0-4748 ultra-cut 100 operator's manual

Art# A-08579

PLASMA CUTTING SYSTEM

100ULTRA-CUT™

Operating ManualRev. AQ Date: September 29, 2009 Manual # 0-4748Operating Features:

WE APPRECIATE YOUR BUSINESS!Congratulations on your new Thermal Dynamics product. We areproud to have you as our customer and will strive to provide youwith the best service and reliability in the industry. This product isbacked by our extensive warranty and world-wide service network.To locate your nearest distributor or service agency call 1-800-426-1888, or visit us on the web at www.thermal-dynamics.com.

This Operating Manual has been designed to instruct you on thecorrect use and operation of your Thermal Dynamics product.Your satisfaction with this product and its safe operation is ourultimate concern. Therefore please take the time to read the entiremanual, especially the Safety Precautions. They will help you toavoid potential hazards that may exist when working with thisproduct.

YOU ARE IN GOOD COMPANY!The Brand of Choice for Contractors and Fabricators Worldwide.

Thermal Dynamics is a Global Brand of manual and automationPlasma Cutting Products for Thermadyne Industries Inc.

We distinguish ourselves from our competition through market-leading, dependable products that have stood the test of time.We pride ourselves on technical innovation, competitive prices,excellent delivery, superior customer service and technicalsupport, together with excellence in sales and marketing expertise.

Above all, we are committed to developing technologicallyadvanced products to achieve a safer working environment withinthe welding industry.

! WARNINGS

Read and understand this entire Manual and your employer’s safety practices beforeinstalling, operating, or servicing the equipment.

While the information contained in this Manual represents the Manufacturer's best judge-ment, the Manufacturer assumes no liability for its use.

Plasma Cutting Power Supply, Ultra-Cut® 100

Operting Manual No. 0-4748Published by:Thermadyne Corporation82 Benning StreetWest Lebanon, New Hampshire, USA 03784(603) 298-5711

www.thermal-dynamics.com

© Copyright 2005, 2006, 2007, 2008, 2009 byThermadyne 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 disclaims any liability toany party for any loss or damage caused by any error or omissionin this Manual, whether such error results from negligence, acci-dent, or any other cause.

Printed in the United States of America

Licensed under U. S. Patent No. 5,070,227

Publication Date: July 1, 2005Revision Date: September 29, 2009Record the following information for Warranty purposes:

Where Purchased: ___________________________________

Purchase Date:______________________________________

Power Supply Serial #:_______________________________

Torch Serial #:_____________________________________

Intentionally blank

TABLE OF CONTENTS

SECTION 1:GENERAL INFORMATION ................................................................................................ 1-1

1.01 Notes, Cautions and Warnings ...................................................................... 1-11.02 Important Safety Precautions ....................................................................... 1-11.03 Publications .................................................................................................. 1-21.04 Note, Attention et Avertissement .................................................................. 1-31.05 Precautions De Securite Importantes ........................................................... 1-31.06 Documents De Reference ............................................................................. 1-51.07 Declaration of Conformity ............................................................................. 1-61.08 Statement of Warranty .................................................................................. 1-7

SECTION 2: SPECIFICATIONS ................................................................................................. 2-1

2.01 General Description Of The System.............................................................. 2-12.02 Plasma Power Supply ................................................................................... 2-12.03 Remote Arc Starter ...................................................................................... 2-12.04 Gas Control Module ...................................................................................... 2-12.05 Precision Plasma Cutting Torch .................................................................... 2-12.06 Specifications & Electrical Requirements ..................................................... 2-22.07 System Component Layout .......................................................................... 2-22.08 Power Supply Dimensions ............................................................................ 2-32.09 Power Supply Rear Panel Features ............................................................... 2-42.10 Gas Requirements ........................................................................................ 2-52.11 Gas Applications .......................................................................................... 2-52.12 XTTM-300 Torch Specifications .................................................................... 2-6

SECTION 3: INSTALLATION ...................................................................................................... 3-1

3.01 Installation Requirements ............................................................................. 3-13.02 System Layout ............................................................................................. 3-23.03 Cables & Leads Identification ....................................................................... 3-33.04 Lift the Power Supply .................................................................................... 3-43.05 Remove the Connections Cover ................................................................... 3-53.06 Ground Connections .................................................................................... 3-103.07 Connect Work Cable and Pilot and Negative Leads......................................3-123.08 Connect Coolant Leads ................................................................................3-133.09 Connect Control Cables for CNC, Remote Arc Starter, and GCM ................. 3-143.10 Connect Fiber Optic Cable (Type 2 internal control module) ........................ 3-153.11 Set Switches on the Command - Control Module (Type 2 Module) ............... 3-163.12 Height Control Connections ......................................................................... 3-183.13 Gas Control Module Installation ................................................................... 3-193.14 Fiber Optic Cable Installation .......................................................................3-213.15 Gas Control Module: Control, Input, and Output Connections.......................3-233.16 Install Remote Arc Starter ........................................................................... 3-243.17 Original & XTL Torch Valve Installation......................................................... 3-333.18 Connecting Torch .........................................................................................3-353.19 Install Consumable Torch Parts ....................................................................3-373.20 Complete the Installation .............................................................................3-41

TABLE OF CONTENTS (continued)

SECTION 4: OPERATION .......................................................................................................... 4-1

4.01 Power Supply Control Panel .......................................................................... 4-14.02 Start-Up Sequence ....................................................................................... 4-24.03 Gas Control Module Operation ...................................................................... 4-34.04 First Time Operation Matching Gas Control to Lead Length .......................... 4-74.05 Sequence Of Operation ................................................................................ 4-74.06 Gas Selection .............................................................................................. 4-104.07 Power Supply Status Codes ........................................................................ 4-114.08 Remote Arc Starter: Service Chart ............................................................. 4-144.09 Remote Arc Starter: Spark Gap Adjustment ...............................................4-15

SECTION 5: MAINTENANCE .................................................................................................... 5-1

5.01 General Maintenance .................................................................................... 5-15.02 External Coolant Filter Cleaning Procedure ................................................... 5-15.03 Internal Coolant Filter Cleaning Procedure .................................................... 5-25.04 Coolant Replacement Procedure ................................................................... 5-2

SECTION 6: REPLACEMENT ASSEMBLIES & PARTS ........................................................... 6-1

6.01 Main Component / System Replacement ...................................................... 6-16.02 System Layout ............................................................................................. 6-26.03 Recommended Gas Supply Hose ................................................................. 6-26.04 Leads and Cables ......................................................................................... 6-36.05 Power Supply External Replacement Parts ................................................... 6-86.06 Power Supply Replacement Parts - Right Side ............................................. 6-96.07 Power Supply Replacement Parts - Right Side ............................................6-106.08 Power Supply Replacement Parts - Right Side ............................................6-116.09 Power Supply Replacement Parts - Front Panel ........................................... 6-126.10 Power Supply Replacement Parts - Front Panel ........................................... 6-136.11 Power Supply Replacement Parts - Right Side ............................................6-146.12 Power Supply Replacement Parts - Rear Panel ............................................6-156.13 Power Supply Replacement Parts - Right Side ............................................6-166.14 Power Supply Replacement Parts ................................................................ 6-176.15 Power Supply Replacement Parts - Right Side ............................................6-186.16 Power Supply Replacement Parts ................................................................ 6-196.17 Power Supply Replacement Parts - Right Side ............................................6-206.18 Gas Control Module (GCM-2010) Replacement Parts .................................. 6-216.19 Gas Control Module (GCM-2010) Replacement Parts .................................. 6-226.20 Remote Arc Starter (RAS-1000) Replacement Parts .................................... 6-236.21 Remote Arc Starter (RAS-1000) Replacement Parts .................................... 6-246.22 Command & Control Module Type 2 - Replacement Parts ......................... 6-256.23 XTL Torch Valve Assembly External Replacement Parts ............................ 6-266.24 XTL Torch Valve Assembly Internal Replacement Parts ............................... 6-27

SECTION 7. TORCH MAINTENANCE.................................................................................... 7-1

7.01 Consumable Removal ................................................................................... 7-17.02 O-Ring Lubrication ........................................................................................ 7-27.03 Parts Wear ................................................................................................... 7-37.04 Torch Consumables Installation .................................................................... 7-47.05 Coolant Leak Trouble-Shooting ...................................................................... 7-6


APPENDIX 1: Remote Arc Starter Schematic .......................................................................... A-1

APPENDIX 2: Gas Control and Torch Valve Schematic ............................................................. A-2

APPENDIX 3: Gas Control Module Plumbing Diagram .............................................................. A-4

APPENDIX 4: Gas Control Module PCB Layout ....................................................................... A-5

APPENDIX 5: Gas Control Display Interface PCB Layout ........................................................ A-6

APPENDIX 6: CCM CPU PCB Layout ..................................................................................... A-7

APPENDIX 7: CCM Input / Output PCB Layout ........................................................................ A-8

CNC functions .................................................................................................... A-10CNC Input / Output Descriptions ......................................................................... A-11Simplified CNC Circuit. ....................................................................................... A-13CNC Connections. .............................................................................................. A-14

APPENDIX 8: Schematic, 230-460V, Chopper Pilot ................................................................. A-16

APPENDIX 8: Schematic, 230-460V, Chopper Pilot Cont. ........................................................ A-18

APPENDIX 9: Schematic, 230-460V, Resistor Pilot ................................................................. A-20

APPENDIX 9: Schematic, 230-460V, Resistor Pilot Cont. ........................................................ A-22

APPENDIX 10: Schematic, CCC 400V, w/ Chopper Pilot ......................................................... A-24

APPENDIX 10: Schematic, CCC 400V, w/ Chopper Pilot Cont. ................................................ A-26

APPENDIX 11: Schematic, CE 400V, Chopper Pilot ................................................................ A-28

APPENDIX 11: Schematic, CE 400V, Chopper Pilot Cont. ....................................................... A-30

APPENDIX 12: Schematic, CE 400V, Resistor Pilot ................................................................ A-32

APPENDIX 12: Schematic, CE 400V, Resistor Pilot Cont. ....................................................... A-34

APPENDIX 13: Schematic, CSA 600V, Chopper Pilot .............................................................. A-36

APPENDIX 13: Schematic, CSA 600V, Chopper Pilot Cont. ..................................................... A-38

APPENDIX 14: PUBLICATION HISTORY................................................................................ A-40

Global Customer Service Contact Information ..................................................... Inside Rear Cover


NOTESECTION 8. TORCH OPERATION, is provided separately.

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SECTION 1:GENERAL INFORMATION

1.01 Notes, Cautions and Warnings

Throughout this manual, notes, cautions, and warnings are used tohighlight important information. These highlights are categorized asfollows:

NOTE

An operation, procedure, or background informationwhich requires additional emphasis or is helpful in effi-cient operation of the system.

CAUTION

A procedure which, if not properly followed, may causedamage to the equipment.

! WARNING

A procedure which, if not properly followed, may causeinjury to the operator or others in the operating area.

1.02 Important Safety Precautions

WARNINGS

OPERATION AND MAINTENANCE OF PLASMA ARCEQUIPMENT CAN BE DANGEROUS AND HAZARDOUSTO YOUR HEALTH.

Plasma arc cutting produces intense electric and mag-netic emissions that may interfere with the proper func-tion of cardiac pacemakers, hearing aids, or other elec-tronic health equipment. Persons who work near plasmaarc cutting applications should consult their medical healthprofessional and the manufacturer of the health equip-ment to determine whether a hazard exists.

To prevent possible injury, read, understand and followall warnings, safety precautions and instructions beforeusing the equipment. Call 1-603-298-5711 or your localdistributor if you have any questions.

GASES AND FUMES

Gases and fumes produced during the plasma cutting process can bedangerous and hazardous to your health.

• Keep all fumes and gases from the breathing area. Keep yourhead out of the welding fume plume.

• Use an air-supplied respirator if ventilation is not adequate toremove all fumes and gases.

• The kinds of fumes and gases from the plasma arc depend on thekind of metal being used, coatings on the metal, and the differentprocesses. You must be very careful when cutting or weldingany metals which may contain one or more of the following:

Antimony Chromium MercuryArsenic Cobalt NickelBarium Copper SeleniumBeryllium Lead SilverCadmium Manganese Vanadium

• Always read the Material Safety Data Sheets (MSDS) that shouldbe supplied with the material you are using. These MSDSs willgive you the information regarding the kind and amount of fumesand gases that may be dangerous to your health.

• For information on how to test for fumes and gases in yourworkplace, refer to item 1 in Subsection 1.03, Publications inthis manual.

• Use special equipment, such as water or down draft cuttingtables, to capture fumes and gases.

• Do not use the plasma torch in an area where combustible orexplosive gases or materials are located.

• Phosgene, a toxic gas, is generated from the vapors of chlori-nated solvents and cleansers. Remove all sources of these va-pors.

• This product, when used for welding or cutting, produces fumesor gases which contain chemicals known to the State of Califor-nia to cause birth defects and, in some cases, cancer. (CaliforniaHealth & Safety Code Sec. 25249.5 et seq.)

ELECTRIC SHOCK

Electric Shock can injure or kill. The plasma arc process uses andproduces high voltage electrical energy. This electric energy can causesevere or fatal shock to the operator or others in the workplace.

• Never touch any parts that are electrically “live” or “hot.”

• Wear dry gloves and clothing. Insulate yourself from the workpiece or other parts of the welding circuit.

• Repair or replace all worn or damaged parts.

• Extra care must be taken when the workplace is moist or damp.

• Install and maintain equipment according to NEC code, refer toitem 9 in Subsection 1.03, Publications.

• Disconnect power source before performing any service or re-pairs.

• Read and follow all the instructions in the Operating Manual.

FIRE AND EXPLOSION

Fire and explosion can be caused by hot slag, sparks, or the plasma arc.

• Be sure there is no combustible or flammable material in theworkplace. Any material that cannot be removed must be pro-tected.

• Ventilate all flammable or explosive vapors from the workplace.

• Do not cut or weld on containers that may have held combus-tibles.

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• Provide a fire watch when working in an area where fire hazardsmay exist.

• Hydrogen gas may be formed and trapped under aluminumworkpieces when they are cut underwater or while using a watertable. DO NOT cut aluminum alloys underwater or on a watertable unless the hydrogen gas can be eliminated or dissipated.Trapped hydrogen gas that is ignited will cause an explosion.

NOISE

Noise can cause permanent hearing loss. Plasma arc processes cancause noise levels to exceed safe limits. You must protect your earsfrom loud noise to prevent permanent loss of hearing.

• To protect your hearing from loud noise, wear protective earplugs and/or ear muffs. Protect others in the workplace.

• Noise levels should be measured to be sure the decibels (sound)do not exceed safe levels.

• For information on how to test for noise, see item 1 in Subsec-tion 1.03, Publications, in this manual.

PLASMA ARC RAYS

Plasma Arc Rays can injure your eyes and burn your skin. The plasmaarc process produces very bright ultra violet and infra red light. Thesearc rays will damage your eyes and burn your skin if you are notproperly protected.

• To protect your eyes, always wear a welding helmet or shield.Also always wear safety glasses with side shields, goggles orother protective eye wear.

• Wear welding gloves and suitable clothing to protect your skinfrom the arc rays and sparks.

• Keep helmet and safety glasses in good condition. Replacelenses when cracked, chipped or dirty.

• Protect others in the work area from the arc rays. Use protectivebooths, screens or shields.

• Use the shade of lens as suggested in the following per ANSI/ASC Z49.1:

Minimum Protective SuggestedArc Current Shade No. Shade No.

Less Than 300* 8 9

300 - 400* 9 12

400 - 800* 10 14

* These values apply where the actual arc is clearly seen.Experience has shown that lighter filters may be usedwhen the arc is hidden by the workpiece.

LEAD WARNING

This product contains chemicals, including lead, or otherwise pro-duces chemicals known to the State of California to cause cancer, birthdefects and other reproductive harm. 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 HEALTH STANDARDS, 29CFR 1910,obtainable from the Superintendent of Documents, U.S.Government Printing Office, Washington, D.C. 20402

2. ANSI Standard Z49.1, SAFETY IN WELDING AND CUTTING,obtainable from the American Welding Society, 550 N.W.LeJeune Rd, Miami, FL 33126

3. NIOSH, SAFETY AND HEALTH IN ARC WELDING AND GASWELDING AND CUTTING, obtainable from the Superinten-dent of Documents, U.S. Government Printing Office, Wash-ington, D.C. 20402

4. ANSI Standard Z87.1, SAFE PRACTICES FOR OCCUPATIONAND EDUCATIONAL EYE AND FACE PROTECTION, obtain-able from American National Standards Institute, 1430Broadway, New York, NY 10018

5. ANSI Standard Z41.1, STANDARD FOR MEN’S SAFETY-TOEFOOTWEAR, obtainable from the American National Stan-dards Institute, 1430 Broadway, New York, NY 10018

6. ANSI Standard Z49.2, FIRE PREVENTION IN THE USE OFCUTTING AND WELDING PROCESSES, obtainable fromAmerican National Standards Institute, 1430 Broadway,New York, NY 10018

7. AWS Standard A6.0, WELDING AND CUTTING CONTAIN-ERS WHICH HAVE HELD COMBUSTIBLES, obtainable fromAmerican Welding Society, 550 N.W. LeJeune Rd, Miami,FL 33126

8. NFPA Standard 51, OXYGEN-FUEL GAS SYSTEMS FORWELDING, CUTTING AND ALLIED PROCESSES, obtainablefrom the National Fire Protection Association, BatterymarchPark, Quincy, MA 02269

9. NFPA Standard 70, NATIONAL ELECTRICAL CODE, obtain-able from the National Fire Protection Association,Batterymarch Park, Quincy, MA 02269

10. NFPA Standard 51B, CUTTING AND WELDING PROCESSES,obtainable from the National Fire Protection Association,Batterymarch Park, Quincy, MA 02269

11. CGA Pamphlet P-1, SAFE HANDLING OF COMPRESSEDGASES IN CYLINDERS, obtainable from the CompressedGas Association, 1235 Jefferson Davis Highway, Suite 501,Arlington, VA 22202

12. CSA Standard W117.2, CODE FOR SAFETY IN WELDINGAND CUTTING, obtainable from the Canadian StandardsAssociation, Standards Sales, 178 Rexdale Boulevard,Rexdale, Ontario, Canada M9W 1R3

13. NWSA booklet, WELDING SAFETY BIBLIOGRAPHY obtain-able from the National Welding Supply Association, 1900Arch Street, Philadelphia, PA 19103

14. American Welding Society Standard AWSF4.1, RECOM-MENDED SAFE PRACTICES FOR THE PREPARATION FORWELDING AND CUTTING OF CONTAINERS AND PIPING

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THAT HAVE HELD HAZARDOUS SUBSTANCES, obtainablefrom the American Welding Society, 550 N.W. LeJeune Rd,Miami, FL 33126

15. ANSI Standard Z88.2, PRACTICE FOR RESPIRATORY PRO-TECTION, obtainable from American National StandardsInstitute, 1430 Broadway, New York, NY 10018

1.04 Note, Attention et Avertissement

Dans ce manuel, les mots “note,” “attention,” et “avertissement” sontutilisés pour mettre en relief des informations à caractère important.Ces mises en relief sont classifiées comme suit :

NOTE

Toute opération, procédure ou renseignement général surlequel il importe d’insister davantage ou qui contribue àl’efficacité de fonctionnement du système.

ATTENTION

Toute procédure pouvant résulter l’endommagement dumatériel en cas de non-respect de la procédure enquestion.

! AVERTISSEMENT

Toute procédure pouvant provoquer des blessures del’opérateur ou des autres personnes se trouvant dans lazone de travail en cas de non-respect de la procédure enquestion.

1.05 Precautions De Securite Importantes

AVERTISSEMENTS

L’OPÉRATION ET LA MAINTENANCE DU MATÉRIEL DESOUDAGE À L’ARC AU JET DE PLASMA PEUVENTPRÉSENTER DES RISQUES ET DES DANGERS DESANTÉ.

Coupant à l’arc au jet de plasma produit de l’énergieélectrique haute tension et des émissions magnétique quipeuvent interférer la fonction propre d’un “pacemaker”cardiaque, les appareils auditif, ou autre matériel de santéelectronique. Ceux qui travail près d’une application àl’arc au jet de plasma devrait consulter leur membreprofessionel de médication et le manufacturier de matérielde santé pour déterminer s’il existe des risques de santé.

Il faut communiquer aux opérateurs et au personnel TOUSles dangers possibles. Afin d’éviter les blessurespossibles, lisez, comprenez et suivez tous lesavertissements, toutes les précautions de sécurité et toutesles consignes avant d’utiliser le matériel. Composez le +603-298-5711 ou votre distributeur local si vous avezdes questions.

FUMÉE et GAZ

La fumée et les gaz produits par le procédé de jet de plasma peuventprésenter des risques et des dangers de santé.

• Eloignez toute fumée et gaz de votre zone de respiration. Gardezvotre tête hors de la plume de fumée provenant du chalumeau.

• Utilisez un appareil respiratoire à alimentation en air si l’aérationfournie ne permet pas d’éliminer la fumée et les gaz.

• Les sortes de gaz et de fumée provenant de l’arc de plasma dépendentdu genre de métal utilisé, des revêtements se trouvant sur le métal etdes différents procédés. Vous devez prendre soin lorsque vouscoupez ou soudez tout métal pouvant contenir un ou plusieurs deséléments suivants:

antimoine cadmium mercureargent chrome nickelarsenic cobalt plombbaryum cuivre séléniumbéryllium manganèse vanadium

• Lisez toujours les fiches de données sur la sécurité des matières(sigle américain “MSDS”); celles-ci devraient être fournies avec lematériel que vous utilisez. Les MSDS contiennent desrenseignements quant à la quantité et la nature de la fumée et des gazpouvant poser des dangers de santé.

• Pour des informations sur la manière de tester la fumée et les gaz devotre lieu de travail, consultez l’article 1 et les documents cités à lapage 5.

• Utilisez un équipement spécial tel que des tables de coupe à débitd’eau ou à courant descendant pour capter la fumée et les gaz.

• N’utilisez pas le chalumeau au jet de plasma dans une zone où setrouvent des matières ou des gaz combustibles ou explosifs.

• Le phosgène, un gaz toxique, est généré par la fumée provenant dessolvants et des produits de nettoyage chlorés. Eliminez toute sourcede telle fumée.

• Ce produit, dans le procéder de soudage et de coupe, produit de lafumée ou des gaz pouvant contenir des éléments reconnu dansL’état de la Californie, qui peuvent causer des défauts de naissance etle cancer. (La sécurité de santé en Californie et la code sécurité Sec.25249.5 et seq.)

CHOC ELECTRIQUE

Les chocs électriques peuvent blesser ou même tuer. Le procédé au jet deplasma requiert et produit de l’énergie électrique haute tension. Cetteénergie électrique peut produire des chocs graves, voire mortels, pourl’opérateur et les autres personnes sur le lieu de travail.

• Ne touchez jamais une pièce “sous tension” ou “vive”; portez desgants et des vêtements secs. Isolez-vous de la pièce de travail ou desautres parties du circuit de soudage.

• Réparez ou remplacez toute pièce usée ou endommagée.

• Prenez des soins particuliers lorsque la zone de travail est humideou moite.

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• Montez et maintenez le matériel conformément au Code électriquenational des Etats-Unis. (Voir la page 5, article 9.)

• Débranchez l’alimentation électrique avant tout travail d’entretienou de réparation.

• Lisez et respectez toutes les consignes du Manuel de consignes.

INCENDIE ET EXPLOSION

Les incendies et les explosions peuvent résulter des scories chaudes,des étincelles ou de l’arc de plasma. Le procédé à l’arc de plasmaproduit du métal, des étincelles, des scories chaudes pouvant mettre lefeu aux matières combustibles ou provoquer l’explosion de fuméesinflammables.

• Soyez certain qu’aucune matière combustible ou inflammable ne setrouve sur le lieu de travail. Protégez toute telle matière qu’il estimpossible de retirer de la zone de travail.

• Procurez une bonne aération de toutes les fumées inflammables ouexplosives.

• Ne coupez pas et ne soudez pas les conteneurs ayant pu renfermerdes matières combustibles.

• Prévoyez une veille d’incendie lors de tout travail dans une zoneprésentant des dangers d’incendie.

• Le gas hydrogène peut se former ou s’accumuler sous les pièces detravail en aluminium lorsqu’elles sont coupées sous l’eau ou surune table d’eau. NE PAS couper les alliages en aluminium sousl’eau ou sur une table d’eau à moins que le gas hydrogène peuts’échapper ou se dissiper. Le gas hydrogène accumulé explosera sienflammé.

RAYONS D’ARC DE PLASMA

Les rayons provenant de l’arc de plasma peuvent blesser vos yeux etbrûler votre peau. Le procédé à l’arc de plasma produit une lumièreinfra-rouge et des rayons ultra-violets très forts. Ces rayons d’arc nuirontà vos yeux et brûleront votre peau si vous ne vous protégez pascorrectement.

• Pour protéger vos yeux, portez toujours un casque ou un écran desoudeur. Portez toujours des lunettes de sécurité munies de paroislatérales ou des lunettes de protection ou une autre sorte de protec-tion oculaire.

• Portez des gants de soudeur et un vêtement protecteur appropriépour protéger votre peau contre les étincelles et les rayons de l’arc.

• Maintenez votre casque et vos lunettes de protection en bon état.Remplacez toute lentille sale ou comportant fissure ou rognure.

• Protégez les autres personnes se trouvant sur la zone de travailcontre les rayons de l’arc en fournissant des cabines ou des écransde protection.

• Utilisez la nuance de lentille qui est suggèrée dans le recommenda-tion qui suivent ANSI/ASC Z49.1:

Nuance Minimum Nuance SuggeréeCourant Arc Protective Numéro Numéro

Moins de 300* 8 9

300 - 400* 9 12

400 - 800* 10 14

* Ces valeurs s’appliquent ou l’arc actuel est observéclairement. L’experience a démontrer que les filtres moinsfoncés peuvent être utilisés quand l’arc est caché parmoiceau de travail.

BRUIT

Le bruit peut provoquer une perte permanente de l’ouïe. Les procédésde soudage à l’arc de plasma peuvent provoquer des niveaux sonoressupérieurs aux limites normalement acceptables. Vous dú4ez vousprotéger les oreilles contre les bruits forts afin d’éviter une pertepermanente de l’ouïe.

• Pour protéger votre ouïe contre les bruits forts, portez des tamponsprotecteurs et/ou des protections auriculaires. Protégez égalementles autres personnes se trouvant sur le lieu de travail.

• Il faut mesurer les niveaux sonores afin d’assurer que les décibels(le bruit) ne dépassent pas les niveaux sûrs.

• Pour des renseignements sur la manière de tester le bruit, consultezl’article 1, page 5.

PLOMB AVERTISSEMENT

Ce produit contient des produits chimiques, comme le plomb, ouengendre des produits chimiques, reconnus par l’état de Californiecomme pouvant être à l’origine de cancer, de malformations fœtales oud’autres problèmes de reproduction. Il faut se laver les mains aprèstoute manipulation. (Code de Californie de la sécurité et santé,paragraphe 25249.5 et suivants)

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1.06 Documents De Reference

Consultez les normes suivantes ou les révisions les plus récentes ayantété faites à celles-ci pour de plus amples renseignements :

1. OSHA, NORMES DE SÉCURITÉ DU TRAVAIL ET DE PROTECTIONDE LA SANTÉ, 29CFR 1910, disponible auprès du Superintendentof Documents, U.S. Government Printing Office, Washington, D.C.20402

2. Norme ANSI Z49.1, LA SÉCURITÉ DES OPÉRATIONS DE COUPE ETDE SOUDAGE, disponible auprès de la Société Américaine deSoudage (American Welding Society), 550 N.W. LeJeune Rd., Mi-ami, FL 33126

3. NIOSH, LA SÉCURITÉ ET LA SANTÉ LORS DES OPÉRATIONS DECOUPE ET DE SOUDAGE À L’ARC ET AU GAZ, disponible auprès duSuperintendent of Documents, U.S. Government Printing Office,Washington, D.C. 20402

4. Norme ANSI Z87.1, PRATIQUES SURES POUR LA PROTECTIONDES YEUX ET DU VISAGE AU TRAVAIL ET DANS LES ECOLES,disponible de l’Institut Américain des Normes Nationales (AmericanNational Standards Institute), 1430 Broadway, New York, NY 10018

5. Norme ANSI Z41.1, NORMES POUR LES CHAUSSURESPROTECTRICES, disponible auprès de l’American National Stan-dards Institute, 1430 Broadway, New York, NY 10018

6. Norme ANSI Z49.2, PRÉVENTION DES INCENDIES LORS DEL’EMPLOI DE PROCÉDÉS DE COUPE ET DE SOUDAGE, disponibleauprès de l’American National Standards Institute, 1430 Broadway,New York, NY 10018

7. Norme A6.0 de l’Association Américaine du Soudage (AWS), LESOUDAGE ET LA COUPE DE CONTENEURS AYANT RENFERMÉ DESPRODUITS COMBUSTIBLES, disponible auprès de la AmericanWelding Society, 550 N.W. LeJeune Rd., Miami, FL 33126

8. Norme 51 de l’Association Américaine pour la Protection contre lesIncendies (NFPA), LES SYSTEMES À GAZ AVEC ALIMENTATIONEN OXYGENE POUR LE SOUDAGE, LA COUPE ET LES PROCÉDÉSASSOCIÉS, disponible auprès de la National Fire Protection Asso-ciation, Batterymarch Park, Quincy, MA 02269

9. Norme 70 de la NFPA, CODE ELECTRIQUE NATIONAL, disponibleauprès de la National Fire Protection Association, Batterymarch Park,Quincy, MA 02269

10. Norme 51B de la NFPA, LES PROCÉDÉS DE COUPE ET DESOUDAGE, disponible auprès de la National Fire Protection Asso-ciation, Batterymarch Park, Quincy, MA 02269

11. Brochure GCA P-1, LA MANIPULATION SANS RISQUE DES GAZCOMPRIMÉS EN CYLINDRES, disponible auprès de l’Associationdes Gaz Comprimés (Compressed Gas Association), 1235 JeffersonDavis Highway, Suite 501, Arlington, VA 22202

12. Norme CSA W117.2, CODE DE SÉCURITÉ POUR LE SOUDAGE ETLA COUPE, disponible auprès de l’Association des NormesCanadiennes, Standards Sales, 178 Rexdale Boulevard, Rexdale,Ontario, Canada, M9W 1R3

13. Livret NWSA, BIBLIOGRAPHIE SUR LA SÉCURITÉ DU SOUDAGE,disponible auprès de l’Association Nationale de Fournitures deSoudage (National Welding Supply Association), 1900 Arch Street,Philadelphia, PA 19103

14. Norme AWSF4.1 de l’Association Américaine de Soudage,RECOMMANDATIONS DE PRATIQUES SURES POUR LAPRÉPARATION À LA COUPE ET AU SOUDAGE DE CONTENEURSET TUYAUX AYANT RENFERMÉ DES PRODUITS DANGEREUX ,disponible auprès de la American Welding Society, 550 N.W. LeJeuneRd., Miami, FL 33126

15. Norme ANSI Z88.2, PRATIQUES DE PROTECTION RESPIRATOIRE,disponible auprès de l’American National Standards Institute, 1430Broadway, New York, NY 10018

ULTRA-CUT 100

1-6 Manual 0-4748

1.07 Declaration of ConformityManufacturer: Thermal Dynamics CorporationAddress: 82 Benning Street

West Lebanon, New Hampshire 03784USA

The equipment described in this manual conforms to all applicable aspects and regulations of the ‘Low Voltage Directive’(European Council Directive 73/23/EEC as amended by Council Directive 93/68/EEC) and to the National legislation for theenforcement of this Directive.

