THERMAL DYNAMICS 200 AUTO-CUT Plasma Cutting System Instruction manual

200

®

AUTO-CUT

PLASMA CUTTING SYSTEM

Operating Manual

Rev. AG Date: October 29, 2007 Manual # 0-4805
Operating Features:

Art # A-04821

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 1-800-426-1888, 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 employer’s 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, Auto-Cut® 200
Operating Manual No. 0-4805

Published by:
Thermadyne Corporation
82 Benning Street
West Lebanon, New Hampshire, USA 03784
[phone]

www.thermal-dynamics.com

© Copyright 2005, 2006, 2007 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

Publication Date: October 29, 2007

Record the following information for Warranty purposes:

Where Purchased: ___________________________________

Purchase Date:______________________________________

Power Supply Serial #:_______________________________

Torch Serial #:_______________________________________

This page intentionally blank

TABLE OF CONTENTS

SECTION 1:

GENERAL INFORMATION ............................................................................................... 1-1

1.01 Notes, Cautions and Warnings ..................................................................... 1-1

1.02 Important Safety Precautions ....................................................................... 1-1

1.03 Publications .................................................................................................. 1-3

1.04 Declaration of Conformity ............................................................................. 1-5

1.05 Statement of Warranty .................................................................................. 1-6

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

General Description Of The System ..................................................................... 2-1

Plasma Power Supply .......................................................................................... 2-1

Gas Control Module / Arc Starter ......................................................................... 2-1

Plasma Cutting Torch ........................................................................................... 2-1

System Component Layout .................................................................................. 2-1

Power Supply Specifications & Electrical Requirements ....................................... 2-2

Power Supply Dimensions .................................................................................... 2-3

Power Supply Rear Panel Features...................................................................... 2-4

Gas Requirements ............................................................................................... 2-5

Gas Applications .................................................................................................. 2-5

XTTM-301 Torch Specifications ............................................................................ 2-6

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

A. Installation Requirements ............................................................................. 3-1

B. Cables and Leads Identification ................................................................... 3-2

C. Position the Power Supply ............................................................................ 3-4

D. Set Command-Control Module Switches ...................................................... 3-5

E. Check / Adjust Input Voltage Configuration ................................................... 3-9

F. Remove the Connections Cover ................................................................. 3-10

G. Connect Work Cable .................................................................................. 3-11

H. Connect Input Power and System Ground Cables ..................................... 3-12

I. Ground Connections .................................................................................. 3-13

J. Connect Gas Supply Lines ......................................................................... 3-17

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

Power Supply Indicators ....................................................................................... 4-1

Control Console Features .................................................................................... 4-2

Operating Set-up .................................................................................................. 4-3

Cut Quality ........................................................................................................... 4-5

System Operation ................................................................................................ 4-7

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

Coolant Filter Cleaning Procedure ....................................................................... 5-1

Water Filter Cleaning Procedure .......................................................................... 5-2

Coolant Replacement Procedure ......................................................................... 5-3

Arc Starter Service ............................................................................................... 5-4

Arc Starter Spark Gap Adjustment ....................................................................... 5-5

TABLE OF CONTENTS (continued)

Section 6: Replacement Assemblies & Parts ........................................................................... 6-1

Leads and Cables ................................................................................................ 6-2

Leads and Cables ................................................................................................ 6-2

Optional Gas Supply Leads .................................................................................. 6-4

Power Supply External Replacement Parts .......................................................... 6-5

Power Supply Replacement Parts - Right Side ..................................................... 6-6

Power Supply Replacement Parts - Right Side ..................................................... 6-7

Power Supply Replacement Parts - Right Side ..................................................... 6-8

Power Supply Replacement Parts - Front Panel ................................................... 6-9

Power Supply Replacement Parts - Front Panel ................................................. 6-10

Power Supply Replacement Parts - Right Side ................................................... 6-11

Power Supply Replacement Parts - Rear Panel ................................................. 6-12

