100

ULTRA-CUT

PLASMA CUTTING SYSTEM

Art# A-08579

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

WE APPRECIATE YOUR BUSINESS!

Congratulations on your new Thermal Dynamics product. We are proud to have you as our customer and will strive to provide you with the best service and reliability in the industry. This product is backed by our extensive warranty and world-wide service network. To locate your nearest distributor or service agency call 1-800426-1888, or visit us on the web at www.thermal-dynamics.com. This Operating Manual has been designed to instruct you on the correct use and operation of your Thermal Dynamics product. Your satisfaction with this product and its safe operation is our ultimate concern. Therefore please take the time to read the entire manual, especially the Safety Precautions. They will help you to avoid potential hazards that may exist when working with this product.

YOU ARE IN GOOD COMPANY!

The Brand of Choice for Contractors and Fabricators Worldwide.
Thermal Dynamics is a Global Brand of manual and automation Plasma Cutting Products for Thermadyne Industries Inc. We distinguish ourselves from our competition through marketleading, dependable products that have stood the test of time. We pride ourselves on technical innovation, competitive prices, excellent delivery, superior customer service and technical support, together with excellence in sales and marketing expertise. Above all, we are committed to developing technologically advanced products to achieve a safer working environment within the welding industry.

WARNINGS

Read and understand this entire Manual and your employers safety practices before installing, operating, or servicing the equipment. While the information contained in this Manual represents the Manufacturer's best judgement, the Manufacturer assumes no liability for its use.
Plasma Cutting Power Supply, Ultra-Cut 100 Operting Manual No. 0-4748 Published by: Thermadyne Corporation 82 Benning Street West Lebanon, New Hampshire, USA 03784 (603) 298-5711 www.thermal-dynamics.com Copyright 2005, 2006, 2007, 2008, 2009 by Thermadyne Corporation All rights reserved. Reproduction of this work, in whole or in part, without written permission of the publisher is prohibited. The publisher does not assume and hereby disclaims any liability to any party for any loss or damage caused by any error or omission in this Manual, whether such error results from negligence, accident, or any other cause. Printed in the United States of America Licensed under U. S. Patent No. 5,070,227 Publication Date: July 1, 2005 Revision Date: September 29, 2009
Record the following information for Warranty purposes:

Where Purchased: ___________________________________ Purchase Date:______________________________________ Power Supply Serial #:_______________________________ Torch Serial #:_____________________________________

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TABLE OF CONTENTS
SECTION 1: GENERAL INFORMATION ................................................................................................ 1-1 1.01 1.02 1.03 1.04 1.05 1.06 1.07 1.08 Notes, Cautions and Warnings ...................................................................... Important Safety Precautions ....................................................................... Publications .................................................................................................. Note, Attention et Avertissement .................................................................. Precautions De Securite Importantes ........................................................... Documents De Reference ............................................................................. Declaration of Conformity ............................................................................. Statement of Warranty .................................................................................. 1-1 1-1 1-2 1-3 1-3 1-5 1-6 1-7

SECTION 2: SPECIFICATIONS ................................................................................................. 2-1 2.01 2.02 2.03 2.04 2.05 2.06 2.07 2.08 2.09 2.10 2.11 2.12 General Description Of The System .............................................................. Plasma Power Supply ................................................................................... Remote Arc Starter ...................................................................................... Gas Control Module ...................................................................................... Precision Plasma Cutting Torch .................................................................... Specifications & Electrical Requirements ..................................................... System Component Layout .......................................................................... Power Supply Dimensions ............................................................................ Power Supply Rear Panel Features ............................................................... Gas Requirements ........................................................................................ Gas Applications .......................................................................................... XTTM-300 Torch Specifications .................................................................... 2-1 2-1 2-1 2-1 2-1 2-2 2-2 2-3 2-4 2-5 2-5 2-6

SECTION 3: INSTALLATION ...................................................................................................... 3-1 3.01 3.02 3.03 3.04 3.05 3.06 3.07 3.08 3.09 3.10 3.11 3.12 3.13 3.14 3.15 3.16 3.17 3.18 3.19 3.20 Installation Requirements ............................................................................. 3-1 System Layout ............................................................................................. 3-2 Cables & Leads Identification ....................................................................... 3-3 Lift the Power Supply .................................................................................... 3-4 Remove the Connections Cover ................................................................... 3-5 Ground Connections .................................................................................... 3-10 Connect Work Cable and Pilot and Negative Leads ...................................... 3-12 Connect Coolant Leads ................................................................................ 3-13 Connect Control Cables for CNC, Remote Arc Starter, and GCM ................. 3-14 Connect Fiber Optic Cable (Type 2 internal control module) ........................ 3-15 Set Switches on the Command - Control Module (Type 2 Module) ............... 3-16 Height Control Connections ......................................................................... 3-18 Gas Control Module Installation ................................................................... 3-19 Fiber Optic Cable Installation ....................................................................... 3-21 Gas Control Module: Control, Input, and Output Connections ....................... 3-23 Install Remote Arc Starter ........................................................................... 3-24 Original & XTL Torch Valve Installation ......................................................... 3-33 Connecting Torch ......................................................................................... 3-35 Install Consumable Torch Parts .................................................................... 3-37 Complete the Installation ............................................................................. 3-41

TABLE OF CONTENTS (continued)

SECTION 4: OPERATION .......................................................................................................... 4-1 4.01 4.02 4.03 4.04 4.05 4.06 4.07 4.08 4.09 Power Supply Control Panel .......................................................................... 4-1 Start-Up Sequence ....................................................................................... 4-2 Gas Control Module Operation ...................................................................... 4-3 First Time Operation Matching Gas Control to Lead Length .......................... 4-7 Sequence Of Operation ................................................................................ 4-7 Gas Selection .............................................................................................. 4-10 Power Supply Status Codes ........................................................................ 4-11 Remote Arc Starter: Service Chart ............................................................. 4-14 Remote Arc Starter: Spark Gap Adjustment ............................................... 4-15

SECTION 5: MAINTENANCE .................................................................................................... 5-1 5.01 5.02 5.03 5.04 General Maintenance .................................................................................... External Coolant Filter Cleaning Procedure ................................................... Internal Coolant Filter Cleaning Procedure .................................................... Coolant Replacement Procedure ................................................................... 5-1 5-1 5-2 5-2

SECTION 6: REPLACEMENT ASSEMBLIES & PARTS ........................................................... 6-1 6.01 6.02 6.03 6.04 6.05 6.06 6.07 6.08 6.09 6.10 6.11 6.12 6.13 6.14 6.15 6.16 6.17 6.18 6.19 6.20 6.21 6.22 6.23 6.24 SECTION 7. Main Component / System Replacement ...................................................... 6-1 System Layout ............................................................................................. 6-2 Recommended Gas Supply Hose ................................................................. 6-2 Leads and Cables ......................................................................................... 6-3 Power Supply External Replacement Parts ................................................... 6-8 Power Supply Replacement Parts - Right Side ............................................. 6-9 Power Supply Replacement Parts - Right Side ............................................ 6-10 Power Supply Replacement Parts - Right Side ............................................ 6-11 Power Supply Replacement Parts - Front Panel ........................................... 6-12 Power Supply Replacement Parts - Front Panel ........................................... 6-13 Power Supply Replacement Parts - Right Side ............................................ 6-14 Power Supply Replacement Parts - Rear Panel ............................................ 6-15 Power Supply Replacement Parts - Right Side ............................................ 6-16 Power Supply Replacement Parts ................................................................ 6-17 Power Supply Replacement Parts - Right Side ............................................ 6-18 Power Supply Replacement Parts ................................................................ 6-19 Power Supply Replacement Parts - Right Side ............................................ 6-20 Gas Control Module (GCM-2010) Replacement Parts .................................. 6-21 Gas Control Module (GCM-2010) Replacement Parts .................................. 6-22 Remote Arc Starter (RAS-1000) Replacement Parts .................................... 6-23 Remote Arc Starter (RAS-1000) Replacement Parts .................................... 6-24 Command & Control Module Type 2 - Replacement Parts ......................... 6-25 XTL Torch Valve Assembly External Replacement Parts ............................ 6-26 XTL Torch Valve Assembly Internal Replacement Parts ............................... 6-27

TORCH MAINTENANCE .................................................................................... 7-1 7.01 7.02 7.03 7.04 7.05 Consumable Removal ................................................................................... O-Ring Lubrication ........................................................................................ Parts Wear ................................................................................................... Torch Consumables Installation .................................................................... Coolant Leak Trouble-Shooting ...................................................................... 7-1 7-2 7-3 7-4 7-6

TABLE OF CONTENTS (continued)

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

TABLE OF CONTENTS (continued) NOTE

SECTION 8. TORCH OPERATION, is provided separately.

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SECTION 1: GENERAL INFORMATION

1.01 Notes, Cautions and Warnings

Use an air-supplied respirator if ventilation is not adequate to remove all fumes and gases. The kinds of fumes and gases from the plasma arc depend on the kind of metal being used, coatings on the metal, and the different processes. You must be very careful when cutting or welding any metals which may contain one or more of the following: Antimony Arsenic Barium Beryllium Cadmium Chromium Cobalt Copper Lead Manganese Mercury Nickel Selenium Silver Vanadium

Throughout this manual, notes, cautions, and warnings are used to highlight important information. These highlights are categorized as follows:

NOTE An operation, procedure, or background information which requires additional emphasis or is helpful in efficient operation of the system.

Always read the Material Safety Data Sheets (MSDS) that should be supplied with the material you are using. These MSDSs will give you the information regarding the kind and amount of fumes and gases that may be dangerous to your health. For information on how to test for fumes and gases in your workplace, refer to item 1 in Subsection 1.03, Publications in this manual. Use special equipment, such as water or down draft cutting tables, to capture fumes and gases. Do not use the plasma torch in an area where combustible or explosive gases or materials are located. Phosgene, a toxic gas, is generated from the vapors of chlorinated solvents and cleansers. Remove all sources of these vapors. This product, when used for welding or cutting, produces fumes or gases which contain chemicals known to the State of California to cause birth defects and, in some cases, cancer. (California Health & Safety Code Sec. 25249.5 et seq.)

CAUTION

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

!
1.02

WARNING

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

Important Safety Precautions

ELECTRIC SHOCK

WARNINGS OPERATION AND MAINTENANCE OF PLASMA ARC EQUIPMENT CAN BE DANGEROUS AND HAZARDOUS TO YOUR HEALTH. Plasma arc cutting produces intense electric and magnetic emissions that may interfere with the proper function of cardiac pacemakers, hearing aids, or other electronic health equipment. Persons who work near plasma arc cutting applications should consult their medical health professional and the manufacturer of the health equipment to determine whether a hazard exists. To prevent possible injury, read, understand and follow all warnings, safety precautions and instructions before using the equipment. Call 1-603-298-5711 or your local distributor if you have any questions.

Electric Shock can injure or kill. The plasma arc process uses and produces high voltage electrical energy. This electric energy can cause severe 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 work piece 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 to item 9 in Subsection 1.03, Publications. Disconnect power source before performing any service or repairs. Read and follow all the instructions in the Operating Manual.

FIRE AND EXPLOSION GASES AND FUMES Gases and fumes produced during the plasma cutting process can be dangerous and hazardous to your health. Keep all fumes and gases from the breathing area. Keep your head out of the welding fume plume. Fire and explosion can be caused by hot slag, sparks, or the plasma arc. Be sure there is no combustible or flammable material in the workplace. Any material that cannot be removed must be protected. Ventilate all flammable or explosive vapors from the workplace. Do not cut or weld on containers that may have held combustibles. 1-1

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Provide a fire watch when working in an area where fire hazards may exist. Hydrogen gas may be formed and trapped under aluminum workpieces when they are cut underwater or while using a water table. DO NOT cut aluminum alloys underwater or on a water table unless the hydrogen gas can be eliminated or dissipated. Trapped hydrogen gas that is ignited will cause an explosion.

1.03

Publications

Refer to the following standards or their latest revisions for more information:

1. OSHA, SAFETY AND HEALTH STANDARDS, 29CFR 1910, obtainable from the Superintendent of Documents, U.S. Government Printing Office, Washington, D.C. 20402 2. ANSI 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 GAS WELDING AND CUTTING, obtainable from the Superintendent of Documents, U.S. Government Printing Office, Washington, D.C. 20402 4. ANSI Standard Z87.1, SAFE PRACTICES FOR OCCUPATION AND EDUCATIONAL EYE AND FACE PROTECTION, obtainable from American National Standards Institute, 1430 Broadway, New York, NY 10018 5. ANSI Standard Z41.1, STANDARD FOR MENS SAFETY-TOE FOOTWEAR, obtainable from the American National Standards Institute, 1430 Broadway, New York, NY 10018 6. ANSI Standard Z49.2, FIRE PREVENTION IN THE USE OF CUTTING AND WELDING PROCESSES, obtainable from American National Standards Institute, 1430 Broadway, New York, NY 10018 7. AWS Standard A6.0, WELDING AND CUTTING CONTAINERS WHICH HAVE HELD COMBUSTIBLES, obtainable from American Welding Society, 550 N.W. LeJeune Rd, Miami, FL 33126 8. NFPA Standard 51, OXYGEN-FUEL GAS SYSTEMS FOR WELDING, CUTTING AND ALLIED PROCESSES, obtainable from the National Fire Protection Association, Batterymarch Park, Quincy, MA 02269 9. NFPA Standard 70, NATIONAL ELECTRICAL CODE, obtainable 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 COMPRESSED GASES IN CYLINDERS, obtainable from the Compressed Gas Association, 1235 Jefferson Davis Highway, Suite 501, Arlington, VA 22202 12. CSA Standard W117.2, CODE FOR SAFETY IN WELDING AND CUTTING, obtainable from the Canadian Standards Association, Standards Sales, 178 Rexdale Boulevard, Rexdale, Ontario, Canada M9W 1R3 13. NWSA booklet, WELDING SAFETY BIBLIOGRAPHY obtainable from the National Welding Supply Association, 1900 Arch Street, Philadelphia, PA 19103 14. American Welding Society Standard AWSF4.1, RECOMMENDED SAFE PRACTICES FOR THE PREPARATION FOR WELDING AND CUTTING OF CONTAINERS AND PIPING
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NOISE Noise can cause permanent hearing loss. Plasma arc processes can cause noise levels to exceed safe limits. You must protect your ears from loud noise to prevent permanent loss of hearing. To protect your hearing from loud noise, wear protective ear plugs 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 Subsection 1.03, Publications, in this manual.

PLASMA ARC RAYS Plasma Arc Rays can injure your eyes and burn your skin. The plasma arc process produces very bright ultra violet and infra red light. These arc rays will damage your eyes and burn your skin if you are not properly protected. To protect your eyes, always wear a welding helmet or shield. Also always wear safety glasses with side shields, goggles or other protective eye wear. Wear welding gloves and suitable clothing to protect your skin from the arc rays and sparks. Keep helmet and safety glasses in good condition. Replace lenses when cracked, chipped or dirty. Protect others in the work area from the arc rays. Use protective booths, screens or shields. Use the shade of lens as suggested in the following per ANSI/ ASC Z49.1:
Arc Current Less Than 300* 300 - 400* 400 - 800* Minimum Protective Shade No. 8 9 10 Suggested Shade No. 9 12 14

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

LEAD WARNING This product contains chemicals, including lead, or otherwise produces chemicals known to the State of California to cause cancer, birth defects and other reproductive harm. Wash hands after handling. (California Health & Safety Code 25249.5 et seq.)

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THAT HAVE HELD HAZARDOUS SUBSTANCES, obtainable from the American Welding Society, 550 N.W. LeJeune Rd, Miami, FL 33126 15. ANSI Standard Z88.2, PRACTICE FOR RESPIRATORY PROTECTION, obtainable from American National Standards Institute, 1430 Broadway, New York, NY 10018
FUME et GAZ La fume et les gaz produits par le procd de jet de plasma peuvent prsenter des risques et des dangers de sant. Eloignez toute fume et gaz de votre zone de respiration. Gardez votre tte hors de la plume de fume provenant du chalumeau. Utilisez un appareil respiratoire alimentation en air si laration fournie ne permet pas dliminer la fume et les gaz. Les sortes de gaz et de fume provenant de larc de plasma dpendent du genre de mtal utilis, des revtements se trouvant sur le mtal et des diffrents procds. Vous devez prendre soin lorsque vous coupez ou soudez tout mtal pouvant contenir un ou plusieurs des lments suivants: antimoine argent arsenic baryum bryllium cadmium mercure chrome cobalt cuivre manganse nickel plomb slnium vanadium

1.04

Note, Attention et Avertissement

Dans ce manuel, les mots note, attention, et avertissement sont utiliss pour mettre en relief des informations caractre important. Ces mises en relief sont classifies comme suit :

NOTE Toute opration, procdure ou renseignement gnral sur lequel il importe dinsister davantage ou qui contribue lefficacit de fonctionnement du systme.

ATTENTION Toute procdure pouvant rsulter lendommagement du matriel en cas de non-respect de la procdure en question.

Lisez toujours les fiches de donnes sur la scurit des matires (sigle amricain MSDS); celles-ci devraient tre fournies avec le matriel que vous utilisez. Les MSDS contiennent des renseignements quant la quantit et la nature de la fume et des gaz pouvant poser des dangers de sant. Pour des informations sur la manire de tester la fume et les gaz de votre lieu de travail, consultez larticle 1 et les documents cits la page 5. Utilisez un quipement spcial tel que des tables de coupe dbit deau ou courant descendant pour capter la fume et les gaz. Nutilisez pas le chalumeau au jet de plasma dans une zone o se trouvent des matires ou des gaz combustibles ou explosifs. Le phosgne, un gaz toxique, est gnr par la fume provenant des solvants et des produits de nettoyage chlors. Eliminez toute source de telle fume. Ce produit, dans le procder de soudage et de coupe, produit de la fume ou des gaz pouvant contenir des lments reconnu dans Ltat de la Californie, qui peuvent causer des dfauts de naissance et le cancer. (La scurit de sant en Californie et la code scurit Sec. 25249.5 et seq.)

AVERTISSEMENT

Toute procdure pouvant provoquer des blessures de loprateur ou des autres personnes se trouvant dans la zone de travail en cas de non-respect de la procdure en question.

1.05

Precautions De Securite Importantes

AVERTISSEMENTS LOPRATION ET LA MAINTENANCE DU MATRIEL DE SOUDAGE LARC AU JET DE PLASMA PEUVENT PRSENTER DES RISQUES ET DES DANGERS DE SANT. Coupant larc au jet de plasma produit de lnergie lectrique haute tension et des missions magntique qui peuvent interfrer la fonction propre dun pacemaker cardiaque, les appareils auditif, ou autre matriel de sant electronique. Ceux qui travail prs dune application larc au jet de plasma devrait consulter leur membre professionel de mdication et le manufacturier de matriel de sant pour dterminer sil existe des risques de sant. Il faut communiquer aux oprateurs et au personnel TOUS les dangers possibles. Afin dviter les blessures possibles, lisez, comprenez et suivez tous les avertissements, toutes les prcautions de scurit et toutes les consignes avant dutiliser le matriel. Composez le + 603-298-5711 ou votre distributeur local si vous avez des questions.

CHOC ELECTRIQUE Les chocs lectriques peuvent blesser ou mme tuer. Le procd au jet de plasma requiert et produit de lnergie lectrique haute tension. Cette nergie lectrique peut produire des chocs graves, voire mortels, pour loprateur et les autres personnes sur le lieu de travail. Ne touchez jamais une pice sous tension ou vive; portez des gants et des vtements secs. Isolez-vous de la pice de travail ou des autres parties du circuit de soudage. Rparez ou remplacez toute pice use ou endommage. Prenez des soins particuliers lorsque la zone de travail est humide ou moite.

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Montez et maintenez le matriel conformment au Code lectrique national des Etats-Unis. (Voir la page 5, article 9.) Dbranchez lalimentation lectrique avant tout travail dentretien ou de rparation. Lisez et respectez toutes les consignes du Manuel de consignes. Utilisez la nuance de lentille qui est suggre dans le recommendation qui suivent ANSI/ASC Z49.1:
Courant Arc Moins de 300* 300 - 400* Nuance Minimum Protective Numro 8 9 10 Nuance Suggere Numro 9 12 14

INCENDIE ET EXPLOSION Les incendies et les explosions peuvent rsulter des scories chaudes, des tincelles ou de larc de plasma. Le procd larc de plasma produit du mtal, des tincelles, des scories chaudes pouvant mettre le feu aux matires combustibles ou provoquer lexplosion de fumes inflammables. Soyez certain quaucune matire combustible ou inflammable ne se trouve sur le lieu de travail. Protgez toute telle matire quil est impossible de retirer de la zone de travail. Procurez une bonne aration de toutes les fumes inflammables ou explosives. Ne coupez pas et ne soudez pas les conteneurs ayant pu renfermer des matires combustibles. Prvoyez une veille dincendie lors de tout travail dans une zone prsentant des dangers dincendie. Le gas hydrogne peut se former ou saccumuler sous les pices de travail en aluminium lorsquelles sont coupes sous leau ou sur une table deau. NE PAS couper les alliages en aluminium sous leau ou sur une table deau moins que le gas hydrogne peut schapper ou se dissiper. Le gas hydrogne accumul explosera si enflamm.

400 - 800*

* Ces valeurs sappliquent ou larc actuel est observ clairement. Lexperience a dmontrer que les filtres moins foncs peuvent tre utiliss quand larc est cach par moiceau de travail.

BRUIT Le bruit peut provoquer une perte permanente de loue. Les procds de soudage larc de plasma peuvent provoquer des niveaux sonores suprieurs aux limites normalement acceptables. Vous d4ez vous protger les oreilles contre les bruits forts afin dviter une perte permanente de loue. Pour protger votre oue contre les bruits forts, portez des tampons protecteurs et/ou des protections auriculaires. Protgez galement les autres personnes se trouvant sur le lieu de travail. Il faut mesurer les niveaux sonores afin dassurer que les dcibels (le bruit) ne dpassent pas les niveaux srs. Pour des renseignements sur la manire de tester le bruit, consultez larticle 1, page 5.

PLOMB AVERTISSEMENT RAYONS DARC DE PLASMA Les rayons provenant de larc de plasma peuvent blesser vos yeux et brler votre peau. Le procd larc de plasma produit une lumire infra-rouge et des rayons ultra-violets trs forts. Ces rayons darc nuiront vos yeux et brleront votre peau si vous ne vous protgez pas correctement. Pour protger vos yeux, portez toujours un casque ou un cran de soudeur. Portez toujours des lunettes de scurit munies de parois latrales ou des lunettes de protection ou une autre sorte de protection oculaire. Portez des gants de soudeur et un vtement protecteur appropri pour protger votre peau contre les tincelles et les rayons de larc. Maintenez votre casque et vos lunettes de protection en bon tat. Remplacez toute lentille sale ou comportant fissure ou rognure. Protgez les autres personnes se trouvant sur la zone de travail contre les rayons de larc en fournissant des cabines ou des crans de protection. Ce produit contient des produits chimiques, comme le plomb, ou engendre des produits chimiques, reconnus par ltat de Californie comme pouvant tre lorigine de cancer, de malformations ftales ou dautres problmes de reproduction. Il faut se laver les mains aprs toute manipulation. (Code de Californie de la scurit et sant, paragraphe 25249.5 et suivants)

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1.06 Documents De Reference
Consultez les normes suivantes ou les rvisions les plus rcentes ayant t faites celles-ci pour de plus amples renseignements : 1. OSHA, NORMES DE SCURIT DU TRAVAIL ET DE PROTECTION DE LA SANT, 29CFR 1910, disponible auprs du Superintendent of Documents, U.S. Government Printing Office, Washington, D.C. 20402 2. Norme ANSI Z49.1, LA SCURIT DES OPRATIONS DE COUPE ET DE SOUDAGE, disponible auprs de la Socit Amricaine de Soudage (American Welding Society), 550 N.W. LeJeune Rd., Miami, FL 33126 3. NIOSH, LA SCURIT ET LA SANT LORS DES OPRATIONS DE COUPE ET DE SOUDAGE LARC ET AU GAZ, disponible auprs du Superintendent of Documents, U.S. Government Printing Office, Washington, D.C. 20402 4. Norme ANSI Z87.1, PRATIQUES SURES POUR LA PROTECTION DES YEUX ET DU VISAGE AU TRAVAIL ET DANS LES ECOLES, disponible de lInstitut Amricain des Normes Nationales (American National Standards Institute), 1430 Broadway, New York, NY 10018 5. Norme ANSI Z41.1, NORMES POUR LES CHAUSSURES PROTECTRICES, disponible auprs de lAmerican National Standards Institute, 1430 Broadway, New York, NY 10018 6. Norme ANSI Z49.2, PRVENTION DES INCENDIES LORS DE LEMPLOI DE PROCDS DE COUPE ET DE SOUDAGE, disponible auprs de lAmerican National Standards Institute, 1430 Broadway, New York, NY 10018 7. Norme A6.0 de lAssociation Amricaine du Soudage (AWS), LE SOUDAGE ET LA COUPE DE CONTENEURS AYANT RENFERM DES PRODUITS COMBUSTIBLES, disponible auprs de la American Welding Society, 550 N.W. LeJeune Rd., Miami, FL 33126 8. Norme 51 de lAssociation Amricaine pour la Protection contre les Incendies (NFPA), LES SYSTEMES GAZ AVEC ALIMENTATION EN OXYGENE POUR LE SOUDAGE, LA COUPE ET LES PROCDS ASSOCIS, disponible auprs de la National Fire Protection Association, Batterymarch Park, Quincy, MA 02269 9. Norme 70 de la NFPA, CODE ELECTRIQUE NATIONAL, disponible auprs de la National Fire Protection Association, Batterymarch Park, Quincy, MA 02269 10. Norme 51B de la NFPA, LES PROCDS DE COUPE ET DE SOUDAGE, disponible auprs de la National Fire Protection Association, Batterymarch Park, Quincy, MA 02269 11. Brochure GCA P-1, LA MANIPULATION SANS RISQUE DES GAZ COMPRIMS EN CYLINDRES, disponible auprs de lAssociation des Gaz Comprims (Compressed Gas Association), 1235 Jefferson Davis Highway, Suite 501, Arlington, VA 22202 12. Norme CSA W117.2, CODE DE SCURIT POUR LE SOUDAGE ET LA COUPE, disponible auprs de lAssociation des Normes Canadiennes, Standards Sales, 178 Rexdale Boulevard, Rexdale, Ontario, Canada, M9W 1R3 13. Livret NWSA, BIBLIOGRAPHIE SUR LA SCURIT DU SOUDAGE, disponible auprs de lAssociation Nationale de Fournitures de Soudage (National Welding Supply Association), 1900 Arch Street, Philadelphia, PA 19103 14. Norme AWSF4.1 de lAssociation Amricaine de Soudage, RECOMMANDATIONS DE PRATIQUES SURES POUR LA PRPARATION LA COUPE ET AU SOUDAGE DE CONTENEURS ET TUYAUX AYANT RENFERM DES PRODUITS DANGEREUX , disponible auprs de la American Welding Society, 550 N.W. LeJeune Rd., Miami, FL 33126 15. Norme ANSI Z88.2, PRATIQUES DE PROTECTION RESPIRATOIRE, disponible auprs de lAmerican National Standards Institute, 1430 Broadway, New York, NY 10018

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1.07 Declaration of Conformity
Thermal Dynamics Corporation 82 Benning Street West Lebanon, New Hampshire 03784 USA Manufacturer: Address:

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 the enforcement of this Directive. The equipment described in this manual conforms to all applicable aspects and regulations of the "EMC Directive" (European Council 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 and date of manufacture. National Standard and Technical Specifications The product is designed and manufactured to a number of standards and technical requirements. * 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 associated accessories. * For environments with increased hazard of electrical shock, Power Supplies bearing the 'S' mark conform to EN50192 when used 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 manufacturing process. This is to ensure the product is safe, when used according to instructions in this manual and related industry standards, and performs as specified. Rigorous testing is incorporated into the manufacturing process to ensure the manufactured 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 area of manufacture. Manufacturers responsible representative: Steve Ward Operations Director Thermadyne Europe Europa Building Chorley N Industrial Park Chorley, Lancashire, England PR6 7BX Among them are:

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1.08 Statement of Warranty
LIMITED WARRANTY: Thermal Dynamics Corporation (hereinafter Thermal) warrants that its products will be free of defects in workmanship or 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 accordance with Thermals 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 Thermals sole option, of any components or parts of 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 PARTICULAR PURPOSE. LIMITATION OF LIABILITY: Thermal shall not under any circumstances be liable for special or consequential damages, such as, but not limited to, damage or loss of purchased or replacement goods, or claims of customers of distributor (hereinafter Purchaser) for service interruption. The remedies of the Purchaser set forth herein are exclusive and the liability of Thermal with respect to any contract, or anything done in connection therewith such as the performance or breach thereof, or from the manufacture, sale, delivery, resale, or use of any goods covered by or furnished by Thermal whether arising out of contract, negligence, 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 OR PERFORMANCE 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 a maximum of two (2) years from date of sale by such distributor to the Purchaser, and with further limitations on such two (2) year period (see chart below). Parts AutoCut and UltraCut Power Supplies and Components 2 Years

Labor 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 facility within thirty (30) days of the repair. No transportation costs of any kind will be paid under this warranty. Transportation charges to send products to an authorized warranty repair facility shall be the responsibility of the customer. All returned goods shall be at the customers risk and expense. This warranty supersedes all previous Thermal warranties.