The equipment described in this manual conforms to all applicable aspects and regulations of the "EMC Directive" (EuropeanCouncil Directive 89/336/EEC) and to the National legislation for the enforcement of this Directive.

Serial numbers are unique with each individual piece of equipment and details description, parts used to manufacture a unit anddate of manufacture.

National Standard and Technical Specifications

The product is designed and manufactured to a number of standards 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 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 cutting equipment and associatedaccessories.

* For environments with increased hazard of electrical shock, Power Supplies bearing the 'S' mark conform to EN50192 whenused in conjunction with hand torches with exposed cutting tips, if equipped with properly installed standoff guides.

* Extensive product design verification is conducted at the manufacturing facility as part of the routine design and manufactur-ing process. This is to ensure the product is safe, when used according to instructions in this manual and related industrystandards, and performs as specified. Rigorous testing is incorporated into the manufacturing process to ensure the manufac-tured product meets or exceeds all design specifications.

Thermal Dynamics has been manufacturing products for more than 30 years, and will continue to achieve excellence in our areaof manufacture.

Manufacturers responsible representative: Steve WardOperations DirectorThermadyne EuropeEuropa BuildingChorley N Industrial ParkChorley, Lancashire,England PR6 7BX

ULTRA-CUT 100

1-7Manual 0-4748

1.08 Statement of Warranty

LIMITED WARRANTY: Thermal Dynamics® Corporation (hereinafter “Thermal”) warrants that its products will be free of defects in workmanshipor material. Should any failure to conform to this warranty appear within the time period applicable to the Thermal products as stated below,Thermal shall, upon notification thereof and substantiation that the product has been stored, installed, operated, and maintained in accordancewith Thermal’s specifications, instructions, recommendations and recognized standard industry practice, and not subject to misuse, repair,neglect, alteration, or accident, correct such defects by suitable repair or replacement, at Thermal’s sole option, of any components or partsof the product determined by Thermal to be defective.

THIS WARRANTY IS EXCLUSIVE AND IS IN LIEU OF ANY WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULARPURPOSE.

LIMITATION OF LIABILITY: Thermal shall not under any circumstances be liable for special or consequential damages, such as, but notlimited to, damage or loss of purchased or replacement goods, or claims of customers of distributor (hereinafter “Purchaser”) for serviceinterruption. The remedies of the Purchaser set forth herein are exclusive and the liability of Thermal with respect to any contract, or anythingdone in connection therewith such as the performance or breach thereof, or from the manufacture, sale, delivery, resale, or use of any goodscovered by or furnished by Thermal whether arising out of contract, negligence, strict tort, or under any warranty, or otherwise, shall not,except as expressly provided herein, exceed the price of the goods upon which such liability is based.

THIS WARRANTY BECOMES INVALID IF REPLACEMENT PARTS OR ACCESSORIES ARE USED WHICH MAY IMPAIR THE SAFETY ORPERFORMANCE OF ANY THERMAL PRODUCT.

THIS WARRANTY IS INVALID IF THE PRODUCT IS SOLD BY NON-AUTHORIZED PERSONS.

The limited warranty periods for this product shall be: A maximum of three (3) years from date of sale to an authorized distributor and amaximum of two (2) years from date of sale by such distributor to the Purchaser, and with further limitations on such two (2) year period (seechart below).

Parts Labor

AutoCut© and UltraCut© Power Supplies and Components 2 Years 1 Year

Torch And Leads

XTTM-300 / XTTM-301 Torch (Excluding Consumable Parts) 1 Year 1 Year

Repair/Replacement Parts 90 Days 90 Days

Warranty repairs or replacement claims under this limited warranty must be submitted by an authorized Thermal Dynamics® repair facilitywithin thirty (30) days of the repair. No transportation costs of any kind will be paid under this warranty. Transportation charges to sendproducts to an authorized warranty repair facility shall be the responsibility of the customer. All returned goods shall be at the customer’s riskand expense. This warranty supersedes all previous Thermal warranties.

Effective August 19, 2005

ULTRA-CUT 100

1-8 Manual 0-4748

Manual No. 0-4748 2-1 SPECIFICATIONS

ULTRA-CUT 100

SECTION 2: SPECIFICATIONS

2.01 General Description Of The System

A typical Ultra-Cut® 100 system configuration will include:

• One Power Supply

• Remote Arc Starter

• Gas Control Module

• Torch Valve Assembly

• Precision Plasma Cutting Torch

• Set Of Connecting Leads

• Torch Spare Parts Kit

The components are connected at installation.

2.02 Plasma Power Supply

The power supply provides the necessary current for cutting operations. The power supply also monitors systemperformance, 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 start the pilot arc. The pilot arc creates a path for the main arc totransfer to the work. When the main arc is established, the pilot arc shuts off.

2.04 Gas Control Module

This module allows remote setting of gas selection, pressures, and flows together with setting of cutting current.

2.05 Precision Plasma Cutting Torch

The torch delivers the controlled current to the work through the main arc, causing the metal to be cut.

SPECIFICATIONS 2-2 Manual No. 0-4748

ULTRA-CUT 100

2.06 Specifications & Electrical Requirements

Input Power & Current 208/230V - 460V, 1/3 ph, 50 / 60 HzMax OCV (U0) 380 vdcMinimum Output Current 10 AmpsMax Output Current 100 AmpsOutput Voltage 60 - 230 vdcDuty Cycle Rating 100% @ 100A, 180VAmbient Temperaturefor Duty Cycle Rating

104F° (40°C)

Operating range 14°F to 122°F (-10°C to + 50°C)Power Factor 0.70 @ 100 A DC OutputCooling Forced Air (Class F)

Ultra-Cut 100 Specifications & Design Features

Input Power Input Current Suggested Sizes (See Note)Voltage Freq. 3-Ph 3-Ph Fuse (Amps) Wire (AWG)(Volts) (Hz) (kVA) (Amps) 3-Ph 3-Ph

208 50/60 23 64 80 #41

230 50/60 24 60 80 #41

400 50 28 40 50 #61

400 (CE) 50 28 40 50 #61

460 50/60 26 33 40 #81

Ultra-Cut 100 Power Supply

Line Voltages with Suggested Circuit Protection and Wire SizesBased on National Electric Code and Canadian Electrical Code

1 Extra Hard Usage Type SO, SOW, SOO, SOOW, ST, STW, STO, STOW, STOO, STOOW

2.07 System Component Layout

Primary power

Work

CNC

RemoteArc

Starter

Art # A-07328_AB

Torch

Coolant Supply

Coolant Return

Control Cable

Pilot Return

Coolant Supply

Coolant Return

Plasma Gas

Shield Gas

Work Cable

FiberOpticCable

Control Cable

Gas ControlModule

Power Supply

Torch Valve

Assembly Positioning Tube

Plasma Gas

Preflow Gas

Water Shield

Shield

Shield Gas

Negative

Pilot Return

Control Cable

100’ / 30.5 m Maximum Length125’ / 38.1 m Maximum Length

175’ / 53.3 m Maximum Length

Shield

I

JG

K

LP

O

A,

B,

C,

D,

E

H,

Q,

R,

S,

T


ULTRA-CUT 100

2.08 Power Supply Dimensions

Art # A-04793

37.75 inch 960 nm

27.5 inch 700 mm

33 inch 840 mm

27 inch 680 mm

41.25 inch1050 mm

343 lb / 156 kg


ULTRA-CUT 100

2.09 Power Supply Rear Panel Features

Terminal Cover Support Panel

Coolant Tank

Coolant Filter

Coolant Connections

Input PowerTerminals

Pilot (Pos) Terminal

Circuit Breaker Panel

Terminal Cover

AC Power Lamp

Ground TerminalsGas Control Console Connector

RETURN SUPPLY

Art # A-04794

CNC Connector

Remote Arc StarterConnector

Work Cable Terminal

Torch (Neg) Terminal

Leads Bracket


ULTRA-CUT 100

2.10 Gas Requirements

The customer will provide all gases and pressure regulators. Gases must be of high quality. Pressure regulatorsshall be double stage. The chart includes gases which may not be used in all applications.

Gas Quality Minimum Pressure Flow

O2 (Oxygen) 99.5% Purity(Liquid recommended)

120 psi8.3 bar / 827 kPa

70 scfh (1982 l/h)

N2 (Nitrogen)

99.5% Purity(Liquid recommended) <1000 ppm O2, <32

ppm H2O)

120 psi8.3 bar / 827 kPa 200 scfh (5700 l/h)

Compressed or Bottled Air

Clean, Dry, Free of Oil (see Note 1)

120 psi8.3 bar / 827 kPa

244 scfh (6910 l/h)

H35 (Argon-Hydrogen)H35 = 35% Hydrogen,

65% Argon

99.995% Purity(gas recommended)

120 psi8.3 bar / 827 kPa 90 scfh (2550 l/h)

H2O (Water) See Note 2 50 psi (3.5 bar) 10 gph (38 lph)

Note 3: Water Pressure Regulator No. 8-6118 is recommended to ensure proper water pressure.

Ultra-Cut 100 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 recommended. Tap water with high levels of particulate matter must be filtered.

Note 1: The air source must be adequately filtered to remove all oil or grease. Oil or grease contamination from compressed or bottled air can cause fires in conjunction with oxygen.

For filtering, a coalescing filter able to filter to 0.01 microns should be placed as close aspossible to the gas inlets on the Gas Control Module.

2.11 Gas Applications

MATERIAL

PREFLOW PLASMA SHIELD PREFLOW PLASMA SHIELD PREFLOW PLASMA SHIELDAir Air Air Air Air AirN2 N2 H20 N2 N2 H20Air Air Air Air Air AirN2 N2 H20 N2 N2 H20Air Air Air Air Air AirN2 N2 H20 N2 N2 H20

85A CUT Air Air AirN2 H35 N2 N2 H35 N2

N2 N2 H20 N2 N2 H20

OPERATION

30A CUT

70 A CUT

100 A CUT

50 A CUT O2

Air

O2

O2

Air

Air

Air

GAS TYPEGAS TYPE GAS TYPE

AirO2

Air

O2

Air

Ultra-Cut-100 Gas ApplicationsMILD STEEL STAINLESS STEEL ALUMINUM


ULTRA-CUT 100

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

2.74"69.55 mm

1.57"39.96 mm

3.54"89.87 mm

6.30"160.10 mm

Art # A-04897

Mounting Tube

End Cap


ULTRA-CUT 100

B. Torch Specifications

AmbientTemperature

104° F40° C

Duty Cycle 100% @ 100 AmpsMaximum Current 100 AmpsVoltage (Vpeak) 500VArc Striking Voltage 10kV

Current Up to 100 Amps, DC,Straight Polarity

Plasma Gases:Compressed Air, Oxygen, Nitrogen, H35

Shield Gases:Compressed Air, Oxygen, Nitrogen, Water

Operating Pressure 125 psi ± 10 psi8.6 bar ± 0.7 bar

Maximum Input Pressure 135 psi / 9.3 barGas flow 10 - 300 scfh

XTTM-300 Torch Ratingsfor use with Ultra-Cut 100 Power Supply

XTTM-300 Torch Gas Specifications

C. Leads Lengths

Feet Meters10 3.0515 4.625 7.635 10.650 15.275 22.8100 30.4125 38.2150 45.7175 53.3

LengthGas Lead Assemblies

D. Torch Parts (Generic Parts Shown)

CartridgeShield Cup

Art # A-04741

ElectrodeTip

Plasma Gas Distributor

Shield Gas Distributor

Shield Cap


ULTRA-CUT 100

Intentionally blank

Manual No. 0-4748 3-1 INSTALLATION

ULTRA-CUT 100

SECTION 3: INSTALLATION

3.01 Installation Requirements

Electric Supply

The electrical supply network, the gas and water supply system must meet local safety standards. Thisconformity shall be checked by qualified personnel.

Input Power Input Current Suggested Sizes (See Note)Voltage Freq. 3-Ph 3-Ph Fuse (Amps) Wire (AWG)(Volts) (Hz) (kVA) (Amps) 3-Ph 3-Ph

208 50/60 23 64 80 #41

230 50/60 24 60 80 #41

400 50 28 40 50 #61

400 (CE) 50 28 40 50 #61

460 50/60 26 33 40 #81

Ultra-Cut 100 Power Supply

Line Voltages with Suggested Circuit Protection and Wire SizesBased on National Electric Code and Canadian Electrical Code

1 Extra Hard Usage Type SO, SOW, SOO, SOOW, ST, STW, STO, STOW, STOO, STOOW

CAUTION

Fuse and wire sizes are for reference only. The installation must conform to national and local codes for the typeand method of wire being used.

Gas Supply

The customer must supply all gases and pressure regulators. Gases must be of high quality. Pressureregulators must be double-stage and installed as close as possible to the gas console. Contaminated gascan cause one or more of the following problems:

• Reduced cutting speed

• Poor cut quality

• Poor cutting precision

• Reduced consumables life.

• Oil or grease contamination from compressed or bottled air can cause fires in conjunction with oxygen.

Cooling System Requirements

Coolant must be added to the system on installation. The amount required varies with torch leads length.

Thermal Dynamics recommends the use of its coolants 7-3580 and 7-3581 (for low temperatures).

Cat. Number and Mixture Mixture Protects To7-3580 'Extra-CoolTM' 25 / 75 10° F / -12° C7-3581 'Ultra-CoolTM' 50 / 50 -27° F / -3° C

7-3582 'Extreme CoolTM' Concentrate* -65° F / -51° C

Coolant Capabilities

* For mixing with D-I CoolTM 7-3583

INSTALLATION 3-2 Manual No. 0-4748

ULTRA-CUT 100

3.02 System Layout

Refer to section 3.05 for ground connections and ground cables.

Primary power

Work

CNC

RemoteArc

Starter

Art # A-07233_AB

Torch

Coolant Supply

Coolant Return

Control Cable

Pilot Return

Coolant Supply

Coolant Return

Plasma Gas

Shield Gas

Work Cable

FiberOpticCable

Control Cable

Gas ControlModule

Power Supply

TorchValve


Plasma Gas

Preflow Gas

Water Shield

Shield

Shield Gas

Negative

Pilot Return

Control Cable



Shield

H

Q

R

T

S

A

B

C

D

E

P

K

L

O

I

JG



ULTRA-CUT 100

3.03 Cables & Leads Identification

Green / Yellow # 4 AWG

Green / Yellow 1/0 (50 mm )

A

Green

Red

Art # A

-07473

#8 AWG Cable

#1 AWG Cable

B

C

D

E

F

F1

K

L

H, Q, R, S,T

Work Cable

CNC Cable (14 Wire)

37

14

Coolant Supply Lead, Power Supply to Arc Starter

1/0 Cable (1/0 (50 mm )

Pilot Return, Power Supplyto Arc Starter

Negative Lead, Power Supplyto Arc Starter

Control Cable, Power Supplyto Arc Starter

Ground Cable

Ground Cable,Remote Arc Starter To Earth Ground

O

P

Fiber Optic Cable, Power Supply to Gas Control Module

Control Cable, Power Supply to Gas Control Module

Green

RedCoolant Return Lead, Power Supply to Arc Starter

2

2

14

GShielded Torch Lead Assembly, Remote Arc Starter to Torch

Plasma Gas Lead,Torch Valve to Torch

Shield Gas Lead,Torch Valve to Torch

I

J


ULTRA-CUT 100

3.04 Lift the Power Supply

WARNINGS

Do not touch live electrical parts.

Disconnect input power conductors from de-energized supply line before moving unit.

FALLING EQUIPMENT can cause serious personal injury and equipment damage.

Use 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 andvertical. Do not lift it any further than necessary to clear the shipping pallet.

Art # A-04796

Set the power supply on a solid, level surface. The installer may fasten the power supply to the floor or asupporting fixture with hardware passing through the horizontal parts of the power supply feet.


ULTRA-CUT 100

3.05 Remove the Connections Cover

The primary power cable 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 aground wire connected to the inside of the panel. Do not disconnect this wire.

Connections Cover(Removed)

Connection Panel

Art # A-04797


ULTRA-CUT 100

Check / Adjust Input Voltage Configuration

1. The power supply includes a voltage configuration board which must be positioned to match the primaryinput voltage. Remove the power supply left side panel and locate the voltage configuration board. The inputvoltage 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-install it withthe correct input voltage shown at the top of the board.

3. Re-connect the jumper. Re-install the power supply side panel.

Art # A-04856_AB

1. Unplug connector

2. Remove bolts.3. Invert board.4. Re-install board.5. Plug in connector.

208/230V / 460V Input Voltage Board

(Shown in 460V Position)

Inverter Module


ULTRA-CUT 100

Connect Input Power and System Ground Cables

1. Carefully cut back the outer sheath on the primary input power cable to expose the individual cords. Cut backthe insulation on the individual cords. Route the cable upward through leads bracket at the bottom of the rearpanel, then through the connections cover support panel on the rear panel of the power supply.

2. Install ring tongue terminals on the individual cords. Fasten the terminals to the individual cords securely.

3. Connect the individual cords as shown. Connect the power cable ground cord to the ground terminal block.

CAUTION

The clear connections cover must remain in place.

4. If required pass a system ground cable (F1) through the last opening in the connections cover support panelnext to the input power cable. Connect the cable to the ground terminal block on the power supply rear panel.Refer to the Ground Connections Section for full details and procedures on proper system grounding.

PILOT

WORK

TORCH

Input power cable

Ground Terminal Block

Connections Cover Support Panel

System Ground Cable

Art # A-07659_AB

to Remote Arc Starter

Connections CoverConnection Panel

Leads Bracket

to Remote Arc Starter

AC INPUT

System Ground Cable

Input power cable ground

L1

L2

L3

L1L2

L3

5. Re-install the connections cover on the power supply. Snug the hardware securely by hand. Do not over-tighten.


ULTRA-CUT 100

0 - 10 ft (0 - 3 m) Ideal20 ft (6 m) Maximum

1/0Ground Cable

Power Supply

‘Star’Ground

Earth Ground Rod

1/0 Ground Cable

CNC Device

Torch

Cutting Table

Cutting Machine / Gantry

1/0 Work Cable

Remote ArcStarter (RAS-1000)


Gas Control Module

Power Supply

‘Star’Ground

Earth Ground Rod

CNC Device

Torch

Cutting Table


1/0 Work Cable

Remote ArcStarter (RAS-1000)

1/0Ground Cable

(F1)

Star Ground on Cutting Table

Star Ground on Cutting Table

1/0Ground Cable

Ultra-Cut or

Auto-Cut O2

Note: The gas control module can be mounted on top of the power supply. If it is, it should be grounded directly to the power supply with #4 AWG ground, (F). This alternate location requires grounding the power supply to the ‘Star’ ground with the 1/0 Ground Cable (F1).

Gas Control ModulePrimary location

#4 AWGGround

(F)

#4 AWG Ground (F)(Factory Installed)

Art # A-08253_AC

Customer supplied

Customer supplied

1/0Ground Cable

(F1)

Auto-Cut W/RAS


ULTRA-CUT 100


1/0Ground Cable

Customer Supplied

#4 AWG Ground (F)(Factory Installed)

GCM-1000Gas Control Module

Auto-Cut Power Supply

‘Star’Ground

Earth Ground Rod

1/0 Ground Cable(F1)

CNC Device

Torch

Cutting Table


1/0 Work Cable

Auto-Cut Basic SystemWithout RAS

Art # A-08254_AC


ULTRA-CUT 100

3.06 Ground Connections

A. Electromagnetic Interference (EMI)

Pilot arc starting generates a certain amount of electromagnetic interference (EMI), commonly called RF noise.This RF noise may interfere with other electronic equipment such as CNC controllers, remote controls, heightcontrollers, etc. To minimize RF interference, follow these grounding procedures when installing mechanizedsystems:

B. Grounding

1. The preferred grounding arrangement is a single point or “Star” ground. The single point, usually on the cuttingtable, is connected with 1/0 AWG (European 50 mm2) or larger wire to a good earth ground (measuring leassthan 3 ohms; an ideal ground measures 1 ohm or less. Refer to paragraph ‘C’, Creating An Earth Ground. Theground rod must be placed as close as possible to the cutting table, ideally less than 10 ft (3.0 m), but no morethan 20 ft (6.1 m) from the cutting table.

NOTE

All ground wires should be as short as possible. Long wires will have increased resistance to RFfrequencies. Smaller diameter wire has increased resistance to RF frequencies, so using a largerdiameter wire is better.

2. Grounding for components mounted on the cutting table (CNC controllers, height controllers, plasma remotecontrols, etc.) should follow the manufacturer’s recommendations for wire size, type, and connection pointlocations.

For Thermal Dynamics components (except Remote Arc Starter and Gas Control Module) it is recommendedto use a minimum of 10 AWG (European 6 mm2) wire or flat copper braid with cross section equal to or greaterthan 10 AWG connected to the cutting table frame. The Remote Arc Starter uses 1/0 earth ground wire and theGas Control Module should use minimum # 4 AWG wire. The connection point must be to clean bare metal; rustand paint make poor connections. For all components, wires larger than the recommended minimum can beused and may improve noise protection.

3. The cutting machine frame is then connected to the “Star” point using 1/0 AWG (European 50 mm2) or largerwire.

4. The plasma power supply work cable (see NOTE) is connected to the cutting table at the single point “Star” ground.

NOTE

Do Not connect the work cable directly to the ground rod.

5. Make sure work cable and ground cables are properly connected. The work cable must have a solid connectionto the cutting table. The work and ground connections must be free from rust, dirt, grease, oil and paint. Ifnecessary grind or sand down to bare metal. Use lock washers to keep the connections tight. Using electricaljoint compound to prevent corrosion is also recommended.

6. The plasma power supply chassis is connected to the power distribution system ground as required by electri-cal codes. If the plasma supply is close to the cutting table (see NOTE) a second ground rod is not usuallyneeded, in fact it could be detrimental as it can set up ground loop currents that cause interference.

When the plasma power supply is far away from the ground rod and interference is experienced, it may help toinstall a second earth ground rod next to the plasma power supply. The plasma power supply chassis wouldthen be connected to this ground rod.

NOTE

It is recommended that the Plasma Power Supply be within 20 - 30 ft (6.1 – 9.1 m) of the cutting table,if possible.

7. The plasma control cable should be shielded with the shield connected only at the cutting machine end.Connecting the shield at both ends will allow ground loop currents which may cause more interference than withno shield at all.


ULTRA-CUT 100

Creating An Earth Ground

1. To create a solid, low resistance, earth ground, drive a 1/2 in (12 mm) or greater diameter copper clad groundrod at least 6 - 8 ft (1.8 - 2.4 m) into the earth so that the rod contacts moist soil over most of its length.Depending on location, a greater depth may be required to obtain a low resistance ground (see NOTE). Groundrods, typically 10 ft (3.0 m) long, may be welded end to end for greater lengths. Locate the rod as close aspossible to the work table. Install a ground wire, 1/0 AWG (European 50 mm2) or greater, between the groundrod and the star ground point on the cutting table.

NOTE

Ideally, a properly installed ground rod will have a resistance of three ohms or less.

To test for a proper earth ground, refer to the following diagram. Ideally, the reading on the multimeter should be asshown.

CAUTION

No other connections should be made at the ground rod being tested.

This test assumes the 115 or 230 VAC source neutral is connected to the utility earth ground.

Art # A-07252

WARNING

Use extreme caution. Thistest uses live voltage.

NEUTRALEarth Grounded

HOTOn 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 Incandescentlight bulb*

* Can replace light bulb with a 100w resistor.Use 100 ohm for 115VAC.Use 500 ohm for 230VAC

NEUTRALPROBE

VAC

HOTPROBE

Ground Testing

2. Increasing the ground rod length beyond 20 - 30 ft (6.1 – 9.1 m) does not generally increase the effectivenessof the ground rod. A larger diameter rod which has more surface area may help. Sometimes keeping the soilaround the ground rod moist by continuously running a small amount of water into it will work. Adding salt to thesoil by soaking it in salt water may also reduce its resistance. When these methods are used, periodicchecking of the ground resistance is required to make sure the ground is still good.

D. Routing Of Torch Leads

1. To minimize RF interference, position torch leads as far as possible from any CNC components, drive motors,control cables, or primary power lines. If cables have to pass over torch leads, do so at an angle. Do not run theplasma control or other control cables in parallel with the torch leads in power tracts.

2. Keep torch leads clean. Dirt and metal particles bleed off energy, which causes difficult starting and increasedchance of RF interference.


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3.07 Connect Work Cable and Pilot and Negative Leads

1. Pass the ends of the work cable and pilot and negative leads upward through the leads bracket at thebottom edge of the rear panel, then through the openings in the connections cover 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.

PILOTWORK

TORCH

Connection Panel

AC INPUT

L1

L2

L3

Work Lead

Torch Lead - To Remote Arc Starter

WorkTorch

Lead Connection Detail

Connections CoverSupport Panel

Art # A-07660_AB

Connections Cover

Pilot

To Cutting TableLeads Bracket

Pilot Lead - To Remote Arc Starter


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3.08 Connect Coolant Leads

1. Connect the color-coded coolant hoses to the coolant connections on the power supply rear panel. Thesupply line (out) is flagged green, the return line (in) is flagged red.

Coolant Connections

RETURN SUPPLYRETURN SUPPLY

Art # A-04800

To Remote Arc Starter

COOLANT

RED

GREEN


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3.09 Connect Control Cables for CNC, Remote Arc Starter, and GCM

1. Connect one end of each cable to the power supply.

2. Connect the other end of the CNC cable to the CNC device.

3. The CNC cable shield must be attached to ground.

RETURN SUPPLY

Art # A-04802

To CNC

To Remote Arc Starter

To Gas Control Module

Customer WiringAccess Hole


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3.10 Connect Fiber Optic Cable (Type 2 internal control module)

CAUTION

Check the type of internal control module. Use this section for connections to an internal control module withoutan external connections cover. Use the preceding section for connections to an internal module with an externalconnections cover.

1. Connect one end of each cable to the power supply as shown.

a. Remove the strain relief securing nut from the strain relief on the fiber optic cable(s). Loosen the strainrelief dome nut from the strain relief.

b. Pass the cable connector through the appropriate opening. Slide the strain relief securing nut onto thecable. Make a loop of the cable; carefully press the cable connector into the appropriate receptacle on theinternal control module.

c. Tighten the strain relief onto the cable(s). Do not overtighen.

To Gas Control Module

To Remote HMI (if installed)

Profile Detail, Fiber Optic Cable Installation

Cable Receptacles

To Slave Power Supply(if installed)

Art # A-06793


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3.11 Set Switches on the Command - Control Module (Type 2 Module)

Compare the command - control module to the illustration. Follow instructions in this section for a modulewithout an external connection cover.

Remove the power supply right side. Set switches on the CCM (Command-Control Module) per the illustrations.Switch settings and connection details are provided in the Appendix.

CAUTION

Printed circuit boards in the Command - Control Module are static - sensitive. Discharge any built-up staticcharges in your body or surroundings before touching the printed circuit boards.

SW1 SW3 SW4 SW5 SW8

3 41 2 3 41 21 2 1 2 1 2 1 2

SW-1-1: Auto Pilot Restart. 1 = ON = Auto Pilot Function enabled. 1 = OFF = Auto Pilot Function disabled (Factory default setting).SW-1-2: Pilot Delay 2 = OFF, 3 = OFF, 4 = OFF: 0 Seconds (Factory default setting).SW-1-3: Pilot Delay 2 = ON, 3 = OFF, 4 = OFF: 0.1 SecondsSW-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-4: Postflow Time 1 = OFF, 2 = OFF: 10 Seconds (Factory default setting). 1 = ON, 2 = OFF: 20 Seconds 1 = OFF, 2 = ON: 5 Seconds 1 = ON, 2 = ON: 0 Seconds

SW-5-1: Tip Saver Reserved for Factory use. SW-5-2: Off Plate Reserved for Factory use.

SW 8-1: Pilot Time 1 = OFF = Short (85 ms.) (Factory default setting).

1 = ON = Long (3 s.)

ON

ON

Active only when SW-1-1 is set to ON.

Art # A-06791_AB

Future Use

SW-3: Gas Preflow Time 1 = Off, 2 = OFF: 2 seconds 1 = ON, 2 = OFF: 4 seconds 1 = OFF, 2 = ON: 6 seconds 1 = ON, 2 = ON: 8 seconds

SW 8-2: Remote Current 1 = OFF = Disabled (Factory default setting). 1 = ON = (Remote Analog Current Control)*SW 8-3: Auto Transfer Retry1 = OFF = Enabled Up to 3 tries (Factory default setting). 1 = ON = Disabled

SW 8-4: Reserved for Factory use.

* SW 8-3 is reserved for Factory use prior to

Firmware V3.5


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CAUTION

Printed circuit boards in the Command - Control Module are static - sensitive. Discharge any built-up staticcharges in your body or surroundings before touching the printed circuit boards.

SW-6: OK-to-Move: Contact 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 = from CNC. Position A requires that SW-8-2 be ON.

SW-12-1/2/3/4: Divided Arc signal All = OFF = 50:1 (Factory default setting)

1 = ON = 16.6:1 2 = ON = 30:1 3 = ON = 40:1 4 = Not used.

Art # A-06792

Only 1 on at a time.

SW11

SW13

SW6

SW12

No external connection cover

SW13: TVA and XTL Switch positions

SW13

1 2 1 2 TVA XTL TVA


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3.12 Height Control Connections

The terminal strip has Arc Volts (-) connection to power supply negative output TORCH terminal, Arc Volts (+)connection to power supply positive output WORK terminal. These are for a height control that requiresconnection to the full non-divided arc voltage. Also available on the terminal strip are 120VAC (120,0) and 24VAC (24, 0). Note that the two 0’s are not common. The allowable current draw is 100ma @ 120VAC and 1Amp@ 24 VAC.

Art # A-08404

4

There is also a hole added in the rear panel above the J55-GCM receptacle for customer wiring. This, ratherthan the one in the CCM will be the preferred place for customer added wiring (and strain relief) for connec-tions to height controls, etc..


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3.13 Gas Control Module Installation

The Gas Control Module must be installed in a suitable location where it is easily accessible to the systemoperator. The unit must be mounted to a flat horizontal surface. If the Module is mounted to a gantry or to any othersupport subject to vibration or motion, the installer must fasten the module to the support securely.

The Module should be located aas far away as possible from the Arc Starter due to electromagnetic interference.It is acceptable to locate the control cable in the same track as the cables from the Arc Starter.

The Module includes feet which lift the bottom panel off the mounting surface. There are ventilation holes on thebottom panel; the space between the bottom panel and the mounting surface must remain open for ventilating airto enter the module. Louvers on the back panel of the module must also remain unblocked, for the free passageof ventilating air.

Mounting Dimensions

NOTE

Height not shown is 14.125” (359 mm)

Art # A-07962

8.50”

215.90mm

0.28”7.14mm

11.00”

279.40mm

16.18”

410.97mm

13.68”

347.47mm

Gas Box

NOTE

The unit must be mounted so that the Flowmeters are plumb. If the Flowmeters are not plumb, incorrectflow indications may occur.


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Preparation

1. Remove the screws securing the Cover Panel to the Module.

2. Carefully remove the cover from the module noting the attached ground wire. Remove the ground wire ifneeded.

Art # A-06882

Gas Control Module Cover

Do not remove

Remove GroundWire

Cover Removal


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3.14 Fiber Optic Cable Installation

1. Install the through-hole protector for the fiber-optic cable in the hole in connection panel on the back of theModule.

2. Pass the fiber-optic cable connector through the hole in connection panel on the back of the Module. Passenough of the cable into the Module to allow the cable to loop upward as shown.

CAUTION

Avoid kinking, twisting, or bunching the fiber optic cable. The cable can be damaged by being forcedinto tight-radius turns.