Power Supply Replacement Parts - Right Side ................................................... 6-13

Power Supply Replacement Parts ...................................................................... 6-14

Power Supply Replacement Parts - Right Side ................................................... 6-15

Power Supply Replacement Parts ...................................................................... 6-16

Power Supply Replacement Parts - Right Side ................................................... 6-17

Power Supply Replacement Parts - Right Side ................................................... 6-18

Arc Starter & Gas Control Module (GCM-1000) Replacement Parts .................. 6-19

Command & Control Module Type 1 - Replacement Parts ................................ 6-20

Command & Control Module Type 2 - Replacement Parts ................................ 6-21

SECTION 7: Torch Maintenance ............................................................................................. 7-1

A. Consumable Removal .................................................................................. 7-1

B. O-Ring Lubrication ....................................................................................... 7-2

C. Parts Wear ................................................................................................... 7-2

D. Torch Consumables Installation.................................................................... 7-3

Appendix 1: Control Cable Pinouts ........................................................................................... A-1

Appendix 2: Control Cable Pinouts ........................................................................................... A-2

Appendix 3: Command-Control PC Board Layout (A) ............................................................... A-3

Appendix 4: Command-Control PC Board Layout (B) ............................................................... A-4

Appendix 5: CNC - Control Module Board PCB Connections ................................................... A-6

CNC functions. ..................................................................................................... A-7

CNC Input / Output Descriptions .......................................................................... A-8

Simplified CNC Circuit. .........................................................................................A-9

Appendix 6: Arc Starter / Gas Control Module Schematic ....................................................... A-10

Appendix 7: Power Supply Schematic, 230-460V, Chopper Pilot w/ Diode .............................. A-12

Appendix 8: Power Supply Schematic, 230-460V, Resistor Pilot ............................................. A-14

TABLE OF CONTENTS

Appendix 9: Power Supply Schematic, CCC 400V, Chopper Pilot w/ Diode ............................ A-16

Appendix 10: Power Supply Schematic, CE 400V, Chopper Pilot w/ Diode ............................. A-18

Appendix 11: Power Supply Schematic, CE 400V, Resistor Pilot ............................................ A-20

Appendix 12: Power Supply Schematic, CSA 600V, Chopper Pilot w/Diode........................... A-22

APPENDIX 13: PUBLICATION HISTORY ............................................................................... A-24

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

TABLE OF CONTENTS (continued)

SECTION 1:

GENERAL INFORMATION

1.01 Notes, Cautions and Warnings

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.

CAUTION

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

WARNING

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

1.02 Important Safety Precautions

WARNINGS

OPERA TION AND MAINTENANCE OF PLASMA ARC EQUIPMENT CAN BE DANGEROUS AND HAZ­ARDOUS TO YOUR HEAL TH.

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 1-603-298-571 1 or your local distributor if you have any questions.

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.

• 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. Y ou must be very careful when cutting or welding any met als which may contain one
or more of the following:

Antimony Chromium Mercury Beryllium
Arsenic Cobalt Nickel Lead
Barium Copper Selenium Silv e r
Cadmium Manganese V anadium

Manual 0-4805 1-1 GENERAL INFORMATION

• 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
St ate of California to cause birth defects and, in some cases, cancer. (California Health & Safety Code Sec.

25249.5 et seq.)

ELECTRIC SHOCK

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

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.

• 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.

NOISE

Noise can cause permanent hearing loss. Plasma arc processes can cause noise levels to exceed safe limits. Y o u
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 muf fs. 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.

GENERAL INFORMATION 1-2 Manual 0-4805

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 Shade No. Shade No.

Less Than 300* 8 9

300 - 400* 9 12
400 - 800* 10 14

Minimum Protective Suggested

* 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.

