements Note 2 The tap water source does not need to be deionized but in water systems with high mineral content a water softener is recommended Tap water with high levels of particulate matter must b...

Страница 22: ...IFICATIONS 2 12 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 63 66 8 mm 1 57 39 96 mm 3 98 101 1 mm 6 30 160...

Страница 23: ...dge Art A 08304_AC This Art Is For Reference ONLY Cartridge Electrode Shield Shield Gas Distributor Tip Plasma Gas Distributor Shield Retainer Art A 07917_AC This Art Is For Reference ONLY D Parts In...

Страница 24: ...Manual No 0 4818 Auto Cut 3002 2 8 SPECIFICATIONS This Page Intentionally Blank...

Страница 25: ...ype of wire being used and method of installation Gas Supply The customer must supply all gases and pressure regulators Gases must be of high quality Pressure regulators must be double stage and insta...

Страница 26: ...e Coolant Supply w Negative Coolant Return Control Cable Fiber Optic Cable Control Cable Gas Control Module 300 A Power Supply Torch Valve Assembly Shield A B C D E P I J K L H Q R S Shield Plasma Gas...

Страница 27: ...Power Supply to Arc Starter Negative 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 Fiber Optic Cable Power...

Страница 28: ...all four lifting eyes when using 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 no...

Страница 29: ...st 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 th...

Страница 30: ...ere is a voltage configuration board on each inverter module Power supplies with more than one inverter module require that all voltage configuration boards must be configured identically 2 If necessa...

Страница 31: ...round 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 in...

Страница 32: ...try 1 0 Work Cable Remote Arc Starter RAS 1000 1 0 Ground Cable F1 Star Ground on Cutting Table Star Ground on Cutting Table 1 0 Ground Cable 200Amp or less Ultra Cut or Auto Cut O2 Note The gas contr...

Страница 33: ...1 0 Ground Cable Customer Supplied 4 AWG Ground F 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 C...

Страница 34: ...es 1 0 earth 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...

Страница 35: ...test uses live voltage NEUTRAL Earth Grounded HOT On 115V AC Line 3VAC 3 ohms 1VAC 1 ohm On 230V AC Line 1 5VAC 3 ohms 0 5VAC 1 ohm Ground Rod with other connections removed 100W Incandescent light bu...

Страница 36: ...support panel 2 Refer to the illustration Connect the leads as shown Tighten securely Do not overtighten CAUTION The clear connections cover must remain in place NOTE Negative Lead and Torch Lead are...

Страница 37: ...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...

Страница 38: ...ne 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 at the CNC end of the cable Do not ground to the P...

Страница 39: ...able connector through the appropriate opening Slide the strain relief securing nut onto the cable Make a loop of the cable carefully press the cable connector into the appropriate receptacle on the i...

Страница 40: ...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 SW...

Страница 41: ...W 6 OK to Move Contact closure rated at 120VAC 1A Max 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 Po...

Страница 42: ...quires 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 120...

Страница 43: ...cceptable to locate the control cable in the same track as the cables from the Arc Starter The Module includes feet which lift the bottom panel off the mounting surface There are ventilation holes on...

Страница 44: ...INSTALLATION Preparation 1 Remove the screws securing the Cover Panel to the Module 2 Remove the Cover from the Module Remove the ground wire if needed Art A 06882 Gas Control Module Cover Do not remo...

Страница 45: ...tion panel 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...

Страница 46: ...e fiber optic cable connector 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 pro...

Страница 47: ...5 Connect all gas water inputs to the rear panel of the module CAUTION When cutting with O2 oxygen plasma air must be connected to the Module 6 Connect the appropriate control cables to terminals mark...

Страница 48: ...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...

Страница 49: ...e cover to the Arc Starter Remove the upper screws securing the Cover Panel to the Arc Starter NOTE A wire grounds the cover to the Arc Starter base as shown below This wire must remain in place 2 Rem...

Страница 50: ...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...

Страница 51: ...No 0 4818 Auto Cut 3002 3 27 INSTALLATION 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...

Страница 52: ...t Return Cable from Power supply PILOT Return Cable from Power Supply rear panel NOTE The pilot return cable has a strain relief connector that must be installed in the rear panel of the remote arc st...

Страница 53: ...rations Make the following output connections to the Arc Starter NOTE For newer leads with only black wire it must be connected to the pilot return There are no inner shield wires Pilot Lead Connectio...