2

3

Circuit Board

Art # A-04772

Fiber Optic Cable

COMM

PLASMA

OUT

PREFLOW

OUT

J57

J56

SHIELD

OUT

H2O

INPUTS

TVAPOWER

SUPPLY

H35

F5

AIR N

2 O

2

1

COMM

J57

J56

INPUTS

TVAPOWER

SUPPLY

H35

F5

AIR N

2 O

2

SHIELDPLASMA

PREFLOW

H2O

SHIELD

H2O


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3. Insert the fiber-optic cable connector into the receptacle on the vertically-mounted circuit board asshown.Cable must snap into place.

Circuit Board

Fiber Optic Cable

Art # A-04773

4. Tighten the through-hole protector for the fiber-optic cable.

5. Reinstall the Cover Panel making sure the ground wire is attached.


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3.15 Gas Control Module: Control, Input, and Output Connections

1. Make all other connections to the rear of the Module. The connections are labeled. The Module must begrounded; the grounding terminal is marked Use #10 AWG (European 6 mm2) (or thicker) wire forgrounding. Keep the ground wire as short as possible.

2. Position the Module on a flat, horizontal, mounting surface.

3. Ensure that the Flowmeters are plumb.

4. Secure the Module to the mounting surface.

5. Connect all gas / water inputs to the rear panel of the module.

6. Connect the appropriate control cables to terminals marked ‘TVA’ (torch valve assembly) and ‘power sup-ply’.

Gas & Water Inputs (Check Valves)

Connection Panel

To Torch Valve Assembly

To Torch Valve Assembly

To Power Supply

SHIELD PLASMA PREFLOW

H OSHIELD

2 H O2

AIR N2 O2

H35 F5

TVAPOWERSUPPLY

COMMJ57 J56

INPUTS

When Cutting With O2 PlasmaAir MUST BE Connected

Ground Stud

SHIELD PLASMA PREFLOW

H OSHIELD

2 H O2

AIR N2 O2

H35 F5

TVAPOWERSUPPLY

COMMJ57 J56

INPUTS

When Cutting With O2 PlasmaAir MUST BE Connected

Gas Control BoxRear Panel

Art # A-06881


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3.16 Install Remote Arc Starter

Site Location

Select a clean, dry location with good ventilation and adequate working space around all components.

Review the safety precautions in the front of this manual to be sure that the location meets all safety requirements.

Interconnecting cables and hoses attach to the Arc Starter. There must be adequate space around the Arc Starterfor these connections without crimping.

Mounting Dimensions

NOTE

Height not shown is 7.375” ( 187mm )

D.250”3 PLACES

6.35mm

8.00”203.20mm

12.00”304.80mm

2.00”50.80mm

1.49”

37.77mm

10.50”

266.70mm

7.51”190.83mm

.50”12.70mm

Arc Starter Box

Art # A-07961


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Installation

The Remote Arc Starter must be installed in a suitable location near the torch head. If the Arc Starter is mountedto a gantry or to any other support subject to motion or vibration, fasten the Arc Starter to the support securely.

1. Loosen, but do not remove, the lower screws securing the cover to the Arc Starter. Remove the upperscrews securing the Cover Panel to the Arc Starter.

NOTE

A ground wire connects the cover to the Arc Starter base. This wire must remain in place.

2. Remove the Cover Panel from the Arc Starter.

Art # A-07029

Lower screws

Upper screws (4 per side)

Cover

Ground Wire

Cover Removal

3. Position the Arc Starter on a flat, horizontal mounting surface.


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4. Use pre-drilled holes in at least two of the feet on the bottom of the Arc Starter to secure the Arc Starter to themounting surface.

Art # A-04749

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 supply). Hoses and connectors are color-coded; Redfor Return, Green for Supply.

Coolant Supply and Return Hoses(from power supply)

Art # A-04750


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Coolant Return (Red)

Coolant Supply (Green)

Art # A-04751

Coolant Return(Red)

Red

Green

Art # A-04752_AB

Negative Cablefrom power supply

Negative cable must be attached so that it is in contact with the copper plate.

Copper plate

Negative Cable (from Power Supply rear panel)


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Art # A-04753

Pilot Return Cablefrom Power supply

PILOT Return Cable (from Power Supply rear panel)

Art # A-04755

Control Cable from Power Supply rear panel


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Output Connections

1. Refer to the 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 innershield wires.

Pilot Lead Connection Detail

Inner Shield Connection Detail

Inner Shield LeadPilot Lead

Art # A-04933

Pilot Return Cable and Inner Shield Lead (from Torch Leads)


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Art # A-04757

Coolant Return (Red) from Torch

Coolant Supply (Green) to Torch

Some items are removed for clarity.

Coolant Supply Fitting(Tagged with Green)

Coolant Return Fitting(Tagged with Red)

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-07029

Lower screws

Upper screws (4 per side)

Cover

Ground Wire

The Arc Starter must be grounded; the grounding terminal is marked . Refer to the previous section forgrounding details.


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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 Arc Starter as shown.

Art # A-04759

Coolant and Pilot Leads to Torch Valve Assembly

Torch Leads Shield

Shield Clamp


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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 - Input Connection Panel

Remote Arc Starter


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3.17 Original & XTL Torch Valve Installation

General Information

This assembly mounts as close as possible to the torch head. It accepts preflow, plasma, and shield gases fromthe Gas Control Module and supplies these gases to the Torch.

Mounting

1.450”36.83 mm

4.450”113.03 mm

.261” Dia.6.63 mm

Art # A-07648

1. Mount the Valve Kit as close as possible to the Torch. The valve kit can be mounted in any convenientposition, provided the outlet side (with two fittings) is closer to the torch than the inlet side (with three fittingsand a control cable connector).

2. Connect the Valve Kit outlets to the torch leads as shown. (XTL shown)

Art # A-07645

Do not remove brass plugsFront and side

Right-hand Thread:To Torch Shield Gas fitting

Left-hand Thread: To Torch Plasma Gas fitting

Outlet Side


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3. Connect the gas supply lines and the control cable connector from the Gas Control Module to the Valve Kit asshown. Hold the check valves stationary while attaching the gas lines. (XTL shown)

Control Cable

Plasma Gas Inlet

Shield Gas Inlet

Preflow Gas Inlet

WMS™ Inlet

Art # A-07646

Exhaust Muffler

CAUTION

Hold all fittings stationary while attaching hoses or leaks can be created. Side pressure can break the check valvesor weaken their connection to the torch valve assembly. All fittings must be checked for leaks after assembly.


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3.18 Connecting Torch

Connect the Torch as follows:

Art # A-04746

Pilot Lead Connector

Torch Head Assembly

Mounting Tube

O-Ring

Torch Leads End Cap

Plasma Gas(Left Hand Thread)

Shield Gas(Right Hand Thread)

Coolant Supply&

Power Lead (-)

Pilot Lead

Coolant Supply,Coolant Return,and Pilot Leads

Leads Cover

Groove for O-Ring

To Torch Valve

1. Lay out the torch leads on a clean, dry working surface.

2. Hold the Torch Leads 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 of the Mounting Tube.

5. Install the Mounting Tube as follows:

a. Position the Mounting Tube at the end of the leads assemblies as shown.

b. Slide the Mounting Tube upward onto the leads assemblies.

c. Press the upper end of the Mounting Tube into the lower end of the Torch Leads End Cap. Ensure thatthe O-Ring on the Tube engages the mating groove inside the Torch Leads End Cap.

d. Ensure that the Mounting Tube is free to rotate within the Torch Leads End Cap.


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6. Connect the gas and coolant leads to the Torch Head.

a. Coolant supply and return connections to the Torch Head are of different lengths.

b. Plasma and secondary gas connections to the Torch Head are threaded differently; the plasma gasconnection is left-hand thread, the shield gas connection is right-hand thread.

c. Hold the Torch Head leads connectors stationary; turn the leads fittings with a wrench to secure theleads to the Torch Head. Do not overtighten.

CAUTION

The gas and coolant leads include compression fittings. Do not use sealant on these connections.

Slowly apply pressure to the gas lines. Check for leaks at all connections before continuing. If thereare no leaks, shut off the gas supplies and continue with installation.

7. Connect the pilot lead to the Torch Head. Press the two ends of the connector firmly together. Thread theplastic lead cover/connector onto the mating Torch Head connector.

8. Press the Torch Head Assembly upward to connect to the Mounting Tube. Pull the leads back as neededto ensure a proper fit through the Mounting Tube and Torch Leads End Cap. Hold the Torch Head Assemblystationary; rotate the Mounting Tube to thread it onto the Torch Head.

CAUTION

Ensure that the leads do not twist within the mounting tube. Leads must lie as shown in the installation sketch.

9. The lower end of the Mounting Tube includes four threaded holes. Install an Allen set screw in any of thethreaded holes to secure the Torch Head Assembly to the Mounting Tube.

10. Install the appropriate consumable parts as shown on the following pages. The torch manual includesdiagrams showing the correct parts to install, depending on the metal to be cut and the gases in use.


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3.19 Install Consumable Torch Parts

Install the consumable parts as follows to ensure proper operation. These steps will help ensure that parts areseated correctly.

Art # A-03887

WARNINGS

Do not install consumables into the Cartridge while the Cartridge is attached to the Torch Head.Keep foreign materials out of the consumables and Cartridge. Handle all parts carefully to avoid damage, which may affect torch performance.

1. Check the appropriate cut chart for the right combination of parts for the cutting application.

2. For 200 Amp parts only, thread the Shield Retainer onto the Shield Cup.

3. Stack the consumable parts together.

ShieldRetainer

Shield CupShie

ld Cap

Shield

Gas

Distrib

utor

Tip Plasma G

as

Distrib

utor

Electr

ode

Cartrid

geArt # A-08303

A B C1 - 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. Ensure that the large O-ring on the torch tip fitscompletely into the cartridge. If any part of the O-ring protrudes from the cartridge, the parts are notseated properly.

5. Use the cartridge tool to hold the cartridge assembly, while turning the shield cup (and shield retainerfor 200 Amp parts) onto the cartridge assembly. For 300 Amp parts turn the shield retainer onto theshield cup now. When this group is fully assembled, the shield should protrude from the front of theshield cup or shield retainer. Without this protrusion the shield cup is not properly tightened onto thecartridge assembly.

6. Take the cartridge tool off the cartridge. Fit the cartridge assembly onto the torch head. The Speed Lokring should clidk into place and the cartridge assembly should touch the large O-ring on the torch body.


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Torch Head O-Ring Torch Head

Art # A-08300_AB

0.063 - 0.083"(1.6 - 2.1 mm)

Protrusion

Installing Assembled Cartridge Onto Torch Head

6. Slide the ohmic clip over the shield cup if using ohmic torch height sensing.


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55 - 100 Amp Parts Assembly

Cartridge Covers O-Ring on Torch Tip

Shield Cap Protrudes 0.063-0.083" (1.6 - 2.1 mm)

Electrode


Tip


Shield Cap

O-Ring on Tip

1: Stack Parts 2: Press Cartridge onto Stacked Parts

4: Check Shield Cap Protrusion

Art # A-04873

No Gaps Between Parts

3: Thread Shield Cup onto Cartridge

Shield Cap

Shield Cup



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7. Connect the wire lead from the height finder to the ohmic clip if using ohmic torch height

sensing. A-03393

Ohmic Clip

NOTE

Ohmic height sensing is not recommended with water shield. Water on the plate interferes electricallywith the ohmic sensing circuit.


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3.20 Complete the Installation

1. Remove the cap from the coolant tank. Fill the coolant tank to the level shown, with Thermal Dynamicscoolant. The coolant level is visible through the translucent coolant tank. The amount of coolant requiredvaries with torch leads length.

Cat. Number and Mixture Mixture Protects To7-3580 'Extra-CoolTM' 25 / 75 10° F / -12° C7-3581 'Ultra-CoolTM' 50 / 50 27° F / -33° C

7-3582 'Extreme CoolTM' Concentrate* -65° F / -51° C

Coolant Capabilities

* For mixing with D-I CoolTM 7-3583

RETURN SUPPLY

RETURN SUPPLY

Art # A-04803

COOLANT

Fill Range

Coolant Tank

2. After the complete system has been installed, check that the coolant has been pumped through thesystem as follows (see NOTE):


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NOTE

Depending on the length of the torch leads, the system may require more coolant after turning thesystem 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 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 torchleads this sequence may need to be done three to five times.

f. After the system stays operational allow the pump to operate for ten minutes to properly purge any airfrom the coolant lines before using the system.

3. Re-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 areevident, consult the coolant leak trouble-shooting guide in the maintenance section of this manual.

Manual No. 0-4748 4-1 OPERATION

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SECTION 4: OPERATION

4.01 Power Supply Control Panel

Art # A-04862

AC Indicator

Temp Indicator

Gas Indicator

DC Indicator

Status Indicator

AC Power Indicator

Indicates AC power is being supplied to the inverters when the ON/OFF switch is in ON position. Whenswitch is first set to ON, the indicator stays off until the inrush cycle is complete and the correct voltage isconfirmed.

TEMP Indicator: Normally OFF. Indicator turns ON when the internal temperature sensors detect tempera-

tures above normal limits. Let the unit cool before continuing operation.

GAS Indicator: Normally ON. Indicates gas control is ready for operation. The indicator blinks during the

purge cycle or when the gas control is not in the RUN mode or when there is a communication error. Indicatoris off when there is no call for gas flow.

DC Indicator: Indicates the power supply is generating output DC voltage.

Status Indicator: Shows system status. The number of flashes indicates the status. Refer to the Status

Code Section for details. On power supply start-up, the indicator flashes to show the revision level of theoperating software installed in the system.

OPERATION 4-2 Manual No. 0-4748

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4.02 Start-Up Sequence

1. Connect system to primary input power.

2. Turn ON/OFF switch to ON (up) position. AC Indicator turns ON after about 5 seconds.

POWER

ON

OFFO

IOFF

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 few seconds check that each inverter is correctly configured for theinput voltage and all 3 phases are present. Check Status Indicator for any codes that can help determineproblem.


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4.03 Gas Control Module Operation

Functional Overview

The Gas Control Module provides all Plasma and Secondary gas selection and control instrumentation. There arevarious controls and indicators used to set gas pressures and flows.

ENABLE

DISABLE

PLASMAPOWERSUPPLY

SHIELD

FLOW

GAS

PRESSURE

MODE GAS

GCM

2010

PLASMAPREFLOW

O2 - AIR

O2 - O2

H35 - N2

F5 - N2

AIR - AIR

N2 - H20

N2 - N2

Art # A-04771

MODE GAS

O2 - AIR

O2 - O2

H35 - N2

F5 - N2

AIR - AIR

N2 - H20

N2 - N2

ENABLE

DISABLE

PLASMAPOWER SUPPLY

FLOW

GAS

PRESSURE

99H20 MIST

RUN

SET PREFLOW

SET PLASMA& SHIELD

TEST

RUN

SET PREFLOW

SET PLASMA& SHIELD

TEST


ULTRA-CUT 100Gas Control Module: Controls & Indicators

1. MODE Selection Switch

MODE

RUN

SET PREFLOW

SET PLASMA& SHIELD

TEST

PREFLOW

H2OMIST

PLASMA SHIELD

PRESSURE

PLASMAPOWER SUPPLY

GAS

FLOW

High PrecisionPlasma Cutting System

ENABLE

DISABLE

GASMODE

RUN

SET PREFLOW

SET PLASMA& SHIELD

TEST

O2 - AIRO2 - O2

H35 -N2

F5 - N2

AIR - AIRN2 - H2O

N2 - N2

Art # A-04765

99

GCM

2010

• Normally in the RUN position during torch operation.

• In the SET PREFLOW position, Preflow or Piloting gas (Air or N2) flows to the torch allowing the operator toadjust 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 allowoperator to set the pressure (regulator & gauge) and flow (knob at top of flowmeter). Gases automatically shutoff after 2 minutes if left in the SET PLASMA & SHIELD position. GCM 2010 gas control revision AG or laterincludes inlet pressure sensors. In SET PLASMA & SHIELD position the LCD display shows alternately theplasma an shield inlet pressure. If either gas pressure is outside the acceptable range, the display shows “PSIlow (or high), the actual pressure and the limit it is below (or above).

• In the TEST position , selected cutting gasses, Plasma & Shield, also flow to the torch. The Plasma outletpressure (pressure going to the torch), is displayed.

• For GCM 2010 gas control revision AG or later the Mode Selection Switch includes a hidden function used atinitial setup to configure the gas control for the gas lead length. See Sequence of Operation, initial setup.


ULTRA-CUT 1002. GAS Selection Switch

Selects combinations of plasma and shield gases.

GAS

O2 - AIRO2 - O2

H35 -N2

F5 - N2

AIR - AIRN2 - H2O

N2 - N2

PREFLOW

H2OMIST

PLASMA SHIELD

PRESSURE

PLASMAPOWER SUPPLY

GAS

FLOW


ENABLE

DISABLE

GASMODE

RUN

SET PREFLOW

SET PLASMA& SHIELD

TEST

O2 - AIRO2 - O2

H35 -N2

F5 - N2

AIR - AIRN2 - H2O

N2 - N2

99

Art # A-04766

GCM

2010

3. LCD Display

LED display shows Gas Control Status, such as Waiting for Communication, Plasma Power Supply Disabled,Initializing, Purging and Output Current setting. It also shows operational states like Preflow, Piloting,Cutting, and Postflow. In addition there are some low level CANBus errors that are indicated by message ̂ E#.

Ê4 = CANBus error unacknowledged message.

Ê5 = CNABus error Bus off

Ê6 = CANBus error communication timed out.


ULTRA-CUT 1004. Current Control

Adjusts the output current of the power supply.


PREFLOW

H2OMIST

PLASMA SHIELD

PRESSURE

PLASMAPOWER SUPPLY

GAS

FLOW


ENABLE

DISABLE

GASMODE

RUN

SET PREFLOW

SET PLASMA& SHIELD

TEST

O2 - AIRO2 - O2

H35 -N2

F5 - N2

AIR - AIRN2 - H2O

N2 - N2

99

Art # A-04767

GCM

2010

5. Plasma Power Supply Enable / Disable Switch

The DISABLE position removes input power from the Power Supply inverters, disables the coolant pump andfan, the pilot contactor & HF and removes AC power from the gsa control solenoids shutting off all gas flow.When the switch is returned to the ENABLE position an automatic gas purge is started and then the system isreturned to normal operation under control of the CNC device.

6. PREFLOW Control Knob and Pressure Gauge

Used to set preflow gas pressure and flow. MODE switch must be in SET PREFLOW position.

7. PLASMA and SHIELD Control Knobs, Pressure Gauges and Flow Meter

Used to set plasma and shield gas pressures and flows. Mode switch must be in SET PLASMA & SHIELDposition.

8. Gas Pressure Flow Switch

At lower flow rates shield gas pressure is first set per the cut charts then the flow is set using the flow meterwith the GAS switch set in the FLOW position. Some torch parts require higher flow rates that execeed thecapacity of the flow meter. In that case, Gas switch is set in the PRESSURE position and the regulator andgauge is used to set pressure per the cut charts when no “Ball” setting is shown.

9. H2O Mist Control Knob and Flow Meter

Used to set water flow rate. MODE switch must be in SET PLASMA & SHIELD position. GAS selection switchmust be in N2-H2O position.

NOTE

Water mist is not used in all applications.


ULTRA-CUT 100

4.04 First Time Operation Matching Gas Control to Lead Length

For initial operation of GCM2010 with software version 2.1 or later.

1. Before applying AC power set the Power Supply ENABLE/DISABLE switch on the gas control module toDISABLE.

2. Set Gas Selection switch to the correct position for cutting process being used.

3. Turn on AC power and set Power Supply ENABLE/DIABLE switch to ENABLE. After a short delay toestablish communications, the gas control will start the Purge and priming sequence. (If torch and coolantleads were not already full of coolant you may be required to repeat this power on cycle and add coolantuntil the priming is complete).

4. Once the purge sequence is finished set the Mofe Switch between Run and Set Precharge. Display says“SET HOSE LENGTH” on the first line and LENGTH xxx FEET on the second. The xxx is most likely thefactory default of 175’ which is the system maximum.

5. Press in and hold the Current Control knob. Display changes to SELECT HOSE LENGTH and second linesteps downwards from 175’ to 50’ in 25’ increments. As soon as the correct length is displayed, release theknob.

6. Set the Mode Switch back to Run.

7. The initial/first time set up is complete and does not have to be done again unless the Gas Control or it’smain PC Board is replaced.

4.05 Sequence Of Operation

For first time operation see previous steps, “First Time Operation...”

1. Set the Plasma Power Supply Enable / Disable switch to Disable.

DANGER

Always shut off input power to the system before changing or inspecting torch parts.

a. Change the torch parts if necessary.

b. Set the Plasma Power Supply Enable / Disable switch (on the Gas Control Module) to Enable. TheModule performs purges of 15 seconds, 11 seconds, and another 11 seconds. This removes water fromthe torch parts.

2. Select the desired plasma and shield gas by setting the Gas Selection switch to the desired position. 2seconds after gas selection, the module purges the new gas(es) through the leads.

3. Set the preflow gas pressure.

a. Set the MODE switch to SET PREFLOW.

b. Use the PREFLOW control knob to set preflow gas pressure. Refer to the torch manual for pressuresettings.

c . Use the AMPERAGE SET-UP control knob to set the desired pre-charge pressure set point. Press the control knob for 2 seconds without rotating. Then rotate the knob to adjust pressure.


ULTRA-CUT 1004. Set the plasma and shield gas pressures and flows.

a. Set the MODE switch to SET PLASMA & SHIELD.

b. Use the PLASMA and SHIELD control knobs, pressure gauges, and flow meters to set plasma andshield gas pressures and flows. Refer to the torch manual for pressure settings.

c. In installations using water shield, use the H2O MIST control knob and flow meter to set water flow rate.Refer to the torch manual for flow rates.

5. Use the AMPERAGE SET-UP control knob to set the desired amperage output. The module will update theamperage every 2 seconds after the last adjustment to the knob. The module keeps the set point in memory.

6. Place the MODE switch to the RUN position.

7. Set the Plasma Power Supply Enable / Disable switch (on the Gas Control Module) to Enable. The Moduleperforms purges of 15 seconds, 11 seconds, and another 11 seconds. This removes water from the torchparts.

NOTE

When switching gases between operations, allow enough purge time to clear the prior gas from the torch leads.

CAUTION

While nothing prevents the operator from switching gases during piloting or cutting it is not recommended to doso. If the operator switches gases during piloting or cutting, the power supply will finish the cut with the first gaschosen. Then the gas control will switch to the new gas. Switching gases during piloting or cutting may damagetorch parts, torch leads, the control module, or the piece being cut.

Cut Quality

Cut quality requirements differ depending on application. For instance, nitride build-up and bevel angle may bemajor factors when the surface will be welded after cutting. Dross-free cutting is important when finish cut qualityis desired to avoid a secondary cleaning operation. Cut quality will vary on different materials and thicknesses.

Right SideCut Angle

Left SideCut Angle

A-00512

Kerf WidthCut SurfaceBevel Angle

Top EdgeRounding

Cut SurfaceDrag Lines

DrossBuild-Up

TopSpatter

A-00007

Cut Surface

The condition (smooth or rough) of the face of the cut.


ULTRA-CUT 100Bevel Angle

The angle between the surface of the cut edge and a plane perpendicular to the surface of the plate. A perfectlyperpendicular cut would result in a 0° bevel angle.

Top-Edge Rounding

Rounding on the top edge of a cut due to wearing from the initial contact of the plasma arc on the workpiece.

Dross Build-up and Top Spatter

Dross is molten material which is not blown out of the cut area and re-solidifies on the plate. Top spatter isdross which accumulates on the top surface of the workpiece. Excessive dross may require secondary clean-up operations after cutting.

Kerf Width

The width of material removed during the cut.

Nitride Build-up

Nitride deposits which may remain on the cut edge of the carbon steel when nitrogen is present in the plasmagas stream. Nitride buildups may create difficulties if the steel is welded after the cutting process.

Direction of Cut

The plasma gas stream swirls as it leaves the torch to maintain a smooth column of gas. This swirl effect resultsin one side of a cut being more square than the other. Viewed along the direction of travel, the right side of thecut is more square than the left.

Right SideCut Angle

Left SideCut Angle

A-00512

Scrap

Clockwise

Counter-Clockwise

Art # A-04182

Workpiece

Scrap

Swirl Effect on Side Characteristics Of Cut

To make a square - edged cut along an inside diameter of a circle, the torch should move counterclockwisearound the circle. To keep the square edge along an outside diameter cut, the torch should travel in a clockwisedirection.

Underwater Cutting

Cutting on a water table either underwater or with the water touching the plate or with a water muffler systemis not recommended. If a water table is used the water level must be a minimum of 4 inches from the bottom ofthe plate. Failure to follow this recommendation could result in poor cut quality and short consumable partslife.

Ohmic Height Sensing

Ohmic height sensing is not recommended with water shield. Water on the plate interferes electrically with theohmic sensing circuit.

Marking

Marking requires adjusting the pre-charge pressures. Refer to the torch data section for details.


ULTRA-CUT 100

4.06 Gas Selection

A. Plasma Gases

1. Air Plasma

• Most often used on ferrous or carbon base materials for good quality at faster cutting speeds.

• Air plasma is normally used with air shield.

• Only clean, dry air is recommended for use as plasma gas. Any oil or moisture in the air supply will substan-tially reduce torch parts life.

• Provides satisfactory results on nonferrous materials.2. Argon/Hydrogen (H35) Plasma

• Recommended for use on 3/4 in (19 mm) and thicker stainless steel. Recommended for 1/2 inch (12 mm) andthicker nonferrous materials. Ar/H2 is not normally used for thinner nonferrous materials because lessexpensive gases can achieve similar cut quality.

• Poor cut quality on ferrous materials.

• Provides faster cutting speeds and high cut quality on thicker materials to offset the higher 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 minimizes nitride build-up on cut surface (nitride build-up can causedifficulties in producing high quality welds if not removed).

4. Nitrogen (N2) Plasma

• Provides better cut quality on nonferrous materials such as stainless steel and aluminum.

• Can be used in place of air plasma with air shield or carbon dioxide (CO2).

• Provides much better parts life than air.

• 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 plasma.

• Improves cut quality on some ferrous materials.

• Inexpensive - reduces operating costs.2. Nitrogen (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 in mechanized applications - never in hand cutting!

• Normally used with nitrogen, Ar/H2, or air plasma.

• Provides very smooth cut surface.

• Reduces smoke and heat input to the workpiece.

• Effective up to 1/2 inch (12.7 mm) maximum material thickness.

• Tap water provides low operating expense.


ULTRA-CUT 100

4.07 Power Supply Status Codes

On start-up and during operation, the power supply control circuitry performs various tests. If the circuitrydetects a condition requiring operator attention, the status indicator on the control panel flashes a 2-part codeto indicate a code group and then a particular condition within the group. After 4 seconds, the sequencerepeats.

Example: Indicator flashes 4 times; the condition is in group 4. After a 1.2 second delay, the indicator blinks3 times; the condition code is 4-3, indicating that the coolant is overheating. After a 4-second delay, theindicator repeats the sequence until the condition is corrected.

Some conditions can be active indefinitely, while others are momentary. The power supply latches momentaryconditions; some momentary conditions can shut down the system. The indicator may show multiple condi-tions in sequence; it is important to recognize all possible conditions that may be displayed.

Note

These codes are for systems with Firmware versions 2.4 or later. If your system’s Firmware is a prior version,contact your distributor for updates.

Error Code Error Remedy / Comments

1-1System not Enabled or Missing AC Input Phase

Plasma Enable Off ; External E-Stop Activated or CCM TB1-1&2 jumper missing; Missing AC Phase; No power to GCM 2000 or 2010 Gas Control, check GCM control cable connected, reset CP4 or CP5 circuit breaker in power supply, blown fuse F19 in GCM.

1-2 Pilot Ignition FailurePilot did not start within 15 seconds. Preflow pressure too high; Defective Arc Starter

1-3 Lost PilotPilot went out without shutoff signal; Preflow pressure too high; cut current set too low for consumables.

1-4 Loss of Transfer Arc transfer (>50 ms.) then arc lost with START still on. Standoff too high; Current set too low.

1-5 Off the Plate Function not currently enabled

1-6 Pilot Timed out w/o Transfer

Must transfer from Pilot to Cutting Arc in 85 ms. (SW8-1 OFF) or 3 sec. (SW8-1 ON). Standoff too high or void in work under torch; cut current too low for consumables; Preflow pressure too low.

1-7 Tip Saver Function not currently enabled.

1-8 Possible Shorted Torch

Detected tip voltage too close to electrode voltage. Plasma flow/pressure too low; Plasma leak; cut current too high; shorted torch body; consumable parts worn out.

Fault Code Key


ULTRA-CUT 100


2-1 Missing Phase Blown fuse, Broken or loose connection on power cable

2-2 Wrong input voltage

Inverter(s) not configured correctly for input voltage; Poor power quality (brownouts, dropouts); Input power capacity / wiring too small causing voltage drop; broken or loose power cable connections.

2-3Inverter or Pilot Regulator Over Temperature

Failed fan; Ambient above 40 deg C. (104 F); Blocked airflow

2-4 Power Supply not Ready Defective inverter

2-5 DC Output LowOutput less than 60 VDC; Defective inverter, shorted output; Shorted pilot regulator (chopper); CCM voltage sense (J6) wire open or disconnected.

2-6 Primary over current faultOver current detected in inverter primary circuit, remove power to reset; defective inverter; voltage surge;

2-7 Unexpected currentCurrent >20A in work or pilot leads before pilot ignition; Possible shorted torch; Defective current sensor.

2-8Unexpected current in pilot circuit

Current > 5A in pilot circuit; wrong or mismatched consumables; Pilot lead shorted to negative in torch tube; Possible shorted torch

2-9Unexpected current in work lead

Current > 5A in work lead; Short to chassis in RAS; Negative lead short to ground.

3-1

Gas Control Communication fault, Cannot establish Communication with gas control.

If GCM 1000: Control cable not connected or Basic ID signal open. GCM 2010 & 2000: Dirt on fiber ends or in connectors, blow out with clean dry air; fiber not locked into connector; sharp bends in fiber; fiber defective; Gas Control PCB defective, replace. CCM defective, replace.

3-2

Gas Control Communication reply fault, connection was established but CCM did receive a reply to a process request.

Gas Control did not reply to signal from CCM in allowed time. Dirt on fiber ends or in connectors, blow out with clean dry air; fiber not locked into connector; sharp bends in fiber; fiber defective. If problem persists Gas Control PCB likely defective, replace board.

3-3 Gas Pressure Low

If GCM 1000, Plasma < 15 PSI; faulty or disconnected pressure SW. If GCM2010_AG, GCM2000_AC or later or Gas Control has been updated with 19X2219_AG or later PCB: Plasma or Shield input out of range 105-135. If GCM2010_AG, GCM2000_AC or later or Gas Control has been updated with 19X2219_AG or later PCB: Plasma or Shield input out of range 105-135 PSI; Unplugged or Faulty pressure sensor.

3-4 Gas Control not ready Purging; not in RUN mode; Gas Control faulty, replace PCB.3-5 Gas Control Protocol Fault Application error or firmware compatibility fault

3-6Invalid Current Control level from GCM

GCM sent output current level outside the range of the power supply, Check firmware compatibility

3-7Gas Control returns wrong command sequence

Check firmware compatibility

3-8CCM and Gas Control type (Autocut-Ultracut) mismatch

Install correct CCM or Gas Control for system

3-9Gas Control Communication reply fault

Reply not compatible with request; Check firmware compatibility

3-10Warning. -- Gas Control firmware needs update

System will function but control may not be optimized for best performance / consumable life

Fault Code Key


ULTRA-CUT 100


4-1 Coolant Level low fault Check coolant level, add as needed.