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 HEAL TH 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 MEN’S 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 S tandard 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

Manual 0-4805 1-3 GENERAL INFORMATION

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 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

GENERAL INFORMATION 1-4 Manual 0-4805

1.04 Declaration of Conformity

Manufacturer: Thermal Dynamics Corporation
Address: 82 Benning Street

West Lebanon, New Hampshire 03784
USA

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. Among them are:

* CSA (Canadian Standards Association) standard C22.2 number 60 for Arc welding equipment.

* UL (Underwriters Laboratory) rating 94VO flammability testing for all printed-circuit boards used.

* ISO/IEC 60974-1 (BS 638-PT10) (EN 60 974-1) (EN50192) (EN50078) applicable to plasma cutting equipment and

associated accessories.

* CENELEC EN50199 EMC Product Standard for Arc Welding Equipment

* 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 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

Manual 0-4805 1-5 GENERAL INFORMATION

1.05 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 Thermal’s specifications, instructions, recommendations and recognized standard industry practice, and not subject to misuse, repair ,
neglect, alteration, or accident, correct such defects by suitable repair or replacement, at Thermal’s sole option, of any components or parts
of the product determined by Thermal to be defective.

THIS WARRANTY IS EXCLUSIVE AND IS IN LIEU OF ANY W ARRANTY OF MERCHANTABILITY OR FITNESS FOR A P ARTICULAR PURPOSE.
LIMITA TION 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 INV ALID IF REPLACEMENT P ARTS OR ACCESSORIES ARE USED WHICH MA Y IMP AIR THE SAFETY OR
PERFORMANCE OF ANY THERMAL PRODUCT .

THIS WARRANTY IS INV ALID 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).

AutoCut

Parts

©

and UltraCut© Power Supplies and Components 2 Years 1 Year

Labor

TorchAnd Leads

TM

XT

-300/XTTM-301 T orch (Excluding Consumable Parts) 1 Y ear 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 transport ation costs of any kind will be paid under this warranty . T ransportation charges to send products
to an authorized warranty repair facility shall be the responsibility of the customer. All returned goods shall be at the customer’s risk and
expense. This warranty supersedes all previous Thermal warranties.

Effective August 19, 2005

GENERAL INFORMATION 1-6 Manual 0-4805

SECTION 2: SPECIFICATIONS

General Description Of The System

A typical Auto-Cut® 200 plasma cutting system includes:

• One Power Supply

• Arc Starter / Gas Control Module (Mounted on Power Supply)

• General Purpose Plasma Cutting Torch with Connecting Leads

• Torch Spare Parts Kit

The components are connected at installation.

Plasma Power Supply

The power supply provides the necessary current for cutting operations, and monitors system performance. The
power supply also cools and circulates the liquid coolant for the torch and leads.

Gas Control Module / Arc Starter

This module mounts to the top of the power supply. This module enables the operator to select gas, set pressures
and flows and set cutting current.

Plasma Cutting Torch

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

System Component Layout

CNC

Ground Cables

Pilot Return

Negative

Coolant Supply

Coolant Return

Control Cable

CNC Cable

Arc Starter /

Gas Control Module

(GCM-1000)

Auto-Cut

Power Supply

Maximum Length 100’ / 30.5 m

Ground

Cable

Control

Cable

Primary power

Work Cable

Torch Lead Set, Shielded

- Coolant Supply w/ Negative

- Coolant Return

- Pilot Return

- Plasma Gas

- Shield Gas

Positioning

Tube

Torch

Work

Art # A-07231

Manual No. 0-4805 2-1 SPECIFICATIONS

Power Supply Specifications & Electrical Requirements

Auto-Cut 200 Power Supply Specifications

Max OCV (U0) 380 vdc
Max Out put Current 200 A m ps
Output V oltage 160 vdc
Duty Cy c l e Rati ng 100% @ 200A @ 160V (32 k W)
Operating range 14°F to 122°F (-10°C to + 50°C)
Power Fac t or 0.70 @ 100 ADC Out put
Cooling F orc ed A i r (Class F)