Страница 54: ...Red from Torch Coolant Supply Green to Torch Coolant Supply and Return Hoses from Torch Reinstall the Arc Starter Cover Ensure that the ground wire is not crimped between the cover and the base Art A...

Страница 55: ...ce Torch Leads Use a clamp to secure the Torch Lead Shield brass ring to the port on the RemoteArc Starter as shown Art A 04759 Coolant and Pilot Leads to Torch Valve Assembly Torch Leads Shield Shiel...

Страница 56: ...Manual No 0 4818 Auto Cut 3002 3 32 INSTALLATION Art A 04801 RETURN SUPPLY RETURN SUPPLY Power Supply Rear Panel COOLANT Remote Arc Starter Input Connection Panel Remote Arc Starter...

Страница 57: ...50 113 03 mm 261 Dia 6 63 mm Art A 08433 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 c...

Страница 58: ...ma Gas Inlet Preflow Gas Inlet Shield Gas Inlet Water Shield Inlet Art A 06926 Torch Valve Inlet Side CAUTION Hold all fittings stationary while attaching hoses or leaks can be created Side pressure c...

Страница 59: ...onnector Coolant Return Check Valve and Connector Plasma Lead Connector Pilot Lead Plasma Lead Art A 07324 Insulating Paper Insulating Paper 2 1 Positioning Tube O Ring O Ring Torch Leads End Cap Groo...

Страница 60: ...tors stationary turn the leads fittings with a wrench to secure the leads to the Torch Head Do not overtighten CAUTION The gas and coolant leads include compression fittings Do not use sealant on thes...

Страница 61: ...r E l e c t r o d e C a r t r i d g e Art A 08303 A B C 1 Assemble A 200 A only 2 Assemble B 3 Assemble B to C 4 Assemble A to B C assembly 4 Insert the stack of consumable parts into the cartridge E...

Страница 62: ...O Ring Torch Head Art A 08300_AB 0 063 0 083 1 6 2 1 mm Protrusion CAUTION Do not force the cartridge if it will not fully tighten Remove the cartridge and gently clean parts and apply oxygen compati...

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

Страница 64: ...already done 3 Assemble B to C 4 Assemble A to B C CAUTION In C there is an insulating sleeve that must be in place on the Cartrudge before the Shield Cup is attached 7 Place the ohmic clip over the s...

Страница 65: ...al Dynamics coolant The coolant 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 Ex...

Страница 66: ...ystem ON for the first time a Place the ON OFF Switch to ON b After about 30 seconds the system may shut down if the leads are not full of coolant c Place the ON OFF switch to OFF d After 10 seconds p...

Страница 67: ...fill the reservoir and re install the filler cap 4 Purge coolant from the torch before firing the torch Ensure there are no leaks before use If leaks are evident consult the coolant leak trouble shoo...

Страница 68: ...Manual No 0 4818 Auto Cut 3002 3 44 INSTALLATION Intentionally Blank...

Страница 69: ...temperatures above normal limits Let the unit cool before continuing operation GAS Indicator The indicator blinks when the gas control is not ready Causes for not being ready are when purging Mode sw...

Страница 70: ...t 5 seconds POWER ON OFF O I OFF O Art A 04812 3 Check the AC indicator If indicator is ON system is ready to operate pending fault checks by internal cir cuitry If indicator does not light after a fe...

Страница 71: ...icators used to set gas pressures and flows ENABLE STATUS DISABLE PLASMA POWER SUPPLY SHIELD FLOW GAS PRESSURE MODE GAS GCM 2000 PLASMA PREFLOW Art A 06889 FLOW GAS PRESSURE AMPS PLASMA POWER SUPPLY E...

Страница 72: ...operator to adjust pressure Gas automatically shuts off after 2 minutes if left in the SET PREFLOW position In the SET PLASMA SHIELD position selected cutting gases Plasma Shield flow to the torch to...

Страница 73: ...tch is changed it initiates a purge of the new gas GAS PREFLOW H2O MIST PLASMA SHIELD PRESSURE PLASMA POWERSUPPL Y GAS FLOW ENABLE DISABLE MODE RUN SET PREFLOW SET PLASMA SHIELD TEST 9 9 Art A 06891_A...