4-2

Low coolant flow after power on purge. Not cutting: < 0.7 gal/min for 15 sec; Cutting: flow between 0.35 to 0.7 gal/min for 3 sec. or immediately if < 0.35gal/min;

Suction leak introducing air into coolant, suspect rear panel filter seal; clogged filter; defective pump.

4-3Coolant overheated (>70 deg. C, 158 deg F)

Coolant fan failed; radiator fins clogged with dirt; Ambient temperature > 40 deg C.

4-4

Coolant System not ready. During power on purge / priming, flow did not reach 0.35 gal/min for at least 5 seconds

If new installation recycle power to restart pump, may take a few times to fill hoses; Damaged torch coolant tube; Suction leak introducing air into coolant, suspect rear panel filter seal; clogged filter; defective pump.

4-5 Low Coolant Level - WarningWhile cutting detected low coolant level, does not stop cut. Add coolant as required.

5-1CANBUS Failure to Acknowledge fault.

If GCM 1000, Basic ID signal missing; Other gas controls, Fiber disconnected or broken, Transceiver (what fiber plugs into) fault, replace Gas control PCB or CCM

5-2CANBUS Off due to excessive data errors;

Dirt on fiber ends or in connectors, blow out with clean dry air; fiber not locked into connector; sharp bends in fiber; fiber defective;

5-3CANBUS data error warning. Errors increasing, will soon fault.

Dirt on fiber ends or in connectors, blow out with clean dry air; fiber not locked into connector; sharp bends in fiber; fiber defective;

5-4 CCM Message not sentDirt on fiber ends or in connectors, blow out with clean dry air; fiber 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 CCM6-2 CCM ADC or DAC error Replace CCM

6-3Coolant Flow too High error, flow > 2.7 gal/min

Torch coolant tube broken or missing; CCM fault, replace CCM

6-4 CCM Data Memory error Replace CCM

Fault Code Key


ULTRA-CUT 100

4.08 Remote Arc Starter: Service Chart

Symptom Cause Check Remedy

Coolant has become conductiveUse conductivity meterFlush system, replace coolant.

Pilot return wire not connected Visual inspection Connect Wire.Spark gap set too close Check with feeler gauge Set to 0.063" ±0.002"High Frequency cap (C4) possibly open

Use capacitance meter Reconnect or replace.

Broken or missing ferrites Visual inspection Replace.

Short across in inductor (L1) Visual inspectionRemove short; increase coil gaps.

Spark gap bus caps (C1, C2, C3) broken or defective

Capacitance meter Replace.

Negative supply not connected correctly

Visual inspection Reconnect.

Spark gap set too large Check with feeler gauge Set to 0.063" ±0.002"Faulty transformer Resistance measurement Replace.

No 120V supply Check input voltage at EMI filter Make connections; replace harness.

No/ loose connection to spark gap

Visual inspection Reconnect.

Faulty EMI filter Voltage/ Resistor measurement Replace.Loose fitting(s) Visual inspection Tighten fittings.Failure to braze joints (L1) Visual inspection Replace HF Coil.Damaged or punctured coolant line(s).

Visual inspection Replace coolant line(s).

Supply & return hose reversedVisual Inspection of color-coded connections

Match coolant connection colorsto arc starter fitting colors.

Blockage in coil orsupply/return hoses

Loosen fitting slightly and check for coolant flow

Flush system.

Shield Drain / Torch lead inner shield connector missing or loose.

Visual inspection of lead attachment to Arc Starter

Reconnect / tighten lead connectors.

Missing or loose ground connection

Visual inspection of ground wire to Arc Starter

Make or tighten connections to good ground.

Cap C5 not connected, open or loose

Visual inspection / capacitor measurement

Replace PCB.

Arc Starter Service Chart

Erratic System Behavior

(EMI Interference)

No Pilot ignition: Spark in Arc Starter

but no ignition

No Pilot ignition: No Spark

in Arc Starter

No cooling or insufficient cooling:

Leaks coolant

No cooling or insufficient cooling:

No Coolant Flow


ULTRA-CUT 100

4.09 Remote Arc Starter: SparkGap Adjustment

Art # A-04857

0.063" ± 0.002"1.6 ± 0.05 mm


ULTRA-CUT 100

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Manual No. 0-4748 5-1 MAINTENANCE

ULTRA-CUT 100

SECTION 5: MAINTENANCE

5.01 General Maintenance

Perform the following checks periodically to ensure proper system performance.

Power Supply Maintenance ScheduleDailyCheck coolant level; add coolant as needed.Check gas hose connections and pressures.

MonthlyCheck cooling fan and radiator; clean as needed.Check gas hoses for cracks, leaks, or abrasion. Replace as needed.Check all electrical connectionsfor cracks or abrasion. Replace as needed.

Six MonthsClean 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 cleaning of the coolant filter ensures maximum coolant flow efficiency. Poor coolant flow causes ineffi-cient torch parts cooling with consequent faster consumable wear.

Clean the coolant filter as follows:

1. Disconnect the system from main input power.

Filter Screen

Filter Holder

Art # A-04811

2. Unscrew and remove the filter bowl by hand. Be sure to keep the O-ring.

3. Remove and clean the filter. Re-install the bowl, tightening it by hand. Be sure the O-ring is in place.

4. Turn the system on and check for leaks.

MAINTENANCE 5-2 Manual No. 0-4748

ULTRA-CUT 100

5.03 Internal Coolant Filter Cleaning Procedure

The in-line filter screen should be cleaned periodically. To gain access to the In-Line Filter Assembly remove theright side panel (viewed from the front of unit) of the Power Supply. Remove the filter screen by unscrewing thefilter holder from the In-Line Filter Assembly. Clean the filter screen by rinsing with hot soapy water. Remove soapresidue by rinsing with clean hot water. Be sure that all the soap has been removed and the screen is dry of waterbefore re-installing in the In-Line Filter Assembly.

5.04 Coolant Replacement Procedure

Replace coolant as follows:

1. Disconnect the system from main input power. At the bottom of the coolant tank, disconnect the coolantline fitting and collect coolant in a disposable container.

2. Connect the system to main input power and turn it on to allow the pump to empty the tank. The pump willrun approximately for 20 seconds before the flow switch causes an interlock. This procedure may berepeated a few times until the tank is completely empty.

3. Connect the coolant line fitting and fill the tank with fresh coolant until the right level is reached.

Manual No. 0-4748 5-3 MAINTENANCE

ULTRA-CUT 100

RETURN SUPPLY

RETURN SUPPLY

Art # A-04803

COOLANT

Fill Range

Coolant Tank

4. Turn system on, let it run for a few minutes and check coolant level, refill if necessary.

MAINTENANCE 5-4 Manual No. 0-4748

ULTRA-CUT 100

This page is blank intentionally.

Manual No. 0-4748 6-1 Power Supply Parts List

ULTRA-CUT 100

SECTION 6: REPLACEMENT ASSEMBLIES & PARTS

6.01 Main Component / System Replacement

Complete Unit / Component Catalog Number

Ultra-Cut® 100 Power Supply, 208/230V 3-9116-1

Ultra-Cut® 100 Power Supply, 460V 3-9116-2

Ultra-Cut® 100 Power Supply, 400V 3-9116-3

Ultra-Cut® 100 Power Supply, 400V (CE) 3-9116-4

Gas Control Module (GCM-2010) with XTL Torch Valve Assembly 3-9131

(Requires Firmware version 3.2 or higher for C.C.M.)

Gas Control Module (GCM-2010) Only 7-4000

Original Torch Valve Assembly Repair Part Only 4-3049

XTL Torch Valve Assembly Only 4-3054

(Requires C.C.M. Firmware version 3.2 or higher and

GCM 2010 Firmware version 3.1 or higher)

Remote Arc Starter (RAS-1000) 3-9130

OPTIONAL EQUIPMENT:

Wheel Kit 9-9379

Power Supply Parts List 6-2 Manual No. 0-4748

ULTRA-CUT 100

6.02 System Layout

Primary power

Work

CNC

RemoteArc

Starter

Art # A-07233_AB

Torch

Coolant Supply

Coolant Return

Control Cable

Pilot Return

Coolant Supply

Coolant Return

Plasma Gas

Shield Gas

Work Cable

FiberOpticCable

Control Cable

Gas ControlModule

Power Supply

TorchValve


Plasma Gas

Preflow Gas

Water Shield

Shield

Shield Gas

Negative

Pilot Return

Control Cable



Shield

H

Q

R

T

S

A

B

C

D

E

P

K

L

O

I

JG


Refer to section 3.05 for ground connections and ground cables.

6.03 Recommended Gas Supply Hose

Item # Qty Description Catalog #

1 3/8”Gray Synflex Hose. No fittings included. Catalog number per foot 9-3616


ULTRA-CUT 100

6.04 Leads and Cables

Green / Yellow # 4 AWG

Green / Yellow 1/0 (50 mm )

A

Green

Red

Art # A

-07473

#8 AWG Cable

#1 AWG Cable

B

C

D

E

F

F1

K

L

H, Q, R, S,T

Work Cable

CNC Cable (14 Wire)

37

14

Coolant Supply Lead, Power Supply to Arc Starter

1/0 Cable (1/0 (50 mm )

Pilot Return, Power Supplyto Arc Starter

Negative Lead, Power Supplyto Arc Starter

Control Cable, Power Supplyto Arc Starter

Ground Cable

Ground Cable,Remote Arc Starter To Earth Ground

O

P

Fiber Optic Cable, Power Supply to Gas Control Module

Control Cable, Power Supply to Gas Control Module

Green

RedCoolant Return Lead, Power Supply to Arc Starter

2

2

14

GShielded Torch Lead Assembly, Remote Arc Starter to Torch

Plasma Gas Lead,Torch Valve to Torch

Shield Gas Lead,Torch Valve to Torch

I

J


ULTRA-CUT 100

Key Description Catalog #

A,B,C,D,E Supply Lead Set, 4’ / 1.3 m (See Note 1) 4-3027








A,B,C,D,E Supply Lead Set, 125' / 38.1 m (See Note 1) 4-3034

A Pilot Return Cable (only), 4' / 1.2 m 9-4890

A Pilot Return Cable (only), 10’ / 3.05 m 9-4891





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 (only), 3’ / 1 m 9-4892

B Negative Cable (only), 10’ / 3.05 m 9-4897








C Hose, Coolant Supply, (only), 3’ / 1 m 9-4886

C Hose, Coolant Supply, (only), 10’ / 3.05 m 9-4887

C Hose, Coolant Supply, (only), 15’ / 4.6 m 9-4780C Hose, Coolant Supply, (only), 20’ / 6 m 9-4781C Hose, Coolant Supply, (only), 25’ / 7.6 m 9-4782C Hose, Coolant Supply, (only), 30’ / 9.1 m 9-4783C Hose, Coolant Supply, (only), 35’ / 10.6 m 9-4784C Hose, Coolant Supply, (only), 40’ / 12 m 9-4785

NOTE 1:

Supply lead sets include Pilot Return Cable, Nega-tive Cable, Coolant Supply & Return Hoses, andControl Cable.


ULTRA-CUT 100


C Hose, Coolant Supply, (only), 50’ / 15.2 m 9-4786C Hose, Coolant Supply, (only), 75’ / 23 m 9-4787C Hose, Coolant Supply, (only), 100’ / 30.5 m 9-4788

D Hose, Coolant Return, (only), 3’ / 1 m 9-4888

D Hose, Coolant Return, (only), 10’ / 3.05 m 9-4889

D Hose, Coolant Return, (only), 15’ / 4.6 m 9-4762D Hose, Coolant Return, (only), 20’ / 6 m 9-4763D Hose, Coolant Return, (only), 25’ / 7.6 m 9-4764D Hose, Coolant Return, (only), 30’ / 9.1 m 9-4765D Hose, Coolant Return, (only), 35’ / 10.6 m 9-4766D Hose, Coolant Return, (only), 40’ / 12 m 9-4767D Hose, Coolant Return, (only), 50’ / 15.2 m 9-4768D Hose, Coolant Return, (only), 75’ / 23 m 9-4769D Hose, Coolant Return, (only), 100’ / 30.5 m 9-4770

E Control Cable (only), Power Supply to Arc Starter 3’ / 1 m 9-4941

E Control Cable (only), Power Supply to Arc Starter 10’ / 3.05 m 9-4916






E Control Cable (only), Power Supply to Arc Starter 125' / 38.1 m 9-4922

F Ground Wire, Power Supply to Gas Control Module, 3' / 1 m 9-4923

F Ground Wire, Power Supply to Gas Control Module, 15’ / 4.5 m 9-4924





F Ground Wire, Power Supply to Gas Control Module, 125' / 38.1 m 9-4929


F1 Ground Wire, Remote Arc Starter to Earth, 3' / 1 m 9-4931

F1 Ground Wire, Remote Arc Starter to Earth, 15’ / 4.5 m 9-4932





F1 Ground Wire, Remote Arc Starter to Earth, 125' / 38.1 m 9-4937



ULTRA-CUT 100

NOTE 2:

Gas lead sets include Plasma Gas Hose, Shield GasHose, Preflow Gas Hose, and Control Cable.


G Assembly, Torch Lead, 10’ / 3.05 m 4-3053G Assembly, Torch Lead, 15’ / 4.6 m 4-3009G Assembly, Torch Lead, 20’ / 6 m 4-3010G Assembly, Torch Lead, 25’ / 7.6 m 4-3011G Assembly, Torch Lead, 30’ / 9.1 m 4-3012G Assembly, Torch Lead, 35’ / 10.6 m 4-3013G Assembly, Torch Lead, 40’ / 12 m 4-3014G Assembly, Torch Lead, 50’ / 15.2 m 4-3015G Assembly, Torch Lead, 75’ / 23 m 4-3016G Assembly, Torch Lead, 100’ / 30.5 m 4-3017

H,Q,R,S,T Gas Lead Set, 10’ / 3.05 m (See Note 2) 4-3035







H,Q,R,S,T Gas Lead Set, 125' / 38.1 m (See Note 2) 4-3041



I Plasma Lead 4’ / 1.22 m (Torch Valve Assembly to Torch) 9-3333

J Shield Lead 4’/ 1.22 m (Torch Valve Assembly to Torch) 9-3334

L Control Cable, Fiber Optic, 3’ / 1 m 9-4898

L Control Cable, Fiber Optic, 15’ / 4.5 m 9-4899






L Control Cable, Fiber Optic, 125' / 38.1 m 9-4904




ULTRA-CUT 100


K Control Cable, Power Supply to Gas Control Module, 3’ / 1 m 9-4907

K Control Cable, Power Supply to Gas Control Module, 15’ / 4.5 m 9-4908






K Control Cable, Power Supply to Gas Control Module, 125' / 38.1 m 9-4913


O Work Cable, 10’ / 3.05 m 9-9300

O Work Cable, 15’ / 4.5 m 9-9301

O Work Cable, 25’ / 7.6 m 9-9302

O Work Cable, 35' / 10.6 m 9-9303

O Work Cable, 50’ / 15.2 m 9-9304

O Work Cable, 75’ / 22.9 m 9-9305

O Work Cable, 100’ /30.5 m 9-9306

O Work Cable, 125' / 38.1 m 9-9307

P Control Cable, CNC to Power Supply, 25’ / 7.6 m 9-8312




P Control Cable, CNC to Power Supply, 125' / 38.1 m 9-8317


ULTRA-CUT 100

6.05 Power Supply External Replacement Parts


1 1 Power Supply Front Panel 9-0440

2 1 Power Supply Rear Panel 9-0441

3 1 Power Supply Top Panel 9-0445

4 1 Power Supply Right Side Panel 9-0442

5 1 Power Supply Left Side Panel 9-0443

6 1 Louver Panel 9-0444

7 1 Power Supply Connections Cover 9-0446

8 1 Lifting Eye 9-9373

Art # A-06888_AB

2

6

1

3

8

7

5

4


ULTRA-CUT 100

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 same fan used with the Inverter

12

Art # A-08308


ULTRA-CUT 100



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 Resistor R9

6 1 Capacitor C2

1

2

Art # A-08309

4

5

6

3


ULTRA-CUT 100



1 Chopper Module 9-9389

1 Sensor HCT1 9-9342

Chopper Module

Art # A-08311

HCT1


ULTRA-CUT 100

6.09 Power Supply Replacement Parts - Front Panel


7 1 Main Power Switch (‘Circuit Protector’) CP1 9-9344 for 230-400-460 VAC units

7

Art # A-08312


ULTRA-CUT 100

6.10 Power Supply Replacement Parts - Front Panel


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 PCB6 9-9347

PCB3

PCB4

PCB6

Art # A-08313


ULTRA-CUT 100



1 1 PCBoard 230-400-460VAC PCB1 9-9362

1 1 PCBoard 600VAC PCB1 9-9491

2 1 Magnetic Contactor MC1 9-9364

ONLY 1 for this unit

Art # A-08314

1 2 2


ULTRA-CUT 100

6.12 Power Supply Replacement Parts - Rear Panel

Item # Qty Description Breaker Rating Cicuit Rating Ref. Des. Catalog #

12 1 Circuit Breaker (RAS) 125V, 2.5 A 120VAC @ 1A CP2 9-9348

13 1 Circuit Breaker (’TDC’) 125V, 3.15A 24VAC @ 2A CP3 9-9349

14 1 Circuit Breaker (AGC) 125V, 10A 24VAC @ 5A CP4 9-9350

15 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 24VDC @ 1A CP8 9-9349

1 Coolant Tank 9-5948

1 Tank Cap 8-5142

1 Filter, Coolant 8-4276

RETURN SUPPLY

Art # A-04932_AB

COOLANT

Coolant Tank

Tank Cap

Filter

RAS125V 2.5A

CCM125V3.15A

GCM125V 10A

GCM125V2.5A

GCM125V2.5A

PUMP250V 10A

FAN125V 3.15A

CIRCUITBREAKERS

J55

J59

J15

GCM

CNC

RAS

CP2

CP3

CP4

CP5

CP6

CP7

CP8

12

13

14

15

16

17

18

Art # A-06017_AC


ULTRA-CUT 100



1 1 Resistor R7 9-93632 1 Rectifier (Diode) D1 9-93453 1 Transformer T1 9-9355

for 230/460 VAC units4 1 Diode D2 9-94865 1 Terminal Strip TB3 N/A

Art # A-08310

1

2

3

4

5


ULTRA-CUT 100

6.14 Power Supply Replacement Parts


29 2 Inverter Module 208/230V 9-9360D2 Inverter Module 400V CE and 400V Non CE 9-9482D2 Inverter Module 600V 9-9485D

Not Shown:2 Inverter Cooling Fan 9-9338

NOTE: The Inverter Cooling Fan is the same fan used for Heat Exchanger cooling.

Art # A-04786_AB


ULTRA-CUT 100



30 1 Sensor (Thermistor) TH1 9-9361

30

Art # A-04787


ULTRA-CUT 100

6.16 Power Supply Replacement Parts


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 9-9346

Art # A-08315

1

2

3


ULTRA-CUT 100



22 1 Sensor (Level Switch) LSW1 9-9354

24 1 Motor MOT1 9-9381

25 1 Pump/Check Valve/Bypass Valve Assembly 9-9380

26 1 Bypass Valve (part of assembly)

27 1 Pump (part of assembly)

28 1 Sensor (Flow Indicator) F1 9-9359Illustration is for Reference ONLY

27

22

25

2426

28

Art # A-08236


ULTRA-CUT 100

6.18 Gas Control Module (GCM-2010) Replacement Parts


1 6 7W Solenoid for O2 use 9-93932 1 Gas Selection Manifold Assembly 9-93913 1 Check Valve, 1/4 NPT .5 PSI 9-93904 1 Mode Switch Assembly 9-94065 1 Gas Selection Switch Assembly 9-94036 1 LCD Display 9-94087 1 Rotary Encoder (Switch) 9-93988 1 Toggle Switch 9-34269 1 Solenoid / Logic PC Board 9-9409

10 1 Cover 9-941011 3 Gauge, 0-160 psi 8-680012 1 Regulator 8-322313 1 Pressure Transducer and wire harness 100 PSI 9-940714 2 Pressure Transducer and wire harness 250 PSI 9-9508

NOT SHOWN:1 Power Supply Connection Wire Harness (J3 & J5 to J56) 9-94001 LCD Interface PC Board Wire Harness 9-94011 Rotary Encoder (Switch) Wire Harness 9-94021 Solenoid Drive A Wire Harness (J12 to Solenoids 1-6) 9-94041 Solenoid Drive B Wire Harness (J1 to Solenoids 7-12) 9-9405

Art # A-07030_AB2

1

1

1

1

3

7

8

45

6

33

1

1

8

910

12

12

14

11

11

13

12

14

11


ULTRA-CUT 100

6.19 Gas Control Module (GCM-2010) Replacement Parts


1 1 1” Black Instrument Knob 9-4233

2 1 Water Flow Meter with Valve 9-7005

3 1 Toggle Switch, 2 position SPDT 9-3426

4 1 Pressure gauge, 2” diameter 8-6800

6 1 Flow Meter 8-6801

Not shown -

Valve Assembly 9-9382

Tube 9-9383

Knob 9-9384

7 1 Protective Display Lens (only) 9-9395

PREFLOW

H2OMIST

PLASMA SHIELD

PRESSURE

PLASMAPOWER SUPPLY

GAS

FLOW

AMPERAGESET-UP


ENABLE

DISABLE

GASMODE

RUN

SET PREFLOW

SET PLASMA& SHIELD

TEST

O2 - AIRO2 - O2

H35 -N2

F5 - N2

AIR - AIRN2 - H2O

N2 - N2

99

GCM

2010

Art # A-04814

3

4

1

2

6

7

3

6

1 1

4


ULTRA-CUT 100

6.20 Remote Arc Starter (RAS-1000) Replacement Parts


1 1 Harness, Internal (Not Shown) 9-4956

2 1 Pilot Cap Assembly 9-4960

3 1 EMI Filter 9-1023

4 1 HF Water Cooled Coil Assembly 9-4958

5 1 HF Transformer Assembly, Arc Starter 9-4959

6 1 Enclosure, Arc Starter Base 9-4961

7 1 Spark Gap/Cap Assembly HF 9-4957

8 1 Ferrite Bead 2" Long 9-4965

Art # A-04898_AB

3

5

4

6

7

8

8

2To TorchValve


ULTRA-CUT 100

6.21 Remote Arc Starter (RAS-1000) Replacement Parts


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

Art # A-048993

4

1

2

1

Coolant Leads,from Power Supply


ULTRA-CUT 100

6.22 Command & Control Module Type 2 - Replacement Parts


1 1 Assembly, CCM (Ultra-Cut) 9-9417

2 1 Plate, CCM Face 9-9419

3 1 Panel, CCM Mount Not Available

4 1 Harness, CCM I/O Board 9-9421

3

4

2

1

Art # A-06867_AB

NOTE

This page covers parts for Command & Control module without an external connections cover. See previouspage for Command & Control module with an external connections cover.


ULTRA-CUT 100

6.23 XTL Torch Valve Assembly External Replacement Parts

NOTE

The XTL Torch Valve Assembly requires Firmware versions 3.2 or higher for the C.C.M. and 3.1 or higher forthe GCM 2010. It also requires the resetting of DIP switches in the C.C.M..


1 1 Torch Valve Assembly 4-3054

2 1 Torch Valve Assembly Harness 9-9413

3 1 Plug, 14 Circuit 9-3294

4 1 Check Valve 8-4512

5 3 Check Valve 9-7006

6 1 1/8 NPT STR.TEE Fitting 8-0352

7 1 Street Elbow (Bushing) 8-3369

8 1 Top Cover 9-3324

9 1 Front Cover 9-3323

1

Art # A-07650

3

7

5

42

6

8

9


ULTRA-CUT 100

6.24 XTL Torch Valve Assembly Internal Replacement Parts

NOTE

The XTL Torch Valve Assembly requires Firmware versions 3.2 or higher for the C.C.M. and 3.1 or higher forthe GCM 2010. It also requires the resetting of DIP switches in the C.C.M..


1 1 Exhaust Muffler 9-3321

2 2 Solenoid 9-3319

3 3 Solenoid 9-9392

Art # A-07651

SOL18SOL19

1

2

3


ULTRA-CUT 100

Intentionally Blank

Manual 0-4748 7-1 TORCH MAINTENANCE

ULTRA-CUT 100

SECTION 7. TORCH MAINTENANCE

7.01 Consumable Removal

1. Use the Cartridge Tool to hold the Shield Cup & Cartridge Assembly stationary. Turn the Shield Cup toremove 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 Cartridge Assembly Use the Cartridge Tool to push the consum-able parts out of the Cartridge.

Cartridge Tool Cartridge Assembly

Art # A-04345_AB

TORCH MAINTENANCE 7-2 Manual 0-4748

ULTRA-CUT 100

7.02 O-Ring Lubrication

Lubricate all three O-Rings on the Cartridge Assembly and all three O-Rings on the Torch Head periodicallywith O-Ring Lubricant supplied. Remove the snap ring on the cartridge assembly and slide the locking ringdownward for access to the O-Ring under the locking ring.

O-Ring, Cat. No. 8-0544

Inner O-Ring (Cat. No. 8-0545) Location (Under Locking Ring)

O-Ring, Cat. No. 8-0540

Art # A-04071_AB

Snap Ring

Cartridge Assembly

O-Rings

Art # A-04066

Cat. No. 8-0539

Cat. No. 8-3487

Cat. No. 8-0530

Torch Head

Cat. No. 9-9041

CAUTION

Use only Thermal Dynamics No. 9-4893 O-Ring Lubricant (Christo Lube MCG-129) with this torch part. Use ofother lubricants may cause irreparable damage to the torch.


ULTRA-CUT 100

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 Electrode Worn ElectrodeGood Tip Worn Tip

Art # A-04745_AB


ULTRA-CUT 100

7.04 Torch Consumables Installation

Art # A-03887

WARNINGS

Do not install consumables into the Cartridge while the Cartridge is attached to the Torch Head.Keep foreign materials out of the consumables and Cartridge. 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 - 2.1 mm)

Electrode


Tip


Shield Cap

Upper O-Ring on Tip

1: Stack Parts 2: Press Cartridge onto Stacked Parts

4: Check Shield Cap Protrusion

Art # A-04716

No Gaps Between Parts

3: Thread Shield Cup onto Cartridge

Shield Cap

Shield Cup


ULTRA-CUT 100

2. Remove the Cartridge Tool from the Cartridge and install the assembled Cartridge onto the Torch Head.

CAUTION

The cartridge assembly must cover the O-Ring on the torch head.

Do not force the cartridge if it will not tighten fully. Remove the cartridge assembly and gently clean the threads onthe 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


3. Slide the ohmic clip over the shield cup if using ohmic torch height control sensing.

A-03393

Ohmic Clip

4. Connect the wire lead from the height finder to the ohmic clip.


ULTRA-CUT 100

Amperage Plasma Gas Recommended Wear Depth for Replacement

Inch mm O2 0.04 1 Air 0.04 2 O2 0.04 1 Air 0.08 2 O2 0.04 1 Air 0.08 2 O2 0.04 1 H35 0.08 2

30

50

70

100

No

Yes

Yes

Are Parts New or Used?

Are Parts fullyassembled into

the Torch?

Unsure?

Disassembly fullyand re-assemble

the Torch Properly.See Installation Manual. Replace Torch Head

Is the Torch Damaged?

Replace ConsumableCartridge and Shield Cup.

Torch still leaks?

Remove and Lubricateall O-rings on Torch Head,Consumables Cartridge,

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.

Order CoolantTube Replacement Kit

Leaking fromCoolant Supply or Coolant Return?

Yes

Yes

Yes

No Return

Supply

Used

Order Coolant Check ValveKit 9-4846

New

Torch leaks

Torch Electrodes

Are Torch Consumable Parts Installed?

Art # A-04704_AB

7.05 Coolant Leak Trouble-Shooting

Never operate the system if coolant leaks from the torch. A steady drip indicates that torch parts are damaged orinstalled improperly. Operating the system in this condition can damage the torch head. Refer to the followingchart for guidance on coolant leakage from the torch head.

Manual 0-4748 A-1 APPENDIX

ULTRA-CUT 100

APPENDIX 1: Remote Arc Starter Schematic

5 5

4 4

3 3

2 2

1 1

DD

CC

BB

AA

NE

G (

from

PS

)

120

VA

C

120

VA

C R

ET

CH

AS

SIS

GN

D

PIL

OT

RE

TUR

N (

from

torc

h)P

ILO

T R

ETU

RN

(fro

m to

rch)

NE

G

PLT

SH

LD

CG

ND

DW

G N

o:She

etof

Sup

erse

des

Sca

le

Dat

e:D

raw

n:

Ref

eren

ces

Dat

eB

yR

evis

ions

Rev

PC

B N

o:A

ssy

No:

Info

rmat

ion

Pro

prie

tary

to T

HE

RM

AL

DY

NA

MIC

S C

OR

PO

RAT

ION

.N

ot F

or R

elea

se, R

epro

duct

ion,

or

Dis

trib

utio

n w

ithou

t Writ

ten

Con

sent

.

NO

TE

: UN

LES

S O

TH

ER

WIS

E S

PE

CIF

IED

-1.

RE

SIS

TOR

VA

LUE

S A

RE

EX

PR

ES

SE

D IN

OH

MS

, 1/4

W 5

%.

2. C

APA

CIT

OR

VA

LUE

S A

RE

EX

PR

ES

SE

D IN

MIC

RO

FAR

AD

S (

uF).

Chk

:A

pp:

TIT

LE:

Last

Mod

ified

:S

ize

SC

HE

MAT

IC,TH

ER

MA

L D

YN

AM

ICS

IND

US

TRIA

L PA

RK

#2

WE

ST

LEB

AN

ON

, NH

037

84(6

03) 2

98-5

711

Tues

day,

Nov

embe

r 01

, 200

514

:47:

17

of

Info

rmat

ion

Pro

prie

tary

to T

HE

RM

AL

DY

NA

MIC

S C

OR

PO

RAT

ION

.