Auto-Cut 200

Input Power Input Current

Power Supply

Sugges t ed S i z es (S ee Note)

Volt age Freq. 3-Ph 3-Ph Fus e (Am ps) W i re (AWG)

(Volts) (Hz) (kVA) (Amps) 3-Ph 3-Ph

208 60 47 130 160
230 60 49 125 150
400505477100

400 (CE) 50 54 77 100

46060597590

#2
#2
#2
#2
#2

2
2
1
1
1

Line Voltages wit h S uggest ed Circui t Prot ect ion and Wire S i z es

Bas ed on Nati onal E l ect ric Code and Canadian Elect rical Code

1

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

2

Extra Hard Usage Type G, G-GC, W

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.

Manual No. 0-4805 2-2 SPECIFICATIONS

Power Supply Dimensions

27 inch
680 mm

41.25 inch
1050 mm

48.75 inch
1238 mm

27.5 inch
700 mm

33 inch
840 mm

37.75 inch
960 mm

397 lb / 180 kg

Art # A-04822

Manual No. 0-4805 2-3 SPECIFICATIONS

Power Supply Rear Panel Features

Gas Entry Ports

Circuit Breaker Panel

Gas Control Connector

CNC Connection

Arc Starter Connector

Gas Control Connector

Pilot (Pos)

Terminal

RETURN

SUPPLY

Arc Starter
Connector

Torch (Neg)

Terminal

Work Cable Terminal

Torch Leads Port

Input Power

Terminals

AC Power Lamp

Ground Terminals

Terminal Cover

Terminal Cover

Support Panel

Coolant Connections

Coolant Filter

Coolant Tank

Leads
Bracket

Art # A-04823

Manual No. 0-4805 2-4 SPECIFICATIONS

Gas Requirements

The customer will provide all gases and pressure regulators. Gases must be of high quality. Pressure regulators
shall be equipped with stainless-steel diaphragms and installed as close as possible to the Gas Console.

Auto-Cut 200 BASIC Powe r S upply: Gas Pressures, Flows, a nd Qua l i ty Require m e nts

Gas Quality Minimum Pressure Flow

(Oxygen)

O

2

99.5% P uri t y

(Liquid recom m ended)

120 psi

8.3 bar / 827 k Pa

200 sc fh (5700 l/h)

99.5% P uri t y

N

(Liquid recom m ended)

(Nitrogen)

2

Compressed

Air

H35 (Argo n-Hydrogen )
H35 = 35% Hy drogen,

65% A rgon

H

O (W at er) See Not e 2 50 psi (3. 5 bar) 10 gph (38 lph)

2

: The air sourc e m us t be adequat el y filtered to remove all oil or grease. Oi l or grease

Note 1

<1000 ppm O

ppm H

2

O)

2

, <32

Clean, Dry,

Free of Oil (see Note 1)

99.9 95% P u ri t y

(gas recom m ended)

120 psi

8.3 bar / 827 k Pa

90 ps i

6.2 bar / 621 k Pa

120 psi

8.3 bar / 827 k Pa

300 sc fh (8496 l/h)

400 scfh (11327 l/h)

200 sc fh (5664 l/h)

cont am i nat ion from c om pres sed or bott l ed air c an caus e fires in conjunc tion with ox y gen.
For filtering, a coalesc ing fil t er able t o fil t er t o 0. 01 m icrons should be plac ed as close as

possible to the gas inlets on the Gas Control Module.

: The tap water s ourc e does not need t o be deioni z ed, but in water sy st ems wit h ext remel y hi gh

Note 2

mineral content a wat er s oftener is rec omm ended. Tap water with high l evels of partic ulat e m at ter must be
filtered.