Effective August 19, 2005

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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 system performance, and cools and circulates the liquid coolant for the torch and leads.

2.03 Remote Arc Starter

This unit produces a temporary HF pulse to start the pilot arc. The pilot arc creates a path for the main arc to transfer to the work. When the main arc is established, the pilot arc shuts off.

2.04 Gas Control Module

This 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.

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2.06 Specifications & Electrical Requirements
Ultra-Cut 100 Specifications & Design Features Input Power & Current 208/230V - 460V, 1/3 ph, 50 / 60 Hz 380 vdc Max OCV (U0 ) Minimum Output Current 10 Amps Max Output Current 100 Amps Output Voltage 60 - 230 vdc Duty Cycle Rating 100% @ 100A, 180V Ambient Temperature 104F (40C) for Duty Cycle Rating Operating range 14F to 122F (-10C to + 50C) Power Factor 0.70 @ 100 A DC Output Cooling Forced Air (Class F)

Ultra-Cut 100 Power Supply 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 Line Voltages with Suggested Circuit Protection and Wire Sizes Based on National Electric Code and Canadian Electrical Code Extra Hard Usage Type SO, SOW, SOO, SOOW, ST, STW, STO, STOW, STOO, STOOW Input

2.07 System Component Layout

175 / 53.3 m Maximum Length 125 / 38.1 m Maximum Length Pilot Return Negative Coolant Supply Coolant Return
Primary power

100 / 30.5 m Maximum Length A, B, C, D, E Remote Arc Starter Pilot Return Shield Coolant Supply Coolant Return Shield Plasma Gas Shield Gas I J

Power Supply

Control Cable

CNC

Fiber Optic Cable Control Cable

Plasma Gas Shield Gas

H, Q,

Torch Gas Control Valve Preflow Gas R, Module Assembly Control Cable S, Water Shield T

Positioning Tube Torch

Art # A-07328_AB

Work Work Cable O

SPECIFICATIONS

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2.08 Power Supply Dimensions

27 inch 680 mm

41.25 inch 1050 mm

33 inch 840 mm
Art # A-04793

27.5 inch 700 mm

37.75 inch 960 nm

343 lb / 156 kg

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2.09 Power Supply Rear Panel Features

Torch (Neg) Terminal AC Power Lamp Pilot (Pos) Terminal Circuit Breaker Panel Input Power Terminals

Gas Control Console Connector CNC Connector Remote Arc Starter Connector
RETURN SUPPLY

Ground Terminals

Terminal Cover Work Cable Terminal

Terminal Cover Support Panel

Coolant Connections

Coolant Filter

Coolant Tank

Leads Bracket

Art # A-04794

SPECIFICATIONS

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

Ultra-Cut 100 Power Supply: Gas Pressures, Flows, and Quality Requirements Gas Quality Minimum Pressure Flow O2 (Oxygen) 99.5% Purity (Liquid recommended) 99.5% Purity (Liquid recommended) <1000 ppm O2, <32 ppm H2O) Compressed or Bottled Air H35 (Argon-Hydrogen) H35 = 35% Hydrogen, 65% Argon H2O (Water) Clean, Dry, 120 psi Free of Oil (see Note 1) 8.3 bar / 827 kPa 99.995% Purity (gas recommended) See Note 2 120 psi 8.3 bar / 827 kPa 50 psi (3.5 bar) 244 scfh (6910 l/h) 120 psi 8.3 bar / 827 kPa 70 scfh (1982 l/h)

N2 (Nitrogen)

120 psi 8.3 bar / 827 kPa

200 scfh (5700 l/h)

90 scfh (2550 l/h)

10 gph (38 lph)

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 as possible to the gas inlets on the Gas Control Module. 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 3: Water Pressure Regulator No. 8-6118 is recommended to ensure proper water pressure.

2.11 Gas Applications

Ultra-Cut-100 Gas Applications MILD STEEL STAINLESS STEEL ALUMINUM GAS TYPE GAS TYPE GAS TYPE OPERATION PREFLOW PLASMA SHIELD PREFLOW PLASMA SHIELD PREFLOW PLASMA SHIELD Air Air Air Air Air Air O2 Air O2 30A CUT N2 H20 N2 N2 H20 N2 Air Air Air Air Air Air Air Air O2 50 A CUT N2 N2 H20 N2 N2 H20 Air Air Air Air Air Air Air O2 Air 70 A CUT N2 H20 N2 N2 H20 N2 Air Air Air 85A CUT H35 N2 N2 H35 N2 N2 Air O2 Air 100 A CUT N2 N2 H20 N2 N2 H20 MATERIAL

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2.12 XTTM-300 Torch Specifications
A. Torch Dimensions

Art # A-04897

End Cap 19.00" 482.68 mm 2.25" 57.15 mm

Mounting Tube 15.50" 393.78 mm 2.0" 50.8 mm

6.30" 160.10 mm

3.54" 89.87 mm 2.74" 69.55 mm 1.57" 39.96 mm

2.39" 60.81 mm

1.49" 37.8 mm

SPECIFICATIONS

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B. Torch Specifications
XTTM-300 Torch Ratings for use with Ultra-Cut 100 Power Supply Ambient 104 F Temperature 40 C Duty Cycle 100% @ 100 Amps Maximum Current 100 Amps Voltage (Vpeak ) 500V Arc Striking Voltage 10kV Current Up to 100 Amps, DC, Straight Polarity XTTM-300 Torch Gas Specifications Plasma Gases: Compressed Air, Oxygen, Nitrogen, H35 Compressed Air, Oxygen, Nitrogen, Water 125 psi 10 psi 8.6 bar 0.7 bar 135 psi / 9.3 bar 10 - 300 scfh

Shield Gases: Operating Pressure Maximum Input Pressure Gas flow

C. Leads Lengths
Gas Lead Assemblies Length Feet 10 15 25 35 50 75 100 125 150 175 Meters 3.05 4.6 7.6 10.6 15.2 22.8 30.4 38.2 45.7 53.3

D. Torch Parts (Generic Parts Shown)

Art # A-04741

Shield Gas Distributor

Plasma Gas Distributor

Shield Cap Shield Cup

Tip

Electrode Cartridge

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Intentionally blank

SPECIFICATIONS

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SECTION 3: INSTALLATION
3.01 Installation Requirements
Electric Supply
The electrical supply network, the gas and water supply system must meet local safety standards. This conformity shall be checked by qualified personnel.
Ultra-Cut 100 Power Supply 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 Line Voltages with Suggested Circuit Protection and Wire Sizes Based on National Electric Code and Canadian Electrical Code Extra Hard Usage Type SO, SOW, SOO, SOOW, ST, STW, STO, STOW, STOO, STOOW Input

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

Gas Supply
The customer must supply all gases and pressure regulators. Gases must be of high quality. Pressure regulators must be double-stage and installed as close as possible to the gas console. Contaminated gas can 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).
Coolant Capabilities Cat. Number and Mixture Mixture 7-3580 'Extra-Cool ' 7-3581 'Ultra-Cool ' 7-3582 'Extreme CoolT M' * For mixing with D-I Cool
TM

Protects To 10 F / -12 C -27 F / -3 C -65 F / -51 C

TM

25 / 75 50 / 50 Concentrate*

TM

7-3583

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3.02 System Layout
Refer to section 3.05 for ground connections and ground cables.

175 / 53.3 m Maximum Length 125 / 38.1 m Maximum Length Pilot Return Negative Coolant Supply
Primary power

100 / 30.5 m Maximum Length A B C D E Remote Arc Starter Pilot Return Shield Coolant Supply Coolant Return Shield Plasma Gas Shield Gas

Power Supply

Coolant Return Control Cable

CNC

Fiber Optic Cable Control Cable

L Gas Control Module K

Plasma Gas Shield Gas Preflow Gas Control Cable Water Shield

H Q R S T Torch Valve Assembly

I J

Positioning Tube Torch

Work Work Cable

Art # A-07233_AB

175 / 53.3 m Maximum Length

INSTALLATION

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3.03 Cables & Leads Identification
#8 AWG Cable A #1 AWG Cable B Negative Lead, Power Supply to Arc Starter Green Red Coolant Supply Lead, Power Supply to Arc Starter Coolant Return Lead, Power Supply to Arc Starter Control Cable, Power Supply to Arc Starter
Art # A-07473

Pilot Return, Power Supply to Arc Starter

Green Red

14

Green / Yellow # 4 AWG Green / Yellow 1/0 (50 mm 2)

Ground Cable Ground Cable, Remote Arc Starter To Earth Ground Shielded Torch Lead Assembly, Remote Arc Starter to Torch Plasma Gas Lead, Torch Valve to Torch Shield Gas Lead, Torch Valve to Torch Control Cable, Power Supply to Gas Control Module Fiber Optic Cable, Power Supply to Gas Control Module

F1

37

H, Q, R, S,T O 1/0 Cable (1/0 (50 mm 2)

Work Cable

14

CNC Cable (14 Wire)

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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 and vertical. 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 a supporting fixture with hardware passing through the horizontal parts of the power supply feet.

INSTALLATION

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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 a ground wire connected to the inside of the panel. Do not disconnect this wire.

Connections Cover (Removed)

Connection Panel

Art # A-04797

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Check / Adjust Input Voltage Configuration
1. The power supply includes a voltage configuration board which must be positioned to match the primary input voltage. Remove the power supply left side panel and locate the voltage configuration board. The input voltage configuration is shown at the top of the board. 2. If necessary, disconnect the jumper at the top right corner of the board, remove the board and re-install it with the correct input voltage shown at the top of the board. 3. Re-connect the jumper. Re-install the power supply side panel.

Inverter Module 1. Unplug connector

208/230V / 460V Input Voltage Board (Shown in 460V Position)

2. 3. 4. 5.

Remove bolts. Invert board. Re-install board. Plug in connector.

Art # A-04856_AB

INSTALLATION

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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 back the insulation on the individual cords. Route the cable upward through leads bracket at the bottom of the rear panel, 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 panel next 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.
Ground Terminal Block

Connections Cover Connection Panel

PUT AC 2IN
L3

to Remote Arc Starter

TORC K WOR T PILO H

L1

L1

L2

L3

System Ground Cable Input power cable ground

Connections Cover Support Panel

Input power cable

System Ground Cable Leads Bracket

to Remote Arc Starter

Art # A-07659_AB

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

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Star Ground on Cutting Table

Remote Arc Starter (RAS-1000) Torch Cutting Machine / Gantry Cutting Table 1/0 Ground Cable (F1) CNC Device

Ultra-Cut or Auto-Cut O2

Power Supply Gas Control Module Primary location #4 AWG Ground (F)

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).

1/0 Ground Cable Customer supplied Earth Ground Rod 0 - 10 ft (0 - 3 m) Ideal 20 ft (6 m) Maximum

1/0 Work Cable 1/0 Ground Cable Star Ground

Star Ground on Cutting Table Auto-Cut W/RAS

Remote Arc Starter (RAS-1000) Torch Cutting Machine / Gantry Cutting Table 1/0 Ground Cable (F1) CNC Device Gas Control Module Power Supply

#4 AWG Ground (F) (Factory Installed)

1/0 Ground Cable Customer supplied Earth Ground Rod 0 - 10 ft (0 - 3 m) Ideal 20 ft (6 m) Maximum

1/0 Work Cable

Star Ground

Art # A-08253_AC

INSTALLATION

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Auto-Cut Basic System Without RAS

Cutting Machine / Gantry Cutting Table

Torch

CNC Device

Auto-Cut Power Supply

GCM-1000 Gas Control Module #4 AWG Ground (F) (Factory Installed)

1/0 Ground Cable Customer Supplied Earth Ground Rod 0 - 10 ft (0 - 3 m) Ideal 20 ft (6 m) Maximum

1/0 Work Cable 1/0 Ground Cable (F1) Star Ground

Art # A-08254_AC

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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, height controllers, etc. To minimize RF interference, follow these grounding procedures when installing mechanized systems:

B. Grounding
1. The preferred grounding arrangement is a single point or Star ground. The single point, usually on the cutting table, is connected with 1/0 AWG (European 50 mm2) or larger wire to a good earth ground (measuring leass than 3 ohms; an ideal ground measures 1 ohm or less. Refer to paragraph C, Creating An Earth Ground. The ground rod must be placed as close as possible to the cutting table, ideally less than 10 ft (3.0 m), but no more than 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 RF frequencies. Smaller diameter wire has increased resistance to RF frequencies, so using a larger diameter wire is better.
2. Grounding for components mounted on the cutting table (CNC controllers, height controllers, plasma remote controls, etc.) should follow the manufacturers recommendations for wire size, type, and connection point locations. For Thermal Dynamics components (except Remote Arc Starter and Gas Control Module) it is recommended to use a minimum of 10 AWG (European 6 mm2) wire or flat copper braid with cross section equal to or greater than 10 AWG connected to the cutting table frame. The Remote Arc Starter uses 1/0 earth ground wire and the Gas Control Module should use minimum # 4 AWG wire. The connection point must be to clean bare metal; rust and paint make poor connections. For all components, wires larger than the recommended minimum can be used 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 larger wire. 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 connection to the cutting table. The work and ground connections must be free from rust, dirt, grease, oil and paint. If necessary grind or sand down to bare metal. Use lock washers to keep the connections tight. Using electrical joint compound to prevent corrosion is also recommended. 6. The plasma power supply chassis is connected to the power distribution system ground as required by electrical codes. If the plasma supply is close to the cutting table (see NOTE) a second ground rod is not usually needed, 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 to install a second earth ground rod next to the plasma power supply. The plasma power supply chassis would then be connected to this ground rod.

NOTE It is recommended that the 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 with no shield at all. INSTALLATION 3-10 Manual No. 0-4748

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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 ground rod 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). Ground rods, typically 10 ft (3.0 m) long, may be welded end to end for greater lengths. Locate the rod as close as possible to the work table. Install a ground wire, 1/0 AWG (European 50 mm2) or greater, between the ground rod 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 as shown.

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.

NEUTRAL Earth Grounded HOT

WARNING
Use extreme caution. This test uses live voltage.

Ground Rod with other connections removed On 115V AC Line: 3VAC = 3 ohms 1VAC = 1 ohm

100W Incandescent light bulb*

VAC

On 230V AC Line: 1.5VAC = 3 ohms 0.5VAC = 1 ohm

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

Art # A-07252

Ground Testing
2. Increasing the ground rod length beyond 20 - 30 ft (6.1 9.1 m) does not generally increase the effectiveness of the ground rod. A larger diameter rod which has more surface area may help. Sometimes keeping the soil around the ground rod moist by continuously running a small amount of water into it will work. Adding salt to the soil by soaking it in salt water may also reduce its resistance. When these methods are used, periodic checking 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 the plasma 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 increased chance of RF interference. Manual No. 0-4748 3-11 INSTALLATION

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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 the bottom 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.

Connections Cover Torch

Connection Panel

Pilot

Work

PUT AC IN L2
L1

L3

H TORC K WOR PILOT

Torch Lead - To Remote Arc Starter Work Lead Connections Cover Support Panel

Pilot Lead To Remote Arc Starter Lead Connection Detail

Art # A-07660_AB

To Cutting Table Leads Bracket

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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. The supply line (out) is flagged green, the return line (in) is flagged red.

COOLANT
RETURN SUPPLY
RETURN SUPPLY

RED Coolant Connections GREEN

To Remote Arc Starter

Art # A-04800

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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.

Customer Wiring Access Hole

To Gas Control Module

To CNC
RETURN SUPPLY

To Remote Arc Starter

Art # A-04802

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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 without an external connections cover. Use the preceding section for connections to an internal module with an external connections 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 strain relief dome nut from the strain relief. b. Pass the cable connector through the appropriate opening. Slide the strain relief securing nut onto the cable. Make a loop of the cable; carefully press the cable connector into the appropriate receptacle on the internal control module. c. Tighten the strain relief onto the cable(s). Do not overtighen.

Cable Receptacles

To Gas Control Module To Remote HMI (if installed) To Slave Power Supply (if installed)

Profile Detail, Fiber Optic Cable Installation

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 module without 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 static charges in your body or surroundings before touching the printed circuit boards.

Future Use

O N 1

SW1

SW3

SW4

SW5

SW8

O N 4

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 Seconds SW-1-4: Pilot Delay 2 = OFF, 3 = ON, 4 = OFF: 0.2 Seconds 2 = ON, 3 = ON, 4 = OFF: 0.4 Seconds 2 = OFF, 3 = OFF, 4 = ON: 0.8 Seconds 2 = ON, 3 = OFF, 4 = ON: 1.0 Seconds 2 = OFF, 3 = ON, 4 = ON: 1.5 Seconds 2 = ON, 3 = ON, 4 = ON: 2.0 Seconds
SW-3: Gas Preflow Time 1 = Off, 1 = ON, 1 = OFF, 1 = ON, 2 = OFF: 2 = OFF: 2 = ON: 2 = ON: 2 seconds 4 seconds 6 seconds 8 seconds

Active only when SW-1-1 is set to O N.

SW-4: Postflow Time

1 = OFF, 1 = ON, 1 = OFF, 1 = ON,

2 = OFF: 10 Seconds (Factory default setting). 2 = OFF: 20 Seconds 2 = ON: 5 Seconds 2 = ON: 0 Seconds

SW-5-1: Tip Saver SW-5-2: Off Plate SW 8-1: Pilot Time

Reserved for Factory use. Reserved for Factory use.

1 = OFF = Short (85 ms.) (Factory default setting). 1 = ON = Long (3 s.) 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

Art # A-06791_AB

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

SW11

SW6

No external connection cover

SW12

SW13 SW-6: OK-to-Move: Contact closure, 120VAC @ 1A (Factory default setting) or DC Volts (16-18vdc@ up to 100 ma.) B = from Gas Control (Factory default setting) or A = from CNC. Position A requires that SW-8-2 be ON.

SW-11: Analog Current Control.

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.

Only 1 on at a time.

Art # A-06792

SW13: TVA and XTL Switch positions

1
TVA

XTL TVA

SW13

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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 requires connection to the full non-divided arc voltage. Also available on the terminal strip are 120VAC (120,0) and 24 VAC (24, 0). Note that the two 0s are not common. The allowable current draw is 100ma @ 120VAC and 1Amp @ 24 VAC.

Art # A-08404

There is also a hole added in the rear panel above the J55-GCM receptacle for customer wiring. This, rather than the one in the CCM will be the preferred place for customer added wiring (and strain relief) for connections 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 system operator. The unit must be mounted to a flat horizontal surface. If the Module is mounted to a gantry or to any other support 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 the bottom panel; the space between the bottom panel and the mounting surface must remain open for ventilating air to enter the module. Louvers on the back panel of the module must also remain unblocked, for the free passage of ventilating air.

Mounting Dimensions
NOTE Height not shown is 14.125 (359 mm)

Gas Box

410.97mm 16.18

7.14mm 0.28

347.47mm 13.68

279.40mm 11.00

215.90mm 8.50

Art # A-07962

NOTE The unit must be mounted so that the Flowmeters are plumb. If the Flowmeters are not plumb, incorrect flow 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 if needed.

Gas Control Module Cover

Remove Ground Wire Do not remove

Art # A-06882

Cover Removal

INSTALLATION

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

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

Circuit Board

2 3 Fiber Optic Cable

MM

CO

J56 J57 ER POW LY PP F5 SU

A SM PLA T OU

W FLO PRE UT O

TVA H35 UTS INP N2 AIR O2

H2O LD SHIET OU

CO

MM

J56 J57 R WE PO LY PP F5 SU

SHIEL

PLAS

MA

PREF

LOW
UTS INP N2 O2

TVA H35

AIR

H2O SHIELD

H2O

Art # A-04772

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

Circuit Board Fiber Optic Cable

Art # A-04773

4. Tighten the through-hole 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 be grounded; the grounding terminal is marked Use #10 AWG (European 6 mm2) (or thicker) wire for grounding. 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 supply.

To Torch Valve Assembly

J57 SHIELD PLASMA PREFLOW When Cutting With O2 Plasma Air MUST BE Connected H 2O SHIELD H2O AIR INPUTS H35 N2 O2 TVA J56

To Power Supply

COMM

F5

POWER SUPPLY

Gas & Water Inputs (Check Valves) To Torch Valve Assembly

Ground Stud

Gas Control Box Rear Panel

J57 SHIELD PLASMA PREFLOW When Cutting With O2 Plasma Air MUST BE Connected H 2O SHIELD H 2O AIR INPUTS H35 N2 O2 TVA

J56

COMM

Connection Panel

F5

POWER SUPPLY

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 Starter for these connections without crimping.

Mounting Dimensions
NOTE Height not shown is 7.375 ( 187mm )

Arc Starter Box

190.83mm 7.51

12.70mm .50

6.35mm D.250 3 PLACES 203.20mm 8.00

304.80mm 12.00

50.80mm 2.00

37.77mm 1.49
Art # A-07961

266.70mm 10.50

INSTALLATION

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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 mounted to 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 upper screws 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.

Upper screws (4 per side)

Cover

Ground Wire Lower screws

Art # A-07029

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 the mounting surface.

Minimum 2

Art # A-04749

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; Red for Return, Green for Supply.

Art # A-04750

Coolant Supply and Return Hoses (from power supply)

INSTALLATION

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Red Coolant Return (Red)

Green

Coolant Supply (Green)

Art # A-04751

Coolant Return (Red)

Copper plate

Negative cable must be attached so that it is in contact with the copper plate.
Art # A-04752_AB

Negative Cable from power supply

Negative Cable (from Power Supply rear panel)

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Art # A-04753

Pilot Return Cable from 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 inner shield wires.

Inner Shield Lead Pilot Lead

Inner Shield Connection Detail

Art # A-04933

Pilot Lead Connection Detail

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

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Art # A-04757

Some items are removed for clarity. Coolant Return Fitting (Tagged with Red) Coolant Supply Fitting (Tagged with Green)

Coolant Supply (Green) to Torch

Coolant Return (Red) from Torch

Coolant Supply and Return Hoses (from Torch)

Reinstall the Arc Starter Cover. Ensure that the ground wire is not crimped between the cover and the base.

Upper screws (4 per side)

Cover

Ground Wire Lower screws

Art # A-07029

The Arc Starter must be grounded; the grounding terminal is marked grounding details.

. Refer to the previous section for

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Art # A-04758

Torch Leads

1 Nut and 1 Washer Remain in Place Ground Cable

Use a clamp to secure the Torch Lead Shield braid to the port on the Remote Arc Starter as shown.

Art # A-04759

Torch Leads Shield Shield Clamp

Coolant and Pilot Leads to Torch Valve Assembly

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Connect Control Cable
1. Connect the Remote Arc Starter cable to the Remote Arc Starter receptacle.

Power Supply Rear Panel

RETURN

SUPPLY

COOLANT
RETURN SUPPLY

Remote Arc Starter

Remote Arc Starter Input Connection Panel

Art # A-04801

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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 from the Gas Control Module and supplies these gases to the Torch.

Mounting

113.03 mm 4.450

6.63 mm .261 Dia.

36.83 mm 1.450

Art # A-07648

1. Mount the Valve Kit as close as possible to the Torch. The valve kit can be mounted in any convenient position, provided the outlet side (with two fittings) is closer to the torch than the inlet side (with three fittings and a control cable connector). 2. Connect the Valve Kit outlets to the torch leads as shown. (XTL shown)
Do not remove brass plugs Front and side

Outlet Side
Art # A-07645

Left-hand Thread: To Torch Plasma Gas fitting Right-hand Thread: To Torch Shield Gas fitting

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

WMS Inlet Shield Gas Inlet Preflow Gas Inlet Plasma Gas Inlet
Art # A-07646

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

INSTALLATION

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3.18 Connecting Torch
Connect the Torch as follows:

Coolant Supply, Coolant Return, and Pilot Leads Leads Cover Torch Leads End Cap Shield Gas (Right Hand Thread)

Groove for O-Ring O-Ring Mounting Tube Pilot Lead

Plasma Gas To Torch Valve (Left Hand Thread) Coolant Supply & Power Lead (-) Pilot Lead Connector Torch Head Assembly
Art # A-04746

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 that the 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 gas connection 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 the leads 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 there are 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 the plastic 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 needed to ensure a proper fit through the Mounting Tube and Torch Leads End Cap. Hold the Torch Head Assembly stationary; 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 the threaded 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 includes diagrams showing the correct parts to install, depending on the metal to be cut and the gases in use.

INSTALLATION

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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 are seated correctly.

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.
Art # A-03887

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.
Art # A-08303

Di ield st rib Ga ut s or Tip

Pl a Di sm st a rib Ga ut s or

Ca

de

A
1 - Assemble A 200 A only. 2 - Assemble B.

B
3 - Assemble B to C.

El

Shield Retainer

Sh

Sh

ec

Shield Cup

tro

iel

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 fits completely into the cartridge. If any part of the O-ring protrudes from the cartridge, the parts are not seated properly. 5. Use the cartridge tool to hold the cartridge assembly, while turning the shield cup (and shield retainer for 200 Amp parts) onto the cartridge assembly. For 300 Amp parts turn the shield retainer onto the shield cup now. When this group is fully assembled, the shield should protrude from the front of the shield cup or shield retainer. Without this protrusion the shield cup is not properly tightened onto the cartridge assembly. 6. Take the cartridge tool off the cartridge. Fit the cartridge assembly onto the torch head. The Speed Lok ring should clidk into place and the cartridge assembly should touch the large O-ring on the torch body.

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INSTALLATION

Ca

rtr

id

ge

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Torch Head Torch Head O-Ring

0.063 - 0.083" (1.6 - 2.1 mm) Protrusion

Art # A-08300_AB

Installing Assembled Cartridge Onto Torch Head

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

INSTALLATION

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55 - 100 Amp Parts Assembly

1: Stack Parts

2: Press Cartridge onto Stacked Parts

Electrode

Plasma Gas Distributor

O-Ring on Tip No Gaps Between Parts

Tip

Shield Gas Distributor Shield Cap

Cartridge Covers O-Ring on Torch Tip

3: Thread Shield Cup onto Cartridge

4: Check Shield Cap Protrusion

Shield Cup

Shield Cap

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

Art # A-04873

Installing Assembled Cartridge Onto Torch Head

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

Ohmic Clip

sensing.

A-03393

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

INSTALLATION

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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 Dynamics coolant. The coolant level is visible through the translucent coolant tank. The amount of coolant required varies with torch leads length.
Coolant Capabilities Cat. Number and Mixture Mixture 7-3580 'Extra-CoolTM' 7-3581 'Ultra-CoolTM' 7-3582 'Extreme CoolT M' * For mixing with D-I CoolTM 7-3583 25 / 75 50 / 50 Concentrate*

Protects To 10 F / -12 C 27 F / -33 C -65 F / -51 C

COOLANT
RETURN SUPPLY

RETURN

SUPPLY

Fill Range

Coolant Tank

Art # A-04803

2. After the complete system has been installed, check that the coolant has been pumped through the system 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 the system 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 torch leads 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 air from 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 are evident, consult the coolant leak trouble-shooting guide in the maintenance section of this manual.

INSTALLATION

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SECTION 4: OPERATION
4.01 Power Supply Control Panel
AC Indicator Gas Indicator Temp Indicator DC Indicator Status Indicator

Art # A-04862

AC Power Indicator Indicates AC power is being supplied to the inverters when the ON/OFF switch is in ON position. When switch is first set to ON, the indicator stays off until the inrush cycle is complete and the correct voltage is confirmed. TEMP Indicator: Normally OFF. Indicator turns ON when the internal temperature sensors detect temperatures 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. Indicator is 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 the operating software installed in the system.

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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
I
OFF O

ON

OFF

Art # A-04812

3. Check the AC indicator. If indicator is ON, system is ready to operate (pending fault checks by internal circuitry). If indicator does not light after a few seconds check that each inverter is correctly configured for the input voltage and all 3 phases are present. Check Status Indicator for any codes that can help determine problem.

OPERATION

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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 are various controls and indicators used to set gas pressures and flows.