TIT

LE:

ofT

ITLE

:

8X29

0N

EG

& H

F (t

o To

rch)

8X291

DAT

9-21

-04

RA

S-1

000

AR

C S

TAR

TE

R

PO

WE

R S

UP

PLY

AR

C S

TAR

TE

R

TOR

CH

Jum

per i

n C

able

to ID

Arc

Sta

rter

Con

nect

ed

Wat

er C

oole

d In

duct

or

L1

T1 A

ssem

bly

TOR

CH

LE

AD

IN

NE

R S

HIE

LD

AB

E

CO

101

810

RS

11/0

1/05

14 P

IN

J59

--R

AS

14 P

IN

1 2 3 4 5 6 7 8 9 10 11 12 13 14

T111

X16

1 2

3 4

GA

P1

SPA

RK

GA

P 0

.060

"C2

1900

pf

C4

0.1

uf 1

000V

DC

R1

6.8

K 1

W

<P

art N

umb

er>

C6

0.1

uf 1

000V

DC

Line

1

Line

2

Load

1

Load

2

GN

DP

ILO

T

WO

RK

WO

RK

C3

1900

pf

R2

6.8

K 1

W

<P

art N

umb

er>

C5

0.04

7 uf

100

0VD

C

CH

AS

SIS

GN

D

C1

1900

pf

NE

G

C7

0.04

7 uf

100

0VD

C

16 P

IN

J58

16 P

IN

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

PIL

OT

NE

G (

from

PS

)

Art

# A

-068

96_A

B

WO

RK

42X

1191

1

1

Line

Filt

er 1

ph

AA

I

nitia

l Rel

ease

T

PM

8/26

/05

APPENDIX A-2 Manual 0-4748

ULTRA-CUT 100

APPENDIX 2: Gas Control and Torch Valve Schematic

Art # A-07200

5

5

4

4

3

D

C

B

A

(16) (17) (18) (19) (20) (21) (29) (30) (31) (32)(28) (33)

120 VAC(60)

(61)(61)(61)(61)

(1) (9)(7)(6)(5)(4)(3)

(10)

(14)(13)

(67)

(66)

(65)

(64)

(63)

(62)

(22)

(23)

(24)

(25)

(26)

(27)

(34)

(35)

(36)

(37)(37)(37)

(38)

(39)

(59)

(50)

(51)

(53)

(52)

120 VAC to SOLENOIDS

120 VAC to BOARD POWER

24 VAC

(56)

24 VAC RET

(57)

(54)(54)(54)(54)

)85(+ POTS-E (58))85(+ POTS-E )85(+ POTS-E (58))85(+ POTS-E )85(+ POTS-E (58))85(+ POTS-E )85(+ POTS-E (58))85(+ POTS-EE-STOP -

Shield

(8)(8)(8)(8)(8)(8)(15)

(55)

PLASMA ENABLE -PLASMA ENABLE -PLASMA ENABLE +

120 VAC120 VAC RET

+5VDC

120 VAC

120 VAC RET

24 VAC RET

24 VAC

15 VDC RET

+15 VDC

RUN

TEST

SET PREFLOWSET CUTFLOW

O2 - AIRO2 - O2H35 - N2F5 - N2AIR - AIRN2 - H2ON2 - N2

ENCODER

IN-CIRCUIT SERIALPROGRAMMING

ENCODER w/SW

AB

FLOWPRESSURE

DISABLE

F1 0.125A SOL1F2 0.125A SOL2F3 0.125A SOL3F4 0.125A SOL4F5 0.125A SOL5F6 0.125A SOL6F7 0.125A SOL7F8 0.125A SOL8F9 0.125A SOL9F10 0.125A SOL10F11 0.125A SOL11F12 0.125A SOL12F13 0.125A SOL13F14 0.250A SOL14 *F15 0.250A SOL15 *F16 0.125A SOL16 F17 0.125A SOL17F18 1A ( 120 VAC to Solenoids)F19 1A ( 120 VAC to Low Voltage Power Supply)F20 1A ( to E-Stop Relay)

* 19X2219_AG and earlier F14 & 15 are 0.125A

1AIR

2N2

3O2

4H35

5F5

6AIR

7N2

8AIR

9N2

10O2

SOLENOID MANIFOLD (from rear)

FRONT PANEL (rear)

1711

12

13

SOLENOID LOCATIONS

ULTRACUT GCM 2010 GAS CONTROL

POWER SUPPLY

PLASMA <

SHIELD <

PREFLOW <

FERRITECORE

Safety Gnd(low freq)

RF Gnd(Shield)

ENABLE

PS3

PS4

ShieldFlow

ShieldPress

PlasmaPrecharge/ Bypass

H2O Shield

FIBER-OPTIC

To CCM

U36 U35

SOL11SOL11

F20 1AF20 1A

J1110 PIN

J1110 PIN

1 2 3 4 5 6 7 8 9 10

SOL5SOL5

J5

16 PIN

J5

16 PIN

1

2

3

4

5

6

7

8

9

10

11

12

13

14

16

15

J55J55

12345678910111213141516171819202122232425262728293031323334353637

J12

18 PIN

J12

18 PIN

1 2 3 4 5 6 7 8 9 10 11 12 13 14 171615 19 2018

J75 PIN

J75 PIN

1 2 3 4 5

+

-

PLASMA ENABLE+

-

PLASMA ENABLE

1

2

5

4

SW6PLASMA ENABLE SW6PLASMA ENABLE2

1

3

SOL10SOL10

F18 1AF18 1A

SOL4SOL4

J3J31

2

3

SW7SHIELD FLOW / PRESSURE SW7SHIELD FLOW / PRESSURE21

3

D13GREEND13

GREEN

SOL9SOL9

SW2GASSW2GAS

A1234567

SOL1SOL1 SOL3SOL3

J9J9123456

J16J16

1 2 3 4 5 6

D25GREEND25GREEN

SOL8SOL8

+ -

E-STOP

+ -

E-STOP

1 2

54

E-STOPE-STOP

SOL2SOL2

J56J56

123456789

10111213141516171819202122232425262728293031323334353637

SW3MODESW3MODE

A1234

J10J10

1 2 3 4 5 6

SOL7SOL7

F19 1AF19 1A

J1J1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 18171615SOL12SOL12SOL6SOL6


ULTRA-CUT 100

Art # A-072003

2

2

1

1

D

C

B

A

(46)(47)

(43)

(45)(45)

(42)

(42) (44)

(44)

(40)

(49)

(48)

(40)(40)(40)(40)

(40)(40)

(41)

+5VDC

+5VDC

+5VDC

+5VDC

DWG No:

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SupersedesScale

Date:

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DateByRevisionsRev PCB No:Assy No:

Information Proprietary to THERMAL DYNAMICS CORPORATION.Not For Release, Reproduction, or Distribution without Written Consent.

NOTE: UNLESS 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:

SizeSCHEMATIC,42X1202Monday, January 29, 2007

1 1

<OrgAddr1><OrgAddr2><OrgAddr3>

Ultracut GCM 2010 Gas Control & TVA

Wednesday, January 26, 2005

13:57:13

<OrgName>

DDWG No:

Sheetof

SupersedesScale

Date:

Drawn: References






1 1




13:57:13

<OrgName>

DDWG No:

Sheetof

SupersedesScale

Date:

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1 1




13:57:13

<OrgName>

D

LCD DISPLAY CONNECTOR

CURRENT CONTROL(Thumbwheel) optional

LCD DISPLAY

ULTRACUT TORCH VALVE ASSEMBLY (TVA or TVA-XTL)

DAT

RIBBONCABLE

15 16 1 2

{

INTERFACEBOARD

3 4 5 6 7 8 9 10 11 12 13 14

FERRITECORE

Safety Gnd(low freq)

RF Gnd(Shield)

AA ECO-B214 DAT 07/26/06

AB ECO-B367 RWH 01/29/0715

14

16

TVA-XTL

Preflow

Plasma

Gas Shield

Plasma

Shield

H2O Shield

Inlet sensors in 19X2219 PCB(rev AG or later)

LCD Display Assembly 19X2220

PLASMA EXAUST 1Normally Open

PLASMA EXAUST 2Normally Open

* Additional Solenoids used in TVA-XTL

18 19

Vent

15

14

16

TVA

Preflow

Plasma

Gas Shield

Plasma

Shield

H2O Shield

BOTH SECTIONS ON FOR OPERATIONOFF ONLY FOR PROGRAMMING

SOL15 TVA PLASMA PREFLOWSOL15 TVA PLASMA PREFLOW

JP1JP1 1 2 3 4

SOL18 *SOL18 *

JP3JP31

2

3

4

J6

18 PIN

J6

18 PIN

1

2

3

4

5

6

7

8

9

10

11

12

13

14

16

15

17

18

PS3 Plasma Inlet PressurePS3 Plasma Inlet Pressure

3

1

2 4

SOL17SOL17

J834 DUAL RIBBON HEADER


12

34

56

78

910

1112

1314

1516 18 20 22 24 26

17 19 21 23 2528 30 32 34

27 29 31 33



12

34

56

78

910

1112

1314

1516 18 20 22 24 26

17 19 21 23 2528 30 32 34

27 29 31 33

J13

18 PIN

J13

18 PIN

1 2 3 4 5 6 7 8 9 10 11 12 13 14 1615

SOL19 *SOL19 *

J60J60

1

2

3

4

5

6

7

8

91011121314

SOL13SOL13

SW1SW11 4

2 3

PS1 Plasma Outlet PressurePS1 Plasma Outlet Pressure

3

1

2 4

JP4JP4

1

2

3

4

SOL16 TVA SHIELDSOL16 TVA SHIELDJ57J57

1

2

3

4

5

6

7

8

91011121314

PS4 Shield Inlet PressurePS4 Shield Inlet Pressure

3

1

2 4

SOL14 TVA PLASMA CUTFLOWSOL14 TVA PLASMA CUTFLOW


ULTRA-CUT 100

APPENDIX 3: Gas Control Module Plumbing Diagram

Art # A-07577_AB

AIR

N2

O2

H35

F5

SOL1 SOL2 SOL3

SOL8 SOL9 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 Sensor

SOL18

SOL19

PLASMA

SHIELD

Atmosphere

SOL 18 & 19 normally open. Operate in parallel with normally closed SOL 14 & 15.

SOL 18 & 19 in XTL-TVA only.


ULTRA-CUT 100

APPENDIX 4: Gas Control Module PCB Layout

J13

Art # A-07621

J1 J13

F12 F11

F8 F15F17

F7 F16F9

F13

F14

F10

J12

TP10

TP9

TP8

F5

F3

F1

F2

F4

F6

TP1

J6 J7 J11

TP11 TP12 TP13 TP15

TP14 TP16

J8 J10TP18TP19

J3

F19

F18

TP4

TP2

TP3

F20

J5

JP1

TP6

TP5

TP7


ULTRA-CUT 100

APPENDIX 5: Gas Control Display Interface PCB Layout

R21

D17

R8

R12

19X2220 REV

R7

R16R18

D11

R20

R9

R13

R5

D5

R15

C1

D4D1

8

R4

D1

R6

R19

D12

D2R3

D10

R22 R17

D6D3

D19

R2

R14

D13

R11

D7

D20

R10

68

69

D21

1 33

D15

R23

J1

D22

LCD INTERFACEC 2005TDC

D23

D14

70

D24

R24

D25

D9

D26

D16

R1

C2

16

342

172

+

D8

AB

Art # A-06904

J1


ULTRA-CUT 100

APPENDIX 6: CCM CPU PCB Layout

H1

J4

U6

1

TP11TP10TP9

TP1

TP3

TP6

TP4

TP7

TP5

TP2

TP8

4423

221

U4

1 2

1

SW3

C18

D10

R69

C19

C41

R30

R23

C15

C26

C12

C22

R65

R74

U26

R17

C3

J5

R1

R34D6

C16

C33

R47

R81

U25

R77

U24 1

R22

R9

R46

C13

C49

+

R73

1 21

SW9

R19

R24

R64

C56

C58

U12

R35

R28

L2

C21

C5

R5

C40

R80

U18

C57

C20

R43

R29

R52

C50

+

C27

R6

C38

C36

R82

C4

R15

R88

R45

6 9

51

J1

R56

U16

1

R71

C54

R67

C17

+

C32

L4

R68

R54

D1

R72

R50

L3

C43

C35

1 2

1

SW5

U9

D9

H3

R87

H4

R26

R86

PREFLOW

POST

R10

FLOW FUNCSYS

CONT

R42

AUTO PILOTOK TOMOVE/D

R11

19X2169 REVC 2004 TDC

Y1

C30

C55

R90

R25

R66

C6

C42

+

U30

1

D8

D15

R70

R2

U27

R79

C2

+

U5

R91

D11

R51

C25

R89

R18

R8

C51

D3

D13

U28 1

C8R31

R40

C34

+

R85

R38

C48

D7

R92

R57

R7

R4C1

R36

1 2

1

SW4

C9

R3

R62

R63

U17

R13

160

U14

140

120

80

R27

C31

R59

R55

R32

U13

1

C45

C39

L1

R44

R84

R61

R20

R58

R78

U29

C14

D2

R33

C7

U22

C52

R76

C46

R21

U11

1

R37

R16

C10

R41

D4

R83

R49

U15

R93

R39

C53

C59

+

C47

U23

1

U19

1

C24

C29

R94

D5

R48

R60

D14

C28

R75

R12

C11U10

C44

+

R53

C23

L6

1

U21C37

D12

R14

L5

+15VDAC DAC

-15V+3.3V

CLKO

GND

AGND

+5.0V

TEMPSENSE

+3.3VA

/WR

/RD

R C

GP1

U20GP2

U31

NC

U32

U71

321

1

SW1

4 321

1

TPAD1

SW8

4

U81

1

1

1

H6

H2

H5

1

CPU/COMMUNICATIONS

29

21

J3

30

3029

21

J2

Art # A-06906

ON

Note: Switch Settings May Vary.

AC

Switches

ON

TP9 TP10 TP11

TP2

TP1

TP3 TP4

TP5

TP6

TP7

TP8

J2

J3

J1

1 2

1

SW3

1 2

1

SW9

1 2

1

SW5

PREFLOW

POSTFLOW FUNC

SYSCONTAUTO PILOT

OK TOMOVE/D

1 2

1

SW4

321

1

SW1

4 321

1

SW8

4


ULTRA-CUT 100

APPENDIX 7: CCM Input / Output PCB Layout

H1H1

C75C75

C79C79

C41C41

R149

R149

R144R144

R148R148

R103

R103

C11

C11

U1U111

D34D34

11

U10U10

R88R88

R128

R128

R39R39

R73R73

R118

R118

R120R120

C16C16

R81R81

2929

2211

J3J3

3030

R11R11

11U12U12

D8D8

D10D10

TP6TP6

SW6

SW6

U7U7

11

R75

R75

K5-E

-STO

PK5

-E-S

TOP

R20

R20

R1R1

R151R151

D37D37

J5J5

U14U14

11

U5U5

11

R139R139

U13U13

11

C56C56

C22C22

C50C50

U6U6

11

R10R10

R14R14

R2R2

D6D6

D29

D29

D12

D12

R104

R104

C6C6

R125

R125

D20

D20

R47R47

R5R5

R82R82

J36J36

J4J4

D18D18

R77R77R72R72

R9R9

TP7TP7

11 22

11

SW13SW13

J35J35

C3C3

R131R131

R13R13

C53

C53

C78

C78

R62

R62

C39C39

C77

C77

C87

C87

C33C33

R23

R23

R132

R132

U22U22

11

R145R145

C17C17K1-PSRK1-PSR

D22

D22

R69

R69

D21D21

TP9TP9

R76R76

C26

C26

C58C58

R64

R64

U3U311

R117

R117

R6R6

R79R79

R55R55

C40C40

C68

C68

C7C7

R41

R41

R44R44

R8R8

R66

R66

R121R121

D25

D25

D23D23

R31R31

R28

R28

R45R45

R123

R123

R102

R102

R135

R135

C2C2

D14D14C24C24

TP3TP3

U18

U18

11

R67

R67

R49R49

TP12TP12

U23U2311

C45C45

R57R57

R138R138

R127R127

C76

C76

C66

C66

R12R12

D26D26

C19C19

TP5TP5

R38R38

D7D7

R53

R53

C18C18

D30D30

R27

R27

C47C47

D17

D17

C30C30

BB

AA

SW11

SW11

H2H2

R71

R71

U20U20

H5H5

J1J1

H4H4

R97R97

H6H6

H8H8

R99R99

H9H9

C84C84

19X217419X2174

D2D2

11 11

R141R141

11

111111

11

11

R15R15

11

11

REVREV

C TDC 2005C TDC 2005

C8C8

ALL

SW O

FF F

OR

50:1

(DEF

AULT

)AL

L SW

OFF

FO

R 50

:1 (D

EFAU

LT)

SW12

-1 O

N FO

R 16

.7:1

(SC-

11)

SW12

-1 O

N FO

R 16

.7:1

(SC-

11)

U16U16

OK

TO M

OVE

SEL

ECT

OK

TO M

OVE

SEL

ECT

CONTACTSCONTACTS

11

DC VOLTSDC VOLTS

++

++

++C93C93

++

++U17U17

11

11

++

++

++

R43R43

H10H10

H11H11

OK CNCOK CNC

R46R46PSRPSR

CNC_E-STOPCNC_E-STOP

CNC_STARTCNC_START

HOLD_STARTHOLD_STARTR1

15R1

15

CNC PREFLOWCNC PREFLOW

GAS

ON

GAS

ON

E-ST

OP_

PSE-

STO

P_PS

C65

C65

C35

C35

U24U2411

++

GNDGND

+5V+5V

R80R80

+15V+15V

-15V-15V

+15V+15V -15V-15V

R87R87

+18V+18VGNDGND

ISOLATEDISOLATED

PILOTPILOT

R56R56

DEMANDDEMAND

CUTCUTDEMANDDEMAND

ARC V-ARC V-

R114R114

PILOT VPILOT VCC POTCC POT

D3D3

TP8TP8

R26

R26

K7-G

AS O

NK7

-GAS

ON

C34

C34

U19U19

L2L2

C27

C27

R29

R29

C83C83++

R90R90

C69

C69 ++

C52

C52

U2U2

11

C48C48

U9U9

11

R129

R129

R50R50

C15C15

TB1TB1

R59R59

C20

C20

R83

R83

C82C82

D9D9

C4C4

C23C23

C55

C55

R147R147

C88C88

C95C95

++

K2-STARTK2-START

C46C46

R61R61

R109R109

D4D4

D32D32

J9J9

Q1Q1

R143R143

C71C71

C49

C49

R91R91

R24

R24

R60R60

J6J6

R22

R22

R142

R142

R21

R21

R7R7

R108R108

R63R63

R40R40

R101R101

R37R37

C5C5

C64

C64

C92

C92 T1T1

R30R30

J8J8

R134

R134

R119

R119R1

16R1

16

R89R89

R48

R48

++

K3-E-STOP CNCK3-E-STOP CNC

R78R78

D36D36

D31D31

R140R140

R107R107

C37C37

R65R65

R100R100

C28

C28

R84R84U11U1111

K4-OKK4-OK

D1D1

C73

C73

R25

R25

R110R110

C54C54

D15D15

R133R133

R150R150

R122

R122

R19

R19

C31C31

TP11TP11

D39D39

2929

2211

J2J2

3030

D38

D38

R86R86

R68R68

R42

R42

D13D13

R126R126

R70

R70

R3R3

C80C80

R96R96

U4U4

TB2TB2

11

C21

C21

K6K6

C85C85

++R3

3R3

3

C70C70

D40D40

R17

R17

C51

C51

R136

R136

TP4TP4

D28D28

R93R93

R52

R52

C9C9

TP14TP14

D16D16

C61

C61

D35D35

C13

C13

R58R58

D5D5

R85R85

R98R98

R94

R94

C89C89

C62C62

C25C25

R74R74

R130R130TP1TP1

J7J7

TP13TP13

C91C91

R35

R35

TP10TP10

R18

R18

C29

C29

C72C72

C42C42

C74C74

D19D19

R4R4

++

R124

R124

R95R95

C81C81

D11

D11

R54

R54

C36

C36

D24D24

C12

C12

C86

C86

U21U2111

U15U15

R16

R16

11

L1L1

TP2TP2

C60C60

R32

R32

++

R51

R51

U8U8 C32C32

11

C14

C14

D27

D27

R113R113

D33

D33

C38C38

R105R105

R34

R34

R92R92

C59C59 R112R112

R106R106

H3H3

R146R146

R111R111

R36

R36

C10

C10

C57

C57

11

22

2525

2626

11 22

3333 3434

+29-41 VDC+29-41 VDC

C67C67

C63C63

C90C90

R223

R223

C94

C94

R155R155

C1C1

R158R158

D60

D60

R156R15633221111

SW12

SW12

44

R154

R154

R157R157

D61

D61

SW12

-2 O

N FO

R 30

:1SW

12-2

ON

FOR

30:1

SW12

-3 O

N FO

R 40

:1SW

12-3

ON

FOR

40:1

SW12

-4 S

PARE

SW12

-4 S

PARE

++

++

R152

R152

C44C44

H7H7

R224R224R225R225

C43C43

R227

R227

R228

R228

Q2Q2

R226

R226

Q3Q3

AD+AD+

Art # A-06901

TP14

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


ULTRA-CUT 100

Art # A-04900_AC

TB1-1 E-Stop (Com)TB1-2 E-StopTB1-3 OK 2 Contacts 24V MaxTB1-4 Stop LatchedTB1-5 Start / Stop RetTB1-6 Start / Stop or Start Latched (NO)TB1-7 Divided Arc Voltage (-) TB1-8 Divided Arc Voltage (+) TB1-9 Remote Analog Current Control (0-10V) (-)TB1-10 Remote Analog Current Control (0-10V) (+)TB1-11 +10V @ 10ma For Remote CC POTTB1-12 OK 2 Contacts 24V Max

TB2-1 Hold Start (-)TB2-2 Hold Start (+)TB2-3 Preflow On (-)TB2-4 Preflow On (+)TB2-5TB2-6 Pilot On (Relay Contacts NO)TB2-7TB2-8 Pilot On (Relay Contacts NO)TB2-9TB2-10 OK to Move (Contacts or DC Volts) (-)TB2-11TB2-12 OK to Move (Contacts or DC Volts) (+)

TB

2T

B1

Sustained Start / StopTB1-5

TB1-6

Momentary Start / Stop

TB1-4

TB1-5

TB1-6

Stop

Start

Start / Stop Circuit Configurations

These points are jumpered together at the factory.Remove the jumper to use existing E-Stop circuits.

TB

31

TB3-1

TB3-2 }Marking Input


ULTRA-CUT 100

CNC functions

CNC I/O circuits provide at least 1000V galvanic isolation from the plasma power supply.

While the CNC circuits are isolated from the power supply, many of the signal returns on J15 and TB1 & 2 are commonto each other. J15 pins 1, 4, 5 & 10 and TB1-1, 5, 7, 9, and TB2-1 & 3 are all common. J15 pin 12 and TB2-10 are alsoconnected to the others when SW6 (OK to Move select) is set for voltage.

Rear Panel CNC Connector J15:

14 Circuit (Amp CPC) Remote Standard:

Chassis gnd (for SC-11 cable shield) 11 Start/Stop 3 (+); 4 (-)1 Ok to Move (contacts or voltage 2) 12(-); 14 (+)1 Divided Arc volts (selectable

ratio 50:1; 40:1; 30:1; 16.6:1) 5 (-); 6 (+)

Arc Volts (w/100K series res) 7 (-); 9 (+)1 Analog Current Control (0-10V) 3 10 (-); 11 (+)

Isolated Circuit Comm (for SC-11) 8

Chassis Gnd 13

1 These are also duplicated on TB1 & TB2, use one or the other not both. Additional functions are only available on TB1 & 2.

2 SW6 on CCM I/O PCB selects OK to Move for isolated contact closure or DC Volts (15-18V) at <100ma. When set forcontacts, OK to Move circuit is rated for 120 VAC / 28 VDC @ 1A.

Internal CNC connections. TB1 & TB2 on CCM module.

Connections are provided on the CCM module TB1 & TB2 terminal blocks including most of the rear panel functionsplus some additional features. All these signals are isolated from the plasma power supply but signals marked(comm.) and (-) are common to each other.

Users are expected to install their own CNC cable to these connections. Knockout hole is provided in rear panel of CCMmodule. User shall provide strain relief / cord grip for user installed cable.

Function Connection

E-Stop TB1-1 (comm.) & TB1-2

OK To Move 2 (Contact)5 TB1-3: TB1-12

Stop Latched (NC) 4 TB1-4

Start/Stop Ret 4 TB1-5 (comm.)

Start /Stop or Start Latched (NO) 4 TB1-6

Divided Arc Voltage TB1-7(-); TB1- 8(+)

Remote Analog Current Control (0-10V) TB1-9(-); TB1-10(+)

+10V @ 10ma For Remote CC POT5 TB1-11

Hold Start TB2-1(-); TB2-2(+)

Preflow On TB2-3(-); TB2-4(+)

Pilot On (Relay Contacts NO) TB2-6; TB2-8


ULTRA-CUT 100

Function Connection

OK to Move (Contacts or DC Volts) TB2-10(-); TB2-12(+)

Plasma Marking Remote Select TB3-1: TB3-2

CNC Input / Output Descriptions

E-Stop input— Requires closed connection rated for 35ma. @ 20VDC for unit to operate. Factory installed jumper betweenTB1-1&2 must be removing when connecting user supplied E-Stop circuit.

4 Start/Stop input—Switch (momentary or sustained) rating 35ma. @ 20 VDC

Start / Stop circuit configurations. Momentary Start / Stop (Latched) is only available at TB1.

MOMENTARY START / STOP

START / STOP

TB1-6

TB1-5

TB1-4

SUSTAINED START / STOP

START

STOP

TB1-5

TB1-6

Divided Arc Voltage output — Arc Voltage signal is isolated from plasma supply, however (-) is common with otherisolated CNC signals. Max Divided Arc Voltage signal level depends on actual arc voltage times divide ratio howevercan not exceed approximately 12 V.

3 Analog Current Control input— Analog Current Control includes analog isolation module, separate isolationmodule not usually required however it’s low input is common with the other isolated CNC inputs. Scaling of AnalogCurrent Control input is 0V = 0A, 10V. = MAX output and is linear in between. However MIN output is 10A. User isresponsible for setting correct analog voltage to maintain at least 10A output. To use Analog Current Control on theI/O PCB set SW 11 to down position and on the CPU PCB set SW8-2 ON (up).

Hold Start input—Normally open, close to hold start. Circuit rating 10 ma. @ 20VDC. Delays pilot ignition, gaspreflow continues. Used for synchronizing starts when multiple plasma supplies are used on same cutting table. Usersupplies circuit to keep Hold Start inputs active until all torches have found height.

Preflow On input— Normally open, close to start preflow prior to normal START signal. Circuit rating 10 ma. @20VDC. Torch Height Controls (THC) normally issue START signal to plasma supply after torch height has beenfound. Then the plasma takes 1-2 seconds (or more) to perform preflow before igniting pilot. Some THCs have anoutput that can start preflow early during height finding saving 1-2 seconds on each cut.

Pilot On output – Relay contacts rated 1A @ 120 VAC / 28 VDC. Contacts close when pilot on. Can be wired parallelwith Ok to Move contacts to start machine motion when pilot established. Used when starting over holes. Starting overholes requires setting SW8-1 ON (up) on the CPU PCB for extended pilot time. Using extended pilot time to start overholes or for cutting over holes will reduce parts life.

OK to Move output — Active when cutting arc is established, arc is transferred. Used to signal cutting table to startX-Y motion. Relay contacts rated 1A @ 120 VAC or 28 VDC when SW6 set for contacts. When SW6 is set for DCV, outputsupplies 15-18 VDC @ 100 ma. May be wired parallel with Pilot On to start cutting machine motion as soon as pilotestablished.

5 The following features are available in Ultracut CCM revision level BA and higher or S/N05517201 and higher.

5 OK to Move2 – Provides a second set of N.O. contacts that close when arc transfer is detected. Contacts are rated formaximum of 24 VAC/DC @ 1A.


ULTRA-CUT 100

5 +10V @ 10ma. For Remote CC Pot – Previously CCM versions if one wanted to use a potentiometer for the RemoteAnalog Current Control (CC) input an external 10 V supply was required for Pot High.. Now an isolated (from mainplasma circuits) 10V supply is provided. Recommended value of the pot is 5K or 10K.

Ext. +10V

11 10 9

TB1

+10V WIPER

Art # A-09246

5 Plasma Marking Select (Remote) – Plasma Marking, available only with DFC 3000, may be activated with a contactclosure between TB3-1 & TB3-2 if SW8-4, DIP switch on the CPU board (smaller of the 2 CCM boards), is also on.Opening the connection between TB3-1 & TB3-2 switched back to normal cutting mode. For Ultracut power suppliesIt is OK to leave SW8-4 on whether you are marking or not.


ULTRA-CUT 100

Simplified CNC Circuit.

123456789

Remote Analog Current Control (+)

J15 CNC14 pin CPCrear panel

Remote Analog Current Control (-)

Divided Arc V (-)SC 11 Comm Ref

Divided Arc V (+) 1K

START / STOP (-)START / STOP (+)

ARC V_100K (+)

ARC V_100K (-)

1234567

J4

OK to MOVE (+)

OK to MOVE (-)

Active LOW Logic Input


START / STOP


TB1-5

TB1-4

TB1-6

SUSTAINED START / STOP

START

STOP

TB1-6

TB1-5


ALL SW OFF for 50:1 (default)SW12-1 ON = 16.7:1 (SC-11)SW12-2 ON = 30:1SW12-3 ON = 40:1SW12-4 ON =

ARC V (+)

21

3

54

6

SW6


+16 to 18 VDC(isolated)

PSR

OK to Move

ARC V (-)


100K

36S

W12

-3

45

SW

12-4

18

SW

12-1

27

SW

12-2

21

3SW11

100K

1

87

6

2

+

-

U37ALT1013

Input Circuit Common(isolated)

OK to MOVE (+)

STOP (NC)

PREFLOW ON (+)

START/STOP OR START LATCH (+)START/STOP Ret (-)

PILOT ON output(Contacts)

OK TO MOVE output(contacts orDC Volts)

Remote Analog Current Control input (+)

E-STOP Ret (-)E-STOP input (+)

Remote Analog Current Control ret (-)

123456789

101112

TB1

HOLD START (+)

DIVIDED ARC V (+)

HOLD START (-)

DIVIDED ARC V (-)

123456789

101112

TB2

OK to MOVE (-)

PREFLOW ON (-)

123456789

1011121314

J15

To CPU PCB Analog Input

CCM Module

Art # A-07327_AB

J1


ULTRA-CUT 100

CNC Connections.

A-07632

Start Motion(OK-To-Move)

Cutting Machine CNC Cable Power Supply

Shield

J15

1

3

4

9

6

7

8

13

14

12

5

OK-To-Move

2

(1)

3

4

9

6

7

14

12

5

2

START/STOP

*( )

( )

( )

( )

( )

( )

( )

( )

( ){ *

*

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 - 18 VDC @or 28 VDC) up to 100 ma.)

* Power Supply Gnd not used for CNC cable Do not connect wire #1 to anything.