Gas Applications

MATERIAL

OPERATION

55 A Cut

100 A Cut
200 A Cut

PLASMA SHIELD PLASMA SHIELD PLASMA S HIELD

2 O2 Air A ir Air Air

O

2 Air N2 H20N2 H20

O

35 N2 H35 N2

2

AirO

H

N2 H20N2 H20

Air Air NA NA NA NA

Manual No. 0-4805 2-5 SPECIFICATIONS

ALUMINUMMILD STEEL STAINLESS STEEL

GAS TYPEGAS TYPEGAS TYPE

XTTM-301 Torch Specifications

A. Torch Dimensions

Art # A-05856

End Cap

19.00"

482.68 mm

393.78 mm

15.50"

160.10 mm

6.30"

3.54"

89.87 mm

2.25"

57.15 mm

Mounting Tube

2.0"

50.8 mm

Torch Body

2.39"

60.81 mm

2.74"

69.55 mm

1.57"

39.96 mm

1.49"

37.8 mm

Manual No. 0-4805 2-6 SPECIFICATIONS

B. Torch Leads Lengths

Gas Lead Assemblies

C. Torch Parts (Generic Parts Shown)

Length

Feet Meters

10 3.05
15 4.6
25 7.6
50 15.2
75 22.8

100 30.4

Art # A-04741

Shield Gas

Distributor

Shield Cap

Shield Cup

Tip

Plasma Gas

Distributor

Electrode

Cartridge

D. Parts - In - Place (PIP)

The torch is designed for use with a power supply which senses coolant return flow to confirm that torch
parts are in place. If coolant return flow to the power supply is absent or insufficient the power supply will
not provide power to the torch. Coolant leakage from the torch also indicates that torch parts are absent
or installed improperly.

E. Type Cooling

Combination of gas stream through torch and liquid cooling.

Manual No. 0-4805 2-7 SPECIFICATIONS

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Manual No. 0-4805 2-8 SPECIFICATIONS

SECTION 3: INSTALLATION

A. Installation Requirements

1. 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.

Auto-Cut 200

Input Power Input Current

Power Supply

Sugges t ed S i z es (S ee Note)

Volt age Freq. 3-Ph 3-Ph Fus e (Am ps) W i re (AWG)

(Volts) (Hz) (kVA) (Amps) 3-Ph 3-Ph

208 60 47 130 160
230 60 49 125 150
400505477100

400 (CE) 50 54 77 100

46060597590

Line Voltages wit h S uggest ed Circui t Prot ect ion and Wire S i zes

Bas ed on Nati onal E l ect ric Code and Canadian El ec t ri cal Code

1

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

2

Extra Hard Usage Type G, G-GC, W

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.

2. 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:

#2
#2
#2
#2
#2

2
2
1
1
1

• 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.

3. 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 Capabilit i es

Cat. Number and Mixture Mixture Protects To

7-3580 'E xt ra -Cool

7-3581 'Ultra-Cool

7-3582 'Ext reme Cool

* For mixing with D-I Cool

TM

'

TM

'

TM

' Concentrate* -65° F / -51° C

TM

7-3583

Manual No. 0-4805 3-1 INSTALLATION

25 / 75 10° F / -12° C

50 / 50 27° F / -33° C

B. Cables and Leads Identification

CNC

Ground Cables

Pilot Return

Negative

Coolant Supply

Coolant Return

Control Cable

CNC Cable

Arc Starter /

Gas Control Module

(GCM-1000)

Auto-Cut

Power Supply

Maximum Length 100’ / 30.5 m

Ground

Cable

Control

Cable

Primary power

Work Cable

Torch Lead Set, Shielded

- Coolant Supply w/ Negative

- Coolant Return

- Pilot Return

- Plasma Gas

- Shield Gas

Positioning

Tube

Torch

Work

Art # A-07231

Manual No. 0-4805 3-2 INSTALLATION

#8 AWG Cable

A

Pilot Return, Power Supply
to Arc Starter

B

C

D

E

F1

G

K

#1 AWG Cable

Negative Lead, Power Supply
to Arc Starter

Green

Green

Coolant Leads, Power Supply

Red

Red

to Arc Starter

Control Cable, Power Supply

14

F

Green / Yellow #10 AWG

Green / Yellow 1/0 (50 mm )

2

to Arc Starter

Ground Cable

Ground Cable,
Arc Starter
To Earth Ground

Torch Lead Set

Control Cable,

37

Power Supply to
Gas Control Module

O

1/0 (50 mm ) Cable

P

2

Work Cable

CNC Cable (14 Wire)

4’ / 1.3 m

Q

Ground Cable, Gas Control Module
to Power Supply. Factory Installed.