O2 - AIR O2 - O2
RUN SET PREFLOW SET PLASMA & SHIELD TEST

ENABLE

H35 - N2 F5 - N2 AIR - AIR N2 - H20 N2 - N2

DISABLE PLASMA POWER SUPPLY

MODE

GAS

O2 - AIR O2 - O2
RUN SET PREFLOW

ENABLE

H35 - N2 F5 - N2

SET PLASMA & SHIELD TEST

AIR - AIR N2 - H20 N2 - N2

DISABLE PLASMA POWER SUPPLY

MODE
PREFLOW

GAS
PLASMA SHIELD

9
PRESSURE GAS FLOW

9
H20 MIST

PRESSURE
GCM 2010

GAS
Art # A-04771

FLOW

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Gas Control Module: Controls & Indicators
1. MODE Selection Switch

RUN SET PREFLOW SET PLASMA & SHIELD TEST

MODE

RUN SET PREFLOW SET PLASMA & SHIELD TEST

O2 - AIR O2 - O2 H35 -N2 F5 - N2 AIR - AIR N2 - H2O N2 - N2 GAS

ENABLE

DISABLE

MODE

High Precision Plasma Cutting System

SHIELD

PLASMA POWER SUPPL Y

PREFLOW

PLASMA

H2O MIST

GCM 2010

PRESSURE GAS FLOW

Art # A-04765

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 to adjust pressure. Gas automatically shuts off after 2 minutes if left in the SET PREFLOW position. In the SET PLASMA & SHIELD position, selected cutting gases, Plasma & Shield, flow to the torch to allow operator to set the pressure (regulator & gauge) and flow (knob at top of flowmeter). Gases automatically shut off after 2 minutes if left in the SET PLASMA & SHIELD position. GCM 2010 gas control revision AG or later includes inlet pressure sensors. In SET PLASMA & SHIELD position the LCD display shows alternately the plasma an shield inlet pressure. If either gas pressure is outside the acceptable range, the display shows PSI low (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 outlet pressure (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 at initial setup to configure the gas control for the gas lead length. See Sequence of Operation, initial setup.

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2. GAS Selection Switch Selects combinations of plasma and shield gases.

O2 - AIR O2 - O2 H35 -N2 F5 - N2 AIR - AIR N2 - H2O N2 - N2 GAS

RUN SET PREFLOW SET PLASMA & SHIELD TEST

O2 - AIR O2 - O2 H35 -N2 F5 - N2 AIR - AIR N2 - H2O N2 - N2 GAS

ENABLE

DISABLE

MODE

High Precision Plasma Cutting System

SHIELD

PLASMA POWER SUPPL Y

PREFLOW

PLASMA

H2O MIST

GCM 2010

PRESSURE GAS FLOW

Art # A-04766

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#. ^E4 = CANBus error unacknowledged message. ^E5 = CNABus error Bus off ^E6 = CANBus error communication timed out.

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4. Current Control Adjusts the output current of the power supply.

High Precision Plasma Cutting System

RUN SET PREFLOW SET PLASMA & SHIELD TEST

O2 - AIR O2 - O2 H35 -N2 F5 - N2 AIR - AIR N2 - H2O N2 - N2 GAS

ENABLE

DISABLE

MODE

High Precision Plasma Cutting System

SHIELD

PLASMA POWER SUPPL Y

PREFLOW

PLASMA

H2O MIST

GCM 2010

PRESSURE GAS FLOW

Art # A-04767

5. Plasma Power Supply Enable / Disable Switch The DISABLE position removes input power from the Power Supply inverters, disables the coolant pump and fan, 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 is returned 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 & SHIELD position. 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 meter with the GAS switch set in the FLOW position. Some torch parts require higher flow rates that execeed the capacity of the flow meter. In that case, Gas switch is set in the PRESSURE position and the regulator and gauge 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 switch must be in N2-H2O position. NOTE Water mist is not used in all applications.

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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 to DISABLE. 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 to establish communications, the gas control will start the Purge and priming sequence. (If torch and coolant leads were not already full of coolant you may be required to repeat this power on cycle and add coolant until 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 the factory 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 line steps downwards from 175 to 50 in 25 increments. As soon as the correct length is displayed, release the knob. 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 its main PC Board is replaced.

4.05 Sequence Of Operation

For first time operation see previous steps, First Time Operation... 1. Set the Plasma Power Supply Enable / Disable switch to Disable.

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. The Module performs purges of 15 seconds, 11 seconds, and another 11 seconds. This removes water from the torch parts. 2. Select the desired plasma and shield gas by setting the Gas Selection switch to the desired position. 2 seconds 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 pressure settings. 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.

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4. 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 and shield 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 the amperage 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 Module performs purges of 15 seconds, 11 seconds, and another 11 seconds. This removes water from the torch parts. 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 do so. If the operator switches gases during piloting or cutting, the power supply will finish the cut with the first gas chosen. Then the gas control will switch to the new gas. Switching gases during piloting or cutting may damage torch 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 be major factors when the surface will be welded after cutting. Dross-free cutting is important when finish cut quality is desired to avoid a secondary cleaning operation. Cut quality will vary on different materials and thicknesses.
Kerf Width

Left Side Cut Angle

Cut Surface Bevel Angle

Right Side Cut Angle

Top Spatter

Top Edge Rounding Dross Build-Up

A-00512

Cut Surface Drag Lines

A-00007

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

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Bevel Angle The angle between the surface of the cut edge and a plane perpendicular to the surface of the plate. A perfectly perpendicular cut would result in a 0 bevel angle. Top-Edge Rounding Rounding on the top edge 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 is dross which accumulates on the top surface of the workpiece. Excessive dross may require secondary cleanup 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 plasma gas 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 results in one side of a cut being more square than the other. Viewed along the direction of travel, the right side of the cut is more square than the left.
Clockwise

Left Side Cut Angle

Right Side Cut Angle

CounterClockwise Scrap

Scrap

Workpiece
A-00512
Art # A-04182

Swirl Effect on Side Characteristics Of Cut

To make a square - edged cut along an inside diameter of a circle, the torch should move counterclockwise around the circle. To keep the square edge along an outside diameter cut, the torch should travel in a clockwise direction. Underwater Cutting Cutting on a water table either underwater or with the water touching the plate or with a water muffler system is not recommended. If a water table is used the water level must be a minimum of 4 inches from the bottom of the plate. Failure to follow this recommendation could result in poor cut quality and short consumable parts life. Ohmic Height Sensing Ohmic height sensing is not recommended with water shield. Water on the plate interferes electrically with the ohmic sensing circuit. Marking Marking requires adjusting the pre-charge pressures. Refer to the torch data section for details. Manual No. 0-4748 4-9 OPERATION

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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 substantially 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) and thicker nonferrous materials. Ar/H2 is not normally used for thinner nonferrous materials because less expensive 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 cause difficulties 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.

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4.07 Power Supply Status Codes
On start-up and during operation, the power supply control circuitry performs various tests. If the circuitry detects a condition requiring operator attention, the status indicator on the control panel flashes a 2-part code to indicate a code group and then a particular condition within the group. After 4 seconds, the sequence repeats. Example: Indicator flashes 4 times; the condition is in group 4. After a 1.2 second delay, the indicator blinks 3 times; the condition code is 4-3, indicating that the coolant is overheating. After a 4-second delay, the indicator repeats the sequence until the condition is corrected. Some conditions can be active indefinitely, while others are momentary. The power supply latches momentary conditions; some momentary conditions can shut down the system. The indicator may show multiple conditions 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 systems Firmware is a prior version, contact your distributor for updates.

Fault Code Key Error Code Error Remedy / Comments 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. Pilot did not start within 15 seconds. Preflow pressure too high; Defective Arc Starter Pilot went out without shutoff signal; Preflow pressure too high; cut current set too low for consumables. Arc transfer (>50 ms.) then arc lost with START still on. Standoff too high; Current set too low. Function not currently enabled

1-1

System not Enabled or Missing AC Input Phase

1-2 1-3 1-4 1-5 1-6 1-7 1-8

Pilot Ignition Failure Lost Pilot Loss of Transfer Off the Plate

Must transfer from Pilot to Cutting Arc in 85 ms. (SW8-1 OFF) or 3 sec. (SW8-1 ON). Standoff too Pilot Timed out w/o Transfer high or void in work under torch; cut current too low for consumables; Preflow pressure too low. Tip Saver Possible Shorted Torch Function not currently enabled. 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.

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Fault Code Key Error Code Error 2-1 Missing Phase 2-2 Wrong input voltage Remedy / Comments Blown fuse, Broken or loose connection on power cable 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.

2-3 2-4 2-5 2-6 2-7 2-8 2-9

Inverter or Pilot Regulator Over Failed fan; Ambient above 40 deg C. (104 F); Blocked airflow Temperature Power Supply not Ready Defective inverter Output less than 60 VDC; Defective inverter, shorted output; Shorted pilot DC Output Low regulator (chopper); CCM voltage sense (J6) wire open or disconnected. Primary over current fault Unexpected current Unexpected current in pilot circuit Unexpected current in work lead Gas Control Communication fault, Cannot establish Communication with gas control. Gas Control Communication reply fault, connection was established but CCM did receive a reply to a process request. Over current detected in inverter primary circuit, remove power to reset; defective inverter; voltage surge; Current >20A in work or pilot leads before pilot ignition; Possible shorted torch; Defective current sensor. Current > 5A in pilot circuit; wrong or mismatched consumables; Pilot lead shorted to negative in torch tube; Possible shorted torch Current > 5A in work lead; Short to chassis in RAS; Negative lead short to ground. 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. 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. 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. Purging; not in RUN mode; Gas Control faulty, replace PCB. Application error or firmware compatibility fault GCM sent output current level outside the range of the power supply, Check firmware compatibility Check firmware compatibility Install correct CCM or Gas Control for system Reply not compatible with request; Check firmware compatibility System will function but control may not be optimized for best performance / consumable life

3-1

3-2

3-3

Gas Pressure Low

3-4 3-5 3-6 3-7 3-8 3-9 3-10

Gas Control not ready Gas Control Protocol Fault Invalid Current Control level from GCM Gas Control returns wrong command sequence CCM and Gas Control type (Autocut-Ultracut) mismatch Gas Control Communication reply fault Warning. -- Gas Control firmware needs update

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Fault Code Key Error Error Code 4-1 Coolant Level low fault Remedy / Comments Check coolant level, add as needed.

4-2

Low coolant flow after power on purge. Not cutting: < 0.7 gal/min for 15 Suction leak introducing air into coolant, suspect rear panel filter seal; clogged sec; filter; defective pump. Cutting: flow between 0.35 to 0.7 gal/min for 3 sec. or immediately if < 0.35gal/min; Coolant fan failed; radiator fins clogged with dirt; Ambient temperature > 40 deg C. 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. While cutting detected low coolant level, does not stop cut. Low Coolant Level - Warning Add coolant as required. If GCM 1000, Basic ID signal missing; Other gas controls, Fiber CANBUS Failure to disconnected or broken, Transceiver (what fiber plugs into) fault, replace Acknowledge fault. Gas control PCB or CCM CANBUS Off due to excessive Dirt on fiber ends or in connectors, blow out with clean dry air; fiber not data errors; locked into connector; sharp bends in fiber; fiber defective; CANBUS data error warning. Dirt on fiber ends or in connectors, blow out with clean dry air; fiber not Errors increasing, will soon locked into connector; sharp bends in fiber; fiber defective; fault. CCM Message not sent CCM Analog Voltage Error CCM ADC or DAC error Coolant Flow too High error, flow > 2.7 gal/min CCM Data Memory error Dirt 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) Replace CCM Replace CCM Torch coolant tube broken or missing; CCM fault, replace CCM Replace CCM Coolant overheated (>70 deg. C, 158 deg F) Coolant System not ready. During power on purge / priming, flow did not reach 0.35 gal/min for at least 5 seconds

4-3

4-4

4-5 5-1 5-2 5-3

5-4 6-1 6-2 6-3 6-4

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4.08 Remote Arc Starter: Service Chart

Arc Starter Service Chart Symptom Cause Check Use conductivity meter Coolant has become conductive Pilot return wire not connected Spark gap set too close High Frequency cap (C4) No Pilot ignition: possibly open Spark in Arc Starter Broken or missing ferrites but no ignition Short across in inductor (L1) Spark gap bus caps (C1, C2, C3) broken or defective Negative supply not connected correctly Spark gap set too large Faulty transformer No Pilot ignition: No Spark in Arc Starter No 120V supply Visual inspection Check with feeler gauge Use capacitance meter Visual inspection Visual inspection Capacitance meter Visual inspection Check with feeler gauge Resistance measurement Check input voltage at EMI filter Visual inspection Remedy Flush system, replace coolant. Connect Wire. Set to 0.063" 0.002" Reconnect or replace. Replace. Remove short; increase coil gaps. Replace. Reconnect. Set to 0.063" 0.002" Replace. Make connections; replace harness. Reconnect.

No/ loose connection to spark gap Faulty EMI filter Loose fitting(s) No cooling or Failure to braze joints (L1) insufficient cooling: Damaged or punctured Leaks coolant coolant line(s).

Voltage/ Resistor measurement Replace. Visual inspection Tighten fittings. Visual inspection Replace HF Coil. Visual inspection Replace coolant line(s).

Visual Inspection of color-coded Match coolant connection colors Supply & return hose reversed No cooling or connections to arc starter fitting colors. insufficient cooling: Loosen fitting slightly and check No Coolant Flow Blockage in coil or Flush system. supply/return hoses for coolant flow Shield Drain / Torch lead inner Visual inspection of lead shield connector attachment to Arc Starter missing or loose. Reconnect / tighten lead connectors.

Erratic System Missing or loose Behavior (EMI Interference) ground connection

Cap C5 not connected, open or loose

Make or tighten Visual inspection of ground wire connections to to Arc Starter good ground. Visual inspection / capacitor Replace PCB. measurement

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4.09 Remote Arc Starter: Spark Gap Adjustment

0.063" 0.002" 1.6 0.05 mm

Art # A-04857

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SECTION 5: MAINTENANCE
5.01 General Maintenance
Perform the following checks periodically to ensure proper system performance.
Power Supply Maintenance Schedule Daily Check coolant level; add coolant as needed. Check gas hose connections and pressures. Monthly Check cooling fan and radiator; clean as needed. Check gas hoses for cracks, leaks, or abrasion. Replace as needed. Check all electrical connections for cracks or abrasion. Replace as needed. Six Months Clean or replace external coolant filter. Clean coolant tank. Vacuum out any dust buildup inside power supply. Check internal coolant filter

5.02 External Coolant Filter Cleaning Procedure

Periodic cleaning of the coolant filter ensures maximum coolant flow efficiency. Poor coolant flow causes inefficient 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. Manual No. 0-4748 5-1 MAINTENANCE

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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 the right side panel (viewed from the front of unit) of the Power Supply. Remove the filter screen by unscrewing the filter holder from the In-Line Filter Assembly. Clean the filter screen by rinsing with hot soapy water. Remove soap residue by rinsing with clean hot water. Be sure that all the soap has been removed and the screen is dry of water before 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 coolant line 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 will run approximately for 20 seconds before the flow switch causes an interlock. This procedure may be repeated 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.

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COOLANT
RETURN SUPPLY

RETURN

SUPPLY

Fill Range

Coolant Tank

Art # A-04803

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

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SECTION 6: REPLACEMENT ASSEMBLIES & PARTS

6.01 Main Component / System Replacement
Complete Unit / Component Ultra-Cut 100 Power Supply, 208/230V Ultra-Cut 100 Power Supply, 460V Ultra-Cut 100 Power Supply, 400V Ultra-Cut 100 Power Supply, 400V (CE) Catalog Number 3-9116-1 3-9116-2 3-9116-3 3-9116-4

Gas Control Module (GCM-2010) with XTL Torch Valve Assembly (Requires Firmware version 3.2 or higher for C.C.M.) Gas Control Module (GCM-2010) Only Original Torch Valve Assembly Repair Part Only XTL Torch Valve Assembly Only (Requires C.C.M. Firmware version 3.2 or higher and GCM 2010 Firmware version 3.1 or higher) Remote Arc Starter (RAS-1000) OPTIONAL EQUIPMENT: Wheel Kit

3-9131 7-4000 4-3049 4-3054

3-9130

9-9379

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6.02 System Layout
Refer to section 3.05 for ground connections and ground cables.

175 / 53.3 m Maximum Length 125 / 38.1 m Maximum Length Pilot Return Negative Coolant Supply
Primary power

100 / 30.5 m Maximum Length A B C D E Remote Arc Starter Pilot Return Shield Coolant Supply Coolant Return Shield Plasma Gas Shield Gas

Power Supply

Coolant Return Control Cable

CNC

Fiber Optic Cable Control Cable

L Gas Control Module K

Plasma Gas Shield Gas Preflow Gas Control Cable Water Shield

H Q R S T Torch Valve Assembly

I J

Positioning Tube Torch

Work Work Cable

Art # A-07233_AB

175 / 53.3 m Maximum Length

6.03 Recommended Gas Supply Hose

Item # Qty 1 Description Catalog # 3/8Gray Synflex Hose. No fittings included. Catalog number per foot 9-3616

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6.04 Leads and Cables
#8 AWG Cable A #1 AWG Cable B Negative Lead, Power Supply to Arc Starter Green Red Coolant Supply Lead, Power Supply to Arc Starter Coolant Return Lead, Power Supply to Arc Starter Control Cable, Power Supply to Arc Starter
Art # A-07473

Pilot Return, Power Supply to Arc Starter

Green Red

14

Green / Yellow # 4 AWG Green / Yellow 1/0 (50 mm 2)

Ground Cable Ground Cable, Remote Arc Starter To Earth Ground Shielded Torch Lead Assembly, Remote Arc Starter to Torch Plasma Gas Lead, Torch Valve to Torch Shield Gas Lead, Torch Valve to Torch Control Cable, Power Supply to Gas Control Module Fiber Optic Cable, Power Supply to Gas Control Module

F1

37

H, Q, R, S,T O 1/0 Cable (1/0 (50 mm 2)

Work Cable

14

CNC Cable (14 Wire)

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Key A,B,C,D,E A,B,C,D,E A,B,C,D,E A,B,C,D,E A,B,C,D,E A,B,C,D,E A,B,C,D,E A,B,C,D,E A,B,C,D,E A A A A A A A A A B B B B B B B B B C C C C C C C C Description Supply Lead Set, 4 / 1.3 m (See Note 1) Supply Lead Set, 10 / 3.05 m (See Note 1) Supply Lead Set, 15 / 4.5 m (See Note 1) Supply Lead Set, 25 / 7.6 m (See Note 1) Supply Lead Set, 35 / 10.6 m (See Note 1) Supply Lead Set, 50 / 15.2 m (See Note 1) Supply Lead Set, 75 / 22.9 m (See Note 1) Supply Lead Set, 100 / 30.5 m (See Note 1) Supply Lead Set, 125' / 38.1 m (See Note 1) Pilot Return Cable (only), 4' / 1.2 m Pilot Return Cable (only), 10 / 3.05 m Pilot Return Cable (only), 15 / 4.5 m Pilot Return Cable (only), 25 / 7.6 m Pilot Return Cable (only), 35 / 10.6 m Pilot Return Cable (only), 50 / 15.2 m Pilot Return Cable (only), 75 /22.8 m Pilot Return Cable (only), 100 /30.5 m Pilot Return Cable (only), 125 /38.1m Negative Cable (only), 3 / 1 m Negative Cable (only), 10 / 3.05 m Negative Cable (only), 15 / 4.5 m Negative Cable (only), 25 / 7.6 m Negative Cable (only), 35 / 10.6 m Negative Cable (only), 50 / 15.2 m Negative Cable (only), 75 / 22.8 m Negative Cable (only), 100 / 30.5 m Negative Cable (only), 125 / 38.1 m Hose, Coolant Supply, (only), 3 / 1 m Hose, Coolant Supply, (only), 10 / 3.05 m Hose, Coolant Supply, (only), 15 / 4.6 m Hose, Coolant Supply, (only), 20 / 6 m Hose, Coolant Supply, (only), 25 / 7.6 m Hose, Coolant Supply, (only), 30 / 9.1 m Hose, Coolant Supply, (only), 35 / 10.6 m Hose, Coolant Supply, (only), 40 / 12 m Catalog # 4-3027 4-3028 4-3029 4-3030 4-3050 4-3031 4-3032 4-3033 4-3034 9-4890 9-4891 9-4790 9-4791 9-9426 9-4792 9-4793 9-4794 9-4796 9-4892 9-4897 9-4798 9-4799 9-9427 9-4800 9-4801 9-4802 9-4804 9-4886 9-4887 9-4780 9-4781 9-4782 9-4783 9-4784 9-4785

NOTE 1: Supply lead sets include Pilot Return Cable, Negative Cable, Coolant Supply & Return Hoses, and Control Cable. Power Supply Parts List 6-4 Manual No. 0-4748

ULTRA-CUT 100
Key C C C D D D D D D D D D D D E E E E E E E E F F F F F F F F F1 F1 F1 F1 F1 F1 F1 F1 Description Hose, Coolant Supply, (only), 50 / 15.2 m Hose, Coolant Supply, (only), 75 / 23 m Hose, Coolant Supply, (only), 100 / 30.5 m Hose, Coolant Return, (only), 3 / 1 m Hose, Coolant Return, (only), 10 / 3.05 m Hose, Coolant Return, (only), 15 / 4.6 m Hose, Coolant Return, (only), 20 / 6 m Hose, Coolant Return, (only), 25 / 7.6 m Hose, Coolant Return, (only), 30 / 9.1 m Hose, Coolant Return, (only), 35 / 10.6 m Hose, Coolant Return, (only), 40 / 12 m Hose, Coolant Return, (only), 50 / 15.2 m Hose, Coolant Return, (only), 75 / 23 m Hose, Coolant Return, (only), 100 / 30.5 m Control Cable (only), Power Supply to Arc Starter 3 / 1 m Control Cable (only), Power Supply to Arc Starter 10 / 3.05 m Control Cable (only), Power Supply to Arc Starter 15 / 4.5 m Control Cable (only), Power Supply to Arc Starter 25 / 7.6 m Control Cable (only), Power Supply to Arc Starter 50 / 15.2 m Control Cable (only), Power Supply to Arc Starter 75 / 22.9 m Control Cable (only), Power Supply to Arc Starter 100 / 30.5 m Control Cable (only), Power Supply to Arc Starter 125' / 38.1 m Ground Wire, Power Supply to Gas Control Module, 3' / 1 m Ground Wire, Power Supply to Gas Control Module, 15 / 4.5 m Ground Wire, Power Supply to Gas Control Module, 25 / 7.6 m Ground Wire, Power Supply to Gas Control Module, 50 / 15.2 m Ground Wire, Power Supply to Gas Control Module, 75 / 22.9 m Ground Wire, Power Supply to Gas Control Module, 100 / 30.5 m Ground Wire, Power Supply to Gas Control Module, 125' / 38.1 m Ground Wire, Power Supply to Gas Control Module, 150 / 45.7 m Ground Wire, Remote Arc Starter to Earth, 3' / 1 m Ground Wire, Remote Arc Starter to Earth, 15 / 4.5 m Ground Wire, Remote Arc Starter to Earth, 25 / 7.6 m Ground Wire, Remote Arc Starter to Earth, 50 / 15.2 m Ground Wire, Remote Arc Starter to Earth, 75 / 22.9 m Ground Wire, Remote Arc Starter to Earth, 100 / 30.5 m Ground Wire, Remote Arc Starter to Earth, 125' / 38.1 m Ground Wire, Remote Arc Starter to Earth, 150 / 45.7 m Catalog # 9-4786 9-4787 9-4788 9-4888 9-4889 9-4762 9-4763 9-4764 9-4765 9-4766 9-4767 9-4768 9-4769 9-4770 9-4941 9-4916 9-4917 9-4918 9-4942 9-4943 9-4944 9-4922 9-4923 9-4924 9-4925 9-4926 9-4927 9-4928 9-4929 9-4930 9-4931 9-4932 9-4933 9-4934 9-4935 9-4936 9-4937 9-4938

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Key G G G G G G G G G G H,Q,R,S,T H,Q,R,S,T H,Q,R,S,T H,Q,R,S,T H,Q,R,S,T H,Q,R,S,T H,Q,R,S,T H,Q,R,S,T H,Q,R,S,T H,Q,R,S,T I J L L L L L L L L L L Description Assembly, Torch Lead, 10 / 3.05 m Assembly, Torch Lead, 15 / 4.6 m Assembly, Torch Lead, 20 / 6 m Assembly, Torch Lead, 25 / 7.6 m Assembly, Torch Lead, 30 / 9.1 m Assembly, Torch Lead, 35 / 10.6 m Assembly, Torch Lead, 40 / 12 m Assembly, Torch Lead, 50 / 15.2 m Assembly, Torch Lead, 75 / 23 m Assembly, Torch Lead, 100 / 30.5 m Gas Lead Set, 10 / 3.05 m (See Note 2) Gas Lead Set, 15 / 4.5 m (See Note 2) Gas Lead Set, 25 / 7.6 m (See Note 2) Gas Lead Set, 35 / 10.6 m (See Note 2) Gas Lead Set, 50 / 15.2 m (See Note 2) Gas Lead Set, 75 / 22.9 m (See Note 2) Gas Lead Set, 100 / 30.5 m (See Note 2) Gas Lead Set, 125' / 38.1 m (See Note 2) Gas Lead Set, 150 / 45.7 m (See Note 2) Gas Lead Set, 175 / 53.3 m (See Note 2) Plasma Lead 4 / 1.22 m (Torch Valve Assembly to Torch) Shield Lead 4/ 1.22 m (Torch Valve Assembly to Torch) Control Cable, Fiber Optic, 3 / 1 m Control Cable, Fiber Optic, 15 / 4.5 m Control Cable, Fiber Optic, 25 / 7.6 m Control Cable, Fiber Optic, 35 / 10.6 m Control Cable, Fiber Optic, 50 / 15.2 m Control Cable, Fiber Optic, 75 / 22.9 m Control Cable, Fiber Optic, 100 / 30.5 m Control Cable, Fiber Optic, 125' / 38.1 m Control Cable, Fiber Optic, 150 / 45.7 m Control Cable, Fiber Optic, 175 / 53.3 m Catalog # 4-3053 4-3009 4-3010 4-3011 4-3012 4-3013 4-3014 4-3015 4-3016 4-3017 4-3035 4-3036 4-3037 4-3051 4-3038 4-3039 4-3040 4-3041 4-3042 4-3043 9-3333 9-3334 9-4898 9-4899 9-4900 9-9335 9-4901 9-4902 9-4903 9-4904 9-4905 9-4906

NOTE 2: Gas lead sets include Plasma Gas Hose, Shield Gas Hose, Preflow Gas Hose, and Control Cable. Power Supply Parts List 6-6 Manual No. 0-4748

ULTRA-CUT 100
Key K K K K K K K K K O O O O O O O O P P P P P Description Catalog # 9-4907 9-4908 9-4909 9-9332 9-4910 9-4911 9-4912 9-4913 9-4914 9-9300 9-9301 9-9302 9-9303 9-9304 9-9305 9-9306 9-9307 9-8312 9-8313 9-8315 9-8316 9-8317 Control Cable, Power Supply to Gas Control Module, 3 / 1 m Control Cable, Power Supply to Gas Control Module, 15 / 4.5 m Control Cable, Power Supply to Gas Control Module, 25 / 7.6 m Control Cable, Power Supply to Gas Control Module, 35 / 10.6 m Control Cable, Power Supply to Gas Control Module, 50 / 15.2 m Control Cable, Power Supply to Gas Control Module, 75 / 22.9 m Control Cable, Power Supply to Gas Control Module, 100 / 30.5 m Control Cable, Power Supply to Gas Control Module, 125' / 38.1 m Control Cable, Power Supply to Gas Control Module, 150 / 45.7 m Work Cable, 10 / 3.05 m Work Cable, 15 / 4.5 m Work Cable, 25 / 7.6 m Work Cable, 35' / 10.6 m Work Cable, 50 / 15.2 m Work Cable, 75 / 22.9 m Work Cable, 100 /30.5 m Work Cable, 125' / 38.1 m Control Cable, CNC to Power Supply, 25 / 7.6 m Control Cable, CNC to Power Supply, 50 / 15.2 m Control Cable, CNC to Power Supply, 75 / 22.9 m Control Cable, CNC to Power Supply, 100 / 30.5 m Control Cable, CNC to Power Supply, 125' / 38.1 m

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6.05 Power Supply External Replacement Parts
Item # 1 2 3 4 5 6 7 8 Qty 1 1 1 1 1 1 1 1 Description Power Supply Front Panel Power Supply Rear Panel Power Supply Top Panel Power Supply Right Side Panel Power Supply Left Side Panel Louver Panel Power Supply Connections Cover Lifting Eye Catalog # 9-0440 9-0441 9-0445 9-0442 9-0443 9-0444 9-0446 9-9373