** Cable Shield drain wire must be connected to ground at cutting machine.

*** Used only for special Torch Height Control

**


ULTRA-CUT 100

This Page Intentionally Blank


ULTRA-CUT 100

APPENDIX 8: Schematic, 230-460V, Chopper Pilot

Art # A-06992_AD

1

1

2

2

3

3

4

4

5

5

A

B

C

D

E

F

-15V

INP

UT_

NG

+5V

GN

D

+15V+1

5V

+15V

MIS

SIN

G_P

HA

SE

/ 230

PG

ND

1/ 4

60

/ 460

PG

ND

2460

230

CO

M

L1

L2

L3

E

+15V

+12VDC +12VDC

+12VDC

To PC

B7 C

N2-5

To PC

B7 C

N2-4

To PC

B7 C

N2-2

To PC

B7 C

N2-1

FAN

+ (24 VD

C)

FAN

- (24 VD

C)

To PC

B7 TB

3

To T1 PR

I - 0

V_C

HA

NG

E P

CB

100A INVERTER MODULEP_GND

VAC_IN

LINE to LINE, LINE TO GND CAPS & VARISTORS

PCB 1WK-5630

INPUT POWER INDICATORREAR PANEL

INPUT POWER INDICATORINTERNAL

16 CKT RIBBON CABLE

PCB 5 WK-5602 (partial)

MISSING PHASE

(pulses)<

LED1 DIM = LOW, BRIGHT = OKLED2 DIM = OK, BRIGHT = FAULTLED3 DIM = OK, BRIGHT = FAULTLED4 OFF = OK, ON = FAULTLED5 OFF = OK, ON + FAULT

CN6 16 CKT

BIAS SUPPLY FOR PCB5

(F2 -Sht2)

DC FAN POWER

CN1 CN5 CN6

CN4 CN5 CN6

(A1 Sht2)

(A1 Sht2)

(A1 Sht 2)

(A1 Sht 2)

(A2 Sht 2)

(A2 Sht 2)

CN6 16 CKTON / OFF

PCB3 WK-5694

PCB4 WK-5604

VAC_IN

P_GND

BIAS SUPPLY PCB

DETECTOR PCB

INTERFACE PCB

FILTER PCB

--460--

--230--

--230--

208-230/460 VAC 3 Phase

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_READY9- / PS_START disabled by Input_NG12- / OCR13- / PS_START disabled by OCR14- /TEMP_ERR15- / PS_START disabled by Temp _Err

MC1-CMC1-C

RY2RY2

ACAC

AC

+-

D1

ACAC

AC

+-

D1

CN1CN1

1

2

3

4

5

6

7

TB4TB4

+

RY2

RY2

+

RY2

RY2

230V230V

CN3CN31

4

TT

CN32CN32 1 2 3 4

CN1-230V

6

CN1-230V

6

1234

CN4 - PCB12CN4 - PCB12

2 3 41

C1C1

CN2CN2 12

LED3INPUT NGLED3INPUT NG

MC1-BMC1-B

N2N2

LED2MISSING PHASE

LED2MISSING PHASE

CN2-460VCN2-460V 1 2 3 4

+

-

+

-

1

2

3

45

6

1 2

34

TB3TB3 ++

CN2CN21

2

3

SS

CN1CN1 1 5 8

CN7CN7 1 2 3 4 5

MC1-AMC1-A

CN7CN7 1 2 3 4 5

CN4CN4 14

LED5ERRORLED5ERRORLED5ERRORLED5ERROR

1 2

34

INRUSHINRUSH

NE1NE1

CN2CN2 1 2 3

P (+)P (+)

CN4CN4 1 2 3 4

C.P1C.P1

NE2NE2

CN10CN10 1 2

N (-)N (-)

- +- +

3

1

2

4

CN32CN32 1 2 3 4

TB2TB2 ++

RR

P1P1

CN3CN3 1 2

CN18CN18 1 2 3

- +- +

3

1

2

4

TB1TB1

TB1TB1


ULTRA-CUT 100

Art # A-06992_AD

6

6

7

7

8

8

9

9

10

10

A

B

C

D

E

F

I_se

nseP

GN

DW

+15V

w-1

5Vw

Isen

se_W

GN

DP

CO

MM

ON

Iref_

G

P1

P_r

efP

_ena

GN

DW

GN

D_C

Isen

se_W

-15V

w

TEM

P_C

+15V

w

N2

GN

DP

+12V

-12V

I_se

nseP

SIG

NAL

P_r

efIre

f_G

P_e

na

GN

D_C

TEM

P_C

TORCH (-)

PILOT

WORK (+)

NEG ARC VOLTS

WORK

PILOT (TIP) VOLTS

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42X1209Friday, September 25, 2009

1 2

Industrial Park #2West Lebanon NH 03784603-298-5711

100-Amp Power Supply 208-230/460V (Chopper)

Tuesday, October 03, 2006

08:11:44

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Thermal Dynamics

D

RAS

PILOT CURRENT SIGNAL <

WORK CURRENT SIGNAL <

HCT1 Hall Current Sensor, Pilot (B8, Sht 1)HCT2 Hall Current Sensor, Work (C9, Sht 1)

LSW1 Level SW, coolant, NC (B5, Sht 2)

MC1 Contactor, 3P ,Inv 1 input, Coil (B3, Sht 2) " Contacts (A2, B2, Sht 1) " Aux Contact (B3, Sht 2)MC2 Contactor, pilot, Coil (B3, Sht 2) " Contacts (C8, Sht 1)

MOT1 Motor, Pump 200VAC, 1P (E4, Sht 2)

NE1 Neon indicator, rear panel, 220VAC (C1, Sht 1)NE2 Neon indicator, internal, 220VAC (C1, Sht 1)

R6 Resistor, 20K ,30W (A8, Sht 1)R7 Resistor, 1K ,30W (E2, Sht 2)R9 Resistor, 50 ,40W (A9, Sht 1)

T1 Aux Transformer (D-F1, Sht 2)

TH1 Thermal Sensor, coolant return (B5, Sht 2)

COMPONENT LOCATOR

(C7 & A9, Sht 2)

Power SupplyRear Panel

DAT

< /O

VE

R_T

EM

P(C7, Sht 2)

> P

_DE

M (

P_I

ref)

> P

_Ena

ble

(P_e

na)PILOT REG.

(CHOPPER )PCB2WK-5754

HALL SENSOR

BIASPOWER

I_D

ET

<I_

SE

PILOT REG.(CHOPPER )PCB1WK-5750

<

(C7 & A9, Sht 2)

HALL SENSOR

PILOT REGULATOR (CHOPPER)

PCB 8WK-5687RC &RF CAPS

/PILOT ENABLE >

PILOT DEMAND >

/ OVERTEMP <

C1 Capacitor, 0.1 uf, 1250 VDC (D2, Sht 2)C2 Capacitor, 2 uf, 430VAC (A9, Sht 1)

C.P1 Circuit protector/ON-OFF SW (B2, Sht 1) 15A, 460V, 3PC.P2 Circuit protector 2.5A 125V (D2, Sht 1)C.P3 Circuit protector 3.15A 125V (D2, Sht 1)C.P4 Circuit protector 10A 125V (E2, Sht 1)C.P5 Circuit protector 2.5A 125V (E2, Sht 1)C.P6 Circuit protector 2.5A 125V (F2, Sht 1)C.P7 Circuit protector 5A 125V (E2, Sht 1)C.P8 Circuit protector 3.15A 125V (F3, Sht 1)

D1 Diode Bridge 20A, 1600V, 3P (D2, Sht 1)D2 Diode, Dual, 2x100A, 600V (B8, Sht 1)

FAN1 Fan, Coolant, 24 VDC (F4, Sht 2)FAN3 Fan, Chopper, 24 VDC (A8, Sht 1)

FL1 Flow sensor (B5, Sht 2)

ECO-B402 DAT 2/26/07

AB ECO-B448 DAT 4/13/07ECO-B646 GAC 10/31/07AC

ECO-B1391 TADDA 4-24-2009DATAE ECO-B1535 9-25-09

CN7CN7 12345

TB4TB4

CN4CN4 12345

THS1SW_TEMP_NC

THS1SW_TEMP_NC

MC2-CMC2-C

CN3CN3 1 2 3 4

CN3CN3 12

CN4CN4 1 2 3

LED4CHOPPER TEMP

LED4CHOPPER TEMP

CN6CN6 123

CN2CN2 1 2 3

C22 UFC22 UF

CN2CN2 1 2 3 4

CN33CN33 1 2 3 4TB2TB2

CN17CN17 1 2 3

CN5CN5 1234

TB1TB1

CN1CN1

12

HCT2HCT2

1 2 3 4

CN9CN9 1 2

R620K

30W

R620K

30W

CN8CN8 12

TB3TB3

MC2-AMC2-A

TB5TB5

CN4CN4 1 2 3 4 5

CN1CN11234

D2D2

1A1

2K1

3A2

4K2

CN5CN5 1 2 3 4

FAN3FAN3

+-

CN3CN3 1

R950R950

MC2-BMC2-B

TB2TB2

TB1TB1

WORKWORK

CN2CN2 123

HCT1HCT1

1 2 3 4

CN1CN11234


ULTRA-CUT 100

APPENDIX 8: Schematic, 230-460V, Chopper Pilot Cont.

Art # A-06993_AD

1

1

2

2

3

3

4

4

5

5

A

B

C

D

E

FAC13V @ 2A

AC120V @ 1A

/PUMP

+15V

+15V

/FAN

/RAS

+15V

COM230460

COM230460

460

230

AC200V @ 3A

AC120V-RAS

FAN + (24 VDC)

FAN - (24 VDC)

0V-RAS

DC 15VDC 0V

AC24V-GCM

0V-A (24V ret)

AC120V-GCM

0V-B (120V ret)

To PC

B7 TB

3

To T1 PR

I - 0

To PC

B7 C

N2-1

To PC

B7 C

N2-2

To PC

B7 C

N2-4

To PC

B7 C

N2-5

CCM MODULE

(D9, A10)

COOLANT TEMP(ON COOLANT RETURN)

TO AC

INDICATOR

(on PCB6)

PILOTCONTACTOR

INPUTCONTACTOR

(C9)

FROM CN18 PCB3 sht 1

29-41 VDC +15VDC+5VDC-15VDC

ISOLATED COMM+16 to +18VDC

+15VDC_ISO-15VDC_ISO ISOLATED

VOLTAGES

PILOT DEM to PS

ANALOG DEM to CPU

CUT DEM to PSPILOT (TIP) VOLTAGENEG ARC VOLTS

CIRCUIT COMM (GND)

I/O PCB

CPU PCB

SW6 - OK to MOVE CONTACTS / VOLTS

SW11 - ANALOG CURRENT SELECT "B" DEFAULT, "A" REMOTESW12 - DIVIDED ARC V RATIO SELECT

SW13 - FACTORY ONLY

PCB 5 WK-5602 (partial) INTERFACE PCB

(F1 Sht 1)

(F1 Sht 1)

PCB7 WK-5628RELAY PCB

(F1 Sht 1)

(F1 Sht 1)

(F2 Sht 1)

(F2 Sht 1)

(D9, A10)

COOLANT FLOW (freq) *1 2 3

CN12CN121

2

CN2CN2

1

2

TP4TP4

CN4CN41

2

3

CN3CN31

2

3

D2 E-STOP_PSD2 E-STOP_PSC.P3C.P3

+V

GND

SIG

FL1FLOW_TURBINE_PULSE

+V

GND

SIG


R BG

T1T1460

220

0,

13

0,,

100

0.

200

0..

110

0...

120.

0_

24.

0__

24_

0___

120.

0___

TP10TP10

1 2CN10CN10

1

2

3

TB1TB1

D15 PSRD15 PSR

R71K 30WR7

1K 30W

C.P5C.P5

D12 STATUS CODE D12 STATUS CODE

TP9TP9

1

2

3

CN7CN71

2

3

4

TP14TP14

CN6CN61

2

3

4

CN8CN81

2

3

4

MC2MC2

D1 GAS_OND1 GAS_ON

C.P6C.P6

TP7TP7

CN1CN1 1 2

CN9CN91

2

3

4

5

1 2

TP1TP1

CN14CN14 1 2

TB5TB5

RY3RY3

TP5TP5

CN9CN91

2

3

RY5RY5

D11 INITIALIZING / PROGRAMMINGD11 INITIALIZING / PROGRAMMING

MC1 AUXMC1 AUX

TP3TP3TP2TP2

TP15TP15

C.P7C.P7

D4 OK_CNCD4 OK_CNC

TB4TB4

LED1LEVELLED1LEVEL

CN5CN51

2

3

4

5

6

D23 CNC_STARTD23 CNC_START

FAN1FAN1

+ -

1

2

3

MC1MC1

LSW1-1

SW_LIQUID_LEVEL_NC

LSW1-1

SW_LIQUID_LEVEL_NC

C.P2C.P2

+RY1

+RY1

D21 CNC_E-STOPD21 CNC_E-STOP

RY5RY5

1 2 3

CN11CN11

1

2

CN8CN8 1 2 3 4

+

RY2

RELCOL_0+

RY2

RELCOL_0TP8TP8

C.P8C.P8

TB2TB2

D26 HOLD_STARTD26 HOLD_START

TP12TP12

CN2CN2 1 2 3 4 5

RY4RY4

PUMP

MOT1

PUMP

MOT1

' .

tTH1

tTH1

TP13TP13

TB3TB3

RY3RY3

TP6TP6

TP11TP11

CN13CN13 1 2 3

1

2

CN12CN12 1 2 3

1

2

D28 CNC_PREFLOWD28 CNC_PREFLOW

RY4RY4

D13 +5VD13 +5V

C.P4C.P4


ULTRA-CUT 100

Art # A-06993_AD

6

6

7

7

8

8

9

9

10

10

A

B

C

D

E

F

POT HI (GCM1000)

POT WIPER (GCM1000)

POT LOW (GCM 1000)

PLASMA ENABLE

PRESS OK (GCM 1000)

PLASMA ENABLE

24V

AC

24 V

AC

RE

T

+15V/ AC

/ TEMP

/ STATUS/ DC

/ GAS - COOLANT

- ARC V

- ARC V

AC24V-GCM

0V-A (24V ret)

AC120V-GCM

0V-B (120V ret)

AC120V-RAS

0V-RAS (120V ret)

DC 15V

DC 0V

NE

G A

RC

VO

LTS

PIL

OT

(TIP

) VO

LTS

WO

RK

0V-A (24V ret)

AC24V-GCM

0V-B (120V ret)

AC120V-GCM

WORK

NEG ARC VOLTS

DWG No:

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08:11:44

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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 REAR PANEL

TB1

TB2

DIVIDED ARC V +DIVIDED ARC V -

REMOTE ANALOG CURRENT CONTROL -REMOTE ANALOG CURRENT CONTROL +

E-STOP -E-STOP +

PILOT ON OUTPUT

HOLD START -HOLD START +PREFLOW ON -PREFLOW ON +

OK to MOVE -

OK to MOVE +


START / STOP

STOP

START

+

-

JUMPER IN REMOTEHMI

PLASMA ENABLE

PCB6 DISPLAYWK-5603

START / STOP

DIVIDED ARC VOLTS

REMOTE ANALOG CURRENT CONTROL

OK TO MOVE

DAT

Signal - Basic IDUsed to identifyGCM 1000 present

RIBBON CABLE SIGNALS / = active low digital signal

CN10-J35 - 26 Ckt Ribbon Cable

2-Cut Demand4-Pilot Demand6-/ Start7-/ Start2 9-/ Pilot Enable10-/ HF Enable12-/ Pump Enable13-/ Fan Enable15-/ DC Indicator16-/ Over Temperature Indicator18-/ Gas-Coolant OK Indicator19-/ Status Lamp


1- Output Current Signal 3- / Arc Transferred (CSR)4- / Pilot On 6- Coolant Flow (freq)7- Coolant Temp (analog)9- / Temp OK (Inverter/Chopper)10- / Coolant Level OK12- Missing Phase13- / Ready to Operate15- / Input Volts OK16- / Inverter OCR18- / PS ID "00*"19- / PS ID "0*0"20- / PS ID "*00"21- E-Stop22- E-Stop29,31,33- 24 VAC Supply30,32,34- 24 VAC Return

ECO-B402 DAT 2/26/07

AB ECO-B448 DAT 4/13/07

INTERNAL TERMINAL STRIP TB3(Not in all units)

(E2)

(C9, sht 1)

(A9, sht 1)

UNDIVIDED ARC VOLTSFOR HEIGHT CONTROLS

24 VAC @ 1A

120 VAC @ 100ma.

(A9, sht1)

(B9, sht1)

(C9, sht1)

AC ECO-B646 GAC 10/31/07

* OK2

* OK2* +10VDC @ 10 ma.(for CC pot high)

TB3* REMOTE MARKING +

* REMOTE MARKING -

* Only in CCM w/ 19X2634 I/O PCB. Remote Marking only for DFC 3000 (not isolated)

AD ECO-B1391 DAT 4-24-2009

** RS 485 / 422 on CPU board19X2554 only. Iso

Rx-

Tx+

Rx+

Tx-

Rx-

Tx+

Rx+

Tx-

KEY PLUG

JUMPERfor 2 WIRE(RS485 only) wire to A & B

4W4W

2W

JUMPERfor 4 WIRE usesTX+, TX-RX+, RX-

J14

J14

2W

SW14SW14 - LINE TERMINATIONnormally on(refer to manual)

5

9876

123

4

SW10-ADDRESSnormally 0(refer tomanual)

0

Signal & GNDIsolated from Plasma Supply

RS 485 (2 wire) uses Tx+ & Tx- only(used for TSC 3000)

RS 422 (4 wire) connect TX+ to RX+ of CNC, Tx- to Rx- of CNC

Was 7 pin changed to 14 pin in 2009

GND

GND

& CNC COMM

DATAE ECO-B1535 9-25-09

100K100K

PSRPSR

77

GREEN DCGREEN DC

77

44

99

88

88

J6J6 1 5 8

99

GREEN ACGREEN AC

99

E-STOPE-STOP

J15-CNCJ15-CNC1

2

3

4

5

6

7

8

9

10

11

12

13

14

33

88

100K100K

K6-1K6-1

1010

1K1K

1010

22

11

1111

1111

K6K6

33

J54-REMOTE HMIJ54-REMOTE HMI

1

2

3

4

5

6

7

8

9

10

11

12

13

14

22

77

1212

J59-RASJ59-RAS1

2

3456

7

8

9

1011121314

1212

TP11TP11

22

1212

22

44

OK2 *OK2 *

CN23CN23

1

2

3

4

5

6 REDSTATUS

REDSTATUS

J4J4

1

3

5

7

YELLOW TEMPYELLOW TEMP

11

33

TP1TP1

11

66

1111

11

J55-GCMJ55-GCM12345678910111213141516171819202122232425262728293031323334353637

44

J8J8

1

2

3

4

J1J11

2

3

4

5

6

7

8

9

55CN24CN24

1

2

3

4

5

6

TP12TP12

55

55

GREEN GASGREEN GAS

J7J7

1

2

3

4

5

6

7

8

9

1010

66

J5J51

2

3

4

5

J9J9 1 2 3 4 5 6

J6 **J6 **1

2

3

4

5

6

66

GAS ONGAS ON


ULTRA-CUT 100

APPENDIX 9: Schematic, 230-460V, Resistor Pilot

1

1

2

2

3

3

4

4

5

5

A

B

C

D

E

F

-15V

INP

UT_

NG

+5V

GN

D

+15V+1

5V

GN

D_C

TEM

P_C

+15V

MIS

SIN

G_P

HA

SE

/ 230

PG

ND

1/ 4

60

/ 460

PG

ND

2460

230

CO

M

L1

L2

L3

E

+15V

+12VDC +12VDC

+12VDC

To PC

B7 C

N2-5

To PC

B7 C

N2-4

To PC

B7 C

N2-2

To PC

B7 C

N2-1

FAN

+ (24 VD

C)

FAN

- (24 VD

C)

To PC

B7 TB

3

To T1 PR

I - 0

V_C

HA

NG

E P

CB


VAC_IN


PCB 1WK-5630



16 CKT RIBBON CABLE

/ OVERTEMP <


MISSING PHASE

(pulses)<


CN6 16 CKT


(F2 -Sht2)

DC FAN POWER

CN1 CN5 CN6

CN4 CN5 CN6

(A1 Sht2)

(A1 Sht2)

(A1 Sht 2)

(A1 Sht 2)

(A2 Sht 2)

(A2 Sht 2)

CN6 16 CKTON / OFF

PCB3 WK-5694

PCB4 WK-5604

VAC_IN

P_GND

BIAS SUPPLY PCB

DETECTOR PCB

INTERFACE PCB

FILTER PCB

--460--

--230--

--230--

208-230/460 VAC 3 Phase




TB1TB1

P1P1TB2TB2

N2N2


CN32CN32 1 2 3 4 CN18CN18 1 2 3

P (+)P (+)

LED5ERRORLED5ERROR

CN7CN7 1 2 3 4 5

CN1CN1 1 5 8

1 2

34

CN3CN3 1 2

- +- +

3

1

2

4

C.P1C.P1

TB3TB3

RY2RY2

NE2NE2

CN4CN4 1 2 3 4

MC1-AMC1-A

CN32CN32 1 2 3 4

N (-)N (-)

TB4TB4MC1-CMC1-C

CN2CN2 12

RR

++

CN10CN10 1 2

CN4CN4 14

CN7CN7 1 2 3 4 5

LED2MISSING PHASE

LED2MISSING PHASE

CN2-460VCN2-460V 1 2 3 4

NE1NE1

SS

++

230V230V

CN3CN31

4

TT

CN17CN17 1 2 3

ACAC

AC

+-

D1

ACAC

AC

+-

D1

LED4CHOPPER TEMP

LED4CHOPPER TEMP

CN2CN21

2

3

- +- +

3

1

2

4

CN1CN1

1

2

3

4

5

6

7

1 2

34+

-

+

-

1

2

3

45

6


1 2 3 4

+

RY2

RY2

+

RY2

RY2

TB1TB1

CN2CN2 1 2 3

INRUSHINRUSH

MC1-BMC1-B

CN1-460V

6

CN1-460V

6

1234

C1C1

Art # A-07128_AB


ULTRA-CUT 100

6

6

7

7

8

8

9

9

10

10

A

B

C

D

E

F

N2

P1

+12V

-12V

SIG

NA

LC

OM

MO

N

I_se

nseP

Iref_

G

GN

DW

P_e

na

GN

DW

Isen

se_W

-15V

w+1

5Vw

+15V

w-1

5Vw

Isen

se_W

GN

DP

I_se

nseP

GN

DP

Iref_

GP

_ref

P_e

na

P_r

ef

GN

D_C

TEM

P_C

TORCH (-)

PILOT

WORK (+)

WORK

PILOT (TIP) VOLTS

NEG ARC VOLTS

DWG No:

Sheetof

SupersedesScale

Date:

Drawn: References





SizeSCHEMATIC,

ThermalDynamics

AA

42X1203Wednesday, October 31, 2007

1 2


100-Amp Power Supply 208-230/460V (Resistor)


08:11:44

Thermal Dynamics

DDWG No:

Sheetof

SupersedesScale

Date:

Drawn: References





SizeSCHEMATIC,

ThermalDynamics

AA


1 2




08:11:44

Thermal Dynamics

DDWG No:

Sheetof

SupersedesScale

Date:

Drawn: References





SizeSCHEMATIC,

ThermalDynamics

AA


1 2




08:11:44

Thermal Dynamics

D

RAS


HALL SENSOR

HALL SENSOR


BIASPOWER


< /O

VE

R_T

EM

P

> P

_DE

M (

P_I

ref)

> P

_Ena

ble

(P_e

na)PILOT REG.


I_D

ET

I_S

E<<



/PILOT ENABLE >

PILOT DEMAND >



D1 Diode Bridge 20A, 1600V, 3P (D2, Sht 1)





MC1 Contactor, 3P ,Inv 1 input, Coil (B3, Sht 2) " Contacts (A2, B2, Sht 1) " Aux Contact (B3, Sht 2)MC2 Contactor, pilot, Coil (B3, Sht 2) " Contacts (B8, Sht 1)


NE1 Neon indicator, rear panel, 220VAC (C1, Sht 1)NE2 Neon indicator, internal, 220VAC (C1, Sht 1)

R1 Resistor, Pilot, 4 Ohm, 1 KW (C8, Sht 1)R6 Resistor, 20K ,30W (A8, Sht 1)R7 Resistor, 1K ,30W (E2, Sht 2)R9 Resistor, 50 ,40W (A9, Sht 1)



COMPONENT LOCATOR

(C7, Sht 2)

(C7 & A9,Sht 2)


DAT

For this version of the power supply Pilot Regulator is not used except to provide power and pass signals from HCT1, the pilot current sensor.A Pilot Resistor, R1, is used instead.

ECO-B402 DAT 2/26/07

AB ECO-B448 DAT 4/13/07

(C7 & A9,Sht 2)

AC ECO-B646 GAC 10/31/07

CN2CN2 1 2 3 4

HCT2HCT2

1 2 3 4

CN4CN4 1 2 3

TB1TB1

TB2TB2

TB5TB5

TB1TB1

CN2CN2 123

HCT1HCT1

1 2 3 4

TB2TB2

WORKWORK

CN1CN1

12

CN5CN5 1 2 3 4

CN5CN5 1234FAN3FAN3

+-

CN2CN2 1 2 3 CN3CN3 1

CN33CN33 1 2 3 4

CN3CN3 12

MC2-AMC2-A

TB4TB4

CN4CN4 1 2 3 4 5

R14 Ohm 1KWR14 Ohm 1KW

MC2-BMC2-B

MC2-CMC2-CCN1CN1

1234

CN4CN4 12345

CN7CN7 12345

CN1CN11234

CN6CN6 123

THS1SW_TEMP_NC

THS1SW_TEMP_NC

R620K

30W

R620K

30W

TB3TB3

CN8CN8 12

C22 UFC22 UF

CN9CN9 1 2

R950R950

CN3CN3 1 2 3 4

Art # A-07128_AB


ULTRA-CUT 100

APPENDIX 9: Schematic, 230-460V, Resistor Pilot Cont.

1

1

2

2

3

3

4

4

5

5

A

B

C

D

E

FAC13V @ 2A

AC120V @ 1A

/PUMP

+15V

+15V

/FAN

/RAS

+15V

COM230460

COM230460

460

230

AC200V @ 3A

AC120V-RAS

FAN + (24 VDC)

FAN - (24 VDC)

0V-RAS

DC 15VDC 0V

AC24V-GCM

0V-A (24V ret)

AC120V-GCM

0V-B (120V ret)

To PC

B7 TB

3

To T1 PR

I - 0

To PCB7 C

N2-1

To PCB7 C

N2-2

To PCB7 C

N2-4

To PCB7 C

N2-5

CCM MODULE

(D9, A10)

(D9, A10)


TO AC

INDICATOR

(on PCB6)

PILOTCONTACTOR

INPUTCONTACTOR

(C9)

FROM CN18 PCB3sht 1




VOLTAGES

PILOT DEM to PS

ANALOG DEM to CPU


CIRCUIT COMM (GND)

I/O PCB

CPU PCB



SW13 - FACTORY ONLY


(F1 Sht 1)

(F1 Sht 1)


(F1 Sht 1)

(F1 Sht 1)

(F2 Sht 1)

(F2 Sht 1)

RY3RY3

FAN1FAN1

+ -

TP9TP9


1

2

C.P7C.P7 RY3RY3

1 2

C.P4C.P4


CN14CN14 1 2


C.P3C.P3

CN20CN201

2

3

RY4RY4


CN8CN81

2

3

4

T1T1460

220

0,

13

0,,

100

0.

200

0..

110

0...

120.

0_

24.

0__

24_

0___

120.

0___

+V

GND

SIG


+V

GND

SIG


R BG

TP4TP4

TP13TP13

TP7TP7

MC2MC2

CN6CN61

2

3

4

C.P5C.P5

CN8CN8 1 2 3 4

C.P2C.P2

1 2 3

MC1MC1

TB5TB5

C.P6C.P6D13 +5VD13 +5V

TB3TB3

LED1LEVELLED1LEVEL

RY5RY5

TP1TP1

1 2

CN2CN2

1

2

tTH1

tTH1

1

2

3


CN12CN12 1 2 3

PUMP

MOT1

PUMP

MOT1

' .

1 2 3

TP5TP5

1

2

TB2TB2

TP8TP8

CN9CN91

2

3

4

5

TP14TP14

1

2

3

CN3CN31

2

3

RY5RY5

TP2TP2

CN9CN91

2

3

D1 GAS_OND1 GAS_ON

CN7CN71

2

3

4

TB1TB1

CN13CN13 1 2 3

TP11TP11

+

RY2

RELCOL_0+

RY2

RELCOL_0


MC1 AUXMC1 AUX

R71K 30WR7

1K 30W

CN2CN2 1 2 3 4 5

CN11CN11

1

2

CN10CN101

2

3

4

5

6

CN1CN1 1 2

D15 PSRD15 PSR

RY4RY4

C.P8C.P8

+RY1

+RY1

LSW1-1

SW_LIQUID_LEVEL_NC

LSW1-1

SW_LIQUID_LEVEL_NC

D4 OK_CNCD4 OK_CNC

TP3TP3

CN10CN101

2

3

TP10TP10

TP6TP6

TP12TP12

TB4TB4

D2 E-STOP_PSD2 E-STOP_PS

CN12CN121

2

Art # A-07129_AB


ULTRA-CUT 100

6

6

7

7

8

8

9

9

10

10

A

B

C

D

E

F

POT HI (GCM1000)

POT WIPER (GCM1000)

POT LOW (GCM 1000)

PLASMA ENABLE

PRESS OK (GCM 1000)

PLASMA ENABLE

24VA

C24

VA

C R

ET

+15V/ AC

/ TEMP

/ STATUS/ DC

/ GAS - COOLANT

- ARC V

- ARC V

AC24V-GCM

0V-A (24V ret)

AC120V-GCM

0V-B (120V ret)

AC120V-RAS

0V-RAS (120V ret)

DC 15V

DC 0V

NE

G A

RC

VO

LTS

PIL

OT

(TIP

) VO

LTS

WO

RK

WORK

0V-A (24V ret)

NEG ARC VOLTS

AC24V-GCM

0V-B (120V ret)

AC120V-GCM

DWG No:

Sheetof

SupersedesScale

Date:

Drawn: References





SizeSCHEMATIC,

ThermalDynamics

AA


2 2




08:11:44

Thermal Dynamics

DDWG No:

Sheetof

SupersedesScale

Date:

Drawn: References





SizeSCHEMATIC,

ThermalDynamics

AA


2 2




08:11:44

Thermal Dynamics

DDWG No:

Sheetof

SupersedesScale

Date:

Drawn: References





SizeSCHEMATIC,

ThermalDynamics

AA


2 2




08:11:44

Thermal Dynamics

D

KEY PLUG


J36 34 CKT J35 26 CKT

RIBBON CABLE

TEST SOCKET

RIBBON CABLE

TEST SOCKET

(E2)

(E2)

(E4)

(F4)


TB1

TB2



E-STOP -E-STOP +

PILOT ON OUTPUT


OK to MOVE -

OK to MOVE +


START / STOP

STOP

START

+

-

JUMPER IN REMOTEHMI

PLASMA ENABLE

PCB6 DISPLAYWK-5603

START / STOP

DIVIDED ARC VOLTS


OK TO MOVE

DAT

Signal - Master ID Used to identify resistor pilot unit




2- Cut Demand4- Pilot Demand6- / Start7- / Start2 9- / Pilot Enable10- / HF Enable12- / Pump Enable13- / Fan Enable15- / DC Indicator16- / Over Temperature Indicator18- / Gas-Coolant OK Indicator19- / Status Lamp



ECO-B402 DAT 2/26/07ECO-B448 DAT 4/13/07AB

(A9 SHT1)

(B9 SHT1)

(C9 SHT1)

(E2)

INTERNAL TERMINAL STRIP TB3

(C9, sht 1)

(A9, sht 1)


24 VAC @ 1A

120 VAC @ 100ma.

(Not in all units)

ECO-B646 GAC 10/31/07AC

GREEN GASGREEN GAS88

11

1K1K

33

J4J4

1

3

5

7

44

GAS ONGAS ON

1010

REDSTATUS

REDSTATUS

GREEN ACGREEN AC

88

1212

55

33

J15-CNCJ15-CNC1

2

3

4

5

6

7

8

9

10

11

12

13

14

J55-GCMJ55-GCM12345678910111213141516171819202122232425262728293031323334353637

TP1TP1

CN23CN23

1

2

3

4

5

6

77

J8J8

1

2

3

4

TP11TP11

1212

1010

J9J9 1 2 3 4 5 6

J7J7

1

2

3

4

5

6

7

8

9

55

77

K6K6K6-1K6-1

11

99

22 J1J11

2

3

4

5

6

7

8

9

1212

E-STOPE-STOP

J6J6 1 5 8

33

100K100K

99

77

1010


22

44

J5J51

2

3

4

5

55

PSRPSR

1111

J59-RASJ59-RAS1

2

3

4

5

6

7

8

91011121314

99

11

CN24CN24

1

2

3

4

5

6

44

66


1

2

3

4

5

6

7

1111

66

1111

22

66

TP12TP12

88

GREEN DCGREEN DC

100K100K

Art # A-07129_AB


ULTRA-CUT 100

APPENDIX 10: Schematic, CCC 400V, w/ Chopper Pilot

1

1

2

2

3

3

4

4

5

5

A

B

C

D

E

F

-15V

INP

UT_

NG

+5V

GN

D

+15V+1

5V

+15V

MIS

SIN

G_P

HA

SE

/ 200

PG

ND

1/ 4

00

/ 400

PG

ND

2400

200

CO

M

L1

L2

L3

E

+15V

+12VDC +12VDC

+12VDC

To PC

B7 C

N2-5

To PC

B7 C

N2-4

To PC

B7 C

N2-2

To PC

B7 C

N2-1

FAN

+ (24 VD

C)

FAN

- (24 VD

C)

To PC

B7 TB

3

To T1 PR

I - 0

V_C

HA

NG

E P

CB

400

V o

nly


VAC_IN


PCB 1WK-5630



16 CKT RIBBON CABLE


MISSING PHASE

(pulses)<


CN6 16 CKT


(F2 -Sht2)

DC FAN POWER

CN1 CN5 CN6

CN4 CN5 CN6

(A1 Sht2)

(A1 Sht2)

(A1 Sht 2)

(A1 Sht 2)

(A2 Sht 2)

(A2 Sht 2)

CN6 16 CKTON / OFF

PCB3 WK-5694

PCB4 WK-5604

VAC_IN

P_GND

BIAS SUPPLY PCB

DETECTOR PCB

INTERFACE PCB

FILTER PCB

--400--

400 VAC 3 Phase




CN32CN32 1 2 3 4


N2N2

TB2TB2P1P1

TB1TB1

1 2

34

CN1CN1 1 5 8

CN7CN7 1 2 3 4 5

LED5ERRORLED5ERROR

P (+)P (+)

CN18CN18 1 2 3

RY2RY2

TB3TB3

C.P1C.P1

- +- +

3

1

2

4

CN3CN3 1 2

MC1-AMC1-A

CN4CN4 1 2 3 4

NE2NE2

MC1-CMC1-CTB4TB4

N (-)N (-)

CN32CN32 1 2 3 4

CN2CN2 12

LED2MISSING PHASE

LED2MISSING PHASE

CN1-not usedCN1-not used

1 2 3 4

CN7CN7 1 2 3 4 5

CN4CN4 14

CN10CN10 1 2

++

RR ++

SS

NE1NE1

200V200V

CN3CN31

4

TT

ACAC

AC

+-

D1

ACAC

AC

+-

D1

CN2CN21

2

3

CN1CN1

1

2

3

4

5

6

7

- +- +

3

1

2

4

+

RY2

RY2

+

RY2

RY2


1 2 3 4

+

-

+

-

1

2

3

45

6

1 2

34

CN2-400V

6

CN2-400V

6

1234

MC1-BMC1-B

INRUSHINRUSH

CN2CN2 1 2 3

TB1TB1

C1C1

Art # A-06998_AD


ULTRA-CUT 100

Art # A-06998_AD

6

6

7

7

8

8

9

9

10

10

A

B

C

D

E

F

N2

P1

+12V

-12V

SIG

NAL

CO

MM

ON

I_se

nseP

Iref_

G

GN

DW

P_e

na

GN

D_C

TEM

P_C

GN

DW

Isen

se_W

-15V

w+1

5Vw

+15V

w-1

5Vw

Isen

se_W

GN

DP

I_se

nseP

GN

DP

Iref_

GP

_ref

P_e

na

P_r

ef

GN

D_C

TEM

P_C

TORCH (-)

PILOT

WORK (+)

WORK

PILOT (TIP) VOLTS

NEG ARC VOLTS

DWG No:

Sheetof

SupersedesScale

Date:

Drawn: References





SizeSCHEMATIC,

ThermalDynamics

AA


1 2


100A Power Supply 400V CCC (Chopper)


08:11:44

Thermal Dynamics

DDWG No:

Sheetof

SupersedesScale

Date:

Drawn: References





SizeSCHEMATIC,

ThermalDynamics

AA


1 2




08:11:44

Thermal Dynamics

DDWG No:

Sheetof

SupersedesScale

Date:

Drawn: References





SizeSCHEMATIC,

ThermalDynamics

AA


1 2




08:11:44

Thermal Dynamics

D

RAS


HALL SENSOR

HALL SENSOR


BIASPOWER


< /O

VE

R_T

EM

P

> P

_DE

M (

P_I

ref)

> P

_Ena

ble

(P_e

na)PILOT REG.