#4 AWG

Art # A-07103

Manual No. 0-4805 3-3 INSTALLATION

C. Position 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-04824

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.

Manual No. 0-4805 3-4 INSTALLATION

D. Set Command-Control Module Switches

CAUTION

There are two types of command-control module. Refer to the illustration to determine the type installed.

1. Set Switches for Type 1 Command-Control Module

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

2

SW1

3

O
N

1

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, 2 = OFF: 2 Seconds (Factory default setting).
1 = ON, 2 = OFF: 4 Seconds
1 = OFF, 2 = ON: 6 Seconds
1 = ON, 2 = ON: 8 Seconds

SW-4: Postflow Time 1 = OFF, 2 = OFF: 10 Seconds (Factory default setting).
1 = ON, 2 = OFF: 20 Seconds
1 = OFF, 2 = ON: 5 Seconds
1 = ON, 2 = ON: 0 Seconds (Disabled)

SW-5-1: Tip Saver 1 = OFF = Disabled (Factory default setting).
1 = ON = Enabled

SW-5-2: Off Plate 2 = OFF = Disabled (Factory default setting).
2 = ON = Enabled
SW 8-1: Pilot Time 1 = OFF = Short (85 ms.) (Factory default setting).
1 = ON = Long (3 s.)

SW 8-2: Remote Current 1 = ON (Remote Analog Current Control)
SW8-3, SW 8-4: Reserved for Factory use.

SW3

1

4

2

1

SW4

SW5

1

2

2

SW8

4

1

3

2

O
N

1

2

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

Art # A-04825

Manual No. 0-4805 3-5 INSTALLATION

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

SW12

SW13

SW-6: OK-to-Move: Contact closure, 120VAC @ 1A (Factory default setting) or
DC Volts (16-18vdc@ upt to 100 ma.)
SW-11: Analog Current Control. B = from Basic Gas Control (Factory default setting) or
A = from CNC. Position A requires that SW-8-2 be ON.

SW-12-1/2/3/4: Divided Arc signal

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

SW13: Reserved for Factory Use.

All = OFF = 50:1 (Factory default setting)

Only 1 on at a time.

Art # A-04826

NOTE

Standoff Control SC-11 requires Switch 12-1 set to ON.

Manual No. 0-4805 3-6 INSTALLATION

2. Set Switches for Type 2 Command-Control Module

CAUTION

There are two types of command-control module. Refer to the illustration to determine the type installed.

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

2

SW1

3

O
N

1

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, 2 = OFF: 2 seconds
1 = ON, 2 = OFF: 4 seconds
1 = OFF, 2 = ON: 6 seconds
1 = ON, 2 = ON: 8 seconds

SW-4: Postflow Time 1 = OFF, 2 = OFF: 10 Seconds (Factory default setting).
1 = ON, 2 = OFF: 20 Seconds
1 = OFF, 2 = ON: 5 Seconds
1 = ON, 2 = ON: 0 Seconds

SW-5-1: Tip Saver 1 = OFF = Disabled (Factory default setting).
1 = ON = Enabled

SW-5-2: Off Plate 2 = OFF = Disabled (Factory default setting).
2 = ON = Enabled

SW 8-1: Pilot Time 1 = OFF = Short (85 ms.) (Factory default setting).
1 = ON = Long (3 s.)