8 3

1 7

4 5

Art # A-06888_AB

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6.06 Power Supply Replacement Parts - Right Side
Item # 1 2 Qty 1 1 Description Heat Exchanger Fan Radiator Ref. Des. FAN1 Catalog # 9-9338 9-9339

NOTE: Heat Exchanger Fan is the same fan used with the Inverter

2 1

Art # A-08308

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6.07 Power Supply Replacement Parts - Right Side
Item # 1 2 3 4 5 6 Qty 1 1 1 1 1 1 Description Output Filter PC Sensor Magnetic Contactor, pilot Resistor Resistor Capacitor Ref. Des. PCB8 HCT2 MC2 R6 R9 C2 Catalog # 9-9341 9-9368 9-9343 9-9340

4 5 6

Art # A-08309

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6.08 Power Supply Replacement Parts - Right Side
Item # Qty 1 1 Description Chopper Module Sensor HCT1 Ref. Des. Catalog # 9-9389 9-9342

Chopper Module

HCT1

Art # A-08311

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6.09 Power Supply Replacement Parts - Front Panel
Item # 7 Qty 1 Description Main Power Switch (Circuit Protector) for 230-400-460 VAC units Ref. Des. Catalog # CP1 9-9344

Art # A-08312

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6.10 Power Supply Replacement Parts - Front Panel
Item # Qty 1 1 1 1 Description PC Board PC Board 230/460VAC PC Board 600VAC Display PC Board Ref. Des. Catalog # PCB3 PCB4 PCB4 PCB6 9-9365 9-9370 9-9492 9-9347

PCB3

PCB4

PCB6

Art # A-08313

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6.11 Power Supply Replacement Parts - Right Side
Item # 1 1 2 Qty 1 1 1 Description PCBoard 230-400-460VAC PCBoard 600VAC Magnetic Contactor ONLY 1 for this unit Ref. Des. PCB1 PCB1 MC1 Catalog # 9-9362 9-9491 9-9364

Art # A-08314

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6.12 Power Supply Replacement Parts - Rear Panel
Item # 12 13 14 15 16 17 18 Qty 1 1 1 1 1 1 1 1 1 1 Description Circuit Breaker (RAS) Circuit Breaker (TDC) Circuit Breaker (AGC) Circuit Breaker (AGC) Circuit Breaker (AGC) Circuit Breaker (Fan) Coolant Tank Tank Cap Filter, Coolant Breaker Rating 125V, 2.5 A 125V, 3.15A 125V, 10A 125V, 2.5A 125V, 2.5A 125V, 3.15A Cicuit Rating 120VAC @ 1A 24VAC @ 2A 24VAC @ 5A 120VAC @ 1A 15VDC @ 1A 200VAC @ 3A 24VDC @ 1A Ref. Des. Catalog # CP2 CP3 CP4 CP5 CP6 CP7 CP8 9-9348 9-9349 9-9350 9-9348 9-9348 9-9351 9-9349 9-5948 8-5142 8-4276

Circuit Breaker (Pump) 250V, 10A

CIRCUIT BREAKERS

CP2 CP3 CP4 CP5 CP6 CP7 CP8

12 13 14 15 16
J15 C N C J55 G C M

RAS 125V 2.5A

CCM 125V3.15A

GCM 125V 10A

GCM 125V2.5A

GCM 125V2.5A

COOLANT
RETURN SUPPLY

17 18
J59 R A S

PUMP 250V 10A

Tank Cap

FAN 125V 3.15A

Art # A-06017_AC

Filter

Coolant Tank

Art # A-04932_AB

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6.13 Power Supply Replacement Parts - Right Side
Item # 1 2 3 4 5 Qty 1 1 1 1 1 Description Resistor Rectifier (Diode) Transformer for 230/460 VAC units Diode Terminal Strip Ref. Des. Catalog # R7 D1 T1 D2 TB3 9-9363 9-9345 9-9355 9-9486 N/A

3 2 4

5 1

Art # A-08310

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6.14 Power Supply Replacement Parts
Item # 29 Qty 2 2 2 2 Description Inverter Module 208/230V Inverter Module 400V CE and 400V Non CE Inverter Module 600V Inverter Cooling Fan Catalog # 9-9360D 9-9482D 9-9485D 9-9338

Not Shown:

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

Art # A-04786_AB

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6.15 Power Supply Replacement Parts - Right Side
Item # 30 Qty 1 Description Sensor (Thermistor) Ref. Des. Catalog # TH1 9-9361

30

Art # A-04787

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6.16 Power Supply Replacement Parts
Item # 1 2 3 Qty 1 1 1 Description Relay PC Board 24 VDC Power Supply Internal Control PC Board Ref. Des. Catalog # PCB7 N/A PCB5 9-9366 N/A 9-9346

3 2
Art # A-08315

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6.17 Power Supply Replacement Parts - Right Side
Item # 22 24 25 26 27 Qty 1 1 1 1 1 Description Sensor (Level Switch) Motor Pump/Check Valve/Bypass Valve Assembly Bypass Valve (part of assembly) Pump (part of assembly) F1 9-9359 Ref. Des. Catalog # LSW1 MOT1 9-9354 9-9381 9-9380

28 1 Sensor (Flow Indicator) Illustration is for Reference ONLY

28

25 22

24 26

27
Art # A-08236

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6.18 Gas Control Module (GCM-2010) Replacement Parts
Item # 1 2 3 4 5 6 7 8 9 10 11 12 13 14 NOT SHOWN: 1 1 1 1 1 Power Supply Connection Wire Harness (J3 & J5 to J56) LCD Interface PC Board Wire Harness Rotary Encoder (Switch) Wire Harness Solenoid Drive A Wire Harness (J12 to Solenoids 1-6) Solenoid Drive B Wire Harness (J1 to Solenoids 7-12) 9-9400 9-9401 9-9402 9-9404 9-9405 Qty 6 1 1 1 1 1 1 1 1 1 3 1 1 2 Description 7W Solenoid for O2 use Gas Selection Manifold Assembly Check Valve, 1/4 NPT .5 PSI Mode Switch Assembly Gas Selection Switch Assembly LCD Display Rotary Encoder (Switch) Toggle Switch Solenoid / Logic PC Board Cover Gauge, 0-160 psi Regulator Pressure Transducer and wire harness 100 PSI Pressure Transducer and wire harness 250 PSI Catalog # 9-9393 9-9391 9-9390 9-9406 9-9403 9-9408 9-9398 9-3426 9-9409 9-9410 8-6800 8-3223 9-9407 9-9508

12 12 7 8 11 11 6 5

11 13 4

12

9 10

14

8 1

1 14 3 3 3

1 2
Art # A-07030_AB

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6.19 Gas Control Module (GCM-2010) Replacement Parts
Item # 1 2 3 4 6 Qty 1 1 1 1 1 Description 1 Black Instrument Knob Water Flow Meter with Valve Toggle Switch, 2 position SPDT Pressure gauge, 2 diameter Flow Meter Not shown Valve Assembly Tube Knob 7 1 Protective Display Lens (only) 9-9382 9-9383 9-9384 9-9395 Catalog # 9-4233 9-7005 9-3426 8-6800 8-6801

RUN SET PREFLOW SET PLASMA & SHIELD TEST

O2 - AIR O2 - O2 H35 -N2 F5 - N2 AIR - AIR N2 - H2O N2 - N2 GAS

ENABLE

3
DISABLE

MODE

High Precision Plasma Cutting System

SHIELD

AMPERAGE SET-UP

PLASMA POWER SUPPL Y

PREFLOW

PLASMA

H 2O MIST

GCM 2010
6

PRESSURE GAS FLOW

6
Art # A-04814

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6.20 Remote Arc Starter (RAS-1000) Replacement Parts
Item # 1 2 3 4 5 6 7 8 Qty 1 1 1 1 1 1 1 1 Description Harness, Internal (Not Shown) Pilot Cap Assembly EMI Filter HF Water Cooled Coil Assembly HF Transformer Assembly, Arc Starter Enclosure, Arc Starter Base Spark Gap/Cap Assembly HF Ferrite Bead 2" Long Catalog # 9-4956 9-4960 9-1023 9-4958 9-4959 9-4961 9-4957 9-4965

To Torch Valve

3 4
Art # A-04898_AB

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6.21 Remote Arc Starter (RAS-1000) Replacement Parts
Item # 1 2 3 4 Qty 1 1 1 1 Description Retainer, ABS Wall (Outer) Torch Lead Ground Assembly Bracket, Bulkhead Holder Cover, Arc Starter Catalog # 9-4964 9-4955 9-4963 9-4962

Coolant Leads, from Power Supply

2
Art # A-04899

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6.22 Command & Control Module Type 2 - Replacement Parts
Item # 1 2 3 4 Qty 1 1 1 1 Description Assembly, CCM (Ultra-Cut) Plate, CCM Face Panel, CCM Mount Harness, CCM I/O Board Catalog # 9-9417 9-9419 Not Available 9-9421

2 3

Art # A-06867_AB

NOTE This page covers parts for Command & Control module without an external connections cover. See previous page for Command & Control module with an external connections cover. Manual No. 0-4748 6-25 Power Supply Parts List

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 for the GCM 2010. It also requires the resetting of DIP switches in the C.C.M.. Item # 1 2 3 4 5 6 7 8 9 Qty 1 1 1 1 3 1 1 1 1 Description Torch Valve Assembly Torch Valve Assembly Harness Plug, 14 Circuit Check Valve Check Valve 1/8 NPT STR.TEE Fitting Street Elbow (Bushing) Top Cover Front Cover Catalog # 4-3054 9-9413 9-3294 8-4512 9-7006 8-0352 8-3369 9-3324 9-3323

1 7 2 4 3

8 9 5

6
Art # A-07650

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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 for the GCM 2010. It also requires the resetting of DIP switches in the C.C.M.. Item # 1 2 3 Qty 1 2 3 Description Exhaust Muffler Solenoid Solenoid Catalog # 9-3321 9-3319 9-9392

SO

L19

SO L18

Art # A-07651

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Intentionally Blank

Power Supply Parts List

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SECTION 7.
7.01 Consumable Removal

TORCH MAINTENANCE

1. Use the Cartridge Tool to hold the Shield Cup & Cartridge Assembly stationary. Turn the Shield Cup to remove it from the Cartridge Assembly.

Cartridge Tool

Assembled Cartridge

Art # A-04344_AB

Shield Cup

2. Take the Cartridge Tool off the back of the Cartridge Assembly Use the Cartridge Tool to push the consumable parts out of the Cartridge.
Cartridge Tool Cartridge Assembly

Art # A-04345_AB

Manual 0-4748

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TORCH MAINTENANCE

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 periodically with O-Ring Lubricant supplied. Remove the snap ring on the cartridge assembly and slide the locking ring downward for access to the O-Ring under the locking ring.

O-Rings

Torch Head

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

Cat. No. 9-9041

O-Ring, Cat. No. 8-0544 O-Ring, Cat. No. 8-0540

Cat. No. 8-0539 Cat. No. 8-3487

Cartridge Assembly

Cat. No. 8-0530

Snap Ring
Art # A-04071_AB

Art # A-04066

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

TORCH MAINTENANCE

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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 Tip

Worn Tip

Good Electrode

Worn Electrode

Art # A-04745_AB

Manual 0-4748

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ULTRA-CUT 100
7.04 Torch Consumables Installation

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.
Art # A-03887

1. Install the consumables as follows:

1: Stack Parts

2: Press Cartridge onto Stacked Parts

Electrode

Plasma Gas Distributor

Upper O-Ring on Tip No Gaps Between Parts

Tip

Shield Gas Distributor Shield Cap

Cartridge Covers Upper O-Ring on Torch Tip

3: Thread Shield Cup onto Cartridge

4: Check Shield Cap Protrusion

Shield Cup

Shield Cap

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

Art # A-04716

TORCH MAINTENANCE

7-4

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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 on the torch head with a wire brush. Apply oxygen-compatible lubricant (supplied with the torch) to the threads.

Torch Head

Torch Head O-Ring

0.063 - 0.083" (1.6 - 2.1 mm) Protrusion

Art # A-07202

Installing Assembled Cartridge Onto Torch Head

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

Ohmic Clip

A-03393

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

Manual 0-4748

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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 or installed improperly. Operating the system in this condition can damage the torch head. Refer to the following chart for guidance on coolant leakage from the torch head.
Torch leaks

Are Torch Consumable Parts Installed?

No

Leaking from Coolant Supply or Coolant Return?

Return

Order Coolant Check Valve Kit 9-4846 Order Coolant Tube Replacement Kit

Yes

Supply

The parts probably are worn out. See chart for approximate life expectancy. Are Parts New or Used? Used The torch may be damaged. See page to determine if head damage has occurred.

New

Are Parts fully assembled into the Torch?

Yes

Is the Torch Damaged?

No

Remove and Lubricate all O-rings on Torch Head, Consumables Cartridge, and Consumables. Re-assemble Torch. Still leaks?

Unsure? Yes Yes Disassembly fully and re-assemble the Torch Properly. See Installation Manual.

Replace Torch Head

Yes

Replace Consumable Cartridge and Shield Cup. Torch still leaks?

Amperage Plasma Gas

30 50 70 100 Torch Electrodes

O2 Air O2 Air O2 Air O2 H35

Recommended Wear Depth for Replacement Inch mm 0.04 1 0.04 2 0.04 1 0.08 2 0.04 1 0.08 2 0.04 1 0.08 2
Art # A-04704_AB

TORCH MAINTENANCE

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Manual 0-4748
4 3 2 1

POWER SUPPLY ARC STARTER

8X291

C1
D

Jumper in Cable to ID Arc Starter Connected

1900 pf C2

J59 --RAS T1 Assembly

8X290
3
<Part Number> T1 11X16 R1 6.8K 1W

J58
1900 pf C3

CHASSIS GND

Water Cooled Inductor NEG & HF (to Torch)

L1
C4 0.1 uf 1000VDC PILOT PLT

TORCH LEAD INNER SHIELD

TORCH

120 VAC
Line1
1

Load1 1900 pf
R2 6.8K 1W

120 VAC RET

2

GND Line2
4
<Part Number>

Load2 GAP1 NEG NEG (from PS) 0.1 uf 1000VDC C6 SPARK GAP 0.060"

PILOT RETURN (from torch) WORK

SHLD

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

Line Filter 1ph

14 PIN

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
C5

16 PIN

C7

0.047 uf 1000VDC

0.047 uf 1000VDC

APPENDIX 1: Remote Arc Starter Schematic

A-1
NEG (from PS)
Rev Revisions

NEG

CGND

PILOT

CHASSIS GND

WORK
A

By
TPM

Date
8/26/05

PCB No: Assy No: References

AA AB

Initial Release ECO 101810

RS

11/01/05

THERMAL DYNAMICS INDUSTRIAL PARK #2 WEST LEBANON, NH 03784 (603) 298-5711

Scale 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).

Supersedes Drawn: Chk: TITLE: Last Modified: Tuesday, November 01, 2005 14:47:17 Date: DAT 9-21-04 App: Sheet 1 of 1 DWG No:

SCHEMATIC, RAS-1000 ARC STARTER

3 2

Size

42X1191 Art # A-06896_AB

1

ULTRA-CUT 100

APPENDIX

ULTRA-CUT 100

APPENDIX 2: Gas Control and Torch Valve Schematic

5 4 3

ULTRACUT
D

GCM 2010 GAS CONTROL

SW3 MODE A 1 2 3 4 RUN SET PREFLOW SET CUTFLOW TEST

SW2 GAS A 1 2 3 4 5 6 7 O2 - AIR O2 - O2 H35 - N2 F5 - N2 AIR - AIR N2 - H2O N2 - N2

ENCODER w/SW

(10)

BA
To CCM

J16
1 2 3 4 5 6

(13) (1) FIBEROPTIC (3) (4) (5) (6) (7) (8) (9) (14) (15)
(62) (63) (64) (65) (66) (67) 1 2 3 4 5 6 7 8 9 1 2 3 4 5

J11

10

J7

10 PIN

5 PIN

J10

1 2 3 4 5 6

ENCODER

PLASMA ENABLE
2

SW6

1 3

DISABLE (50) ENABLE

J5
1

U36 U35

+5VDC

(51)

2 3 4 PLASMA ENABLE + 4 5 2 1 D25 GREEN

SHIELD FLOW / PRESSURE2

SW7

1 3

(52) FLOW PRESSURE (53) (54) (55)

J9
1 2 3 4 5 6 IN-CIRCUIT SERIAL PROGRAMMING

5 6 7 8 9 10 11

POWER SUPPLY

J55 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37

J56 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 PLASMA ENABLE + PLASMA ENABLE -

F20 1A

FERRITE CORE

(56) (57)

12 13 14

E-STOP
24 VAC

E-STOP + E-STOP 24 VAC 24 VAC RET

(58) (58) (59)

15 16 16 PIN

D13
GREEN

+15 VDC 15 VDC RET 24 VAC RET

Safety Gnd (low freq)

F18 1A

E-STOP

120 VAC to SOLENOIDS

4 5

Shield

J3
120 VAC 120 VAC RET (60) 120 VAC 1 2 (61) 3

120 VAC 120 VAC RET

F19 1A

F1 F2 F3 F4 F5 F6 F7 F8 F9 F10 F11 F12 F13 F14 F15 F16 F17 F18 F19 F20

0.125A 0.125A 0.125A 0.125A 0.125A 0.125A 0.125A 0.125A 0.125A 0.125A 0.125A 0.125A 0.125A 0.250A 0.250A 0.125A 0.125A 1A ( 1A ( 1A (

SOL1 SOL2 SOL3 SOL4 SOL5 SOL6 SOL7 SOL8 SOL9 SOL10 SOL11 SOL12 SOL13 SOL14 * SOL15 * SOL16 SOL17 120 VAC to Solenoids) 120 VAC to Low Voltage Power Supply) to E-Stop Relay)

2 -

120 VAC to BOARD POWER

* 19X2219_AG and earlier F14 & 15 are 0.125A

RF Gnd (Shield)

10

11

12

13 14 15 16 17 18 19 20

10

11

12

(16) SOL1

(17) SOL3

(18)

(19) SOL5

(20)

(21) SOL7

(28)

(29) SOL9

(30)

(31) SOL11

(32)

(33)

SOL2

SOL4

SOL6

SOL8

SOL10

SOL12

(22) (23) (24) (25) (26) (27)

(34) (35) (36) (37) (38) (39)

18 PIN

SOLENOID LOCATIONS
SOLENOID MANIFOLD
A

(from rear)

PS3

PLASMA <

1 AIR
PS4

2 N2 9 N2 7 N2

3 O2 10 O2 4 H35 5 F5
4

FRONT PANEL (rear) 13

Shield Flow

SHIELD <

8 AIR 6 AIR

PREFLOW <

17
H2O Shield

12
Shield Press

11
Plasma Precharge / Bypass

Art # A-07200

APPENDIX

A-2

Manual 0-4748

13 14 15 16 17 18

J12

J1

ULTRA-CUT 100

LCD Display Assembly

LCD DISPLAY

19X2220
D

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

INTERFACE BOARD

PS1 Plasma Outlet Pressure

11

13

15

17

19

21

23

25

27

29

31

34 DUAL RIBBON HEADER

10 12

33

14

16

18

20

22

24

26

28

30

32

J1
RIBBON CABLE

{
10 12 14 16 18 20 22 24 26 28 30 32 34

34

3
2 4 6 8

J8

11

13

15

17

19

21

23

25

27

29

31

33

34 DUAL RIBBON HEADER

1 3 5 7 9

JP1
+5VDC

J6
18 17 16 15 +5VDC 14 13 12 LCD DISPLAY CONNECTOR

CURRENT CONTROL (Thumbwheel) optional

11 10 9
C

SW1 1 2 4 3

8 7 6 5 4 3 2 1 18 PIN +5VDC 1

BOTH SECTIONS ON FOR OPERATION OFF ONLY FOR PROGRAMMING

PS3 Plasma Inlet Pressure

JP3
1 2 3 4 2 4

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

1 +5VDC

PS4 Shield Inlet Pressure

JP4
1 2 3 4 3
B

J13

ULTRACUT TORCH VALVE ASSEMBLY (TVA or TVA-XTL) J57 J60

SOL16 TVA SHIELD 1 (41) 2 3 4 5 1 2 3 4 SOL14 TVA PLASMA CUTFLOW 5 SOL18 * (40)

10

11

(46) SOL13 (42) (44) (40) (47) SOL17 (49) (40) (48) (42)

12 13 14 15 16

FERRITE CORE

PLASMA EXAUST 1 Normally Open

(43) 6 7 (44) 8 6 7 SOL15 TVA PLASMA PREFLOW 8 SOL19 *

PLASMA EXAUST 2 Normally Open

(45) 18 PIN 9 10 11 12 13 14 9 10 11 12 13 14

Safety Gnd (low freq)

RF Gnd (Shield)

Additional Solenoids used in TVA-XTL

Vent

TVA-XTL TVA

18
Plasma

19
A

14
Plasma Plasma

14
Plasma
Rev Revisions By Date

Preflow

15
Shield Preflow

15
Shield

AA ECO-B214 AB ECO-B367

DAT 07/26/06 RWH 01/29/07

<OrgName> <OrgAddr1> <OrgAddr2> <OrgAddr3> 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). TITLE:

PCB No: Assy No: Scale Date: Wednesday, January 26, 2005 Drawn: DAT Chk: Size App: 1 DWG No: References Sheet of 1 Supersedes

Gas Shield H2O Shield

16
Gas Shield H2O Shield

16
Last Modified: Monday, January 29, 2007 13:57:13
2

SCHEMATIC, Ultracut GCM 2010 Gas Control & TVA

1

42X1202

Art # A-07200

Manual 0-4748

A-3

APPENDIX

ULTRA-CUT 100

APPENDIX 3: Gas Control Module Plumbing Diagram

SOL5 F5 SOL4 H35

New Plasma Inlet Pressure Sensor

SOL11

TVA & XTL-TVA Atmosphere

PLASMA

SOL19 SOL18

SOL1

SOL2

SOL3 SOL6

Pressure Sensor

SOL14 PLASMA SOL15 SHIELD

AIR N2 O2 SOL7 SOL12 SOL8 SOL9 SOL10

PREFLOW

SOL16

SOL 18 & 19 in XTL-TVA only. SOL13

SHIELD GAS MANIFOLD

New Shield Inlet Pressure Sensor H2O WATER

SOL17

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

Art # A-07577_AB

APPENDIX

A-4

Manual 0-4748

ULTRA-CUT 100

APPENDIX 4: Gas Control Module PCB Layout

F10 F12 F11 F8 F9 J1 F17 F7 F15 F16 J13 J13 F13 F14

J3

F19 F18

TP4 J12 F5 TP3 TP2 F3 F1

F2 F4 F6 TP7 F20 J5 JP1 TP5 TP6 TP8 TP9 TP10

TP1

Art # A-07621

TP11 J6 J7

TP12 J11

TP13

TP15 TP14 TP16

TP19

J8 TP18

J10

Manual 0-4748

A-5

APPENDIX

ULTRA-CUT 100

APPENDIX 5: Gas Control Display Interface PCB Layout

J1

70

2 1
D1 D16 D3 D17 D4 D18 D5

J1
D19

34 33
D6 D20 D7 D21 D8 D22 D9 D23 D10

+
C1 D11 D24 D25

C2 R24 D12 D26 R10 R13 R11 R12 D13

69

D14 D2 D15 R23

72

R1 R22

R2 R21

R3 R20
AB

R4 R19

R5 R18

R6 R17

R7 R16

R8 R15

R9 R14

19X2220 REV LCD INTERFACE TDC C 2005

16 1
68
Art # A-06904

APPENDIX

A-6

Manual 0-4748

ULTRA-CUT 100

APPENDIX 6: CCM CPU PCB Layout

Note: Switch Settings May Vary.

AUTO PILOT SW1

O N

PRE FLOW SW3

POST FLOW SW4

FUNC SW5

SYS CONT SW8

OK TO MOVE/D SW9
O N

1
1 2

1 2 3 4

1 2

1 2

1 2 3 4
CPU/COMMUNICATIONS
SYS CONT SW8 OK TO MOVE/D SW9

C1 H2

R1 R7 R10

R2 U6 R3 U7

R4

R5

R6 R8

U5 Switches

R9

1 C3 1 R19 R25 TP1 GND R20 R26 R27 AUTO PILOT SW1

C2 + 1 2 R17

R13

R14

R15

R11

R18 C5

R12

R21

R22

C4

PRE FLOW SW3

POST FLOW SW4

R23

J2
J2

R24

R16

FUNC SW5

TP3 +5.0V

R29

C 2004 TDC 19X2169 REV

R28

AC

TP1
29 C7 30 C8 R33 R34 R38 R41 GP1 1 2

C6

1 2 3 4

1 2

1 2

1 2

1 2 3 4

R31 D1 R32 R35 D3 D6 D4 D5 D7 D9 D10 C12 C19 C18 D8 D2 44 U4 23 R36 TP4 /WR R40 TP6 TEMP SENSE U10 1 R39 22 R42 C16 C15 L1 C20 80 R49 C23 R45 TP7 /RD Y1 1 U8 H6

1 2

R30

1 2
H3

H5

R37

TP3

TP4
U9 C10 C11 R46

C9

1
R44

R43

C13 C14

TP7

C17

TP6
R51 R52 R53
J3

J4

120

R47

1
U13

U11

R48

R56

R57

1 R50

C21

C22 R55

R54 C25

R61

R62

R63

R60

29 C31 + C34 GP2

30

D11

C28 R64 C32 160 R67 1 U14 C35

R65 R66 C33

C29

J3

R69

40

R68

R70

R75

U18 R74 1

1 U20

1 U19

U16

D12 TPAD1 NC

C30

R58

R59

C27

C24
U15

+
U12 C36 R71 +3.3VA TP5 C38 U17

TP5

R78

R76

R83

R85

R88

R86 R90 L5 C49 + U27 C55 J1 1 6 9 5 +

C44 C51 C56 U32 L6 C52 U28 R92 U29 R93 +15V -15V DAC DAC +3.3V TP9 TP10 TP11

U26 R91

C48

C47

R89 R C J5

C50

C53

C54

U31

C26

C58

C57

C59

R94

U30

D15

Art # A-06906

J1 TP8 TP9 TP10 TP11

Manual 0-4748

A-7

H1

+ 1 U23

C43

R87 C46

R84

TP2 AGND C45

R79

R80

R81

R82

C41

C42

L3

L4

U22

TP8 CLKO

U21

R77

C37 L2

D14

C39

R73

C40

D13

R72

U25

U24

TP2

H4

APPENDIX

ULTRA-CUT 100

APPENDIX 7: CCM Input / Output PCB Layout

TP11 J1 TB1 TB2 J4 J9 J2
J5 1 1 TB1 J1 H2 1 TB2 J4 1 R7 R11 DC VOLTS K4-OK D3 R15 R14 J9 R8 TP11 ARC V1 K6 2 J2 C6 1 2 C8 R12 R13 R2 R224 PILOT V TP12 R4 R3 R9 C3 1

TP12 J5 J6
J6

SW11 J7
SW11 B D1 D2
J7

TP9 J8
J8

1 R225 1 U1 R5 R10 1

C2 R223

L2 C1

TP9 CC POT 1

R1

R6

H6

GAS ON E-STOP_PS

C4
U3 C5

H3

U2

R29 R16

R19 R20 R21

OK TO MOVE SELECT

OK CNC

R227

R30 1

K3-E-STOP CNC

D4

R154

R32

R228

D6

R33

R226

D9 K2-START D15

C29

R40

+
L1

C27

29 30
R41

C21

J36

R152

D11

C20

U7 C30

R42

CONTACTS D14

Q2

C16 C17 C18

C22 C23

C24 C25

C26

K1-PSR

D12 D8

C13

R34 C14 R35 R36

Q3

C15

D10

C11

C12

R31

K5-E-STOP

U5 U6

1 R37

D13 R39

R47

K7-GAS ON

SW6

D7

R18

R24 R25 R26 R27 R28

R22 R23

SW6

C7

C10 R17

C9

D5

U4

R52

C28

D17

R62

R43 PSR C31 R56 R58 C33 R59 R72 R80

R60
H10

R64 R48

D16

R51

R53

R54

R55

J36

H7

R38 D18 R57

H8

R44 R45 C19 R46

R49 R50 R68

R69

C36

U8 R74

R67

R66

C32

D19 1 2 PILOT DEMAND TP14 34 CUT DEMAND R105 33 R77 R81 R85 J3 R90 C47 C48 30 C41

R61

R63

R65

1 R78 C37 R87 C42 C39

R70

R71

H9

R73 R79 R82 R88 R93 R100 R109 R114

D20

C34

D21 1 U11

C35

R75

R76 R86 R91 R97 R92 C38

U10 1 U12 C54 R107

TP14

D22

R83

C40 C45 C56

CNC_E-STOP D23 CNC_START D26

U9 R84
R89

+
R102 R104 R103

D24
R94

R96

C43
R98 1 R99 R108

C TDC 2005 19X2174 REV AD+

C44
C55
R113 R121 C63

D25

D27

HOLD_START D28

C52

R101
C57 D29

R106

C51

C46 1 U15

U13

R95

TP13

C49

C53

C50

ALL SW OFF FOR 50:1 (DEFAULT) SW12-1 ON FOR 16.7:1 (SC-11) SW12-2 ON FOR 30:1 SW12-3 ON FOR 40:1 SW12-4 SPARE R128 C64 R129