Страница 74: ...ssure Gauge Used to set preflow gas pressure MODE switch must be in SET PREFLOW position 6 PLASMA and SHIELD Control Knobs Pressure Gauges and Flow Meters Used to set plasma and shield gas pressures a...

Страница 75: ...torch parts if necessary 4 Set the Gas Selection switch to the desired gas process 5 Apply AC power and set the Plasma Power Supply switch on the Gas Control Module to The Module performs purges of co...

Страница 76: ...only the pressure is specified set the Shield Gas switch to Pressure c Set the Shield Pressure using the Shield regulator knob and pressure gauge If required set the Shield flow using the Shield Flow...

Страница 77: ...ngle 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...

Страница 78: ...m of the plate Failure to follow this recommendation could result in poor cut quality and short consumable parts life Ohmic Height Sensing Ohmic Height Sensing is not recommended with water shield wat...

Страница 79: ...ith air shield A good clean welding grade nitrogen should be used B Shield Gases 1 Compressed Air Shield Air shield is normally used when operating with air or oxygen plasma Improves cut quality on so...

Страница 80: ...p 4 After a 1 2 second delay the indicator blinks 3 times the condition code is 4 3 indicating that the coolant is overheating After a 4 second delay the indicator repeats the sequence until the condi...

Страница 81: ...oo high shorted torch body consumable parts worn out 2 1 Missing Phase Blown fuse Broken or loose connection on power cable Inverter s not configured correctly for input voltage Poor power quality bro...

Страница 82: ...compatibility 3 7 Gas Control returns wrong command sequence Check firmware compatibility 3 8 CCM and Gas Control type Autocut Ultracut mismatch Install correct CCM or Gas Control for system 3 9 Gas C...

Страница 83: ...not locked into connector sharp bends in fiber fiber defective CANBUS hardware error CCM or Gas Control PCB 6 1 CCM Analog Voltage Error Replace CCM 6 2 CCM ADC or DAC error Replace CCM Torch coolant...

Страница 84: ...on 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 punctured...

Страница 85: ...Manual No 0 4818 Auto Cut 3002 4 17 OPERATION 4 08 Remote Arc Starter Spark Gap Adjustment Art A 04857 0 063 0 002 1 6 0 05 mm...

Страница 86: ...Intentionally Blank...

Страница 87: ...s 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 cle...

Страница 88: ...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 fittin...

Страница 89: ...230V 3 9115 1 Auto Cut 30O2 Power Supply 460V 3 9115 2 Auto Cut 30O2 Power Supply 400V 3 9115 3 Auto Cut 30O2 Power Supply 400V CE 3 9115 4 Auto Cut 30O2 Power Supply 600V CSA 3 9115 5 Gas Control Mod...

Страница 90: ...Optic Cable Control Cable Gas Control Module 300 A Power Supply Torch Valve Assembly Shield A B C D E P I J K L H Q R S Shield Plasma Gas Shield Gas Plasma Gas Shield Gas Preflow Gas Work Torch Positi...

Страница 91: ...4909 9 4900 9 9302 9 8312 30 9 1 m 4 3066 35 10 6 m 4 3050 9 9427 4 3078 4 3051 9 9332 9 9335 9 9303 50 15 2 m 4 3031 9 4800 9 4926 9 4934 4 3079 4 3038 9 4910 9 4901 9 9304 9 8313 75 22 9 m 4 3032 9...

Страница 92: ...c Starter Negative 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 Fiber Optic Cable Power Supply to Gas Con...

Страница 93: ...talog 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 0455B 4 1 Power Supply Right Side 9 0500G 9 0500B 5 1 Power Supply Left Side 9 0501G 9 0501B...

Страница 94: ...ual No 0 4818 Auto Cut 3002 6 6 Parts List 6 05 Power Supply Replacement Parts Right Side Item Qty Description Ref Des Catalog 1 1 Heat Exchanger Fan FAN1 FAN2 9 9338 2 1 Radiator 9 9339 1 2 Art A 082...

Страница 95: ...er 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 R...

Страница 96: ...0 4818 Auto Cut 3002 6 8 Parts List 6 07 Power Supply Replacement Parts Front Panel Item Qty Description Ref Des Catalog 7 1 Main Power Switch Circuit Protector CP1 9 9344 for 230 460 VAC units 7 Art...

Страница 97: ...l No 0 4818 Auto Cut 3002 6 9 Parts List 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 Art A 07064_AB...

Страница 98: ...aker 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 24VDC 1A CP8...