SW 8-2: Remote Current 1 = ON (Remote Analog Current Control)
SW8-3, SW 8-4: Reserved for Factory use.

SW3

1

4

2

1

SW4

SW5

1

2

2

SW8

4

1

3

2

O
N

1

2

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

Art # A-06869

Manual No. 0-4805 3-7 INSTALLATION

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.)

SW-11: Analog Current Control. B = from Gas Control (Factory default setting) or A = from CNC.
Position A requires that SW-8-2 be ON.

SW-12-1/2/3/4: Divided Arc signal

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

SW13-1, SW13-2: Reserved for Factory Use.

All = OFF = 50:1 (Factory default setting)

Only 1 on at a time.

Art # A-06870

NOTE

Standoff Control SC-11 requires Switch 12-1 set to ON.

Manual No. 0-4805 3-8 INSTALLATION

E. 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 from the top-right corner of the board, remove the board and re-install with
the correct input voltage shown at the top of the board. Reconnect the jumper to the top-right corner of the
board.

3. Re-install the power supply side panel.

Inverter Module

1. Disconnect jumper

208/230V / 460V

Input Voltage Board

(Shown in 460V Position)

2. Remove bolts.

3. Invert board.

4. Re-install board.

5. Connect jumper.

Art # A-04856

Manual No. 0-4805 3-9 INSTALLATION

F. Remove the Connections Cover

The primary power cable must be supplied by the end user and connected to the power supply. Refer to local and
national electrical codes for suggested cable and fuse sizes.

Remove the connections cover on the rear of the Power Supply. Use caution when removing the panel; there is a
ground wire connected to the inside of the panel. Do not disconnect this wire.

Connection Panel

Connections Cover
(Removed)

Art # A-04827

Manual No. 0-4805 3-10 INSTALLATION

G. Connect Work Cable

1. Pass the end of the work cable upward through the leads bracket at the bottom of the power supply rear
panel, then up through the opening in the connections cover support panel.

2. Refer to the illustration. Connect the lead as shown. Tighten securely. Do not overtighten.

WARNINGS

Ensure that lead attachment hardware is properly sized. Excess length may cause damage if hardware contacts
other parts of the system.

The clear connections cover must remain in place.

Connections Cover

Work Cable

PILOT WORK TORCH

Work Lead

Connection Panel

AC INPUT

L2

L1

L3

Connections Cover
Support Panel

Work Lead Connection Detail

Leads Bracket

To Cutting Table

Art # A-04845

Manual No. 0-4805 3-11 INSTALLATION

H. 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 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.
Tighten the hardware securely. Do not overtighten.

WARNING

The clear connections cover must remain in place.

4. Pass a system ground cable through the same opening in the connections cover support panel as 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

Clear Connections Cover

Connection Panel

PILOT

WORK TORCH

AC INPUT

L2 L3

L1

Input power cable

L1

L2

L3

System Ground Cable

Leads Bracket

System Ground Cable

Input power cable ground

Connections Cover
Support Panel

Art # A-04846

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

Manual No. 0-4805 3-12 INSTALLATION

WARNING

Dangerous high voltage is present when the power supply is connected to input power. Do not connect input
power or operate the power supply unless the connections cover is fastened in place.

I. 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 mm
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.

2

) or larger wire to a good earth ground (measuring leass

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 manufacturer’s recommendations for wire size, type, and connection point
locations.

For Thermal Dynamics components (except 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.

Manual No. 0-4805 3-13 INSTALLATION

Star Ground on Cutting Table

Ultra-Cut

or

Auto-Cut O2

Remote Arc

Starter (RAS-1000)

Cutting Machine / Gantry

Cutting Table

1/0

Ground Cable

Ground Cable

Earth Ground

Rod

Torch

1/0

0 - 10 ft (0 - 3 m) Ideal

20 ft (6 m) Maximum

CNC

Device

Star Ground on Cutting Table / Auto-Cut W/RAS

Gas Control Module

Primary location

#4 AWG
Ground

1/0 Work Cable

1/0 Ground Cable

Power Supply

Gas Control Module

Alternate location

#4 AWG Ground

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.