R116

R118 R119

R123

C65

R124

R126

R122

26 25
H11

C62

U17

1 R127

R132 C69

U18

R136 C73

R131 D31

R134

SW12 TP7 TP6

U19

C78 R135

C72

C70 C74 TP5 -15V TP3 +15V

TP1 GND

C68

C71 R133

D61

R130

D60

1 + +

R125
1

J35 2

C61

CNC PREFLOW

TP4 R110 +5V

C58

D30 1

U16 R111

+ C59

29

R112

U14 C60 R120

R115

R117

+
C67

C66

+
C75

SW12

C77

C86

4 3

C76

2 1

TP7

SW13

1 R141 D40

R142

ISOLATED TP6 H1 +15V GND TP10

R157 R156 R155 R158 C84

TP2 +29-41 VDC

Q1

D32 C81 R139 R140

D33

C82

+
C87

+ C79
+ C83 D34 D35 C88 C91 C89

C80

R138 C85 C93

C90 D36

U20 U21 1

U22

+
D37 R151

U23

R144 U24

T1

+ +
-15V +18V TP8 C95

C92

C94

R146 R143 R150 R145 R147

D38

R149

D39 1 H5

H4

R148

1 2

J35 TP10 TP8 TP4 TP3 TP2 SW13 TP5 TP1 TP13

J3

Art # A-06901

APPENDIX

A-8

Manual 0-4748

ULTRA-CUT 100

These points are jumpered together at the factory. TB1-1 E-Stop (Com) Remove the jumper to use existing E-Stop circuits. TB1-2 E-Stop TB1-3 OK 2 Contacts 24V Max TB1-4 Stop Latched TB1-5 Start / Stop Ret TB1-6 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 POT TB1-12 OK 2 Contacts 24V Max

TB1 TB2
Art # A-04900_AC

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

TB3-1 TB3-2

Marking Input

Start / Stop Circuit Configurations TB1-5 TB1-6 Stop TB1-4 Start TB1-5 TB1-6 Momentary Start / Stop Sustained Start / Stop

TB3

Manual 0-4748

A-9

APPENDIX

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 common to 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 also connected 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)
1 1 1

1 3 (+); 4 (-) 12(-); 14 (+) 5 (-); 6 (+) 7 (-); 9 (+)

Start/Stop Ok to Move (contacts or voltage ) Divided Arc volts (selectable

2

ratio 50:1; 40:1; 30:1; 16.6:1) Arc Volts (w/100K series res)
1

Analog Current Control (0-10V)

10 (-); 11 (+) 8 13

Isolated Circuit Comm (for SC-11) Chassis Gnd

1 2

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

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

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 functions plus 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 CCM module. User shall provide strain relief / cord grip for user installed cable. Function E-Stop OK To Move 2 (Contact)5 Stop Latched (NC) 4 Start/Stop Ret 4 Start /Stop or Start Latched (NO) 4 Divided Arc Voltage Remote Analog Current Control (0-10V) +10V @ 10ma For Remote CC POT5 Hold Start Preflow On Pilot On (Relay Contacts NO) Connection TB1-1 (comm.) & TB1-2 TB1-3: TB1-12 TB1-4 TB1-5 (comm.) TB1-6 TB1-7(-); TB1- 8(+) TB1-9(-); TB1-10(+) TB1-11 TB2-1(-); TB2-2(+) TB2-3(-); TB2-4(+) TB2-6; TB2-8

APPENDIX

A-10

Manual 0-4748

ULTRA-CUT 100
Function OK to Move (Contacts or DC Volts) Plasma Marking Remote Select Connection TB2-10(-); TB2-12(+) 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 between TB1-1&2 must be removing when connecting user supplied E-Stop circuit.
4

Start/Stop inputSwitch (momentary or sustained) rating 35ma. @ 20 VDC

Start / Stop circuit configurations. Momentary Start / Stop (Latched) is only available at TB1.
SUSTAINED START / STOP START / STOP TB1-5 TB1-6 START MOMENTARY STOP START / STOP TB1-4 TB1-5 TB1-6

Divided Arc Voltage output Arc Voltage signal is isolated from plasma supply, however (-) is common with other isolated CNC signals. Max Divided Arc Voltage signal level depends on actual arc voltage times divide ratio however can not exceed approximately 12 V.
3

Analog Current Control input Analog Current Control includes analog isolation module, separate isolation module not usually required however its low input is common with the other isolated CNC inputs. Scaling of Analog Current Control input is 0V = 0A, 10V. = MAX output and is linear in between. However MIN output is 10A. User is responsible for setting correct analog voltage to maintain at least 10A output. To use Analog Current Control on the I/O PCB set SW 11 to down position and on the CPU PCB set SW8-2 ON (up). Hold Start inputNormally open, close to hold start. Circuit rating 10 ma. @ 20VDC. Delays pilot ignition, gas preflow continues. Used for synchronizing starts when multiple plasma supplies are used on same cutting table. User supplies 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 been found. Then the plasma takes 1-2 seconds (or more) to perform preflow before igniting pilot. Some THCs have an output 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 parallel with Ok to Move contacts to start machine motion when pilot established. Used when starting over holes. Starting over holes requires setting SW8-1 ON (up) on the CPU PCB for extended pilot time. Using extended pilot time to start over holes 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 start X-Y motion. Relay contacts rated 1A @ 120 VAC or 28 VDC when SW6 set for contacts. When SW6 is set for DCV, output supplies 15-18 VDC @ 100 ma. May be wired parallel with Pilot On to start cutting machine motion as soon as pilot established.

The following features are available in Ultracut CCM revision level BA and higher or S/N 05517201 and higher.

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

Manual 0-4748

A-11

APPENDIX

ULTRA-CUT 100
5

+10V @ 10ma. For Remote CC Pot Previously CCM versions if one wanted to use a potentiometer for the Remote Analog Current Control (CC) input an external 10 V supply was required for Pot High.. Now an isolated (from main plasma circuits) 10V supply is provided. Recommended value of the pot is 5K or 10K.
Ext. +10V TB1 11 +10V 10 WIPER 9
Art # A-09246
5

Plasma Marking Select (Remote) Plasma Marking, available only with DFC 3000, may be activated with a contact closure 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 supplies It is OK to leave SW8-4 on whether you are marking or not.

APPENDIX

A-12

Manual 0-4748

ULTRA-CUT 100
Simplified CNC Circuit.

CCM Module
SUSTAINED START / STOP START / STOP TB1-5 TB1-6
E-STOP Ret (-) E-STOP input (+) STOP (NC) START/STOP Ret (-) START/STOP OR START LATCH (+) DIVIDED ARC V (-) DIVIDED ARC V (+) Remote Analog Current Control ret (-) Remote Analog Current Control input (+)

TB1
1 2 3 4 5 6 7 8 9 10 11 12 Active LOW Logic Input Active LOW Logic Input Active LOW Logic Input U37A LT1013 7 SW11 3 1 2
1 2 3

6 + 2

ALL SW OFF for 50:1 (default) SW12-1 ON = 16.7:1 (SC-11) SW12-2 ON = 30:1 SW12-3 ON = 40:1 SW12-4 ON = 8 1
5 SW12-4 4 SW12-1 SW12-2 7 SW12-3 6

MOMENTARY START / STOP STOP TB1-4 TB1-5 START TB1-6

To CPU PCB Analog Input

TB2
HOLD START (-) HOLD START (+) PREFLOW ON (-) PREFLOW ON (+) PILOT ON output (Contacts) OK TO MOVE output (contacts or DC Volts) OK to MOVE (-) OK to MOVE (+) 1 2 3 4 5 6 7 8 9 10 11 12 Active LOW Logic Input Active LOW Logic Input SW6 PSR 1 2 3 4 5 OK to Move 6 +16 to 18 VDC (isolated) Input Circuit Common (isolated)

J4
ARC V_100K (+) ARC V_100K (-)

100K ARC V (+) 100K ARC V (-)

J15
1 2 3 4 5 6 7 8 9 10 11 12 13 14

OK to MOVE (-) OK to MOVE (+)

1 2 3 4 5 6 7

J15 CNC 14 pin CPC rear panel

J1
Remote Analog Current Control (-) START / STOP (+) START / STOP (-) Remote Analog Current Control (+) Divided Arc V (-) SC 11 Comm Ref Divided Arc V (+) 1 2 3 4 5 6 7 8 9

1K

Art # A-07327_AB

Manual 0-4748

A-13

APPENDIX

ULTRA-CUT 100
CNC Connections.

Cutting Machine

CNC Cable J15 * (1) ( 2) (3) 1 2 3 4 5 6 7 8 (9) ( ) 10 (11) (12) 9 10 11 12 13 * (14) Shield
**

Power Supply

* NC .......... Source, 16 VDC, 10 ma.

START/STOP

(4) ( 5) (6) ( 7)

... Divided Arc V (-) .......... .......... Divided Arc V (+) Arc V (-) through 100K ***

.......... ... ..........

Arc V (+) through 100K *** Remote Analog Current Control (-) Remote Analog Current Control (+) OK-To-Move Relay DCV (-) Contact or (1A @ DCV (+) 120 VAC ( 15 - 18 VDC @ or 28 VDC) up to 100 ma.)

Start Motion (OK-To-Move)

14

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.

A-07632

**

*** Used only for special Torch Height Control

APPENDIX

A-14

Manual 0-4748

ULTRA-CUT 100

This Page Intentionally Blank

Manual 0-4748

A-15

APPENDIX

ULTRA-CUT 100

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

1 2 3 4 5

100A INVERTER MODULE

4 3 2

N (-)

3 Phase

INRUSH TB1 MC1-A L1

--230-1 2 4 + 4 3
2 3

CN1-230V

P1 TB2
--460--

+ 1

208-230/460 VAC

MC1-B L2

1 2 3

V_CHANGE PCB

--230--

MC1-C L3

TB3 TB4 N2

2 4 + 1

P (+)

3
2

CN4 - PCB12 CN2-460V

1 2 3 1 2 3

ON / OFF
460 COM PGND1 / 230

C.P1

230

CN6 16 CKT
PGND2 / 460

CN1

LINE to LINE, LINE TO GND CAPS & VARISTORS

NE1

CN3
1 4

PCB 1 WK-5630 FILTER PCB

RIBBON CABLE SIGNALS CN6 - 16 Ckt Ribbon Cable 2,4- I_REF (Scaled Cut Demand) 5- PS_START (Start) 6- REDUNDANT_START (Start2) 8- INV_READY 9- / PS_START disabled by Input_NG 12- / OCR 13- / PS_START disabled by OCR 14- /TEMP_ERR 15- / PS_START disabled by Temp _Err

TB1
4 1

NE2

INPUT POWER INDICATOR INTERNAL

CN4

CN2

VAC_IN

P_GND

INPUT POWER INDICATOR REAR PANEL

CN1
7 6 5

PCB3

WK-5694

BIAS SUPPLY PCB

D1
AC AC +

4 3

C1
-

2 1

AC

CN2
1

D
/ 460

VAC_IN P_GND

2 3

CN2

CN4

CN4 CN1

CN5 CN5

CN6 CN6

BIAS SUPPLY FOR PCB5 CN32 CN18

1 2 3 4

DC FAN POWER
1 2 3

+12VDC RY2

RY2

DETECTOR PCB
230V
+12VDC +12VDC

RY2

CN10

CN3

CN7

(F2 -Sht2)
GND +5V +15V

E
MISSING_PHASE

INPUT_NG

+15V

+15V

CN7
+15V

CN32

MISSING PHASE (pulses)<

CN6

LED2
MISSING PHASE

LED3
INPUT NG

PCB 5 WK-5602 (partial)

INTERFACE PCB
Art # A-06992_AD
1 2 3 4

LED1 LED2 LED3 LED4 LED5

DIM DIM DIM OFF OFF

= = = = =

LOW, BRIGHT = OK OK, BRIGHT = FAULT OK, BRIGHT = FAULT OK, ON = FAULT OK, ON + FAULT

APPENDIX

A-16

16 CKT

-15V

RIBBON CABLE

PCB4

WK-5604
FAN + (24 VDC) FAN - (24 VDC)

16 CKT

LED5
ERROR

To T1 PRI - 0 (A1 Sht2)

To PCB7 TB3 (A1 Sht2)

To PCB7 CN2-2 (A1 Sht 2) To PCB7 CN2-1 (A1 Sht 2)

To PCB7 CN2-4 (A2 Sht 2)

To PCB7 CN2-5 (A2 Sht 2)

Manual 0-4748

ULTRA-CUT 100

9
NEG ARC VOLTS
(C7 & A9, Sht 2) TB2 TB3 TORCH (-) Power Supply Rear Panel

10

RAS

CN1 R6 20K 30W

1 2 3 4

N2

P1

PCB 8 WK-5687
RC & RF CAPS CN2 CN3

TB1

C2 2 UF R9 50
WORK

PILOT REGULATOR (CHOPPER)

1 2 3

CN5

4 3 2 1

CN1 TB2
2 1

BIAS POWER

TB5

TB1

+12V -12V SIGNAL COMMON

PILOT REG. (CHOPPER ) PCB1 WK-5750

TB4
THS1 SW_TEMP_NC

FAN3 HCT1
HALL SENSOR
1 2 3 4

PILOT

PILOT (TIP) VOLTS

(C7, Sht 2)

CN3

CN4

CN2

B
4 2

2 1

5 4 3 2 1

3 2 1

D2

K2

CN8

CN7

CN9

> P_Enable (P_ena)

> P_DEM (P_Iref)

< /OVER_TEMP

I_DET

I_SE

PILOT REG. (CHOPPER ) PCB2 WK-5754

CN4

CN1
1 2 3 4

CN2

CN5

1 2 3

1 2 3 4

< <

TEMP_C

GND_C

I_senseP GNDP

P_ena

Iref_G

P_ref

MC2-A

MC2-B

MC2-C

A1

CN6

2 1

5 4 3 2 1

3 2 1

1 2

A2

K1

C
HCT2
HALL SENSOR
1 2 3 4

WORK (+)

WORK
+15Vw -15Vw Isense_W GNDW

(C7 & A9, Sht 2)

COMPONENT LOCATOR
C1 C2 C.P1 C.P2 C.P3 C.P4 C.P5 C.P6 C.P7 C.P8 D1 D2 FAN1 FAN3 FL1 Capacitor, 0.1 uf, 1250 VDC Capacitor, 2 uf, 430VAC Circuit protector/ON-OFF SW 15A, 460V, 3P Circuit protector 2.5A 125V Circuit protector 3.15A 125V Circuit protector 10A 125V Circuit protector 2.5A 125V Circuit protector 2.5A 125V Circuit protector 5A 125V Circuit protector 3.15A 125V Diode Bridge 20A, 1600V, 3P Diode, Dual, 2x100A, 600V Fan, Coolant, 24 VDC Fan, Chopper, 24 VDC Flow sensor (D2, Sht 2) (A9, Sht 1) (B2, Sht 1) (D2, (D2, (E2, (E2, (F2, (E2, (F3, Sht Sht Sht Sht Sht Sht Sht 1) 1) 1) 1) 1) 1) 1) HCT1 HCT2 Hall Current Sensor, Pilot Hall Current Sensor, Work (B8, Sht 1) (C9, Sht 1) (B5, Sht 2) (B3, (A2, (B3, (B3, (C8, Sht B2, Sht Sht Sht 2) Sht 1) 2) 2) 1)

LSW1 Level SW, coolant, NC MC1 MC2 Contactor, 3P ,Inv 1 input, Coil " Contacts " Aux Contact Contactor, pilot, Coil " Contacts

MOT1 Motor, Pump 200VAC, 1P NE1 NE2 R6 R7 R9 T1 TH1 Neon indicator, rear panel, 220VAC Neon indicator, internal, 220VAC Resistor, 20K ,30W Resistor, 1K ,30W Resistor, 50 ,40W Aux Transformer Thermal Sensor, coolant return

(E4, Sht 2) (C1, Sht 1) (C1, Sht 1) (A8, Sht 1) (E2, Sht 2) (A9, Sht 1) (D-F1, Sht 2)

(D2, Sht 1) (B8, Sht 1) (F4, Sht 2) (A8, Sht 1) (B5, Sht 2)

E
(B5, Sht 2)

Isense_W
3

I_senseP

TEMP_C

GND_C

P_ena

CN17

CN33

CN3

GNDP

Iref_G

P_ref

CN4

GNDW
5

+15Vw

/ OVERTEMP <

/PILOT ENABLE > PILOT DEMAND >

-15Vw

PILOT CURRENT SIGNAL <

WORK CURRENT SIGNAL <

Art # A-06992_AD
Rev Revisions By Date AA ECO-B402

DAT

2/26/07

LED4

AB ECO-B448 AC ECO-B646

DAT 4/13/07 GAC 10/31/07

CHOPPER TEMP

AD ECO-B1391 AE ECO-B1535

DAT 4-24-2009 Information Proprietary to THERMAL DYNAMICS CORPORATION. DAT 9-25-09 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). TITLE:

Thermal Dynamics

Thermal Dynamics Industrial Park #2 West Lebanon NH 03784 603-298-5711

PCB No: Assy No: Scale Date: Tuesday, October 03, 2006 Drawn: References App: 1 DWG No: Sheet of 2

F
Supersedes

DAT
Chk: Size

SCHEMATIC,

Last Modified: Friday, September 25, 2009

08:11:44

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

42X1209

10

Manual 0-4748

A-17

APPENDIX

ULTRA-CUT 100

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

1 2 3 4 5

To PCB7 CN2-1 (F1 Sht 1)

To PCB7 CN2-2 (F1 Sht 1)

To PCB7 CN2-4 (F2 Sht 1)

To PCB7 CN2-5 (F2 Sht 1)

To T1 PRI - 0 (F1 Sht 1)

To PCB7 TB3 (F1 Sht 1)

A
CN2
2 1

PCB 5 WK-5602 (partial)

INTERFACE PCB

CN9
TO AC INDICATOR (on PCB6)
1 2 3

LED1
LEVEL

INPUT CONTACTOR
MC1 MC2

4 5

CN12 MC1 AUX

CN8

CN1

CN13

CN14

1 1 1

+15V

TH1
SIG GND

+V

COOLANT TEMP (ON COOLANT FL1 RETURN) FLOW_TURBINE_PULSE

LSW1-1
SW_LIQUID_LEVEL_NC

CCM MODULE
I/O PCB
C
CN2
TB3
1 2 3 4 5

TP1 TP2 TP3 TP4 TP5 TP9 TP11

CIRCUIT COMM (GND) 29-41 VDC

+15VDC +5VDC -15VDC

ANALOG DEM to CPU NEG ARC VOLTS PILOT (TIP) VOLTAGE CUT DEM to PS PILOT DEM to PS COOLANT FLOW (freq) *

230 460 CN9

TB4

+
RY1

TP12 TP13 TP14 TP15 TP6

TB5

C.P2
460 120.

AC120V @ 1A

COM

RY2

D
CN10
220 0___ 1

460 230 COM

C.P3
24_ 0___ 0__

2 3

C.P4
24.

PCB7 WK-5628 RELAY PCB

AC24V-GCM

(D9, A10)
0_

0V-A (24V ret)

RY5

RY4

RY3

C.P5
120.

AC120V-GCM

(D9, A10)
0...

CN6
0V-B (120V ret)
1 2

RY5

110

R7
1K 30W
0..

3 4

C.P7
200

AC200V @ 3A

CN3
1 2 3

RY3

0.

RY4 C.P8 TB1

100

FAN + (24 VDC) FROM CN18 PCB3 sht 1 FAN - (24 VDC)
C.P6

TB2

0,, 13

AC13V @ 2A

1 2

0,

CN11

Art # A-06993_AD
1 2 3 4 5

APPENDIX

T1

1 2

460 230
RELCOL_0

TP7 TP8 TP10

+15VDC_ISO -15VDC_ISO
+16 to +18VDC ISOLATED COMM GAS_ON E-STOP_PS OK_CNC PSR CNC_E-STOP CNC_START

2 2

1 1

2 2

3 3

+15V

PILOT CONTACTOR

ISOLATED VOLTAGES

D1 D2 D4 D15 CN8
1 2 3 4

+15V /PUMP /FAN /RAS

D21 D23 D26 D28

HOLD_START CNC_PREFLOW

CN7
1 2 3 4

AC120V-RAS (C9) 0V-RAS

PUMP

SW6 - OK to MOVE CONTACTS / VOLTS SW11 - ANALOG CURRENT SELECT "B" DEFAULT, "A" REMOTE SW12 - DIVIDED ARC V RATIO SELECT SW13 - FACTORY ONLY

CN4
1 2 3 1 1 2 2 3 3 ' .

MOT1

CN5
1 2 3 4 5 6 1 1 2 2 + -

CPU PCB
D11 D12 D13 INITIALIZING / PROGRAMMING STATUS CODE +5V

FAN1

CN12
1 2

DC 15V DC 0V

A-18

Manual 0-4748

ULTRA-CUT 100

9
INTERNAL TERMINAL STRIP TB3

10

PCB6 DISPLAY WK-5603

GREEN CN23
1 2 3 4 5 6

(Not in all units)

0V-A (24V ret)

1 2 3 4 5 6 7

(E2)

AC24V-GCM 0V-B (120V ret) AC120V-GCM

24 VAC @ 1A 120 VAC @ 100ma.

AC TEMP GAS DC STATUS

CN24

+15V / AC / TEMP / GAS - COOLANT / DC / STATUS

1 2 3 4 5 6

YELLOW

GREEN GREEN RED

(C9, sht 1)

WORK

8 9 10 11 UNDIVIDED ARC VOLTS FOR HEIGHT CONTROLS

NEG ARC VOLTS

(A9, sht 1)

12

POWER SUPPLY REAR PANEL J54-REMOTE HMI & CNC COMM

1

Was 7 pin changed to 14 pin in 2009

CN10

26 CKT

CN11

34 CKT
PILOT (TIP) VOLTS NEG ARC VOLTS

2 3 4

JUMPER IN REMOTE HMI

PLASMA ENABLE

(B9, sht1)

(A9, sht1)

(C9, sht1)

RIBBON

CABLE

RIBBON

CABLE

5 6 7 8 9 10 11

WORK

KEY PLUG Tx+ GND GND TxRx+ Rx-

TEST SOCKET

TEST SOCKET

RS 485 (2 wire) uses Tx+ & Tx- only (used for TSC 3000) RS 422 (4 wire) connect TX+ to RX+ of CNC, Tx- to Rxof CNC

J35

26 CKT

J6 TP11

J9 TP1

J36

34 CKT

12 13 14

24VAC

TP12 - ARC V

24 VAC RET

RIBBON CABLE SIGNALS / = active low digital signal CN10-J35 - 26 Ckt Ribbon Cable 2-Cut Demand 4-Pilot Demand 6-/ Start 7-/ Start2 9-/ Pilot Enable 10-/ HF Enable 12-/ Pump Enable 13-/ Fan Enable 15-/ DC Indicator 16-/ Over Temperature Indicator 18-/ Gas-Coolant OK Indicator 19-/ Status Lamp CN11-J36 - 34 Ckt Ribbon Cable 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 OK 12- Missing Phase 13- / Ready to Operate 15- / Input Volts OK 16- / Inverter OCR 18- / PS ID "00*" 19- / PS ID "0*0" 20- / PS ID "*00" 21- E-Stop 22- E-Stop 29,31,33- 24 VAC Supply 30,32,34- 24 VAC Return

K6

K6-1

J59-RAS
1 2 3 4 5 6

** RS 485 / 422 on CPU board 19X2554 only.

Signal & GND Isolated from Plasma Supply

J6 **
1 Iso 2

KEY PLUG
C

AC120V-RAS

7 8

RxTx+ Rx+ TxJUMPER for 4 WIRE uses TX+, TXRX+, RXJ14

3 4 5 6

(E4)
0V-RAS (120V ret)

9 10 11 12 13 14

SW10-ADDRESS normally 0 (refer to 90 1 8 2 manual) 7 3 6 4

5

J5
1 2 3 4

4W 2W

J55-GCM
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37

J14 JUMPER for 2 WIRE (RS485 only) wire to A & B

4W 2W

SW14 - LINE SW14 TERMINATION normally on (refer to manual)

J7
1 2 3 4

PLASMA ENABLE PLASMA ENABLE PRESS OK (GCM 1000)

Signal - Basic ID Used to identify GCM 1000 present

5 6 7 8 9

POT HI (GCM1000) POT WIPER (GCM1000) POT LOW (GCM 1000)

AC24V-GCM (E2) 0V-A (24V ret) DC 15V (F4) DC 0V AC120V-GCM (E2) 0V-B (120V ret)

J8 GAS ON E-STOP
1 2

TB1
MOMENTARY STOP START / STOP

3 4

E-STOP E-STOP + * OK2

START / STOP

1 2 3 4 OK2 *
1 2 3 4 5 6 1K 7 8 9

J1

J15-CNC
1 2 3 4 5 6 7 8 9 10

- 5 + 6 DIVIDED ARC V - 7 DIVIDED ARC V + 8 REMOTE ANALOG CURRENT CONTROL - 9 REMOTE ANALOG CURRENT CONTROL + 10 * +10VDC @ 10 ma.(for CC pot high) 11 12 * OK2 TB2 HOLD START - 1 HOLD START + 2 PREFLOW ON - 3 PREFLOW ON + 4
START

START / STOP DIVIDED ARC VOLTS

100K

J4
1

11 12 13

REMOTE ANALOG CURRENT CONTROL OK TO MOVE

100K 3

14

- ARC V
5

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

PILOT ON OUTPUT OK to MOVE OK to MOVE + * REMOTE MARKING * REMOTE MARKING + -

6 7 8 9 10 11 12 PSR

7 Rev AA Revisions By Date

Art # A-06993_AD
ECO-B402 ECO-B448 ECO-B646 DAT DAT 2/26/07 4/13/07 AB AC GAC 10/31/07

TB3
1 2

AD ECO-B1391 AE ECO-B1535

DAT 4-24-2009 Information Proprietary to THERMAL DYNAMICS CORPORATION. DAT 9-25-09 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). TITLE:

Thermal Dynamics

Thermal Dynamics Industrial Park #2 West Lebanon NH 03784 603-298-5711

PCB No: Assy No: Scale Date: Tuesday, October 03, 2006 Drawn: References App: 2 DWG No: Sheet of 2

F
Supersedes

DAT
Chk: Size

SCHEMATIC,

Last Modified: Friday, September 25, 2009

08:11:44

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

42X1209

10

Manual 0-4748

A-19

APPENDIX

ULTRA-CUT 100

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

1 2 3 4 5

100A INVERTER MODULE

4 3 2

N (-)

3 Phase

INRUSH TB1 L1 MC1-A

6

CN1-460V

--230--

2 4 + 1

P1 TB2
+

V_CHANGE PCB

208-230/460 VAC

MC1-B L2

1 2 3

--460--

--230--

MC1-C L3

TB3 TB4 N2

2 4 + 1

P (+)

CN4 - PCB12 CN2-460V

1 2 3 1 2 3

ON / OFF
460 230 COM

C.P1

PGND1

CN1

LINE to LINE, LINE TO GND CAPS & VARISTORS

NE1

CN3
1 4

PCB 1 WK-5630 FILTER PCB

TB1
4 1

NE2

INPUT POWER INDICATOR INTERNAL

CN4

CN2

VAC_IN

P_GND

INPUT POWER INDICATOR REAR PANEL

CN1
7 6 5

PGND2

/ 230

/ 460

PCB3

WK-5694

BIAS SUPPLY PCB

D1
AC AC +

4 3

C1
-

2 1

AC

CN2
1

D
/ 460

VAC_IN P_GND

2 3

CN2

CN4
RY2

CN4 CN1

CN5 CN5

CN6 CN6

BIAS SUPPLY FOR PCB5 CN32 CN18

1 2 3 4

DC FAN POWER
1 2 3

CN6 16 CKT

RIBBON CABLE SIGNALS CN6 - 16 Ckt Ribbon Cable

+12VDC RY2

DETECTOR PCB
230V
+12VDC +12VDC

RIBBON CABLE 16 CKT

PCB4
RY2

WK-5604
FAN + (24 VDC) FAN - (24 VDC)

CN10

GND

+5V

MISSING_PHASE

INPUT_NG

+15V

+15V

+15V

-15V

TEMP_C

CN7
+15V

CN32

MISSING PHASE (pulses)<

LED4 LED3
INPUT NG CHOPPER TEMP

LED2
MISSING PHASE

PCB 5 WK-5602 (partial)

INTERFACE PCB

LED1 LED2 LED3 LED4 LED5

DIM DIM DIM OFF OFF

= = = = =

LOW, BRIGHT = OK OK, BRIGHT = FAULT OK, BRIGHT = FAULT OK, ON = FAULT OK, ON + FAULT

/ OVERTEMP <
LED5
ERROR

Art # A-07128_AB
1 2 3 4 5

APPENDIX

A-20

Manual 0-4748

CN6

16 CKT

CN17

GND_C

+
CN3

CN7

(F2 -Sht2)

2,4- I_REF (Scaled Cut Demand) 5- PS_START (Start) 6- REDUNDANT_START (Start2) 8- INV_READY 9- / PS_START disabled by Input_NG 12- / OCR 13- / PS_START disabled by OCR 14- /TEMP_ERR 15- / PS_START disabled by Temp _Err

To T1 PRI - 0 (A1 Sht2)

To PCB7 TB3 (A1 Sht2)

To PCB7 CN2-2 (A1 Sht 2) To PCB7 CN2-1 (A1 Sht 2)

To PCB7 CN2-4 (A2 Sht 2)

To PCB7 CN2-5 (A2 Sht 2)

ULTRA-CUT 100

9
NEG ARC VOLTS
(C7 & A9,Sht 2) TB2 TB3 TORCH (-) Power Supply Rear Panel

10

RAS

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.