I_D

ET

I_S

E<<



/ OVERTEMP <

/PILOT ENABLE >

PILOT DEMAND >










NE1 Neon indicator, rear panel, 220VAC (C1, Sht 1)

NE2 Neon indicator, internal, 220VAC (C1, Sht 1)




COMPONENT LOCATOR

(C7, Sht 2)


DAT

ECO-B402 DAT 2/26/07

AB ECO-B448 DAT 4/13/07

(C7 & A9,Sht 2)

(C7 & A9,Sht 2)

ECO-B646 GAC 10/31/07ACECO-B1391 DAT 4-24-09AD

AE DATECO-B1535 9-25-09

CN2CN2 1 2 3 4

TB1TB1

CN4CN4 1 2 3

HCT2HCT2

1 2 3 4

TB5TB5

TB2TB2

D2D2

1A1

2K1

3A2

4K2

TB1TB1

TB2TB2

HCT1HCT1

1 2 3 4

CN2CN2 123

CN5CN5 1234

CN5CN5 1 2 3 4

CN1CN1

12

WORKWORK

CN33CN33 1 2 3 4

CN3CN3 1CN2CN2 1 2 3

MC2-AMC2-A

CN3CN3 12

MC2-BMC2-B

CN4CN4 1 2 3 4 5

TB4TB4

MC2-CMC2-C

CN17CN17 1 2 3

CN1CN11234

LED4CHOPPER TEMP

LED4CHOPPER TEMP

CN4CN4 12345

CN1CN11234

CN7CN7 12345

FAN3FAN3

+-

R620K

30W

R620K

30W

THS1SW_TEMP_NC

THS1SW_TEMP_NC

CN6CN6 123

R950R950

CN9CN9 1 2

C22 UFC22 UF

CN8CN8 12

TB3TB3

CN3CN3 1 2 3 4


ULTRA-CUT 100

APPENDIX 10: Schematic, CCC 400V, w/ Chopper PilotCont.

1

1

2

2

3

3

4

4

5

5

A

B

C

D

E

F

400

AC

120 @ 1A

AC13V @ 2A

/PUMP

+15V

+15V

400

/FAN

200-not used

/RAS

COM200400

COM

AC200V @ 3A

200

+15V

0V-A (24V ret)

To PC

B7 C

N2-1

AC120V-GCM

0V-B (120V ret)

To PC

B7 C

N2-2

To PC

B7 C

N2-4

To PC

B7 C

N2-5

To PC

B7 TB

3

0V-RAS

AC120V-RAS

FAN + (24 VDC)

DC 15VDC 0V

FAN - (24 VDC)

AC24V-GCM

To T1 PR

I - 0(F1 Sht 1)

(F1 Sht 1)

PILOTCONTACTOR

INPUTCONTACTOR

(D9, A10)

PILOT (TIP) VOLTAGE



CCM MODULE


+15VDC_ISO-15VDC_ISO

(F1 Sht 1)

(F1 Sht 1)

(F2 Sht 1)

ISOLATEDVOLTAGES

(D9, A10)

(F2 Sht 1)

NEG ARC VOLTS



SW13 - FACTORY ONLY


CIRCUIT COMM (GND)

(C9)


PILOT DEM to PS

ANALOG DEM to CPU

CUT DEM to PS

TO AC

INDICATOR

(on PCB6)


COOLANT FLOW (freq) *

I/O PCB

CPU PCB

RY11RY11

CN2CN2 1 2 3 4 5

LED1LEVELLED1LEVEL

1

2

TP12TP12



FAN1FAN1

+ -

D9 GAS_OND9 GAS_ON

C.P7C.P7

TP18TP18

1

2

CN8CN8 1 2 3 4

C.P3C.P3

1 2 3

CN9CN91

2

3



TP8TP8

D8 OK_CNCD8 OK_CNC

+

RY10

+

RY10

1 2

CN1CN1 1 2

TP2TP2

LSW1-1

SW_LIQUID_LEVEL_NC

LSW1-1

SW_LIQUID_LEVEL_NC

CN9CN91

2

3

4

5

MC2MC2

TP6TP6

CN10CN101

2

3

D13 +5VD13 +5VCN12CN12

1

2

CN5CN51

2

3

4

5

6

TP7TP7

D15 PSRD15 PSR

MC1 AUXMC1 AUX

1 2

CN6CN61

2

3

4R8

1K 30WR8

1K 30W

TB5TB5

RY3RY3

TP17TP17

RY4RY4

CN11CN11

1

2

CN7CN71

2

3

4


CN3CN31

2

3

RY5RY5

1 2 3

TB1TB1

RY7RY7

1

2

3

TP16TP16

C.P5C.P5

+V

GND

SIG


+V

GND

SIG


R BG

C.P2C.P2

TP5TP5

tTH1

tTH1

CN14CN14 1 2


C.P6C.P6

TP14TP14

+RY1

+RY1

CN12CN12 1 2 3

CN2CN2

1

2

TB2TB2

TB4TB4

MC1MC1

T1T1460

220

0,

13

0,,

100

0.

200

0..

110

0...

120.

0_

24.

0__

24_

0___

120.

0___

1

2

3

TP15TP15

PUMP

MOT1

PUMP

MOT1

' .

TP9TP9

RY9RY9

TP4TP4

CN13CN13 1 2 3

TB3TB3

C.P8C.P8

C.P4C.P4

TP3TP3

CN8CN81

2

3

4

CN4CN41

2

3

TP10TP10


Art # A-06999_AD


ULTRA-CUT 100

Art # A-06999_AD

6

6

7

7

8

8

9

9

10

10

A

B

C

D

E

F

PLASMA ENABLE

PRESS OK (GCM 1000)

24V

AC

24 V

AC

RE

T

PLASMA ENABLE

+15V/ AC

/ TEMP

/ STATUS/ DC

/ GAS - COOLANT

POT HI (GCM1000)

POT WIPER (GCM1000)

POT LOW (GCM 1000)

- ARC V

- ARC V

WORK

DC 15V

DC 0V

AC120V-RAS

0V-RAS (120V ret)

0V-A (24V ret)

NEG ARC VOLTS

NE

G A

RC

VO

LTS

AC24V-GCM

AC24V-GCM

0V-A (24V ret)

AC120V-GCM

0V-B (120V ret)

PIL

OT

(TIP

) VO

LTS

0V-B (120V ret)

WO

RK

AC120V-GCM

DWG No:

Sheetof

SupersedesScale

Date:

Drawn: References





SizeSCHEMATIC,

ThermalDynamics

AA


2 2




08:11:44

Thermal Dynamics

DDWG No:

Sheetof

SupersedesScale

Date:

Drawn: References





SizeSCHEMATIC,

ThermalDynamics

AA


2 2




08:11:44

Thermal Dynamics

DDWG No:

Sheetof

SupersedesScale

Date:

Drawn: References





SizeSCHEMATIC,

ThermalDynamics

AA


2 2




08:11:44

Thermal Dynamics

D

DAT

ECO-B402 DAT 2/26/07

AB ECO-B448 DAT 4/13/07AC ECO-B646 GAC 10/31/07

ECO-B1391 DAT 4-24-09ADAE DAT

(E2)


START / STOP

* REMOTE MARKING -

STOP

START


Rx-

Tx+

Rx+

Tx-



KEY PLUG

TB1

TB2

(C9, sht 1)

+

-



RIBBON CABLE

TEST SOCKET


DIVIDED ARC V +

(E2)

(E2)

DIVIDED ARC V -


JUMPER IN REMOTEHMI

** RS 485 / 422 on CPU board19X2554 only.

(A9, sht1)

(B9, sht1)

(C9, sht1)

TB3

KEY PLUG


(E4)

(F4)


START / STOP

DIVIDED ARC VOLTS

PILOT ON OUTPUT


* OK2

Iso

J36 34 CKT

PCB6 DISPLAYWK-5603


4W4W

2W


J35 26 CKT

J14

J14

2W


* OK2

RIBBON CABLE

5

9876

123

4


0

TEST SOCKET

HOLD START -HOLD START +

(A9, sht 1)


* +10VDC @ 10 ma.(for CC pot high)

OK TO MOVE

GND

GND

& CNC COMM

PREFLOW ON -PREFLOW ON +

PLASMA ENABLE

24 VAC @ 1A

120 VAC @ 100ma.

(Not in all units)

OK to MOVE -


E-STOP -E-STOP +

* REMOTE MARKING +






Rx-

Tx+

Rx+

Tx-

OK to MOVE +

ECO-B1535 9-25-09

88

66

33

GAS ONGAS ON

OK2 *OK2 *

GREEN2 DCGREEN2 DC

GREEN1 GASGREEN1 GAS

1111

99

J9J9 1 2 3 4 5 6

2211


REDSTATUS

REDSTATUS

77

TP1TP1

33

44

J7J7

1

2

3

4

5

6

7

8

9

100K14100K14

1K1K

22

CN24CN24

1

2

3

4

5

6

55

11

88

99

K7-1K7-1

66

77

22

TP11TP11


1

2

3

4

5

6

7

8

9

10

11

12

13

14

J1J11

2

3

4

5

6

7

8

9

1111

J8J8

1

2

3

4

J4J4

1

3

5

7

J5J51

2

3

4

5

J6 **J6 **1

2

3

4

5

6

1010

E-STOPE-STOP

77

55

22

1111

PSRPSR

K6K6 J59-RASJ59-RAS1

2

3456

7

8

9

1011121314

1212

44

GREEN ACGREEN AC

1212

1212

J55-GCMJ55-GCM12345678910111213141516171819202122232425262728293031323334353637

TP13TP13

100K100K

1010

11

66

88

44

55

J6J6 1 5 8

J15-CNCJ15-CNC1

2

3

4

5

6

7

8

9

10

11

12

13

14

CN23CN23

1

2

3

4

5

6

33

11

99

1010


ULTRA-CUT 100

APPENDIX 11: Schematic, CE 400V, Chopper Pilot

Art # A-06996_AD

1

1

2

2

3

3

4

4

5

5

A

B

C

D

E

F

-15V

INP

UT_

NG

+5V

GN

D

+15V+1

5V

+15V

MIS

SIN

G_P

HA

SE

/ 200

PG

ND

1/ 4

00

/ 400

PG

ND

2400

200

CO

M

L1

L2

L3

E

+15V

+12VDC +12VDC

+12VDC

To PC

B7 C

N2-5

To PC

B7 C

N2-4

To PC

B7 C

N2-2

To PC

B7 C

N2-1

FAN

+ (24 VD

C)

FAN

- (24 VD

C)

To PC

B7 TB

3

To T1 PR

I - 0

V_C

HA

NG

E P

CB

400

V o

nly


VAC_IN


PCB 1WK-5630



16 CKT RIBBON CABLE


MISSING PHASE

(pulses)<


CN6 16 CKT


(F2 -Sht2)

DC FAN POWER

CN1 CN5 CN6

CN4 CN5 CN6

(A1 Sht2)

(A1 Sht2)

(A1 Sht 2)

(A1 Sht 2)

(A2 Sht 2)

(A2 Sht 2)

CN6 16 CKT

ON / OFF

PCB3 WK-5694

PCB4 WK-5604

VAC_IN

P_GND

BIAS SUPPLY PCB

DETECTOR PCB

INTERFACE PCB

FILTER PCB

--400--

400 VAC 3 Phase




MC1-CMC1-C

RY2RY2

ACAC

AC

+-

D1

ACAC

AC

+-

D1

CN1CN1

1

2

3

4

5

6

7

TB4TB4

+

RY2

RY2

+

RY2

RY2

200V200V

L1L1

TT

CN3CN31

4

CN32CN32 1 2 3 4

CN2-400V

6

CN2-400V

6

1234

L7L7


1 2 3 4

C1C1

CN2CN2 12


MC1-BMC1-B

N2N2


1 2 3 4

LED2MISSING PHASE

LED2MISSING PHASE

+

-

+

-

1

2

3

45

6

1 2

34

EMIFILTER

NFC1

EMIFILTER

NFC1

L1

L2

L3

L4

L6

L5

TB3TB3 ++

CN2CN21

2

3

SS

CN1CN1 1 5 8

L3L3

CN7CN7 1 2 3 4 5

MC1-AMC1-A

CN7CN7 1 2 3 4 5

CN4CN4 14

LED5ERRORLED5ERROR

1 2

34

INRUSHINRUSH

NE1NE1

CN2CN2 1 2 3

P (+)P (+)

L2L2

CN4CN4 1 2 3 4

C.P1C.P1

L4L4

NE2NE2

CN10CN10 1 2

N (-)N (-)

- +- +

3

1

2

4

L5L5

CN32CN32 1 2 3 4

TB2TB2 ++

RR

P1P1

CN3CN3 1 2

CN18CN18 1 2 3

L6L6

- +- +

3

1

2

4

TB1TB1

TB1TB1


ULTRA-CUT 100

Art # A-06996_AD

6

6

7

7

8

8

9

9

10

10

A

B

C

D

E

F

N2

P1

+12V

-12V

SIG

NAL

CO

MM

ON

I_se

nseP

Iref_

G

GN

DW

P_e

na

GN

D_C

TEM

P_C

GN

DW

Isen

se_W

-15V

w+1

5Vw

+15V

w-1

5Vw

Isen

se_W

GN

DP

I_se

nseP

GN

DP

Iref_

GP

_ref

P_e

na

P_r

ef

GN

D_C

TEM

P_C

TORCH (-)

PILOT

WORK (+)

WORK

PILOT (TIP) VOLTS

NEG ARC VOLTS

DWG No:

Sheetof

SupersedesScale

Date:

Drawn: References





SizeSCHEMATIC,

ThermalDynamics

AA


1 2


100A Power Supply 400V CE (Chopper)


08:11:44

Thermal Dynamics

DDWG No:

Sheetof

SupersedesScale

Date:

Drawn: References





SizeSCHEMATIC,

ThermalDynamics

AA


1 2




08:11:44

Thermal Dynamics

DDWG No:

Sheetof

SupersedesScale

Date:

Drawn: References





SizeSCHEMATIC,

ThermalDynamics

AA


1 2




08:11:44

Thermal Dynamics

D

RAS


HALL SENSOR

HALL SENSOR


BIASPOWER


< /O

VE

R_T

EM

P

> P

_DE

M (

P_I

ref)

> P

_Ena

ble

(P_e

na)PILOT REG.


I_D

ET

I_S

E<<



/ OVERTEMP <

/PILOT ENABLE >

PILOT DEMAND >


C.P1 Circuit protector/ON-OFF SW (C2, Sht 1) 15A, 460V, 3PC.P2 Circuit protector 2.5A 125V (D2, Sht 1)C.P3 Circuit protector 3.15A 125V (D2, Sht 1)C.P4 Circuit protector 10A 125V (E2, Sht 1)C.P5 Circuit protector 2.5A 125V (E2, Sht 1)C.P6 Circuit protector 2.5A 125V (F2, Sht 1)C.P7 Circuit protector 5A 125V (E2, Sht 1)C.P8 Circuit protector 3.15A 125V (F3, Sht 1)





L1 Toroid Core input common mode filter (A2, Sht 1)L2-7 Toroid Core common mode filter (B1, C1, Sht 1)L8 Toroid Core output common mode filter (A6, Sht 1)




NE1 Neon indicator, rear panel, 220VAC (C1, Sht 1)NE2 Neon indicator, internal, 220VAC (D1, Sht 1)

NFC1 Noise Filter, EMI, input (A2, Sht 1)




COMPONENT LOCATOR

(C7, Sht 2)


DAT

ECO-B402 DAT 2/26/07

AB ECO-B448 DAT 4/13/07

(C7 & A9,Sht 2)

(C7 & A9,Sht 2)

ECO-B646 GAC 10/31/07AC4-24-09DATECO-B1391AD

DATAE ECO-B1535 9-25-09

R950R950

TB1TB1

CN33CN33 1 2 3 4CN17CN17 1 2 3

CN2CN2 1 2 3 4CN9CN9 1 2

TB2TB2

CN3CN3 1 2 3 4

HCT1HCT1

1 2 3 4

D2D2

1A1

2K1

3A2

4K2

CN5CN5 1234

TB5TB5

MC2-AMC2-A

TB2TB2

CN3CN3 1

C22 UFC22 UF

MC2-BMC2-B

MC2-CMC2-C

CN8CN8 12

FAN3FAN3

+-

CN5CN5 1 2 3 4

R620K

30W

R620K

30W

CN4CN4 1 2 3

CN1CN11234

CN1CN11234

CN2CN2 1 2 3

L8L8

CN1CN1

12

CN2CN2 123

TB1TB1

THS1SW_TEMP_NC

THS1SW_TEMP_NC

HCT2HCT2

1 2 3 4

CN6CN6 123

CN4CN4 1 2 3 4 5

LED4CHOPPER TEMP

LED4CHOPPER TEMP

CN4CN4 12345

TB4TB4

CN3CN3 12

WORKWORK

TB3TB3

CN7CN7 12345


ULTRA-CUT 100

APPENDIX 11: Schematic, CE 400V, Chopper Pilot Cont.

Art # A-06997_AD

1

1

2

2

3

3

4

4

5

5

A

B

C

D

E

F

400

AC

120 @ 1A

AC13V @ 2A

/PUMP

+15V

+15V

400

/FAN

200-not used

/RAS

COM200400

COM

AC200V @ 3A

200

+15V

0V-A (24V ret)

To PC

B7 C

N2-1

AC120V-GCM

0V-B (120V ret)

To PC

B7 C

N2-2

To PC

B7 C

N2-4

To PC

B7 C

N2-5

To PC

B7 TB

3

0V-RAS

AC120V-RAS

FAN + (24 VDC)

DC 15VDC 0V

FAN - (24 VDC)

AC24V-GCM

To T1 PR

I - 0(F1 Sht 1)

(F1 Sht 1)

PILOTCONTACTOR

INPUTCONTACTOR

(D9, A10)

PILOT (TIP) VOLTAGE



CCM MODULE



(F1 Sht 1)

(F1 Sht 1)

(F2 Sht 1)

ISOLATEDVOLTAGES

(D9, A10)

(F2 Sht 1)

NEG ARC VOLTS



SW13 - FACTORY ONLY


CIRCUIT COMM (GND)

(C9)


PILOT DEM to PS

ANALOG DEM to CPU

CUT DEM to PS

TO AC

INDICATOR

(on PCB6)



I/O PCB

CPU PCB

+V

GND

SIG


+V

GND

SIG


R BG

RY3RY3

TP17TP17

CN9CN91

2

3

4

5

CN2CN2

1

2

D8 OK_CNCD8 OK_CNC

LED1LEVELLED1LEVEL

PUMP

MOT1

PUMP

MOT1

' .

CN14CN14 1 2

C.P7C.P7

TP18TP18

CN6CN61

2

3

4

CN5CN51

2

3

4

5

6

MC2MC2

R81K 30WR8

1K 30W

TB2TB2

+

RY10

+

RY10

1

2

CN9CN91

2

3


TP10TP10

1 2

C.P6C.P6

C.P2C.P2

CN3CN31

2

3

1

2

3

RY4RY41

2


TB4TB4

TP14TP14

TP6TP6

TP3TP3

TP9TP9

TP5TP5

RY9RY9

RY5RY5

TP2TP2

TP12TP12



TP16TP16

CN10CN101

2

3

CN8CN81

2

3

4

CN1CN1 1 2

tTH1

tTH1

CN11CN11

1

2

MC1MC1

1 2 3


TP4TP4


CN13CN13 1 2 3

+RY1

+RY1

C.P5C.P5

TB1TB1

T1T1460

220

0,

13

0,,

100

0.

200

0..

110

0...

120.

0_

24.

0__

24_

0___

120.

0___

D13 +5VD13 +5V

TB3TB3

CN7CN71

2

3

4

1

2

3

TP7TP7

RY11RY11

TP8TP8

C.P8C.P8

FAN1FAN1

+ -

TB5TB5

TP15TP15

D15 PSRD15 PSR

CN8CN8 1 2 3 4

CN12CN121

2

C.P3C.P3

D9 GAS_OND9 GAS_ON


LSW1-1

SW_LIQUID_LEVEL_NC

LSW1-1

SW_LIQUID_LEVEL_NC

CN4CN41

2

3

CN12CN12 1 2 3

MC1 AUXMC1 AUX

RY7RY7

1 2

1 2 3

C.P4C.P4

CN2CN2 1 2 3 4 5


ULTRA-CUT 100

Art # A-06997_AD

6

6

7

7

8

8

9

9

10

10

A

B

C

D

E

F

PLASMA ENABLE

PRESS OK (GCM 1000)

24V

AC

24 V

AC

RE

T

PLASMA ENABLE

+15V/ AC

/ TEMP

/ STATUS/ DC

/ GAS - COOLANT

POT HI (GCM1000)

POT WIPER (GCM1000)

POT LOW (GCM 1000)

- ARC V

- ARC V

WORK

DC 15V

DC 0V

AC120V-RAS

0V-RAS (120V ret)

0V-A (24V ret)

NEG ARC VOLTS

NE

G A

RC

VO

LTS

AC24V-GCM

AC24V-GCM

0V-A (24V ret)

AC120V-GCM

0V-B (120V ret)

PIL

OT

(TIP

) VO

LTS

0V-B (120V ret)

WO

RK

AC120V-GCM

DWG No:

Sheetof

SupersedesScale

Date:

Drawn: References





SizeSCHEMATIC,

ThermalDynamics

AA


2 2




08:11:44

Thermal Dynamics

DDWG No:

Sheetof

SupersedesScale

Date:

Drawn: References





SizeSCHEMATIC,

ThermalDynamics

AA


2 2




08:11:44

Thermal Dynamics

DDWG No:

Sheetof

SupersedesScale

Date:

Drawn: References





SizeSCHEMATIC,

ThermalDynamics

AA


2 2




08:11:44

Thermal Dynamics

D

DAT

ECO-B402 DAT 2/26/07

AB ECO-B448 DAT 4/13/07AC ECO-B646 GAC 10/31/07AD ECO-B1391 DAT 4-24-09

DATAE

(E2)


START / STOP

* REMOTE MARKING -

STOP

START


Rx-

Tx+

Rx+

Tx-



KEY PLUG

TB1

TB2

(C9, sht 1)

+

-



RIBBON CABLE

TEST SOCKET


DIVIDED ARC V +

(E2)

(E2)

DIVIDED ARC V -


JUMPER IN REMOTEHMI


(A9, sht1)

(B9, sht1)

(C9, sht1)

TB3

KEY PLUG


(E4)

(F4)


START / STOP

DIVIDED ARC VOLTS

PILOT ON OUTPUT


* OK2

Iso

J36 34 CKT

PCB6 DISPLAYWK-5603


4W4W

2WJUMPERfor 4 WIRE usesTX+, TX-RX+, RX-

J35 26 CKT

J14

J14

2W


* OK2

RIBBON CABLE

5

9876

123

4


0

TEST SOCKET


(A9, sht 1)



OK TO MOVE

GND

GND

& CNC COMM


PLASMA ENABLE

24 VAC @ 1A

120 VAC @ 100ma.

(Not in all units)

OK to MOVE -


E-STOP -E-STOP +

* REMOTE MARKING +






Rx-

Tx+

Rx+

Tx-

OK to MOVE +

ECO-B1535 9-25-09

88

22

55

1212

J6J6 1 5 8

J4J4

1

3

5

7

K6K6

J5J51

2

3

4

5

CN24CN24

1

2

3

4

5

6


REDSTATUS

REDSTATUS

33

77

33

11

TP11TP11

44

66

TP1TP1

GAS ONGAS ON

J15-CNCJ15-CNC1

2

3

4

5

6

7

8

9

10

11

12

13

14

100K100K

22

2211

55

CN23CN23

1

2

3

4

5

6

88

J59-RASJ59-RAS1

2

3456

7

8

9

1011121314

GREEN1 GASGREEN1 GAS

J6 **J6 **1

2

3

4

5

6


1

2

3

4

5

6

7

8

9

10

11

12

13

14

66

1212

66

OK2 *OK2 *

1111

99

1K1K

1010

77

J1J11

2

3

4

5

6

7

8

9

PSRPSR

4455

1111

88

GREEN ACGREEN AC33

1010

J8J8

1

2

3

4

11

1212

99

44

K7-1K7-1

GREEN2 DCGREEN2 DC

77

E-STOPE-STOP

J7J7

1

2

3

4

5

6

7

8

9

1010

J9J9 1 2 3 4 5 6

22

J55-GCMJ55-GCM12345678910111213141516171819202122232425262728293031323334353637

11

1111

99

TP13TP13

100K6100K6


ULTRA-CUT 100

APPENDIX 12: Schematic, CE 400V, Resistor Pilot

1

1

2

2

3

3

4

4

5

5

A

B

C

D

E

F

-15V

INP

UT_

NG

+5V

GN

D

+15V+1

5V

GN

D_C

TEM

P_C

+15V

MIS

SIN

G_P

HA

SE

/ 200

PG

ND

1/ 4

00

/ 400

PG

ND

2400

200

CO

M

L1

L2

L3

E

+15V

+12VDC +12VDC

+12VDC

To PC

B7 C

N2-5

To PC

B7 C

N2-4

To PC

B7 C

N2-2

To PC

B7 C

N2-1

FAN

+ (24 VD

C)

FAN

- (24 VD

C)

To PC

B7 TB

3

To T1 PR

I - 0

V_C

HAN

GE

PCB

400

V o

nly


VAC_IN


PCB 1WK-5630



16 CKT RIBBON CABLE

/ OVERTEMP <


MISSING PHASE

(pulses)<


CN6 16 CKT


(F2 -Sht2)

DC FAN POWER

CN1 CN5 CN6

CN4 CN5 CN6

(A1 Sht2)

(A1 Sht2)

(A1 Sht 2)

(A1 Sht 2)

(A2 Sht 2)

(A2 Sht 2)

CN6 16 CKT

ON / OFF

PCB3 WK-5694

PCB4 WK-5604

VAC_IN

P_GND

BIAS SUPPLY PCB

DETECTOR PCB

INTERFACE PCB

FILTER PCB

--400--

400 VAC 3 Phase




CN32CN32 1 2 3 4


N2N2

TB2TB2P1P1

TB1TB1

1 2

34

CN1CN1 1 5 8

CN7CN7 1 2 3 4 5

LED5ERRORLED5ERROR

P (+)P (+)

CN18CN18 1 2 3

RY2RY2

TB3TB3

C.P1C.P1

L5L5

- +- +

3

1

2

4

CN3CN3 1 2

MC1-AMC1-A

CN4CN4 1 2 3 4

NE2NE2

MC1-CMC1-CTB4TB4

N (-)N (-)

CN32CN32 1 2 3 4

CN2CN2 12

L6L6

LED2MISSING PHASE

LED2MISSING PHASE


1 2 3 4

CN7CN7 1 2 3 4 5

CN4CN4 14

L4L4

CN10CN10 1 2

++

RR

EMIFILTER

NFC1

EMIFILTER

NFC1

L1

L2

L3

L4

L6

L5

++

SS

NE1NE1

200V200V

CN17CN17 1 2 3

CN3CN31

4

TT

ACAC

AC

+-

D1

ACAC

AC

+-

D1

L7L7

L8L8

CN2CN21

2

3

LED4CHOPPER TEMP

LED4CHOPPER TEMP

CN1CN1

1

2

3

4

5

6

7

L1L1

- +- +

3

1

2

4

+

RY2

RY2

+

RY2

RY2


1 2 3 4

+

-

+

-

1

2

3

45

6

L3L3

1 2

34

CN2-400V

6

CN2-400V

6

1234

MC1-BMC1-B

INRUSHINRUSH

CN2CN2 1 2 3

L2L2

TB1TB1

C1C1

Art # A-06994_AB


ULTRA-CUT 100

6

6

7

7

8

8

9

9

10

10

A

B

C

D

E

F

N2

P1

+12V

-12V

SIG

NA

LC

OM

MO

N

I_se

nseP

Iref_

G

GN

DW

P_e

na

GN

DW

Isen

se_W

-15V

w+1

5Vw

+15V

w-1

5Vw

Isen

se_W

GN

DP

I_se

nseP

GN

DP

Iref_

GP

_ref

P_e

na

P_r

ef

GN

D_C

TEM

P_C

TORCH (-)

PILOT

WORK (+)

WORK

PILOT (TIP) VOLTS

NEG ARC VOLTS

DWG No:

Sheetof

SupersedesScale

Date:

Drawn: References





SizeSCHEMATIC,

ThermalDynamics

AA


1 2


100A Power Supply 400V CE (Resistor)


08:11:44

Thermal Dynamics

DDWG No:

Sheetof

SupersedesScale

Date:

Drawn: References





SizeSCHEMATIC,

ThermalDynamics

AA


1 2




08:11:44

Thermal Dynamics

DDWG No:

Sheetof

SupersedesScale

Date:

Drawn: References





SizeSCHEMATIC,

ThermalDynamics

AA


1 2




08:11:44

Thermal Dynamics

D

RAS


HALL SENSOR

HALL SENSOR


BIASPOWER


< /O

VE

R_T

EM

P

> P

_DE

M (

P_I

ref)

> P

_Ena

ble

(P_e

na)PILOT REG.