Страница 99: ...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...

Страница 100: ...o Cut 3002 6 12 Parts List 6 11 Power Supply Replacement Parts Item Qty Description Catalog 3 Inverter Module 208 230V 9 9360D 3 Inverter Module 400V CE and 400V Non CE 9 9482D 3 Inverter Module 600V...

Страница 101: ...Manual No 0 4818 Auto Cut 3002 6 13 Parts List 6 12 Power Supply Replacement Parts Right Side Item Qty Description Ref Des Catalog 30 1 Sensor Thermistor TH1 9 9361 30 Art A 04787...

Страница 102: ...arts List 6 13 Power Supply Replacement Parts Left Side 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...

Страница 103: ...Parts List 6 14 Power Supply Replacement Parts Left Side Item Qty Description Ref Des Catalog 1 1 PCBoard 230 460 and 400VAC PCB1 9 9362 1 1 PCBoard 600 VAC PCB1 9 9491 2 1 Magnetic Contactor MC1 MC3...

Страница 104: ...6 16 Parts List 6 15 Power Supply Replacement Parts Right Side Item Qty Description Ref Des Catalog 1 1 Relay PC Board PCB7 9 9366 2 1 24 VDC Power Supply DCS1 9 9493 3 1 Internal Control PC Board PC...

Страница 105: ...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 ValveAssembly 9 9380 4 1 Bypass Valve part of assembly Call 5 1 Motor MOT1 9 93...

Страница 106: ...18 Parts List 6 17 Command Control Module Type 2 Replacement Parts Item Qty Description Catalog 1 1 Assembly CCM Auto Cut 9 9418 2 1 Plate CCM Face 9 9419 3 1 Panel CCM Mount Call 4 1 Harness CCM I O...

Страница 107: ...Manual No 0 4818 Auto Cut 3002 6 19 Parts List This page is blank intentionally...

Страница 108: ...Mode Selection Switch Assembly 9 9406 5 2 Flowmeter 0 150 8 6801 Not shown Valve Assembly 9 9382 Tube 9 9383 Knob 9 9384 6 1 Switching PCBAssembly Current control 9 9481 7 1 Pressure Transducer 100 P...

Страница 109: ...A POWERSUPPL Y GAS FLOW ENABLE DISABLE GAS MODE RUN SET PREFLOW SET PLASMA SHIELD TEST 9 9 GCM 2000 AMPS Automated Plasma Cutting System Thermal Dynamics O2 AIR H35 N2 AIR AIR N2 H2O 15 5 5 COMM J57 J...

Страница 110: ...lve Assembly Replacement Parts Item Qty Description Catalog 1 1 Torch ValveAssembly 9 9436 2 1 Control Cable Harness 9 9479 3 1 Fuel B Fitting Call 4 1 Check Valve 9 7006 5 1 Fitting Call 6 1 Fitting...

Страница 111: ...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 TransformerAssembly Arc Starter 9 4959 6 1 Enclosure Arc Star...

Страница 112: ...nt Parts Item Qty Description Catalog 1 1 Retainer ABS Wall 9 4964 2 1 Outer Torch Lead GroundAssembly 9 4955 3 1 Bracket Bulkhead Holder 9 4963 4 1 Cover Arc Starter 9 4962 5 1 Strain Relief large 9...

Страница 113: ...Turn the Shield Cup to remove it from the Cartridge Assembly Assembled Cartridge Cartridge Tool Shield Cup Art A 04344_AB 2 Take the Cartridge tool off the back of the CartridgeAssembly Use the cartr...

Страница 114: ...and slide the locking ring downward for access to the O Ring under the locking ring O Ring Cat No 9 3029 Inner O Ring Cat No 9 3030 Location Under Locking Ring O Ring Cat No 9 3028 Art A 07087_AD 300...

Страница 115: ...7 03 Parts Wear Replace the Gas Distributor if it is charred or cracked Replace the Gas Distributor if the flange is damaged in any way Replace the tip and or electrode if they are worn Good Electrod...

Страница 116: ...d 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 Order C...

Страница 117: ...L DYNAMICS INDUSTRIAL 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...

Страница 118: ...SOL10 F11 0 125A SOL11 F12 0 125A SOL12 F13 0 125A SOL13 F14 0 250A SOL14 F15 0 250A SOL15 F16 0 125A SOL16 F17 0 125A SOL17 F18 1 6A 120 VAC to Solenoids F19 1A 120 VAC to Low Voltage Power Supply F...