CN1 R6 20K 30W

1 2 3 4

N2

P1

PCB 8 WK-5687
RC & RF CAPS CN2 CN3

TB1

C2 2 UF R9 50
WORK

CN5

4 3 2 1

PILOT REGULATOR (CHOPPER)

1 2 3

CN1 TB2
2 1

BIAS POWER

TB5

TB1

+12V -12V SIGNAL COMMON

PILOT REG. (CHOPPER ) PCB1 WK-5750

TB4
THS1 SW_TEMP_NC

FAN3 HCT1
HALL SENSOR

PILOT

1 2 3 4

PILOT (TIP) VOLTS

(C7, Sht 2)

CN3

CN4

CN2

MC2-A

2 1

5 4 3 2 1

3 2 1

CN8

CN7

CN6

2 1

5 4 3 2 1

3 2 1

CN9

> P_Enable (P_ena)

> P_DEM (P_Iref)

< /OVER_TEMP

I_DET

I_SE

PILOT REG. (CHOPPER ) PCB2 WK-5754

CN4

1 2

MC2-B CN1
1 2 3 4

MC2-C

CN2

CN5

1 2 3

TEMP_C

GND_C

I_senseP GNDP

P_ena

Iref_G

P_ref

1 2 3 4

R1 4 Ohm 1KW

< <

C
HCT2
HALL SENSOR

WORK (+)

1 2 3 4

WORK
+15Vw -15Vw Isense_W GNDW

(C7 & A9,Sht 2)

COMPONENT LOCATOR
C1 C2 C.P1 C.P2 C.P3 C.P4 C.P5 C.P6 C.P7 C.P8 D1 FAN1 FAN3 FL1 Capacitor, 0.1 uf, 1250 VDC Capacitor, 2 uf, 430VAC Circuit protector/ON-OFF SW 15A, 460V, 3P Circuit protector 2.5A 125V Circuit protector 3.15A 125V Circuit protector 10A 125V Circuit protector 2.5A 125V Circuit protector 2.5A 125V Circuit protector 5A 125V Circuit protector 3.15A 125V Diode Bridge 20A, 1600V, 3P Fan, Coolant, 24 VDC Fan, Chopper, 24 VDC Flow sensor (D2, Sht 2) (A9, Sht 1) (B2, Sht 1) (D2, Sht 1) (D2, Sht 1) (E2, Sht 1) (E2, Sht 1) (F2, Sht 1) (E2, Sht 1) (F3, Sht 1) (D2, Sht 1) (F4, Sht 2) (A8, Sht 1) (B5, Sht 2) HCT1 HCT2 Hall Current Sensor, Pilot Hall Current Sensor, Work (B8, Sht 1) (C9, Sht 1) (B5, Sht 2)

LSW1 Level SW, coolant, NC MC1 MC2 Contactor, 3P ,Inv 1 input, Coil " Contacts " Aux Contact Contactor, pilot, Coil " Contacts

(B3, Sht 2) (A2, B2, Sht 1) (B3, Sht 2) (B3, Sht 2) (B8, Sht 1) (E4, Sht 2) (C1, Sht 1) (C1, Sht 1) (C8, (A8, (E2, (A9, Sht Sht Sht Sht 1) 1) 2) 1)

MOT1 Motor, Pump 200VAC, 1P NE1 NE2 R1 R6 R7 R9 T1 TH1 Neon indicator, rear panel, 220VAC Neon indicator, internal, 220VAC Resistor, Resistor, Resistor, Resistor, Pilot, 4 Ohm, 1 KW 20K ,30W 1K ,30W 50 ,40W

Aux Transformer Thermal Sensor, coolant return

(D-F1, Sht 2) (B5, Sht 2)

Isense_W
3

I_senseP

P_ena

CN33

CN3

GNDP

Iref_G

P_ref

CN4

GNDW
5

+15Vw

/PILOT ENABLE > PILOT DEMAND >

-15Vw

PILOT CURRENT SIGNAL <

WORK CURRENT SIGNAL <

Art # A-07128_AB
Rev Revisions By Date AA ECO-B402

DAT DAT

2/26/07 4/13/07

AB ECO-B448 AC ECO-B646

GAC 10/31/07

Thermal Dynamics
TITLE:

Thermal Dynamics Industrial Park #2 West Lebanon NH 03784 603-298-5711

PCB No: Assy No: Scale Date: Tuesday, October 03, 2006 Drawn: References Sheet of 2 Supersedes

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).

DAT
Chk: Size App: 1 DWG No:

SCHEMATIC,

Last Modified: Wednesday, October 31, 2007 08:11:44

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

42X1203

10

Manual 0-4748

A-21

APPENDIX

ULTRA-CUT 100

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

1 2 3 4 5
To PCB7 CN2-1 (F1 Sht 1) To PCB7 CN2-2 (F1 Sht 1) To PCB7 CN2-4 (F2 Sht 1) To PCB7 CN2-5 (F2 Sht 1) To T1 PRI - 0 (F1 Sht 1) To PCB7 TB3 (F1 Sht 1)

A
CN2
2 1

PCB 5 WK-5602 (partial)

INTERFACE PCB

CN9 TO AC INDICATOR (on PCB6)

1 2 3

LED1
LEVEL

INPUT CONTACTOR
MC1 MC2

4 5

CN12 MC1 AUX

CN8

CN1

CN13

CN14

1
1 1

+15V

+15V

PILOT CONTACTOR

TH1
SIG GND +V

COOLANT TEMP (ON COOLANT FL1 RETURN) FLOW_TURBINE_PULSE

LSW1-1
SW_LIQUID_LEVEL_NC

CCM MODULE
C
CN2
TB3

I/O PCB
1 2 3 4 5

TP1 TP2 TP3 TP4

CIRCUIT COMM (GND) 29-41 VDC

230 460 CN9

C.P2
460 120.

TB4

+
RY1

TP5 TP9 TP11 TP12 TP13 TP14

+15VDC +5VDC -15VDC

ANALOG DEM to CPU NEG ARC VOLTS PILOT (TIP) VOLTAGE CUT DEM to PS PILOT DEM to PS

TB5

COM

RY2

D
CN10
220 0___ 1

460 230 COM

C.P3
24_ 0___ 0__

2 3

C.P4
24.

PCB7 WK-5628 RELAY PCB

AC24V-GCM

(D9, A10)
0_

0V-A (24V ret)

RY5

RY4

RY3

C.P5
120.

AC120V-GCM

(D9, A10)
0...

CN6
0V-B (120V ret)

AC120V @ 1A

RY5

1 2

110

R7
1K 30W
0..

3 4

C.P7
200

CN3
AC200V @ 3A
1 2 3

RY3

0.

RY4 C.P8 TB1

100

0,,

FAN + (24 VDC) FROM CN18 PCB3 sht 1 FAN - (24 VDC)
C.P6

TB2

13

AC13V @ 2A

1 2

0,

CN11

Art # A-07129_AB
1 2 3 4 5

APPENDIX

A-22

T1

1 2

460 230
RELCOL_0

TP6 TP7 TP8 TP10

+15VDC_ISO -15VDC_ISO
+16 to +18VDC ISOLATED COMM GAS_ON E-STOP_PS OK_CNC PSR CNC_E-STOP CNC_START

2 2

1 1

2 2

3 3

ISOLATED VOLTAGES

D1 D2 D4 CN8
1 2 3 4

+15V /PUMP /FAN /RAS

D15 D21 D23 D26 D28

HOLD_START CNC_PREFLOW

CN7
1 2 3 4

AC120V-RAS (C9) 0V-RAS

PUMP

CN20
1 2 3
1 1 2 2 3 3

'

SW6 - OK to MOVE CONTACTS / VOLTS SW11 - ANALOG CURRENT SELECT "B" DEFAULT, "A" REMOTE SW12 - DIVIDED ARC V RATIO SELECT SW13 - FACTORY ONLY

MOT1

CN10
1 2 3 4 5 6
1 1 2 2

CPU PCB
D11 D12 D13 INITIALIZING / PROGRAMMING STATUS CODE +5V

FAN1

CN12
1 2

DC 15V DC 0V

Manual 0-4748

ULTRA-CUT 100

10
INTERNAL TERMINAL STRIP TB3

PCB6 DISPLAY WK-5603

GREEN CN23
1 2 3 4 5 6

(Not in all units)

0V-A (24V ret)

1 2 3 4 5 6 7 120 VAC @ 100ma. 24 VAC @ 1A

(E2)

AC24V-GCM 0V-B (120V ret) AC120V-GCM

AC TEMP GAS DC STATUS

CN24

+15V / AC / TEMP / GAS - COOLANT / DC / STATUS

1 2 3 4 5 6

YELLOW

GREEN GREEN RED

(C9, sht 1)

WORK

8 9 10 11 UNDIVIDED ARC VOLTS FOR HEIGHT CONTROLS

NEG ARC VOLTS

(A9, sht 1)

12

POWER SUPPLY REAR PANEL J54-REMOTE HMI CN10 26 CKT CN11 34 CKT
1 2 3

JUMPER IN REMOTE HMI

PILOT (TIP) VOLTS

NEG ARC VOLTS

RIBBON

CABLE

RIBBON

CABLE

PLASMA ENABLE
5 6

(B9 SHT1)

(A9 SHT1)

(C9 SHT1)

WORK

J59-RAS
1 2 3 4 5

TEST SOCKET

TEST SOCKET

KEY PLUG

J35

26 CKT

J6 TP11

J9 TP1

J36

34 CKT

24 VAC RET

AC120V-RAS

7 8

24VAC

RIBBON CABLE SIGNALS / = active low digital signal CN10-J35 - 26 Ckt Ribbon Cable 2- Cut Demand 4- Pilot Demand 6- / Start 7- / Start2 9- / Pilot Enable 10- / HF Enable 12- / Pump Enable 13- / Fan Enable 15- / DC Indicator 16- / Over Temperature Indicator 18- / Gas-Coolant OK Indicator 19- / Status Lamp CN11-J36 - 34 Ckt Ribbon Cable 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 OK 12- Missing Phase 13- / Ready to Operate 15- / Input Volts OK 16- / Inverter OCR 18- / PS ID "00*" 19- / PS ID "0*0" 20- / PS ID "*00" 21- E-Stop 22- E-Stop 29,31,33- 24 VAC Supply 30,32,34- 24 VAC Return

TP12

(E4)
K6-1 K6 J5
1

0V-RAS (120V ret)

- ARC V

9 10 11 12 13 14

Signal - Basic ID Used to identify GCM 1000 present Signal - Master ID Used to identify resistor pilot unit

2 3 4 5

J55-GCM
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37

J7
1 2 3 4 5 6 7 8 9

PLASMA ENABLE PLASMA ENABLE PRESS OK (GCM 1000)

POT HI (GCM1000) POT WIPER (GCM1000) POT LOW (GCM 1000)

AC24V-GCM (E2) 0V-A (24V ret) DC 15V (F4) DC 0V AC120V-GCM (E2) 0V-B (120V ret)

J8 GAS ON E-STOP
1 2 3 4

TB1 E-STOP E-STOP +

1 2 3 4

MOMENTARY STOP

START / STOP

J1
1 2 3 4 5 6
1K

J15-CNC
1 2 3 4 5 6 7 8 9 10

- 5 START START / STOP + 6 DIVIDED ARC V - 7 DIVIDED ARC V + 8 REMOTE ANALOG CURRENT CONTROL - 9 REMOTE ANALOG CURRENT CONTROL + 10
11 12

START / STOP DIVIDED ARC VOLTS

7 8 9

TB2 HOLD START HOLD START PREFLOW ON PREFLOW ON PILOT ON OUTPUT OK to MOVE OK to MOVE + + +
1 2 3 4 5 6 7 8 9 10 11 12
Rev AA Revisions By Date 100K 100K

J4
1

11 12 13 14

REMOTE ANALOG CURRENT CONTROL OK TO MOVE

- ARC V
5

PSR
7

Art # A-07129_AB
ECO-B402 DAT 2/26/07 AB ECO-B448 AC ECO-B646 DAT 4/13/07 GAC 10/31/07

Thermal Dynamics
TITLE:

Thermal Dynamics Industrial Park #2 West Lebanon NH 03784 603-298-5711

PCB No: Assy No: Scale Date: Tuesday, October 03, 2006 Drawn: References Sheet of 2 Supersedes

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).

DAT
Chk: Size App: 2 DWG No:

SCHEMATIC,

Last Modified: Wednesday, October 31, 2007 08:11:44

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

42X1203

10

Manual 0-4748

A-23

APPENDIX

ULTRA-CUT 100

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

1 2 3 4 5

CN1-not used
4 3 2 1

100A INVERTER MODULE

N (-)

A
MC1-A L1 T
4

INRUSH TB1
6

2 4 + 1

3 Phase

P1
+

V_CHANGE PCB 400V only

TB2
--400--

3
2

MC1-B L2

1 2 3

400 VAC

MC1-C L3

TB3 TB4 N2

2 4 + 1

P (+)

3
2

CN4 - PCB12 CN2-400V

1 2 3 4 1 2 3 4

COM

400

200

B
ON / OFF
C.P1

PGND1

CN6 16 CKT
PGND2 / 400

CN1

LINE to LINE, LINE TO GND CAPS & VARISTORS

NE1

CN3
1 4

PCB 1 WK-5630 FILTER PCB

/ 200

RIBBON CABLE SIGNALS CN6 - 16 Ckt Ribbon Cable 2,4- I_REF (Scaled Cut Demand) 5- PS_START (Start) 6- REDUNDANT_START (Start2) 8- INV_READY 9- / PS_START disabled by Input_NG 12- / OCR 13- / PS_START disabled by OCR 14- /TEMP_ERR 15- / PS_START disabled by Temp _Err

TB1
4 1

NE2

INPUT POWER INDICATOR INTERNAL

CN4

CN2

VAC_IN

P_GND

INPUT POWER INDICATOR REAR PANEL

CN1
7 6 5

PCB3

WK-5694

BIAS SUPPLY PCB

D1
AC AC +

4 3

C1
-

2 1

AC

CN2
1

D
/ 400

VAC_IN P_GND

2 3

CN2

CN4
RY2

CN4 CN1

CN5 CN5

CN6 CN6

BIAS SUPPLY FOR PCB5 CN32 CN18

1 2 3 4

DC FAN POWER
1 2 3

+12VDC

DETECTOR PCB
200V
+12VDC +12VDC

RY2

CN10

CN3

CN7

(F2 -Sht2)
GND +5V +15V

E
MISSING_PHASE

INPUT_NG

+15V

+15V

CN7
+15V

CN32

MISSING PHASE (pulses)<

CN6

LED5 LED3
INPUT NG ERROR

LED2
MISSING PHASE

PCB 5 WK-5602 (partial)

INTERFACE PCB

LED1 LED2 LED3 LED4 LED5

DIM DIM DIM OFF OFF

= = = = =

LOW, BRIGHT = OK OK, BRIGHT = FAULT OK, BRIGHT = FAULT OK, ON = FAULT OK, ON + FAULT

Art # A-06998_AD
1 2 3 4 5

APPENDIX

A-24

16 CKT

-15V

RIBBON CABLE

RY2

PCB4

WK-5604
FAN + (24 VDC) FAN - (24 VDC)

+ +

16 CKT

To PCB7 CN2-5 (A2 Sht 2) To PCB7 CN2-4 (A2 Sht 2)

To T1 PRI - 0 (A1 Sht2)

To PCB7 TB3 (A1 Sht2)

To PCB7 CN2-1 (A1 Sht 2)

To PCB7 CN2-2 (A1 Sht 2)

Manual 0-4748

ULTRA-CUT 100

9
NEG ARC VOLTS
(C7 & A9,Sht 2) TB2 TB3 TORCH (-) Power Supply Rear Panel

10

RAS

CN1 R6 20K 30W

1 2 3 4

N2

P1

PCB 8 WK-5687
RC & RF CAPS CN2 CN3

TB1

C2 2 UF R9 50
WORK

PILOT REGULATOR (CHOPPER)

1 2 3

CN5

4 3 2 1

CN1 TB2
2 1

BIAS POWER

TB5

TB1

+12V -12V SIGNAL COMMON

PILOT REG. (CHOPPER ) PCB1 WK-5750

TB4
THS1 SW_TEMP_NC

FAN3 HCT1
HALL SENSOR
1 2 3 4

PILOT

PILOT (TIP) VOLTS

(C7, Sht 2)

CN3

CN4

CN2

B
4 2 K2 K1 1 A1

2 1

5 4 3 2 1

3 2 1

D2

CN8

CN7

CN6
> P_Enable (P_ena)

2 1

5 4 3 2 1

3 2 1

CN9

1 2

> P_DEM (P_Iref)

< /OVER_TEMP

I_DET

I_SE

PILOT REG. (CHOPPER ) PCB2 WK-5754

CN4

CN1
1 2 3 4

A2

MC2-A

MC2-B CN5
4 1 2 3 4

CN2

1 2 3

< <

MC2-C
TEMP_C P_ena
I_senseP GNDP

GND_C

Iref_G

P_ref

C
HCT2
HALL SENSOR
1 2 3 4

WORK (+)

WORK
+15Vw -15Vw Isense_W GNDW

(C7 & A9,Sht 2)

COMPONENT LOCATOR
C1 C2 C.P1 C.P2 C.P3 C.P4 C.P5 C.P6 C.P7 C.P8 D1 D2 FAN1 FAN3 FL1 Capacitor, 0.1 uf, 1250 VDC Capacitor, 2 uf, 430VAC Circuit protector/ON-OFF SW 15A, 460V, 3P Circuit protector 2.5A 125V Circuit protector 3.15A 125V Circuit protector 10A 125V Circuit protector 2.5A 125V Circuit protector 2.5A 125V Circuit protector 5A 125V Circuit protector 3.15A 125V Diode Bridge 20A, 1600V, 3P Diode, Dual, 2x100A, 600V Fan, Coolant, 24 VDC Fan, Chopper, 24 VDC Flow sensor (D2, Sht 2) (A9, Sht 1) (B2, Sht 1) (D2, (D2, (E2, (E2, (F2, (E2, (F3, Sht Sht Sht Sht Sht Sht Sht 1) 1) 1) 1) 1) 1) 1) HCT1 HCT2 Hall Current Sensor, Pilot Hall Current Sensor, Work (B8, Sht 1) (C9, Sht 1) (B5, Sht 2) (B3, (A2, (B3, (B3, (C8, Sht B2, Sht Sht Sht 2) Sht 1) 2) 2) 1)

LSW1 Level SW, coolant, NC MC1 MC2 Contactor, 3P ,Inv 1 input, Coil " Contacts " Aux Contact Contactor, pilot, Coil " Contacts

MOT1 Motor, Pump 200VAC, 1P NE1 NE2 Neon indicator, rear panel, 220VAC Neon indicator, internal, 220VAC Resistor, 20K ,30W Resistor, 1K ,30W Resistor, 50 ,40W Aux Transformer Thermal Sensor, coolant return

(E4, Sht 2) (C1, Sht 1) (C1, Sht 1) (A8, Sht 1) (E2, Sht 2) (A9, Sht 1) (D-F1, Sht 2) (B5, Sht 2)

(D2, Sht 1) (B8, Sht 1) (F4, Sht 2) (A8, Sht 1) (B5, Sht 2)

R6 R7 R9 T1 TH1

Isense_W
3

I_senseP

TEMP_C

GND_C

P_ena

CN17

CN33

CN3

GNDP

Iref_G

P_ref

CN4

GNDW
5

+15Vw

/ OVERTEMP <

/PILOT ENABLE > PILOT DEMAND >

PILOT CURRENT SIGNAL <

-15Vw

WORK CURRENT SIGNAL <

Art # A-06998_AD
Rev AA Revisions By Date

ECO-B402

DAT

2/26/07

LED4
CHOPPER TEMP

AB ECO-B448 AC ECO-B646

DAT 4/13/07 GAC 10/31/07

AD ECO-B1391 AE ECO-B1535

DAT 4-24-09 Information Proprietary to THERMAL DYNAMICS CORPORATION. DAT 9-25-09 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). TITLE:

Thermal Dynamics

Thermal Dynamics Industrial Park #2 West Lebanon NH 03784 603-298-5711

PCB No: Assy No: Scale Date: Tuesday, October 03, 2006 Drawn: References App: 1 DWG No: Sheet of 2

F
Supersedes

DAT
Chk: Size

SCHEMATIC,

Last Modified: Friday, September 25, 2009

08:11:44

100A Power Supply 400V CCC (Chopper)

42X1212

10

Manual 0-4748

A-25

APPENDIX

ULTRA-CUT 100

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

1
To PCB7 CN2-1 (F1 Sht 1) To PCB7 CN2-2 (F1 Sht 1) To PCB7 CN2-4 (F2 Sht 1) To PCB7 CN2-5 (F2 Sht 1) To T1 PRI - 0 (F1 Sht 1) To PCB7 TB3 (F1 Sht 1)

A
CN2
2 1

PCB 5 WK-5602 (partial)

INTERFACE PCB

CN9
TO AC INDICATOR (on PCB6)
1 2 3

LED1
LEVEL

INPUT CONTACTOR
MC1 MC2

4 5

CN12 MC1 AUX

CN8

CN1

CN13

CN14

1 1 1

TH1
SIG GND

+V

COOLANT TEMP (ON COOLANT FL1 RETURN) FLOW_TURBINE_PULSE

LSW1-1
SW_LIQUID_LEVEL_NC

CCM MODULE
I/O PCB
TP3

C
CN2
TB3
1 2 3 4 5

TP2 TP4 TP5 TP6 TP17 TP14

CIRCUIT COMM (GND) 29-41 VDC

+15VDC +5VDC -15VDC

ANALOG DEM to CPU NEG ARC VOLTS PILOT (TIP) VOLTAGE CUT DEM to PS PILOT DEM to PS COOLANT FLOW (freq) *

200-not used 400 CN9

TB4

+
RY1

TP12 TP15 TP16 TP18 TP7

TB5

C.P2
460 120.

COM

RY10

D
220 0___

CN10
1

400 200 COM

C.P3
24_ 0___

2 3

0__

C.P4
24.

PCB7 WK-5628 RELAY PCB

RY7 RY9 RY3

+15V

AC24V-GCM

(D9, A10)
0_

0V-A (24V ret)

C.P5
120.

AC120V-GCM

(D9, A10)
0... 110

CN6
0V-B (120V ret)
1 2

RY5

R8
1K 30W
0..

3 4

C.P7
200

AC200V @ 3A

CN3
1 2 3

RY11

0.

RY4 C.P8 TB1

100

FAN + (24 VDC) FROM CN18 PCB3 sht 1 FAN - (24 VDC)
C.P6

TB2

0,, 13

AC13V @ 2A

1 2

0,

CN11

Art # A-06999_AD
1 2 3 4 5

APPENDIX

+ +

T1

1 2

400 200

TP8 TP9 TP10

+15VDC_ISO -15VDC_ISO
+16 to +18VDC ISOLATED COMM GAS_ON E-STOP_PS OK_CNC PSR CNC_E-STOP CNC_START

2 2

1 1

2 2

3 3

+15V

PILOT CONTACTOR

ISOLATED VOLTAGES

D9 D7 D8 D15 D21 D23 D26 D28

AC120 @ 1A

CN8
1 2 3 4

+15V /PUMP /FAN /RAS

HOLD_START CNC_PREFLOW

CN7
1 2 3 4

AC120V-RAS (C9) 0V-RAS

PUMP

SW6 - OK to MOVE CONTACTS / VOLTS SW11 - ANALOG CURRENT SELECT "B" DEFAULT, "A" REMOTE SW12 - DIVIDED ARC V RATIO SELECT SW13 - FACTORY ONLY

CN4
1 2 3 1 1 2 2 3 3 ' .