I_D

ET

I_S

E<<



/PILOT ENABLE >

PILOT DEMAND >


C.P1 Circuit protector/ON-OFF SW (C2, Sht 1) 15A, 460V, 3PC.P2 Circuit protector 2.5A 125V (D2, Sht 1)C.P3 Circuit protector 3.15A 125V (D2, Sht 1)C.P4 Circuit protector 10A 125V (E2, Sht 1)C.P5 Circuit protector 2.5A 125V (E2, Sht 1)C.P6 Circuit protector 2.5A 125V (F2, Sht 1)C.P7 Circuit protector 5A 125V (E2, Sht 1)C.P8 Circuit protector 3.15A 125V (F3, Sht 1)

D1 Diode Bridge 20A, 1600V, 3P (D2, Sht 1)




L1 Toroid Core input common mode filter (A2, Sht 1)L2-7 Toroid Core common mode filter (B1, C1, Sht 1)L8 Toroid Core output common mode filter (A6, Sht 1)


MC1 Contactor, 3P ,Inv 1 input, Coil (B3, Sht 2) " Contacts (A2, B2, Sht 1) " Aux Contact (B3, Sht 2)MC2 Contactor, pilot, Coil (B3, Sht 2) " Contacts (B8, Sht 1)


NE1 Neon indicator, rear panel, 220VAC (C1, Sht 1)NE2 Neon indicator, internal, 220VAC (D1, Sht 1)

NFC1 Noise Filter, EMI, input (A2, Sht 1)

R1 Resistor, Pilot, 4 Ohm, 1 KW (C8, Sht 1)R6 Resistor, 20K ,30W (A8, Sht 1)R7 Resistor, 1K ,30W (E2, Sht 2)R9 Resistor, 50 ,40W (A9, Sht 1)



COMPONENT LOCATOR

(C7, Sht 2)


DAT

For this version of the power supply Pilot Regulator is not used except to provide power and pass signals from HCT1, the pilot current sensor.A Pilot Resistor, R1, is used instead.

ECO-B402 DAT 2/26/07

AB ECO-B448 DAT 4/13/07

(C7 & A9,Sht 2)

(C7 & A9,Sht 2)

ECO-B646 GAC 10/31/07AC

CN2CN2 1 2 3 4

TB1TB1

CN4CN4 1 2 3

HCT2HCT2

1 2 3 4

TB5TB5

TB2TB2

TB1TB1

TB2TB2

HCT1HCT1

1 2 3 4

CN2CN2 123

CN5CN5 1234

CN5CN5 1 2 3 4

CN1CN1

12

WORKWORK

CN33CN33 1 2 3 4


MC2-AMC2-ACN3CN3 12

MC2-BMC2-B

CN4CN4 1 2 3 4 5

TB4TB4

MC2-CMC2-C

CN1CN11234

R14 Ohm 1KWR14 Ohm 1KW

CN4CN4 12345

CN1CN11234

CN7CN7 12345

FAN3FAN3

+-

R620K

30W

R620K

30W

THS1SW_TEMP_NC

THS1SW_TEMP_NC

CN6CN6 123

R950R950

CN9CN9 1 2

C22 UFC22 UF

CN8CN8 12

TB3TB3

CN3CN3 1 2 3 4

Art # A-06994_AB


ULTRA-CUT 100

APPENDIX 12: Schematic, CE 400V, Resistor Pilot Cont.1

1

2

2

3

3

4

4

5

5

A

B

C

D

E

FAC13V @ 2A

AC120V @ 1A

/PUMP

+15V

+15V

/FAN

/RAS

+15V

COM200400

COM200400

400

200 (not used)

AC200V @ 3A

AC120V-RAS

FAN + (24 VDC)

FAN - (24 VDC)

0V-RAS

DC 15VDC 0V

AC24V-GCM

0V-A (24V ret)

AC120V-GCM

0V-B (120V ret)

To PC

B7 TB

3

To T1 PR

I - 0

To PCB7 C

N2-1

To PC

B7 C

N2-2

To PC

B7 C

N2-4

To PC

B7 C

N2-5

CCM MODULE

(D9, A10)

(D9, A10)


TO AC

INDICATOR

(on PCB6)

PILOTCONTACTOR

INPUTCONTACTOR

(C9)

FROM CN18 PCB3sht 1




VOLTAGES

PILOT DEM to PS

ANALOG DEM to CPU


CIRCUIT COMM (GND)

I/O PCB

CPU PCB



SW13 - FACTORY ONLY


(F1 Sht 1)

(F1 Sht 1)


(F1 Sht 1)

(F1 Sht 1)

(F2 Sht 1)

(F2 Sht 1)

1 2 3

CN12CN121

2

CN2CN2

1

2

TP4TP4

CN20CN201

2

3

+

RY2

RELCOL_0+

RY2

RELCOL_0

CN3CN31

2

3


C.P8C.P8

+V

GND

SIG


+V

GND

SIG


R BG

T1

TX1P8S

T1

TX1P8S

400

200

0,

13

0,,

100

0.

200

0..

110

0...

120.

0_

24.

0__

24_

0___

120.

0___

TP10TP10

1 2

CN10CN101

2

3

TB1TB1

D15 PSRD15 PSR

C.P5C.P5

R71K 30WR7

1K 30W


C.P2C.P2

TP9TP9

1

2

3

CN7CN71

2

3

4

TP14TP14

CN6CN61

2

3

4

CN8CN81

2

3

4

MC2MC2

D1 GAS_OND1 GAS_ON

TP7TP7

CN1CN1 1 2

CN9CN91

2

3

4

5

1 2

TP1TP1

CN14CN14 1 2

C.P6C.P6

TB5TB5

RY3RY3

TP5TP5

CN9CN91

2

3

RY5RY5


C.P3C.P3

MC1 AUXMC1 AUX

TP3TP3TP2TP2

D4 OK_CNCD4 OK_CNC

TB4TB4

LED1LEVELLED1LEVEL

CN10CN101

2

3

4

5

6


FAN1FAN1

+ -

1

2

3

MC1MC1

LSW1-1LSW1-1

+RY1

+RY1


RY5RY5

1 2 3

CN11CN11

1

2

CN8CN8 1 2 3 4

TP8TP8

TB2TB2


TP12TP12

CN2CN2 1 2 3 4 5

C.P7C.P7

RY4RY4

PUMP

MOT1

PUMP

MOT1

' .

tTH1

tTH1

TP13TP13

TB3TB3

RY3RY3

TP6TP6

TP11TP11

CN13CN13 1 2 3

1

2

CN12CN12 1 2 3

C.P4C.P4

1

2


RY4RY4

D13 +5VD13 +5V

Art # A-06995_AB


ULTRA-CUT 100

Art # A-06995_AB

6

6

7

7

8

8

9

9

10

10

A

B

C

D

E

F

POT HI (GCM1000)

POT WIPER (GCM1000)

POT LOW (GCM 1000)

PLASMA ENABLE

PRESS OK (GCM 1000)

PLASMA ENABLE

24VA

C24

VA

C R

ET

+15V/ AC

/ TEMP

/ STATUS/ DC

/ GAS - COOLANT

- ARC V

- ARC V

AC24V-GCM

0V-A (24V ret)

AC120V-GCM

0V-B (120V ret)

AC120V-RAS

0V-RAS (120V ret)

DC 15V

DC 0V

NE

G A

RC

VO

LTS

PIL

OT

(TIP

) VO

LTS

WO

RK

WORK

0V-A (24V ret)

NEG ARC VOLTS

AC24V-GCM

0V-B (120V ret)

AC120V-GCM

DWG No:

Sheetof

SupersedesScale

Date:

Drawn: References





SizeSCHEMATIC,

ThermalDynamics

AA


2 2




08:11:44

Thermal Dynamics

DDWG No:

Sheetof

SupersedesScale

Date:

Drawn: References





SizeSCHEMATIC,

ThermalDynamics

AA


2 2




08:11:44

Thermal Dynamics

DDWG No:

Sheetof

SupersedesScale

Date:

Drawn: References





SizeSCHEMATIC,

ThermalDynamics

AA


2 2




08:11:44

Thermal Dynamics

D

KEY PLUG


J36 34 CKT J35 26 CKT

RIBBON CABLE

TEST SOCKET

RIBBON CABLE

TEST SOCKET

(E2)

(E2)

(E4)

(F4)


TB1

TB2



E-STOP -E-STOP +

PILOT ON OUTPUT


OK to MOVE -

OK to MOVE +


START / STOP

STOP

START

+

-

JUMPER IN REMOTEHMI

PLASMA ENABLE

PCB6 DISPLAYWK-5603

START / STOP

DIVIDED ARC VOLTS


OK TO MOVE

DAT


Signal - Master ID Used to identify resistor pilot unit



2- Cut Demand4- Pilot Demand6- / Start7- / Start2 9- / Pilot Enable10- / HF Enable12- / Pump Enable13- / Fan Enable15- / DC Indicator16- / Over Temperature Indicator18- / Gas-Coolant OK Indicator19- / Status Lamp


1- Output Current Signal 3- / Arc Transferred (CSR)4- / Pilot On 6- Coolant Flow (freq)7- Coolant Temp (analog)9- / Temp OK (Inverter/Chopper)10- / Coolant Level OK12- Missing Phase13- / Ready to Operate15- / Input Volts OK16- / Inverter OCR18- / PS ID "00*"19- / PS ID "0*0"20- / PS ID "*00"21- E-Stop22- E-Stop29,31,33 - 24 VAC Supply30,32,34 - 24 VAC Return

ECO-B402 DAT 2/26/07

AB ECO-B448 DAT 4/13/07

(E2)


(C9, sht 1)

(A9, sht 1)


24 VAC @ 1A

120 VAC @ 100ma.

(Not in all units)

(A9 SHT1)

(B9 SHT1)

(C9 SHT1)

AC ECO-B646 GAC 10/31/07

100K100K

1212

PSRPSR

22

GREEN DCGREEN DC

77

44

99

33

88

11

J6J6 1 5 8

GREEN ACGREEN AC 44

99

E-STOPE-STOP

J15-CNCJ15-CNC1

2

3

4

5

6

7

8

9

10

11

12

13

14

33

88

100K100K

K6-1K6-1

55

1K1K

1010

77

1111

K6K6


1

2

3

4

5

6

7

22

77

1212

J59-RASJ59-RAS1

2

3

4

5

6

7

8

91011121314

66

TP11TP11

1212

22

CN23CN23

1

2

3

4

5

6 REDSTATUS

REDSTATUS

J4J4

1

3

5

7

88


11

33

TP1TP1

SW_LIQUID_LEVEL_NCSW_LIQUID_LEVEL_NC

66

1111

11

99

J55-GCMJ55-GCM12345678910111213141516171819202122232425262728293031323334353637

44

J8J8

1

2

3

4

1010

J1J11

2

3

4

5

6

7

8

9

CN24CN24

1

2

3

4

5

6

TP12TP12

55

55

GREEN GASGREEN GAS

J7J7

1

2

3

4

5

6

7

8

9

1010

1111

J5J51

2

3

4

5

J9J9 1 2 3 4 5 6

66

GAS ONGAS ON


ULTRA-CUT 100

APPENDIX 13: Schematic, CSA 600V, Chopper Pilot

1

1

2

2

3

3

4

4

5

5

A

B

C

D

E

F

-15V

INP

UT_

NG

+5V

GN

D

+15V+1

5V

+15V

MIS

SIN

G_P

HA

SE

/ 200

PG

ND

1/ 6

00

/ 600

PG

ND

2600

200

CO

M

L1

L2

L3

E

+15V

+12VDC +12VDC

+12VDC

To PC

B7 C

N2-5

To PC

B7 C

N2-4

To PC

B7 C

N2-2

To PC

B7 C

N2-1

FAN

+ (24 VD

C)

FAN

- (24 VD

C)

To PC

B7 TB

3

To T1 PR

I - 0

V_C

HA

NG

E P

CB

600

V o

nly


VAC_IN


PCB 1WK-5857



16 CKT RIBBON CABLE


MISSING PHASE

(pulses)<


CN6 16 CKT


(F2 -Sht2)

DC FAN POWER

CN1 CN5 CN6

CN4 CN5 CN6

(A1 Sht2)

(A1 Sht2)

(A1 Sht 2)

(A1 Sht 2)

(A2 Sht 2)

(A2 Sht 2)

CN6 16 CKTON / OFF

PCB3 WK-5694

PCB4 WK-5604

VAC_IN

P_GND

BIAS SUPPLY PCB

DETECTOR PCB

INTERFACE PCB

FILTER PCB

--600--

600 VAC 3 Phase




CN32CN32 1 2 3 4


N2N2

TB2TB2P1P1

TB1TB1

1 2

34

CN1CN1 1 5 8

CN7CN7 1 2 3 4 5

LED5ERRORLED5ERROR

P (+)P (+)

CN18CN18 1 2 3

RY2RY2

TB3TB3

C.P1C.P1

- +- +

3

1

2

4

CN3CN3 1 2

MC1-AMC1-A

CN4CN4 1 2 3 4

NE2NE2

MC1-CMC1-CTB4TB4

N (-)N (-)

CN32CN32 1 2 3 4

CN2CN2 12


1 2 3 4

LED2MISSING PHASE

LED2MISSING PHASE

CN7CN7 1 2 3 4 5

CN4CN4 14

CN10CN10 1 2

++

RR ++

SS

NE1NE1

230V230V

TT

CN3CN31

4

ACAC

AC

+-

D1

ACAC

AC

+-

D1

CN2CN21

2

3

CN1CN1

1

2

3

4

5

6

7

- +- +

3

1

2

4

+

RY2

RY2

+

RY2

RY2


1 2 3 4

+

-

+

-

1

2

3

45

6

1 2

34

CN2-600V

6

CN2-600V

6

1234

MC1-BMC1-B

INRUSHINRUSH

CN2CN2 1 2 3

TB1TB1

C1C1

Art # A-07000_AD


ULTRA-CUT 100

6

6

7

7

8

8

9

9

10

10

A

B

C

D

E

F

+12V

-12V

SIG

NAL

CO

MM

ON

I_se

nseP

Iref_

G

GN

DW

P_e

na

GN

D_C

TEM

P_C

GN

DW

Isen

se_W

-15V

w+1

5Vw

+15V

w-1

5Vw

Isen

se_W

GN

DP

I_se

nseP

GN

DP

Iref_

GP

_ref

P_e

na

P_r

ef

GN

D_C

TEM

P_C

TORCH (-)

PILOT

WORK (+)

WORK

PILOT (TIP) VOLTS

NEG ARC VOLTS

N2 P1

DWG No:

Sheetof

SupersedesScale

Date:

Drawn: References





SizeSCHEMATIC,

ThermalDynamics

AA


1 2


100A Power Supply 600V CSA (Chopper)


08:11:44

Thermal Dynamics

DDWG No:

Sheetof

SupersedesScale

Date:

Drawn: References





SizeSCHEMATIC,

ThermalDynamics

AA


1 2




08:11:44

Thermal Dynamics

DDWG No:

Sheetof

SupersedesScale

Date:

Drawn: References





SizeSCHEMATIC,

ThermalDynamics

AA


1 2




08:11:44

Thermal Dynamics

D

RAS


HALL SENSOR

HALL SENSOR


BIASPOWER


< /O

VE

R_T

EM

P

> P

_DE

M (

P_I

ref)

> P

_Ena

ble

(P_e

na)PILOT REG.


I_D

ET

I_S

E<<



/ OVERTEMP <

/PILOT ENABLE >

PILOT DEMAND >

C1 Capacitor, 0.1 uf, 1250 VDC (D2, Sht 2)C2 Capacitor, 2 uf, 430VAC (A9, Sht 1)C3 Capacitor 47 uf 400V (C1, Sht 2)

C.P1 Circuit protector/ON-OFF SW (B2, Sht 1) 10A, 690V, 3PhC.P2 Circuit protector 2.5A 125V (D2, Sht 1)C.P3 Circuit protector 3.15A 125V (D2, Sht 1)C.P4 Circuit protector 10A 125V (E2, Sht 1)C.P5 Circuit protector 2.5A 125V (E2, Sht 1)C.P6 Circuit protector 2.5A 125V (F2, Sht 1)C.P7 Circuit protector 5A 125V (E2, Sht 1)C.P8 Circuit protector 3.15A 125V (F3, Sht 1)

D1 Diode Bridge 20A, 1600V, 3Ph (D2, Sht 1)D2 Diode, Dual, 2x100A, 600V (B8, Sht 1)D3 Diode Bridge 25A, 800V, 1Ph (C1, Sht 2)







NE1 Neon indicator, rear panel, 220VAC (C1, Sht 1)

NE2 Neon indicator, internal, 220VAC (C1, Sht 1)




COMPONENT LOCATOR

(C7, Sht 2)


DAT

(C2, Sht 2)

ECO-B402 DAT 2/26/07AB ECO-B448 DAT 4/13/07

(C7 & A9,Sht 2)

(C7 & A9,Sht 2)

ECO-B646 GAC 10/31/07ACAD ECO-B1391 DAT 4-24-09

DATAE ECO-B1535 9-25-09

CN2CN2 1 2 3 4

TB1TB1

CN4CN4 1 2 3

HCT2HCT2

1 2 3 4

TB5TB5

TB2TB2

D2D2

1A1

2K1

3A2

4K2

TB1TB1

TB2TB2

HCT1HCT1

1 2 3 4

CN2CN2 123

CN5CN5 1234

CN5CN5 1 2 3 4

CN1CN1

12

WORKWORK

CN33CN33 1 2 3 4


MC2-AMC2-A

CN3CN3 12

MC2-BMC2-B

CN4CN4 1 2 3 4 5

TB4TB4

MC2-CMC2-C

CN17CN17 1 2 3

CN1CN11234

LED4CHOPPER TEMP

LED4CHOPPER TEMP

CN4CN4 12345

CN1CN11234

CN7CN7 12345

FAN3FAN3

+-

R620K

30W

R620K

30W

THS1SW_TEMP_NC

THS1SW_TEMP_NC

CN6CN6 123

R950R950

CN9CN9 1 2

C22 UFC22 UF

CN8CN8 12

TB3TB3

CN3CN3 1 2 3 4

Art # A-07000_AD


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APPENDIX 13: Schematic, CSA 600V, Chopper Pilot Cont.

1

1

2

2

3

3

4

4

5

5

A

B

C

D

E

F

600

AC120 @

1A

AC13V @ 2A

/PUMP

+15V

+15V

600

/FAN

200-not used

/RAS

COM200600

COM

AC200V @ 3A

200

+15V

0V-A (24V ret)To P

CB

7 CN

2-1

AC120V-GCM

0V-B (120V ret)

To PC

B7 C

N2-2

To PC

B7 C

N2-4

To PC

B7 C

N2-5

To PC

B7 TB

3

0V-RAS

AC120V-RAS

FAN + (24 VDC)

DC 15VDC 0V

FAN - (24 VDC)

AC24V-GCM

To T1 PR

I - 0(F1 Sht 1)

(F1 Sht 1)

PILOTCONTACTOR

INPUTCONTACTOR

(D9, A10)

PILOT (TIP) VOLTAGE



CCM MODULE



(F1 Sht 1)

(F1 Sht 1)

(F2 Sht 1)

ISOLATEDVOLTAGES

(D9, A10)

(F2 Sht 1)

NEG ARC VOLTS



SW13 - FACTORY ONLY


CIRCUIT COMM (GND)

(C9)


PILOT DEM to PS

ANALOG DEM to CPU

CUT DEM to PS

TO AC

INDICATOR

(on PCB6)



I/O PCB

CPU PCB


TP10TP10

CN4CN41

2

3


TP12TP12

1

2

LED1LEVELLED1LEVEL

CN2CN2 1 2 3 4 5

RY11RY11


1

2

TP18TP18

C.P7C.P7

D9 GAS_OND9 GAS_ON

FAN1FAN1

+ -


CN9CN91

2

3

1 2 3

C.P3C.P3

CN12CN12 1 2 3 4 CN1CN1 1 2

1 2

+

RY10

+

RY10

D8 OK_CNCD8 OK_CNC

TP8TP8


TP2TP2

CN10CN101

2

3

TP6TP6

MC2MC2

CN9CN91

2

3

4

5

LSW1-1

SW_LIQUID_LEVEL_NC

LSW1-1

SW_LIQUID_LEVEL_NC

CN5CN51

2

3

4

5

6

CN12CN121

2

D13 +5VD13 +5V

R81K 30WR8

1K 30W

CN6CN61

2

3

4

1 2

MC1 AUXMC1 AUX

D15 PSRD15 PSR

TP7TP7

RY4RY4

TP17TP17

RY3RY3

TB5TB5

CN11CN11

1

2

RY5RY5

CN3CN31

2

3


CN7CN71

2

3

4

1 2 3

TP16TP16

1

2

3

RY7RY7

TB10TB10

TP5TP5

C.P2C.P2

+V

GND

SIG


+V

GND

SIG


R BG

C.P5C.P5

tTH1

tTH1

TP14TP14

C.P6C.P6


CN14CN14 1 2

TB4TB4

TB9TB9

CN2CN2

1

2

CN12CN12 1 2 3

+RY1

+RY1

MC1MC1

RY9RY9

TP9TP9

PUMP

MOT1

PUMP

MOT1

' .

TP15TP15

1

2

3

T1T1460

220

0,

13

0,,

100

0.

200

0..

110

0...

120.

0_

24.

0__

24_

0___

120.

0___

TP4TP4

CN8CN81

2

3

4

TP3TP3

C.P4C.P4

C.P8C.P8

TB3TB3

CN13CN13 1 2 3

Art # A-07001_AD


ULTRA-CUT 100

6

6

7

7

8

8

9

9

10

10

A

B

C

D

E

F

PLASMA ENABLE

PRESS OK (GCM 1000)

24V

AC

24 V

AC

RE

T

PLASMA ENABLE

+15V/ AC

/ TEMP

/ STATUS/ DC

/ GAS - COOLANT

POT HI (GCM1000)

POT WIPER (GCM1000)

POT LOW (GCM 1000)

- ARC V

- ARC V

WORK

DC 15V

DC 0V

AC120V-RAS

0V-RAS (120V ret)

0V-A (24V ret)

NEG ARC VOLTS

NE

G A

RC

VO

LTS

AC24V-GCM

AC24V-GCM

0V-A (24V ret)

AC120V-GCM

0V-B (120V ret)

PIL

OT

(TIP

) VO

LTS

0V-B (120V ret)

WO

RK

AC120V-GCM

DWG No:

Sheetof

SupersedesScale

Date:

Drawn: References





SizeSCHEMATIC,

ThermalDynamics

AA


2 2




08:11:44

Thermal Dynamics

DDWG No:

Sheetof

SupersedesScale

Date:

Drawn: References





SizeSCHEMATIC,

ThermalDynamics

AA


2 2




08:11:44

Thermal Dynamics

DDWG No:

Sheetof

SupersedesScale

Date:

Drawn: References





SizeSCHEMATIC,

ThermalDynamics

AA


2 2




08:11:44

Thermal Dynamics

D

DAT

ECO-B402 DAT 2/26/07

AB ECO-B448 DAT 4/13/07AC ECO-B646 GAC 10/31/07

ECO-B1391 TADDA 4-24-09DATAE

(E2)


START / STOP

* REMOTE MARKING -

STOP

START


Rx-

Tx+

Rx+

Tx-



KEY PLUG

TB1

TB2

(C9, sht 1)

+

-



RIBBON CABLE

TEST SOCKET


DIVIDED ARC V +

(E2)

(E2)

DIVIDED ARC V -


JUMPER IN REMOTEHMI


(A9, sht1)

(B9, sht1)

(C9, sht1)

TB3

KEY PLUG


(E4)

(F4)


START / STOP

DIVIDED ARC VOLTS

PILOT ON OUTPUT


* OK2

Iso

J36 34 CKT

PCB6 DISPLAYWK-5603


4W4W

2W


J35 26 CKT

J14

J14

2W


* OK2

RIBBON CABLE

5

9876

123

4


0

TEST SOCKET


(A9, sht 1)



OK TO MOVE

GND

GND

& CNC COMM


PLASMA ENABLE

24 VAC @ 1A

120 VAC @ 100ma.

(Not in all units)

OK to MOVE -


E-STOP -E-STOP +

* REMOTE MARKING +






Rx-

Tx+

Rx+

Tx-

OK to MOVE +

ECO-B1535 9-25-09

99

11

1010

OK2 *OK2 *

GAS ONGAS ON

33

66

88

GREEN1 GASGREEN1 GASGREEN2 DCGREEN2 DC

1122

J9J9 1 2 3 4 5 6

99

1111

TP1TP1

77

REDSTATUS

REDSTATUS


22

1K1K

100K5100K5

J7J7

1

2

3

4

5

6

7

8

9

44

33

55

CN24CN24

1

2

3

4

5

6

99

88

11

77

66

K7-1K7-1


1

2

3

4

5

6

7

8

9

10

11

12

13

14TP11TP11

22 J1J11

2

3

4

5

6

7

8

9

J6 **J6 **1

2

3

4

5

6

J5J51

2

3

4

5

J4J4

1

3

5

7

J8J8

1

2

3

4

1111

1010

1111

22

55

77

E-STOPE-STOP

PSRPSR

J59-RASJ59-RAS1

2

3456

7

8

9

1011121314

K6K6

1212

1010

100K100K

TP13TP13

J55-GCMJ55-GCM12345678910111213141516171819202122232425262728293031323334353637

1212

1212

GREEN ACGREEN AC

44

88

66

11

CN23CN23

1

2

3

4

5

6

J15-CNCJ15-CNC1

2

3

4

5

6

7

8

9

10

11

12

13

14

J6J6 1 5 8

55

44

33

Art # A-07001_AD


ULTRA-CUT 100

APPENDIX 14: PUBLICATION HISTORY

Cover Date Rev Change(s)

July 1, 2005 - - First issue

Aug. 1, 2005 - - Updated: CCM switch settings and coolant specs, added: static discharge warn-ing, torch O-ring lubrication data, catalog numbers for RAS, torch valve, gascontrol module, external power supply replacement parts, gas control box catalognumbers.

Aug. 19, 2005 - - Added: internal coolant filter cleaning, torch valve parts catalog numbers, metriccut charts.

Sep. 2, 2005 - - Modified warranty statement, corrected torch parts identification, added revisionhistory.

Sep. 30, 2005 - - Added optional hose selection chart, corrected input power ratings, correctedtorch consumables selection charts.

Oct. 21, 2005 - - Updated speed charts, updated fault chart, added voltages, added CCM info,added 30A SS N2/H20 towater shield in torch sections.

Jan. 4, 2006 - - Updated layout sketches to show new water lead between GCM-2010 and TorchValve. Updated GCM-2010 and Torch Valve to show new water lead. Added infoon routing input cables through bracket on lower back edge of power supply.Updated grounding method for Remote Arc Starter Cover. Added marking data totorch section. Updated Remote Arc Starter Schematic.

Jan. 28, 2006 - - Updated gas specs chart, section 2.

Feb. 20, 2006 - - Updated torch sections for 30A MS O2/O2 (new chart); 70A SS & AL, new partnumbers and charts; 100A SS & AL, new part numbers. Updated grounding data.Updated shield cup installation art; added info on setting pre-charge pressure formarking; updated schematic for GCM. Added system schematics.

Apr. 25, 2006 AA In Section 8, updated 30A Aluminum N2/H20 speeds. Corrected minimum outputcurrent to 10A. Added maximum input gas pressure. Added preflow gases togas applications chart. Added torch specifications. Changed ‘F1’ ground wiresize from 1/0 to #4. Added note, ‘side pressure can break check valves/connec-tions to torch valve’. Added error code group 6, Non-recoverable fault, ContactTDC for resolution’ (CCM software V2.3.1). Started using new cover styles.Ref: ECO B-122.

Aug 25, 2006 AA.01 Added leads lengths C and D as part of ECO B122 missed earlier. Corrected artpages 2-2, 3-2, 3-3, 6-2 and 6-3. inserted Gas Control Module diagram in Apdx 3.Updated rev. to new version to include numbers.

Oct 10, 2006 AB.01 Added 400V, 400V CE and 600V inerter module part numbers.

Jan. 10, 2007 AC.01 Updated Error codes in section 4 and added notice to update to Firmware revision2.4 or later. Updated Gas Control PCB layout in the Appendix. Added CNC cableshiel grounding.

Mar. 5, 2007 AD.01 Updated with new XTL TVA art and part numbers per ECOB356. Correctedplasma and shield hose lengths to 4’ with new part numbers. Corrected art insection 3 showing hookup of work leads, input power etc..

Mar. 8, 2007 AE.01 Corrected Switch setting errors pgs. 3-5, 3-6 and 3-7 for SW8-2.

Mar. 28, 2007 AF.01 Updated the Gas Requirement table in section 2.

July 10, 2007 AG.01 Added mounting dimensions for the GCM, RAS and the XTL TVA section 6.

Oct 15, 2007 AH Removed ref. to deionizer parts per ECOB524 and updated new pump and motorassemblies per ECOB444.

Oct. 29, 2007 AI Added star grounding information ECOB653, updated o-ring number ECOB467


ULTRA-CUT 100

Cover Date Rev Change(s)

Jan. 14, 2008 AJ Added flow meter replacement parts per ECOB704. Updated Schematics perECOB402.

Jan. 28, 2008 AK Per ECOB738 added GCM plumbing diagram.

Feb. 5, 2008 AL Per ECOB646 added input terminal strip information to sections 3 and 6.

Mar. 25, 2008 AM Per ECOB846 updated sw13 information for CCM switch settings section 3.

Apr. 11, 2008 AN Per ECOB475 updated art for GCM PCB on pg.A-5 and multiple additions andcorrections to sections 3, 4 and 6. Also added pilot transfer retry info switchsetting per ECOB799 pg. 3-16

Nov. 11, 2008 AO Updated section 3 per ECOB1163 to show single shielded leads. Also updatedsome sheet metal repair parts Catalog numbers from section 6.

July 16, 2009 AP Corrected part number for item 13 on page 6-21 to show 9-9407 per ECOB1477.

Sept. 29, 2009 AQ Updated Appendix with new CNC Functions information and system schematics with serial communication connector per ECOB1535.

NOTE

Before April 25, 2006, Thermal Dynamics used the date on the manual cover to indicate the most recentrevision.


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Intentionally Blank

Thermadyne USA2800 Airport RoadDenton, Tx 76207 USATelephone: (940) 566-2000800-426-1888Fax: 800-535-0557Email: [email protected]

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Thermadyne ItalyOCIM, S.r.L.Via Benaco, 320098 S. GiulianoMilan, ItalyTel: (39) 02-98 80320Fax: (39) 02-98 281773

Thermadyne South Africa209 Risi Ave.LinmeyerJohannesberg, 2197South AfricaTel: (27) 11-917 3600Fax: (27) 11-917 8580

Thermadyne International2070 Wyecroft RoadOakville, OntarioCanada, L6L5V6Telephone: (905)-827-9777Fax: 905-827-9797

Global Customer Service Contact Information

Corporate Headquarters16052 Swingley Ridge RoadSuite 300St. Louis, MO 63017Telephone: 636-728-3000Email: [email protected]