Страница 119: ...OTHERWISE SPECIFIED 1 RESISTOR VALUES ARE EXPRESSED IN OHMS 1 4W 5 2 CAPACITOR VALUES ARE EXPRESSED IN MICROFARADS uF Chk App TITLE Last Modified Size SCHEMATIC 42X1224 Tuesday January 30 2007 1 1 Org...

Страница 120: ...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...

Страница 121: ...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 F19 F18 TP4 TP2 TP3 F20 J5 JP1 TP6 TP5 T...

Страница 122: ...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 C3...

Страница 123: ...ISOLATED 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...

Страница 124: ...Manual 0 4818 Auto Cut 3002 A 8 APPENDIX This page intentionally blank...

Страница 125: ...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 TB2...

Страница 126: ...onal functions are only available onTB1 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...

Страница 127: ...nal isolation module will have to be used It was not specifically designed to be used to remote a potentiometer but it could work if the pot high is connected to an accurate external 10 VDC whose comm...

Страница 128: ...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 1 3 SW11 100K 1 8 7 6...

Страница 129: ...Manual 0 4818 Auto Cut 3002 A 13 APPENDIX This page intentionally blank...

Страница 130: ...2 middle same as 1 D3 Sht 2 CN6 100A INVERTER MODULE 3 bottom same as 1 D3 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 IN...

Страница 131: ...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 CURR...

Страница 132: ...TOP_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_ 0___ 120 0___ TP10 TP10 1 2 C P3 C P3 1 2 CN10 CN10...

Страница 133: ...NH 03784 603 298 5711 300 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 RIB...

Страница 134: ...1 D3 Sht 2 CN6 100A INVERTER MODULE 3 bottom same as 1 D3 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_READY 9 PS_STA...

Страница 135: ...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_SE...

Страница 136: ...TOP_PS D2 E STOP_PS V GND SIG FL1 FLOW_TURBINE_PULSE V GND SIG FL1 FLOW_TURBINE_PULSE R B G T1 T1 400 200 0 13 0 100 0 200 0 110 0 120 0_ 24 0__ 24_ 0___ 120 0___ TP10 TP10 1 2 C P3 C P3 1 2 CN10 CN10...

Страница 137: ...H 03784 603 298 5711 300 Amp 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 CA...

Страница 138: ...MODULE 2 middle same as 1 D3 Sht 2 CN6 100A INVERTER MODULE 3 bottom same as 1 D3 Sht 2 CN32 CN32 1 2 3 4 LED3 INPUT NG LED3 INPUT NG N2 N2 TB2 TB2 P1 P1 TB1 TB1 S S MC3 C MC3 C 1 2 3 4 CN1 CN1 1 5 8...

Страница 139: ...Pilot B8 Sht 1 HCT2 Hall Current Sensor Work C9 Sht 1 L1 9 11 Toroid Core input common mode filter A2 B2 C2 Sht 1 L2 7 Toroid Core common mode filter B1 C1 Sht 1 L8 10 12 Toroid Core output common mo...

Страница 140: ...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 400 200 0 13 0 100 0 200 0 110 0 120 0_ 24 0__ 24_ 0___ 120 0___ TP10 TP10 1...

Страница 141: ...5711 300 Amp 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 E...

Страница 142: ...2 CN6 100A INVERTER MODULE 3 bottom same as 1 D3 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_READY 9 PS_START disable...

Страница 143: ...ILOT 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 P...

Страница 144: ...NC_PREFLOW 1 2 RY3 RY3 MC4 MC4 1 2 D26 HOLD_START D26 HOLD_START RY2 RELCOL_0 RY2 RELCOL_0 FAN2 FAN2 CN14 CN14 1 2 D12 STATUS CODE D12 STATUS CODE CN4 CN4 1 2 3 RY4 RY4 1 2 AC AC D3 AC AC D3 D23 CNC_S...

Страница 145: ...11 300 Amp 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 SOCKET E2...

Страница 146: ...July 24 2008 AF Per ECOB1007 update negative cable connection for the RAS section 3 Nov 11 2008 AG Updated section 3 per ECOB1163 to show new single shielded leads Also up dated some sheetmetal repair...

Страница 147: ...This Page Intentionally Blank...

Страница 148: ...g 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...

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