MOT1

CN5
1 2 3 4 5 6 1 1 2 2 + -

CPU PCB
D11 D12 D13 INITIALIZING / PROGRAMMING STATUS CODE +5V

FAN1

CN12
1 2

DC 15V DC 0V

A-26

Manual 0-4748

ULTRA-CUT 100

9
INTERNAL TERMINAL STRIP TB3

10

PCB6 DISPLAY WK-5603

GREEN CN23
1 2 3 4 5 6

(Not in all units)

0V-A (24V ret)

1 2 3 4 5 6 7

(E2)

AC24V-GCM 0V-B (120V ret) AC120V-GCM

24 VAC @ 1A 120 VAC @ 100ma.

AC TEMP GAS DC STATUS

CN24

+15V / AC / TEMP / GAS - COOLANT / DC / STATUS

1 2 3 4 5 6

YELLOW

GREEN1 GREEN2 RED

(C9, sht 1)

WORK

8 9 10 11 UNDIVIDED ARC VOLTS FOR HEIGHT CONTROLS

NEG ARC VOLTS

(A9, sht 1)

12

POWER SUPPLY REAR PANEL J54-REMOTE HMI & CNC COMM

1

Was 7 pin changed to 14 pin in 2009

CN10

26 CKT

CN11

34 CKT
PILOT (TIP) VOLTS NEG ARC VOLTS

2 3 4

JUMPER IN REMOTE HMI

PLASMA ENABLE

(B9, sht1)

(A9, sht1)

(C9, sht1)

RIBBON

CABLE

RIBBON

CABLE

5 6 7 8 9 10 11

WORK

KEY PLUG Tx+ GND GND TxRx+ Rx-

TEST SOCKET

TEST SOCKET

RS 485 (2 wire) uses Tx+ & Tx- only (used for TSC 3000) RS 422 (4 wire) connect TX+ to RX+ of CNC, Tx- to Rxof CNC

J35

26 CKT

J6 TP11

J9 TP1

J36

34 CKT

12 13 14

24VAC

TP13 - ARC V

24 VAC RET

RIBBON CABLE SIGNALS / = active low digital signal CN10-J35 - 26 Ckt Ribbon Cable 2-Cut Demand 4-Pilot Demand 6-/ Start 7-/ Start2 9-/ Pilot Enable 10-/ HF Enable 12-/ Pump Enable 13-/ Fan Enable 15-/ DC Indicator 16-/ Over Temperature Indicator 18-/ Gas-Coolant OK Indicator 19-/ Status Lamp CN11-J36 - 34 Ckt Ribbon Cable 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 OK 12- Missing Phase 13- / Ready to Operate 15- / Input Volts OK 16- / Inverter OCR 18- / PS ID "00*" 19- / PS ID "0*0" 20- / PS ID "*00" 21- E-Stop 22- E-Stop 29,31,33- 24 VAC Supply 30,32,34- 24 VAC Return

K6

K7-1

J59-RAS
1 2 3 4 5 6

** RS 485 / 422 on CPU board 19X2554 only.

Signal & GND Isolated from Plasma Supply

J6 **
1 Iso 2

KEY PLUG
C

AC120V-RAS

7 8

RxTx+ Rx+ TxJUMPER for 4 WIRE uses TX+, TXRX+, RXJ14

3 4 5 6

(E4)
0V-RAS (120V ret)

9 10 11 12 13 14

SW10-ADDRESS normally 0 (refer to 9 01 2 8 manual) 3 7 6 4

5

J5
1 2 3 4

4W 2W

J55-GCM
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37

J14 JUMPER for 2 WIRE (RS485 only) wire to A & B

4W 2W

SW14 - LINE SW14 TERMINATION normally on (refer to manual)

J7
1 2 3 4

PLASMA ENABLE PLASMA ENABLE PRESS OK (GCM 1000)

Signal - Basic ID Used to identify GCM 1000 present

5 6 7 8 9

POT HI (GCM1000) POT WIPER (GCM1000) POT LOW (GCM 1000)

AC24V-GCM (E2) 0V-A (24V ret) DC 15V (F4) DC 0V AC120V-GCM (E2) 0V-B (120V ret)

J8 GAS ON E-STOP
1 2

TB1
MOMENTARY STOP START / STOP

3 4

E-STOP E-STOP + * OK2

START / STOP

1 2 3 4 OK2 *
1 2 3 4 5 6 1K 7 8 9

J1

J15-CNC
1 2 3 4 5 6 7 8 9 10

- 5 + 6 DIVIDED ARC V - 7 DIVIDED ARC V + 8 REMOTE ANALOG CURRENT CONTROL - 9 REMOTE ANALOG CURRENT CONTROL + 10 * +10VDC @ 10 ma.(for CC pot high) 11 12 * OK2 TB2 HOLD START - 1 HOLD START + 2 PREFLOW ON - 3 PREFLOW ON + 4
START

START / STOP

E
DIVIDED ARC VOLTS

100K

J4
1

11 12 13

REMOTE ANALOG CURRENT CONTROL OK TO MOVE

100K14 3

14

- ARC V
5

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

PILOT ON OUTPUT OK to MOVE OK to MOVE + * REMOTE MARKING * REMOTE MARKING + -

6 7 8 9 10 11 12 PSR

7 Rev AA Revisions By Date

Art # A-06999_AD
ECO-B402 DAT 2/26/07 AB ECO-B448 AC ECO-B646 DAT 4/13/07 GAC 10/31/07

TB3
1 2

AD ECO-B1391 AE ECO-B1535

DAT 4-24-09 Information Proprietary to THERMAL DYNAMICS CORPORATION. DAT 9-25-09 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). TITLE:

Thermal Dynamics

Thermal Dynamics Industrial Park #2 West Lebanon NH 03784 603-298-5711

PCB No: Assy No: Scale Date: Tuesday, October 03, 2006 Drawn: References App: 2 DWG No: Sheet of 2

F
Supersedes

DAT
Chk: Size

SCHEMATIC,

Last Modified: Friday, September 25, 2009

08:11:44

100A Power Supply 400V CCC (Chopper)

42X1212

10

Manual 0-4748

A-27

APPENDIX

ULTRA-CUT 100

APPENDIX 11: Schematic, CE 400V, Chopper Pilot

1 2 3 4 5

CN1-not used
4 3 2 1

100A INVERTER MODULE

N (-)

A
L1

L1 NFC1 MC1-A
L4

INRUSH TB1
4 6

2 4 + 1

3 Phase

L1

P1
+

V_CHANGE PCB 400V only

TB2
--400--

3
2

L2

EMI FILTER
L2 L5

MC1-B

1 2 3

400 VAC

MC1-C L3
L3 L6

TB3 TB4 N2

2 4 + 1

P (+)

3
2

L2

CN4 - PCB12 CN2-400V

1 2 3 1 2 3 4 4

L3
COM 400 200

B
L4

PGND1

CN6 16 CKT
PGND2 / 400

L5

/ 200

L6

RIBBON CABLE SIGNALS CN6 - 16 Ckt Ribbon Cable

L7

ON / OFF
C.P1

CN1

LINE to LINE, LINE TO GND CAPS & VARISTORS

NE1

CN3
1 4

PCB 1 WK-5630 FILTER PCB

2,4- I_REF (Scaled Cut Demand) 5- PS_START (Start) 6- REDUNDANT_START (Start2) 8- INV_READY 9- / PS_START disabled by Input_NG 12- / OCR 13- / PS_START disabled by OCR 14- /TEMP_ERR 15- / PS_START disabled by Temp _Err

TB1
4 1

CN4
NE2

CN2

VAC_IN

P_GND

INPUT POWER INDICATOR REAR PANEL

CN1
7 6 5

PCB3

WK-5694

INPUT POWER INDICATOR INTERNAL

BIAS SUPPLY PCB

D1
AC AC +

4 3

C1
-

2 1

AC

CN2
1

D
/ 400

VAC_IN P_GND

2 3

CN2

CN4
RY2

CN4 CN1

CN5 CN5

CN6 CN6

BIAS SUPPLY FOR PCB5 CN32 CN18

1 2 3 4

DC FAN POWER
1 2 3

+12VDC

DETECTOR PCB
200V
+12VDC +12VDC

RY2

CN10

CN3

CN7

(F2 -Sht2)
GND +5V +15V

E
MISSING_PHASE

INPUT_NG

+15V

+15V

CN7
+15V

CN32

MISSING PHASE (pulses)<

CN6

LED5 LED3
INPUT NG ERROR

LED2
MISSING PHASE

PCB 5 WK-5602 (partial)

INTERFACE PCB

LED1 LED2 LED3 LED4 LED5

DIM DIM DIM OFF OFF

= = = = =

LOW, BRIGHT = OK OK, BRIGHT = FAULT OK, BRIGHT = FAULT OK, ON = FAULT OK, ON + FAULT

Art # A-06996_AD
1 2 3 4 5

APPENDIX

A-28

16 CKT

-15V

RIBBON CABLE

RY2

PCB4

WK-5604
FAN + (24 VDC) FAN - (24 VDC)

16 CKT

To PCB7 TB3 (A1 Sht2)

To T1 PRI - 0 (A1 Sht2)

To PCB7 CN2-4 (A2 Sht 2)

To PCB7 CN2-5 (A2 Sht 2)

To PCB7 CN2-1 (A1 Sht 2)

To PCB7 CN2-2 (A1 Sht 2)

Manual 0-4748

ULTRA-CUT 100

9
NEG ARC VOLTS
(C7 & A9,Sht 2) TB2 TB3 TORCH (-) Power Supply Rear Panel

10

RAS

CN1 L8 R6 20K 30W

1 2 3 4

N2

P1

PCB 8 WK-5687
RC & RF CAPS CN2 CN3

TB1

C2 2 UF R9 50
WORK

PILOT REGULATOR (CHOPPER)

1 2 3

CN5

4 3 2 1

CN1 TB2
2 1

BIAS POWER

TB5

TB1

+12V -12V SIGNAL COMMON

PILOT REG. (CHOPPER ) PCB1 WK-5750

TB4
THS1 SW_TEMP_NC

FAN3 HCT1
HALL SENSOR
1 2 3 4

PILOT

PILOT (TIP) VOLTS

(C7, Sht 2)

CN3

CN4

CN2

B
4 2 K2 K1 1 A1

2 1

5 4 3 2 1

3 2 1

D2

CN8

CN7

CN6
> P_Enable (P_ena)

2 1

5 4 3 2 1

3 2 1

CN9

1 2

> P_DEM (P_Iref)

< /OVER_TEMP

I_DET

I_SE

PILOT REG. (CHOPPER ) PCB2 WK-5754

CN4

CN1
1 2 3 4

A2

MC2-A

MC2-B CN5
4 1 2 3 4

CN2

1 2 3

< <

MC2-C
TEMP_C P_ena
I_senseP GNDP

GND_C

Iref_G

P_ref

C
HCT2
HALL SENSOR
1 2 3 4

WORK (+)

WORK
+15Vw -15Vw Isense_W GNDW

(C7 & A9,Sht 2)

COMPONENT LOCATOR
C1 C2 C.P1 C.P2 C.P3 C.P4 C.P5 C.P6 C.P7 C.P8 D1 D2 FAN1 FAN3 FL1 Capacitor, 0.1 uf, 1250 VDC Capacitor, 2 uf, 430VAC Circuit protector/ON-OFF SW 15A, 460V, 3P Circuit protector 2.5A 125V Circuit protector 3.15A 125V Circuit protector 10A 125V Circuit protector 2.5A 125V Circuit protector 2.5A 125V Circuit protector 5A 125V Circuit protector 3.15A 125V Diode Bridge 20A, 1600V, 3P Diode, Dual, 2x100A, 600V Fan, Coolant, 24 VDC Fan, Chopper, 24 VDC Flow sensor (D2, Sht 2) (A9, Sht 1) (C2, Sht 1) (D2, (D2, (E2, (E2, (F2, (E2, (F3, Sht Sht Sht Sht Sht Sht Sht 1) 1) 1) 1) 1) 1) 1) HCT1 HCT2 Hall Current Sensor, Pilot Hall Current Sensor, Work (B8, Sht 1) (C9, Sht 1)

D 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)
LSW1 Level SW, coolant, NC MC1 MC2 Contactor, 3P ,Inv 1 input, Coil " Contacts " Aux Contact Contactor, pilot, Coil " Contacts (B5, Sht 2) (B3, (A2, (B3, (B3, (C8, Sht B2, Sht Sht Sht 2) Sht 1) 2) 2) 1)

(D2, Sht 1) (B8, Sht 1) (F4, Sht 2) (A8, Sht 1) (B5, Sht 2) NFC1 R6 R7 R9 T1 NE1 NE2

MOT1 Motor, Pump 200VAC, 1P Neon indicator, rear panel, 220VAC Neon indicator, internal, 220VAC Noise Filter, EMI, input Resistor, 20K ,30W Resistor, 1K ,30W Resistor, 50 ,40W Aux Transformer Thermal Sensor, coolant return

(E4, Sht 2) (C1, Sht 1) (D1, Sht 1) (A2, Sht 1) (A8, Sht 1) (E2, Sht 2) (A9, Sht 1) (D-F1, Sht 2) (B5, Sht 2)

Isense_W

I_senseP

TEMP_C

GND_C

GNDP

Iref_G

GNDW

+15Vw

-15Vw

P_ena

CN17

P_ref

TH1

CN33

CN3

CN4

/ OVERTEMP <

/PILOT ENABLE > PILOT DEMAND >

PILOT CURRENT SIGNAL <

WORK CURRENT SIGNAL <

Art # A-06996_AD
Rev AA Revisions By Date

ECO-B402 ECO-B448 ECO-B646

DAT

2/26/07

LED4
CHOPPER TEMP

AB AC

DAT 4/13/07 GAC 10/31/07

AD ECO-B1391 AE ECO-B1535

Information Proprietary to THERMAL DYNAMICS CORPORATION. DAT 4-24-09 DAT 9-25-09 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). TITLE:

Thermal Dynamics

Thermal Dynamics Industrial Park #2 West Lebanon NH 03784 603-298-5711

PCB No: Assy No: Scale Date: Tuesday, October 03, 2006 Drawn: References App: 1 DWG No: Sheet of 2 Supersedes

DAT
Chk: Size

SCHEMATIC,

Last Modified: Friday, September 25, 2009

08:11:44

100A Power Supply 400V CE (Chopper)

42X1211

10

Manual 0-4748

A-29

APPENDIX

ULTRA-CUT 100

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

1 2 3 4 5
To PCB7 CN2-1 (F1 Sht 1) To PCB7 CN2-2 (F1 Sht 1) To PCB7 CN2-4 (F2 Sht 1) To PCB7 CN2-5 (F2 Sht 1) To T1 PRI - 0 (F1 Sht 1) To PCB7 TB3 (F1 Sht 1)

A
CN2
2 1

PCB 5 WK-5602 (partial)

INTERFACE PCB

CN9
TO AC INDICATOR (on PCB6)
1 2 3

LED1
LEVEL

INPUT CONTACTOR
MC1 MC2

4 5

CN12 MC1 AUX

CN8

CN1

CN13

CN14

1 1 1

TH1
SIG GND

+V

COOLANT TEMP (ON COOLANT FL1 RETURN) FLOW_TURBINE_PULSE

LSW1-1
SW_LIQUID_LEVEL_NC

CCM MODULE
I/O PCB
C
CN2
TB3
1 2 3 4 5

TP3 TP2 TP4 TP5 TP6 TP17 TP14

CIRCUIT COMM (GND) 29-41 VDC

+15VDC +5VDC -15VDC

ANALOG DEM to CPU NEG ARC VOLTS PILOT (TIP) VOLTAGE CUT DEM to PS PILOT DEM to PS COOLANT FLOW (freq) *

200-not used

TB4

+
RY1

TP12 TP15 TP16 TP18 TP7

TB5

400 CN9
400 COM

TP8 TP9
RY10

+15VDC_ISO -15VDC_ISO
+16 to +18VDC ISOLATED COMM GAS_ON E-STOP_PS OK_CNC PSR CNC_E-STOP CNC_START

2 2

1 1

2 2

3 3

+15V

PILOT CONTACTOR

C.P2
460 120.

D
CN10
220 0___ 1

400 200 COM

C.P3
24_ 0___

2 3

0__

C.P4
24.

PCB7 WK-5628 RELAY PCB

RY7 RY9 RY3

+15V

AC24V-GCM

(D9, A10)
0_

0V-A (24V ret)

C.P5
120.

AC120V-GCM

(D9, A10)
0...

CN6
0V-B (120V ret)
1 2

RY5

110

R8
1K 30W
0..

3 4

C.P7
200

AC200V @ 3A

CN3
1 2 3

RY11

0.

RY4 C.P8 TB1

100

FAN + (24 VDC) FROM CN18 PCB3 sht 1 FAN - (24 VDC)
C.P6

TB2

0,, 13

AC13V @ 2A

1 2

0,

CN11

Art # A-06997_AD
1 2 3 4 5

APPENDIX

T1

1 2

200

ISOLATED VOLTAGES

TP10

D9 D7 D8 D15 D21 D23 D26 D28

AC120 @ 1A

CN8
1 2 3 4

+15V /PUMP /FAN /RAS

HOLD_START CNC_PREFLOW

CN7
1 2 3 4

AC120V-RAS (C9) 0V-RAS

PUMP

SW6 - OK to MOVE CONTACTS / VOLTS SW11 - ANALOG CURRENT SELECT "B" DEFAULT, "A" REMOTE SW12 - DIVIDED ARC V RATIO SELECT SW13 - FACTORY ONLY

CN4
1 2 3 1 1 2 2 3 3 ' .

MOT1

CN5
1 2 3 4 5 6 1 1 2 2 + -

CPU PCB
D11 D12 D13 INITIALIZING / PROGRAMMING STATUS CODE +5V

FAN1

CN12
1 2

DC 15V DC 0V

A-30

Manual 0-4748

ULTRA-CUT 100

9
INTERNAL TERMINAL STRIP TB3

10

PCB6 DISPLAY WK-5603

GREEN CN23
1 2 3 4 5 6

(Not in all units)

0V-A (24V ret)

1 2 3 4 5 6 7

(E2)

AC24V-GCM 0V-B (120V ret) AC120V-GCM

24 VAC @ 1A 120 VAC @ 100ma.

AC TEMP GAS DC STATUS

CN24

+15V / AC / TEMP / GAS - COOLANT / DC / STATUS

1 2 3 4 5 6

YELLOW

GREEN1 GREEN2 RED

(C9, sht 1)

WORK

8 9 10 11 UNDIVIDED ARC VOLTS FOR HEIGHT CONTROLS

NEG ARC VOLTS

(A9, sht 1)

12

POWER SUPPLY REAR PANEL J54-REMOTE HMI & CNC COMM

1

Was 7 pin changed to 14 pin in 2009

CN10

26 CKT

CN11

34 CKT
PILOT (TIP) VOLTS NEG ARC VOLTS

2 3 4

JUMPER IN REMOTE HMI

PLASMA ENABLE

(B9, sht1)

(A9, sht1)

(C9, sht1)

RIBBON

CABLE

RIBBON

CABLE

5 6 7 8 9 10 11

WORK

KEY PLUG Tx+ GND GND TxRx+ Rx-

TEST SOCKET

TEST SOCKET

RS 485 (2 wire) uses Tx+ & Tx- only (used for TSC 3000) RS 422 (4 wire) connect TX+ to RX+ of CNC, Tx- to Rxof CNC

J35

26 CKT

J6 TP11

J9 TP1

J36

34 CKT

12 13 14

24VAC

TP13 - ARC V

24 VAC RET

RIBBON CABLE SIGNALS / = active low digital signal CN10-J35 - 26 Ckt Ribbon Cable 2-Cut Demand 4-Pilot Demand 6-/ Start 7-/ Start2 9-/ Pilot Enable 10-/ HF Enable 12-/ Pump Enable 13-/ Fan Enable 15-/ DC Indicator 16-/ Over Temperature Indicator 18-/ Gas-Coolant OK Indicator 19-/ Status Lamp CN11-J36 - 34 Ckt Ribbon Cable 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 OK 12- Missing Phase 13- / Ready to Operate 15- / Input Volts OK 16- / Inverter OCR 18- / PS ID "00*" 19- / PS ID "0*0" 20- / PS ID "*00" 21- E-Stop 22- E-Stop 29,31,33- 24 VAC Supply 30,32,34- 24 VAC Return

K6

K7-1

J59-RAS
1 2 3 4 5 6

** RS 485 / 422 on CPU board 19X2554 only.

Signal & GND Isolated from Plasma Supply

J6 **
1 Iso 2

KEY PLUG
C

AC120V-RAS

7 8

RxTx+ Rx+ TxJ14 JUMPER for 4 WIRE uses TX+, TXRX+, RX-

3 4 5 6

(E4)
0V-RAS (120V ret)

9 10 11 12 13 14

SW10-ADDRESS normally 0 (refer to 9 01 2 8 manual) 3 7 6 4

5

J5
1 2 3 4

4W 2W

J55-GCM
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37

J14 JUMPER for 2 WIRE (RS485 only) wire to A & B

4W 2W

SW14 - LINE SW14 TERMINATION normally on (refer to manual)

J7
1 2 3 4

PLASMA ENABLE PLASMA ENABLE PRESS OK (GCM 1000)

Signal - Basic ID Used to identify GCM 1000 present

5 6 7 8 9

POT HI (GCM1000) POT WIPER (GCM1000) POT LOW (GCM 1000)

AC24V-GCM (E2) 0V-A (24V ret) DC 15V (F4) DC 0V AC120V-GCM (E2) 0V-B (120V ret)

J8 GAS ON E-STOP
1 2

TB1
MOMENTARY STOP START / STOP

3 4

E-STOP E-STOP + * OK2

1 2 3 4 OK2 *
1 2 3 4 5 6 1K 7 8 9

J1

J15-CNC
1 2 3 4 5 6 7 8 9 10

- 5 START START / STOP + 6 DIVIDED ARC V - 7 DIVIDED ARC V + 8 REMOTE ANALOG CURRENT CONTROL - 9 REMOTE ANALOG CURRENT CONTROL + 10 * +10VDC @ 10 ma.(for CC pot high) 11 12 * OK2 TB2 HOLD START - 1 HOLD START + 2 PREFLOW ON - 3 PREFLOW ON + 4
5

START / STOP DIVIDED ARC VOLTS

100K

J4
1

11 12 13

REMOTE ANALOG CURRENT CONTROL OK TO MOVE

100K6 3

14

- ARC V
5

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

PILOT ON OUTPUT OK to MOVE OK to MOVE + * REMOTE MARKING * REMOTE MARKING + -

6 7 8 9 10 11 12 PSR

7 Rev AA Revisions By Date

Art # A-06997_AD
ECO-B402 ECO-B448 ECO-B646 DAT 2/26/07 AB AC DAT 4/13/07 GAC 10/31/07

TB3
1 2

AD ECO-B1391 AE ECO-B1535

DAT 4-24-09 Information Proprietary to THERMAL DYNAMICS CORPORATION. DAT 9-25-09 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). TITLE:

Thermal Dynamics

Thermal Dynamics Industrial Park #2 West Lebanon NH 03784 603-298-5711

PCB No: Assy No: Scale Date: Tuesday, October 03, 2006 Drawn: References App: 2 DWG No: Sheet of 2

F
Supersedes

DAT
Chk: Size

SCHEMATIC,

Last Modified: Friday, September 25, 2009

08:11:44

100A Power Supply 400V CE (Chopper)

42X1211

10

Manual 0-4748

A-31

APPENDIX

ULTRA-CUT 100

APPENDIX 12: Schematic, CE 400V, Resistor Pilot

1 2 3 4 5

CN1-not used
4 3 2 1

100A INVERTER MODULE

N (-)

A
L1

L1 NFC1 MC1-A
L4

INRUSH TB1
4 6

L8
3
1 2 4 + + 1

3 Phase

L1

P1
+

V_CHANGE PCB 400V only

TB2

MC1-B
L5

L2

1 2 3

L2

400 VAC

--400--

EMI FILTER

MC1-C L3
L3 L6

TB3 TB4 N2

2 4 + 1

P (+)

L2

CN4 - PCB12 CN2-400V

1 2 3 1 2 3 4 4

L3

COM

400

200

B
L4

PGND1

L5

L6

L7

ON / OFF
C.P1

CN1

LINE to LINE, LINE TO GND CAPS & VARISTORS

NE1

CN3
1 4

PCB 1 WK-5630 FILTER PCB

TB1
4 1

CN4
NE2

CN2

VAC_IN

P_GND

INPUT POWER INDICATOR REAR PANEL

CN1
7 6 5

PGND2

/ 200

/ 400

PCB3

WK-5694

INPUT POWER INDICATOR INTERNAL

BIAS SUPPLY PCB

D1
AC AC +

4 3

C1
-

2 1

AC

CN2
1

D
/ 400

VAC_IN P_GND

2 3

CN2

CN4
RY2

CN4 CN1

CN5 CN5

CN6 CN6

BIAS SUPPLY FOR PCB5 CN32 CN18

1 2 3 4

DC FAN POWER
1 2 3

+12VDC RY2

DETECTOR PCB
200V
+12VDC +12VDC

RIBBON CABLE 16 CKT

PCB4
RY2

WK-5604
FAN + (24 VDC) FAN - (24 VDC)

CN6 16 CKT

RIBBON CABLE SIGNALS CN6 - 16 Ckt Ribbon Cable 2,4- I_REF (Scaled Cut Demand) 5- PS_START (Start) 6- REDUNDANT_START (Start2) 8- INV_READY 9- / PS_START disabled by Input_NG 12- / OCR 13- / PS_START disabled by OCR 14- /TEMP_ERR 15- / PS_START disabled by Temp _Err

CN10

GND

+5V

MISSING_PHASE

INPUT_NG

+15V

+15V

+15V

-15V

TEMP_C

CN7
+15V

CN32

MISSING PHASE (pulses)<

LED4
CHOPPER TEMP

LED2
MISSING PHASE

LED3
INPUT NG

PCB 5 WK-5602 (partial)

INTERFACE PCB

LED1 LED2 LED3 LED4 LED5

DIM DIM DIM OFF OFF

= = = = =

LOW, BRIGHT = OK OK, BRIGHT = FAULT OK, BRIGHT = FAULT OK, ON = FAULT OK, ON + FAULT

/ OVERTEMP <
LED5
ERROR

Art # A-06994_AB
1 2 3 4 5

APPENDIX

A-32

Manual 0-4748

CN6

16 CKT

CN17

GND_C

+ +
CN3

CN7

(F2 -Sht2)

To T1 PRI - 0 (A1 Sht2)

To PCB7 TB3 (A1 Sht2)

To PCB7 CN2-2 (A1 Sht 2) To PCB7 CN2-1 (A1 Sht 2)

To PCB7 CN2-4 (A2 Sht 2)

To PCB7 CN2-5 (A2 Sht 2)

ULTRA-CUT 100

9
NEG ARC VOLTS
(C7 & A9,Sht 2) TB2 TB3 TORCH (-) Power Supply Rear Panel

10

RAS

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.

CN1 R6 20K 30W

1 2 3 4

N2

P1

PCB 8 WK-5687
RC & RF CAPS CN2 CN3

TB1

C2 2 UF R9 50
WORK

CN5

4 3 2 1

PILOT REGULATOR (CHOPPER)

1 2 3

CN1 TB2
2 1

BIAS POWER

PILOT REG. (CHOPPER ) PCB1 WK-5750

TB5

TB4
THS1 SW_TEMP_NC

FAN3 HCT1
HALL SENSOR

PILOT

1 2 3 4

PILOT (TIP) VOLTS

(C7, Sht 2)

TB1

+12V -12V SIGNAL COMMON

CN3

CN4

CN2

B
MC2-A

2 1

5 4 3 2 1

CN8

CN7

CN6

3 2 1

CN9

MC2-B CN1

2 1

5 4 3 2 1

3 2 1

> P_Enable (P_ena)

> P_DEM (P_Iref)

< /OVER_TEMP

I_DET

1 2 3

1 2 3 4

CN4

CN2

CN5

< <

I_SE

PILOT REG. (CHOPPER ) PCB2 WK-5754

1 2

1 2 3 4

MC2-C

R1 4 Ohm 1KW

TEMP_C

GND_C

I_senseP GNDP

P_ena

Iref_G

P_ref

C
HCT2
HALL SENSOR

WORK (+)

1 2 3 4

WORK
+15Vw -15Vw Isense_W GNDW

(C7 & A9,Sht 2)

COMPONENT LOCATOR
C1 C2 C.P1 C.P2 C.P3 C.P4 C.P5 C.P6 C.P7 C.P8 D1 FAN1 FAN3 FL1 Capacitor, 0.1 uf, 1250 VDC Capacitor, 2 uf, 430VAC Circuit protector/ON-OFF SW 15A, 460V, 3P Circuit protector 2.5A 125V Circuit protector 3.15A 125V Circuit protector 10A 125V Circuit protector 2.5A 125V Circuit protector 2.5A 125V Circuit protector 5A 125V Circuit protector 3.15A 125V Diode Bridge 20A, 1600V, 3P Fan, Coolant, 24 VDC Fan, Chopper, 24 VDC Flow sensor (D2, Sht 2) (A9, Sht 1) (C2, Sht 1) (D2, Sht 1) (D2, Sht 1) (E2, Sht 1) (E2, Sht 1) (F2, Sht 1) (E2, Sht 1) (F3, Sht 1) (D2, Sht 1) (F4, Sht 2) (A8, Sht 1) (B5, Sht 2) HCT1 HCT2 Hall Current Sensor, Pilot Hall Current Sensor, Work (B8, Sht 1) (C9, Sht 1)

D 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)
LSW1 Level SW, coolant, NC MC1 MC2 Contactor, 3P ,Inv 1 input, Coil " Contacts " Aux Contact Contactor, pilot, Coil " Contacts (B5, Sht 2) (B3, Sht 2) (A2, B2, Sht 1) (B3, Sht 2) (B3, Sht 2) (B8, Sht 1) (E4, Sht 2) (C1, Sht 1) (D1, Sht 1) (A2, Sht 1) (C8, (A8, (E2, (A9, Sht Sht Sht Sht 1) 1) 2) 1)

MOT1 Motor, Pump 200VAC, 1P NE1 NE2 NFC1 R1 R6 R7 R9 Neon indicator, rear panel, 220VAC Neon indicator, internal, 220VAC Noise Filter, EMI, input Resistor, Resistor, Resistor, Resistor, Pilot, 4 Ohm, 1 KW 20K ,30W 1K ,30W 50 ,40W

Isense_W

I_senseP

P_ena

GNDP

Iref_G

P_ref

GNDW

+15Vw

-15Vw

T1 TH1

Aux Transformer Thermal Sensor, coolant return

(D-F1, Sht 2) (B5, Sht 2)

CN33

CN3

CN4

/PILOT ENABLE > PILOT DEMAND >

PILOT CURRENT SIGNAL <

WORK CURRENT SIGNAL <

Art # A-06994_AB
Rev AA Revisions By Date

ECO-B402

DAT DAT

2/26/07 4/13/07

AB ECO-B448 AC ECO-B646

GAC 10/31/07

Thermal Dynamics
TITLE:

Thermal Dynamics Industrial Park #2 West Lebanon NH 03784 603-298-5711

PCB No: Assy No: Scale Date: Tuesday, October 03, 2006 Drawn: References Sheet of 2 Supersedes

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).

DAT
Chk: Size App: 1 DWG No:

SCHEMATIC,

Last Modified: Wednesday, October 31, 2007 08:11:44

100A Power Supply 400V CE (Resistor)

42X1210

10

Manual 0-4748

A-33

APPENDIX

ULTRA-CUT 100

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

1 2 3 4 5
To PCB7 CN2-1 (F1 Sht 1) To PCB7 CN2-2 (F1 Sht 1) To PCB7 CN2-4 (F2 Sht 1) To PCB7 CN2-5 (F2 Sht 1) To T1 PRI - 0 (F1 Sht 1) To PCB7 TB3 (F1 Sht 1)

A
CN2
2 1

PCB 5 WK-5602 (partial)

INTERFACE PCB

CN9

TO AC INDICATOR (on PCB6)

1 2 3

LED1
LEVEL

INPUT CONTACTOR
MC1 MC2

4 5

CN12 MC1 AUX

CN8

CN1

CN13

CN14

1
1 1

+15V

+15V

PILOT CONTACTOR

TH1
SIG GND +V

COOLANT TEMP (ON COOLANT FL1 RETURN) FLOW_TURBINE_PULSE

LSW1-1

CCM MODULE
C
CN2
TB3

I/O PCB
1 2 3 4 5

TP1 TP2 TP3 TP4

CIRCUIT COMM (GND) 29-41 VDC

200 (not used) 400 CN9

C.P2
400

TB4

+
RY1

TP5 TP9 TP11 TP12 TP13 TP14

+15VDC +5VDC -15VDC

ANALOG DEM to CPU NEG ARC VOLTS PILOT (TIP) VOLTAGE CUT DEM to PS PILOT DEM to PS

TB5

120.

COM

RY2

D
CN10
200 0___ 1

400 200 COM

C.P3
24_ 0___ 0__

2 3

C.P4
24.

PCB7 WK-5628 RELAY PCB

AC24V-GCM

(D9, A10)
0_

0V-A (24V ret)

RY5

RY4

RY3

C.P5
120.

AC120V-GCM

(D9, A10)
0...

CN6
0V-B (120V ret)

AC120V @ 1A

RY5

1 2

110

R7
1K 30W
0..

3 4

C.P7
200

CN3
AC200V @ 3A
1 2 3

RY3

0.

RY4 C.P8 TB1

100

0,,

FAN + (24 VDC) FROM CN18 PCB3 sht 1 FAN - (24 VDC)
C.P6

TB2

13

AC13V @ 2A

F
TX1P8S

1 2

0,

CN11

Art # A-06995_AB
1 2 3 4 5

APPENDIX

A-34

T1

1 2

400 200
RELCOL_0

TP6 TP7 TP8 TP10

+15VDC_ISO -15VDC_ISO
+16 to +18VDC ISOLATED COMM GAS_ON E-STOP_PS OK_CNC PSR CNC_E-STOP CNC_START

2 2

1 1

2 2

3 3

ISOLATED VOLTAGES

D1 D2 D4 CN8
1 2 3 4

+15V /PUMP /FAN /RAS

D15 D21 D23 D26 D28

HOLD_START CNC_PREFLOW

CN7
1 2 3 4

AC120V-RAS (C9) 0V-RAS

PUMP

CN20
1 2 3
1 1 2 2 3 3

'

SW6 - OK to MOVE CONTACTS / VOLTS SW11 - ANALOG CURRENT SELECT "B" DEFAULT, "A" REMOTE SW12 - DIVIDED ARC V RATIO SELECT SW13 - FACTORY ONLY

MOT1

CN10
1 2 3 4 5 6
1 1 2 2

CPU PCB
D11 D12 D13 INITIALIZING / PROGRAMMING STATUS CODE +5V

FAN1

CN12
1 2

DC 15V DC 0V

Manual 0-4748

ULTRA-CUT 100

10
INTERNAL TERMINAL STRIP TB3

PCB6 DISPLAY WK-5603

GREEN CN23
1 2 3 4 5 6

(Not in all units)

0V-A (24V ret)

1 2 3 4 5 6 7 120 VAC @ 100ma. 24 VAC @ 1A

(E2)

AC24V-GCM 0V-B (120V ret) AC120V-GCM

AC TEMP GAS DC STATUS

CN24

+15V / AC / TEMP / GAS - COOLANT / DC / STATUS

1 2 3 4 5 6

YELLOW

GREEN GREEN RED

(C9, sht 1)

WORK

8 9 10 11 UNDIVIDED ARC VOLTS FOR HEIGHT CONTROLS

NEG ARC VOLTS

(A9, sht 1)

12

POWER SUPPLY REAR PANEL J54-REMOTE HMI CN10 26 CKT CN11 34 CKT
1 2 3 4

JUMPER IN REMOTE HMI

PILOT (TIP) VOLTS

PLASMA ENABLE
5 6

NEG ARC VOLTS

RIBBON

CABLE

RIBBON

CABLE

(A9 SHT1)

(B9 SHT1)

(C9 SHT1)

WORK

J59-RAS
1 2 3 4 5

SW_LIQUID_LEVEL_NC

TEST SOCKET

TEST SOCKET

KEY PLUG

J35

26 CKT

J6 TP11

J9 TP1

J36

34 CKT

AC120V-RAS

7 8

24 VAC RET

24VAC

RIBBON CABLE SIGNALS / = active low digital signal CN10-J35 - 26 Ckt Ribbon Cable 2- Cut Demand 4- Pilot Demand 6- / Start 7- / Start2 9- / Pilot Enable 10- / HF Enable 12- / Pump Enable 13- / Fan Enable 15- / DC Indicator 16- / Over Temperature Indicator 18- / Gas-Coolant OK Indicator 19- / Status Lamp CN11-J36 - 34 Ckt Ribbon Cable 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 OK 12- Missing Phase 13- / Ready to Operate 15- / Input Volts OK 16- / Inverter OCR 18- / PS ID "00*" 19- / PS ID "0*0" 20- / PS ID "*00" 21- E-Stop 22- E-Stop 29,31,33 - 24 VAC Supply 30,32,34 - 24 VAC Return

TP12

(E4)
K6-1 K6 J5
1

0V-RAS (120V ret)

- ARC V

9 10 11 12 13 14

Signal - Basic ID Used to identify GCM 1000 present Signal - Master ID Used to identify resistor pilot unit

2 3 4 5

J55-GCM
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37

J7
1 2 3 4 5 6 7 8 9

PLASMA ENABLE PLASMA ENABLE PRESS OK (GCM 1000)

POT HI (GCM1000) POT WIPER (GCM1000) POT LOW (GCM 1000)

AC24V-GCM (E2) 0V-A (24V ret) DC 15V (F4) DC 0V AC120V-GCM (E2) 0V-B (120V ret)

J8 GAS ON E-STOP
1 2 3 4

TB1 E-STOP E-STOP +

1 2 3 4

MOMENTARY STOP

START / STOP

J1
1 2 3 4 5 6
1K

J15-CNC
1 2 3 4 5 6 7 8 9 10

- 5 START START / STOP + 6 DIVIDED ARC V - 7 DIVIDED ARC V + 8 REMOTE ANALOG CURRENT CONTROL - 9 REMOTE ANALOG CURRENT CONTROL + 10
11 12

START / STOP DIVIDED ARC VOLTS

7 8 9

TB2 HOLD START HOLD START PREFLOW ON PREFLOW ON PILOT ON OUTPUT OK to MOVE OK to MOVE + + +
1 2 3 4 5 6 7 8 9 10 11 12
Rev AA Revisions By Date 100K 100K

J4
1

11 12 13 14

REMOTE ANALOG CURRENT CONTROL OK TO MOVE

- ARC V
5

PSR
7

Art # A-06995_AB
ECO-B402 DAT 2/26/07 AB ECO-B448 AC ECO-B646 DAT 4/13/07 GAC 10/31/07

Thermal Dynamics
TITLE:

Thermal Dynamics Industrial Park #2 West Lebanon NH 03784 603-298-5711

PCB No: Assy No: Scale Date: Tuesday, October 03, 2006 Drawn: References Sheet of 2 Supersedes

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).

DAT
Chk: Size App: 2 DWG No:

SCHEMATIC,

08:11:44 Last Modified: Wednesday, October 31, 2007

100A Power Supply 400V CE (Resistor)

42X1210

10

Manual 0-4748

A-35

APPENDIX

ULTRA-CUT 100

APPENDIX 13: Schematic, CSA 600V, Chopper Pilot

1 2 3 4 5

CN1-not used
4 3 2 1

100A INVERTER MODULE

N (-)

A
MC1-A L1 T
4

INRUSH TB1
6

2 4 + 1

3 Phase

P1
+

V_CHANGE PCB 600V only

TB2
--600--

3
2

MC1-B L2

1 2 3

600 VAC

MC1-C L3

TB3 TB4 N2

2 4 + 1

P (+)

3
2

CN4 - PCB12 CN2-600V

1 2 3 4 1 2 3 4

COM

600

200

B
ON / OFF
C.P1

PGND1

CN6 16 CKT
PGND2 / 600

CN1

LINE to LINE, LINE TO GND CAPS & VARISTORS

NE1

CN3
1 4

PCB 1 WK-5857 FILTER PCB

/ 200

RIBBON CABLE SIGNALS CN6 - 16 Ckt Ribbon Cable 2,4- I_REF (Scaled Cut Demand) 5- PS_START (Start) 6- REDUNDANT_START (Start2) 8- INV_READY 9- / PS_START disabled by Input_NG 12- / OCR 13- / PS_START disabled by OCR 14- /TEMP_ERR 15- / PS_START disabled by Temp _Err

TB1
4 1

NE2

INPUT POWER INDICATOR INTERNAL

CN4

CN2

VAC_IN

P_GND

INPUT POWER INDICATOR REAR PANEL

CN1
7 6 5

PCB3

WK-5694

BIAS SUPPLY PCB

D1
AC AC +

4 3

C1
-

2 1

AC

CN2
1

D
/ 600

VAC_IN P_GND

2 3

CN2

CN4
RY2

CN4 CN1

CN5 CN5

CN6 CN6

BIAS SUPPLY FOR PCB5 CN32 CN18

1 2 3 4

DC FAN POWER
1 2 3

+12VDC

DETECTOR PCB
230V
+12VDC +12VDC

RY2

CN10

CN3

CN7

(F2 -Sht2)
GND +5V +15V

E
MISSING_PHASE

INPUT_NG

+15V

+15V

CN7
+15V

CN32

MISSING PHASE (pulses)<

CN6

LED5 LED3
INPUT NG ERROR

LED2
MISSING PHASE

PCB 5 WK-5602 (partial)

INTERFACE PCB
Art # A-07000_AD
1 2 3 4

LED1 LED2 LED3 LED4 LED5

DIM DIM DIM OFF OFF

= = = = =

LOW, BRIGHT = OK OK, BRIGHT = FAULT OK, BRIGHT = FAULT OK, ON = FAULT OK, ON + FAULT

APPENDIX

A-36

16 CKT

-15V

RIBBON CABLE

RY2

PCB4

WK-5604
FAN + (24 VDC) FAN - (24 VDC)

16 CKT

To T1 PRI - 0 (A1 Sht2)

To PCB7 TB3 (A1 Sht2)

To PCB7 CN2-2 (A1 Sht 2) To PCB7 CN2-1 (A1 Sht 2)

To PCB7 CN2-4 (A2 Sht 2)

To PCB7 CN2-5 (A2 Sht 2)

Manual 0-4748

ULTRA-CUT 100

9
NEG ARC VOLTS
(C7 & A9,Sht 2) TB2 TB3 TORCH (-) Power Supply Rear Panel

10

RAS

(C2, Sht 2) N2 P1

CN1 R6 20K 30W

1 2 3 4

PCB 8 WK-5687
RC & RF CAPS CN2 CN3

TB1

C2 2 UF R9 50
WORK

PILOT REGULATOR (CHOPPER)

1 2 3

CN5

4 3 2 1

CN1 TB2
2 1

BIAS POWER

TB5

TB1

+12V -12V SIGNAL COMMON

PILOT REG. (CHOPPER ) PCB1 WK-5750

TB4
THS1 SW_TEMP_NC

FAN3 HCT1
HALL SENSOR
1 2 3 4

PILOT

PILOT (TIP) VOLTS

(C7, Sht 2)

CN3

CN4

CN2

B
4 2 K2 K1 1 A1

2 1

5 4 3 2 1

3 2 1

D2

CN8

CN7

CN6
> P_Enable (P_ena)

2 1

5 4 3 2 1

3 2 1

CN9

1 2

> P_DEM (P_Iref)

< /OVER_TEMP

I_DET

I_SE

PILOT REG. (CHOPPER ) PCB2 WK-5754

CN4

CN1
1 2 3 4

A2

MC2-A

MC2-B CN5
4 1 2 3 4

CN2

1 2 3

< <

MC2-C
TEMP_C P_ena
I_senseP GNDP

GND_C

Iref_G

P_ref

C
HCT2
HALL SENSOR
1 2 3 4

WORK (+)

WORK
+15Vw -15Vw Isense_W GNDW

(C7 & A9,Sht 2)

COMPONENT LOCATOR
(B8, Sht 1) (C9, Sht 1) (B5, Sht 2) (B3, (A2, (B3, (B3, (C8, Sht B2, Sht Sht Sht 2) Sht 1) D 2) 2) 1)

C1 C2 C3 C.P1 C.P2 C.P3 C.P4 C.P5 C.P6 C.P7 C.P8 D1 D2 D3 FAN1 FAN3 FL1

Capacitor, 0.1 uf, 1250 VDC Capacitor, 2 uf, 430VAC Capacitor 47 uf 400V Circuit protector/ON-OFF SW 10A, 690V, 3Ph Circuit protector 2.5A 125V Circuit protector 3.15A 125V Circuit protector 10A 125V Circuit protector 2.5A 125V Circuit protector 2.5A 125V Circuit protector 5A 125V Circuit protector 3.15A 125V Diode Bridge 20A, 1600V, 3Ph Diode, Dual, 2x100A, 600V Diode Bridge 25A, 800V, 1Ph Fan, Coolant, 24 VDC Fan, Chopper, 24 VDC Flow sensor

(D2, Sht 2) (A9, Sht 1) (C1, Sht 2) (B2, Sht 1)

HCT1 HCT2

Hall Current Sensor, Pilot Hall Current Sensor, Work

LSW1 Level SW, coolant, NC MC1 (D2, (D2, (E2, (E2, (F2, (E2, (F3, Sht Sht Sht Sht Sht Sht Sht 1) 1) 1) 1) 1) 1) 1) MC2 Contactor, 3P ,Inv 1 input, Coil " Contacts " Aux Contact Contactor, pilot, Coil " Contacts

MOT1 Motor, Pump 200VAC, 1P NE1 Neon indicator, rear panel, 220VAC Neon indicator, internal, 220VAC Resistor, 20K ,30W Resistor, 1K ,30W Resistor, 50 ,40W Aux Transformer Thermal Sensor, coolant return

(E4, Sht 2) (C1, Sht 1) (C1, Sht 1) (A8, Sht 1) (E2, Sht 2) (A9, Sht 1) (D-F1, Sht 2) (B5, Sht 2)

(D2, Sht 1) (B8, Sht 1) (C1, Sht 2) (F4, Sht 2) (A8, Sht 1) (B5, Sht 2)

NE2 R6 R7 R9 T1 TH1

Isense_W
3

I_senseP

TEMP_C

GND_C

P_ena

CN17

CN33

CN3

GNDP

Iref_G

P_ref

CN4

GNDW
5

+15Vw

/ OVERTEMP <

/PILOT ENABLE > PILOT DEMAND >

PILOT CURRENT SIGNAL <

-15Vw

WORK CURRENT SIGNAL <

Art # A-07000_AD
Rev AA Revisions By Date

ECO-B402

DAT

2/26/07

LED4

AB ECO-B448 AC ECO-B646

DAT 4/13/07 GAC 10/31/07

CHOPPER TEMP

AD ECO-B1391 AE ECO-B1535

DAT 4-24-09 Information Proprietary to THERMAL DYNAMICS CORPORATION. DAT 9-25-09 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). TITLE:

Thermal Dynamics

Thermal Dynamics Industrial Park #2 West Lebanon NH 03784 603-298-5711

PCB No: Assy No: Scale Date: Tuesday, October 03, 2006 Drawn: References App: 1 DWG No: Sheet of 2

F
Supersedes

DAT
Chk: Size

SCHEMATIC,

Last Modified: Friday, September 25, 2009

08:11:44

100A Power Supply 600V CSA (Chopper)

42X1213

10

Manual 0-4748

A-37

APPENDIX

ULTRA-CUT 100

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

1 2 3 4 5
To PCB7 CN2-1 (F1 Sht 1) To PCB7 CN2-2 (F1 Sht 1) To PCB7 CN2-4 (F2 Sht 1) To PCB7 CN2-5 (F2 Sht 1) To T1 PRI - 0 (F1 Sht 1) To PCB7 TB3 (F1 Sht 1)

A
CN2
2 1

PCB 5 WK-5602 (partial)

INTERFACE PCB

CN9

TO AC INDICATOR (on PCB6)

1 2 3

LED1
LEVEL

INPUT CONTACTOR
MC1 MC2

4 5

CN12 MC1 AUX

CN12

CN1

CN13

CN14

1 1 1

+15V

TH1
SIG GND

+V

COOLANT TEMP (ON COOLANT FL1 RETURN) FLOW_TURBINE_PULSE

LSW1-1
SW_LIQUID_LEVEL_NC

CCM MODULE
I/O PCB
TP3

C
CN2
TB3
1 2 3 4 5

TP2 TP4 TP5 TP6 TP17 TP14

CIRCUIT COMM (GND) 29-41 VDC

+15VDC +5VDC -15VDC

ANALOG DEM to CPU NEG ARC VOLTS PILOT (TIP) VOLTAGE CUT DEM to PS PILOT DEM to PS COOLANT FLOW (freq) *

200-not used

TB4

+
RY1

TP12 TP15 TP16 TP18 TP7

TB5

600 CN9
600 COM

TP8 TP9
RY10

+15VDC_ISO -15VDC_ISO
+16 to +18VDC ISOLATED COMM GAS_ON E-STOP_PS OK_CNC PSR CNC_E-STOP CNC_START

2 2

1 1

2 2

3 3

+15V

PILOT CONTACTOR

C.P2
460 120.

D
220 0___

CN10
1

600 200 COM

C.P3
24_ 0___

2 3

0__

C.P4
24.

PCB7 WK-5628 RELAY PCB

RY7 RY9 RY3

AC24V-GCM

(D9, A10)
0_

0V-A (24V ret)

C.P5
120.

AC120V-GCM

(D9, A10)
0...

CN6
0V-B (120V ret)
1 2

RY5

110

R8
1K 30W
0..

3 4

C.P7
200

AC200V @ 3A

CN3
1 2 3

RY11

0.

RY4 C.P8 TB10

100

FAN + (24 VDC) FROM CN18 PCB3 sht 1 FAN - (24 VDC)
C.P6

TB9

0,, 13

AC13V @ 2A

1 2

0,

CN11

Art # A-07001_AD
1 2 3 4 5

APPENDIX

A-38

T1

1 2

200

ISOLATED VOLTAGES

TP10

D9 D7 D8 D15 CN8
1 2 3 4

AC120 @ 1A

+15V /PUMP /FAN /RAS

D21 D23 D26 D28

HOLD_START CNC_PREFLOW

CN7
1 2 3 4

AC120V-RAS (C9) 0V-RAS

PUMP

SW6 - OK to MOVE CONTACTS / VOLTS SW11 - ANALOG CURRENT SELECT "B" DEFAULT, "A" REMOTE SW12 - DIVIDED ARC V RATIO SELECT SW13 - FACTORY ONLY

CN4
1 2 3 1 1 2 2 3 3 ' .

MOT1

CN5
1 2 3 4 5 6 1 1 2 2 + -

CPU PCB
D11 D12 D13 INITIALIZING / PROGRAMMING STATUS CODE +5V

FAN1

CN12
1 2

DC 15V DC 0V

Manual 0-4748

ULTRA-CUT 100

9
INTERNAL TERMINAL STRIP TB3

10

PCB6 DISPLAY WK-5603

GREEN CN23
1 2 3 4 5 6

(Not in all units)

0V-A (24V ret)

1 2 3 4 5 6 7

(E2)

AC24V-GCM 0V-B (120V ret) AC120V-GCM

24 VAC @ 1A 120 VAC @ 100ma.

AC TEMP GAS DC STATUS

CN24

+15V / AC / TEMP / GAS - COOLANT / DC / STATUS

1 2 3 4 5 6

YELLOW

GREEN1 GREEN2 RED

(C9, sht 1)

WORK

8 9 10 11 UNDIVIDED ARC VOLTS FOR HEIGHT CONTROLS

NEG ARC VOLTS

(A9, sht 1)

12

POWER SUPPLY REAR PANEL J54-REMOTE HMI & CNC COMM

1

Was 7 pin changed to 14 pin in 2009

CN10

26 CKT

CN11

34 CKT

PILOT (TIP) VOLTS

2 3 4

NEG ARC VOLTS

JUMPER IN REMOTE HMI

PLASMA ENABLE

(B9, sht1)

(A9, sht1)

(C9, sht1)

RIBBON

CABLE

RIBBON

CABLE

5 6 7 8 9 10 11

WORK

KEY PLUG Tx+ GND GND TxRx+ Rx-

TEST SOCKET

TEST SOCKET

RS 485 (2 wire) uses Tx+ & Tx- only (used for TSC 3000) RS 422 (4 wire) connect TX+ to RX+ of CNC, Tx- to Rxof CNC

J35

26 CKT

J6 TP11

J9 TP1

J36

34 CKT

12 13 14

24VAC

TP13 - ARC V

24 VAC RET

RIBBON CABLE SIGNALS / = active low digital signal CN10-J35 - 26 Ckt Ribbon Cable 2-Cut Demand 4-Pilot Demand 6-/ Start 7-/ Start2 9-/ Pilot Enable 10-/ HF Enable 12-/ Pump Enable 13-/ Fan Enable 15-/ DC Indicator 16-/ Over Temperature Indicator 18-/ Gas-Coolant OK Indicator 19-/ Status Lamp CN11-J36 - 34 Ckt Ribbon Cable 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 OK 12- Missing Phase 13- / Ready to Operate 15- / Input Volts OK 16- / Inverter OCR 18- / PS ID "00*" 19- / PS ID "0*0" 20- / PS ID "*00" 21- E-Stop 22- E-Stop 29,31,33- 24 VAC Supply 30,32,34- 24 VAC Return

K6

K7-1

J59-RAS
1 2 3 4 5 6

** RS 485 / 422 on CPU board 19X2554 only.

Signal & GND Isolated from Plasma Supply

J6 **
1 Iso 2

KEY PLUG
C

AC120V-RAS

7 8

RxTx+ Rx+ TxJUMPER for 4 WIRE uses TX+, TXRX+, RXJ14

3 4 5 6

(E4)
0V-RAS (120V ret)

9 10 11 12 13 14

SW10-ADDRESS normally 0 (refer to 9 0 1 2 8 manual) 3 7 6 4

5

J5
1 2 3 4

4W 2W
J14

J55-GCM
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37

JUMPER for 2 WIRE (RS485 only) wire to A & B

SW14 - LINE SW14 TERMINATION normally on (refer to manual)

4W 2W

J7
1 2 3 4

PLASMA ENABLE PLASMA ENABLE PRESS OK (GCM 1000)

Signal - Basic ID Used to identify GCM 1000 present

5 6 7 8 9

POT HI (GCM1000) POT WIPER (GCM1000) POT LOW (GCM 1000)

AC24V-GCM (E2) 0V-A (24V ret) DC 15V (F4) DC 0V AC120V-GCM (E2) 0V-B (120V ret)

J8 GAS ON E-STOP
1 2

TB1
MOMENTARY STOP START / STOP

3 4

E-STOP E-STOP + * OK2

START / STOP

1 2 3 4 OK2 *
1 2 3 4 5 6 1K 7 8 9

J1

J15-CNC
1 2 3 4 5 6 7 8 9 10

- 5 + 6 DIVIDED ARC V - 7 DIVIDED ARC V + 8 REMOTE ANALOG CURRENT CONTROL - 9 REMOTE ANALOG CURRENT CONTROL + 10 * +10VDC @ 10 ma.(for CC pot high) 11 12 * OK2 TB2 HOLD START - 1 HOLD START + 2 PREFLOW ON - 3 PREFLOW ON + 4
START

START / STOP DIVIDED ARC VOLTS

100K

J4
1

11 12 13

REMOTE ANALOG CURRENT CONTROL OK TO MOVE

100K5 3

14

- ARC V
5

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

PILOT ON OUTPUT OK to MOVE OK to MOVE + * REMOTE MARKING * REMOTE MARKING + -

6 7 8 9 10 11 12 PSR

7 Rev AA Revisions By Date

Art # A-07001_AD
ECO-B402 DAT DAT 2/26/07 4/13/07 AB ECO-B448 AC ECO-B646

GAC 10/31/07

TB3
1 2

AD ECO-B1391 AE ECO-B1535

DAT 4-24-09 Information Proprietary to THERMAL DYNAMICS CORPORATION. DAT 9-25-09 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). TITLE:

Thermal Dynamics

Thermal Dynamics Industrial Park #2 West Lebanon NH 03784 603-298-5711

PCB No: Assy No: Scale Date: Tuesday, October 03, 2006 Drawn: References App: 2 DWG No: Sheet of 2 Supersedes

DAT
Chk: Size

SCHEMATIC,

Last Modified: Friday, September 25, 2009

08:11:44

100A Power Supply 600V CSA (Chopper)

42X1213

10

Manual 0-4748

A-39

APPENDIX

ULTRA-CUT 100

APPENDIX 14: PUBLICATION HISTORY

Cover Date July 1, 2005 Aug. 1, 2005 Rev --Change(s) First issue Updated: CCM switch settings and coolant specs, added: static discharge warning, torch O-ring lubrication data, catalog numbers for RAS, torch valve, gas control module, external power supply replacement parts, gas control box catalog numbers. Added: internal coolant filter cleaning, torch valve parts catalog numbers, metric cut charts. Modified warranty statement, corrected torch parts identification, added revision history. Added optional hose selection chart, corrected input power ratings, corrected torch consumables selection charts. Updated speed charts, updated fault chart, added voltages, added CCM info, added 30A SS N2/H20 towater shield in torch sections. Updated layout sketches to show new water lead between GCM-2010 and Torch Valve. Updated GCM-2010 and Torch Valve to show new water lead. Added info on routing input cables through bracket on lower back edge of power supply. Updated grounding method for Remote Arc Starter Cover. Added marking data to torch section. Updated Remote Arc Starter Schematic. Updated gas specs chart, section 2. Updated torch sections for 30A MS O2/O2 (new chart); 70A SS & AL, new part numbers and charts; 100A SS & AL, new part numbers. Updated grounding data. Updated shield cup installation art; added info on setting pre-charge pressure for marking; updated schematic for GCM. Added system schematics. In Section 8, updated 30A Aluminum N2/H20 speeds. Corrected minimum output current to 10A. Added maximum input gas pressure. Added preflow gases to gas applications chart. Added torch specifications. Changed F1 ground wire size from 1/0 to #4. Added note, side pressure can break check valves/connections to torch valve. Added error code group 6, Non-recoverable fault, Contact TDC for resolution (CCM software V2.3.1). Started using new cover styles. Ref: ECO B-122.

Aug. 19, 2005 Sep. 2, 2005 Sep. 30, 2005 Oct. 21, 2005 Jan. 4, 2006

------

Jan. 28, 2006 Feb. 20, 2006

---

Apr. 25, 2006

AA

Aug 25, 2006

AA.01 Added leads lengths C and D as part of ECO B122 missed earlier. Corrected art pages 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. AB.01 Added 400V, 400V CE and 600V inerter module part numbers. AC.01 Updated Error codes in section 4 and added notice to update to Firmware revision 2.4 or later. Updated Gas Control PCB layout in the Appendix. Added CNC cable shiel grounding. AD.01 Updated with new XTL TVA art and part numbers per ECOB356. Corrected plasma and shield hose lengths to 4 with new part numbers. Corrected art in section 3 showing hookup of work leads, input power etc.. AE.01 Corrected Switch setting errors pgs. 3-5, 3-6 and 3-7 for SW8-2. AF.01 AH AI Updated the Gas Requirement table in section 2. Removed ref. to deionizer parts per ECOB524 and updated new pump and motor assemblies per ECOB444. Added star grounding information ECOB653, updated o-ring number ECOB467 AG.01 Added mounting dimensions for the GCM, RAS and the XTL TVA section 6.

Oct 10, 2006 Jan. 10, 2007

Mar. 5, 2007

Mar. 8, 2007 Mar. 28, 2007 July 10, 2007 Oct 15, 2007 Oct. 29, 2007

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ULTRA-CUT 100
Cover Date Jan. 14, 2008 Jan. 28, 2008 Feb. 5, 2008 Mar. 25, 2008 Apr. 11, 2008 Rev AJ AK AL AM AN Change(s) Added flow meter replacement parts per ECOB704. Updated Schematics per ECOB402. Per ECOB738 added GCM plumbing diagram. Per ECOB646 added input terminal strip information to sections 3 and 6. Per ECOB846 updated sw13 information for CCM switch settings section 3. Per ECOB475 updated art for GCM PCB on pg.A-5 and multiple additions and corrections to sections 3, 4 and 6. Also added pilot transfer retry info switch setting per ECOB799 pg. 3-16 Updated section 3 per ECOB1163 to show single shielded leads. Also updated some sheet metal repair parts Catalog numbers from section 6. Corrected part number for item 13 on page 6-21 to show 9-9407 per ECOB1477. Updated Appendix with new CNC Functions information and system schematics with serial communication connector per ECOB1535.

Nov. 11, 2008 July 16, 2009 Sept. 29, 2009

AO AP AQ

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

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Global Customer Service Contact Information

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