‘Star’

Ground

Remote Arc

Starter (RAS-1000)

Cutting Machine / Gantry

Cutting Table

1/0

Ground Cable

Ground Cable

Earth Ground

Rod

Torch

1/0

0 - 10 ft (0 - 3 m) Ideal

20 ft (6 m) Maximum

CNC

Device

Gas Control Module

Power Supply

1/0 Work Cable

1/0 Ground Cable

‘Star’

Ground

#4 AWG Ground

(Factory Installed)

Note: The gas control module
can be mounted to the cutting table.
If it is, it should be grounded
directly to the star ground with
#4 AWG ground.

Art # A-08253

Manual No. 0-4805 3-14 INSTALLATION

Auto-Cut Basic System

Without RAS

Cutting Machine / Gantry

Cutting Table

Ground Cable

Earth Ground

Rod

0 - 10 ft (0 - 3 m) Ideal

Torch

1/0

20 ft (6 m) Maximum

CNC

Device

Auto-Cut

Power Supply

1/0 Work Cable

1/0 Ground Cable

(F1)

‘Star’

Ground

GCM-1000

Gas Control Module

#4 AWG Ground

(Factory Installed)

Art # A-08254

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.

Manual No. 0-4805 3-15 INSTALLATION

C. 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

3 VAC for 115VAC line, or 1.5 VAC for 230 VAC line.

CAUTION

Remove all other connections from the ground rod during this test.

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

NEUTRAL
Earth Grounded

NEUTRAL
PROBE

WARNING

Use extreme caution. This

test uses live voltage.

HOT

100W Incandescent
light bulb*

HOT
PROBE

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

Ground Rod
with other
connections removed

On 115V AC Line:
3VAC = 3 ohms
1VAC = 1 ohm

VAC

On 230V AC Line:

1.5VAC = 3 ohms

0.5VAC = 1 ohm

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. 0-4805 3-16 INSTALLATION

J. Connect Gas Supply Lines

1. Connect the gas supply lines to the appropriate input ports as shown.

Plasma Gas - In

Water - In

Shield Gas - In

RETURN

SUPPLY

RETURN

Art # A-04844

SUPPLY

K. Connect CNC Cable

1. Connect one end of the CNC cable to the power supply receptacle marked ‘CNC’.

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

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

Manual No. 0-4805 3-17 INSTALLATION

To CNC

RETURN

SUPPLY

RETURN

SUPPLY

Art # A-04829

L. Connect Torch Leads to the Gas Control Module / Arc Starter

1. Remove the top cover from the Gas Control Module / Arc Starter.

2. Pass the torch leads and coolant leads through the torch leads port on the back of the module. Ensure that the
leads outer jacket slides into the port.

CAUTION

Use protective gloves when handling the leads. Do not kink or bend the leads.

Manual No. 0-4805 3-18 INSTALLATION

3. Inside the module, slide the leads clamp over the leads.

4. Connect the leads to the module in the sequence shown. Coolant leads and connectors are color-tagged; red for
coolant return, green for coolant supply. Shield gas and plasma gas connections are left- and right- hand
threaded and will not interchange.

Torch Leads: Coolant Supply & Return
Plasma Gas
Shield Gas
Inner Leads Shield
Outer Leads Shield

2

1

Clamp * (Clamp type may vary)

Art # A-04934

4

3

2

Inner Shield Lead
Connection Detail

CAUTION:

Keep two terminals

arranged as shown.

Manual No. 0-4805 3-19 INSTALLATION

Coolant Return
Connection (Tagged Red)

Coolant Supply
Connection (Tagged Green)

Plasma Gas
Connection

Shield Gas
Connection

Torch Leads

Art # A-04832

5. Fold the end of the leads outer jacket back over the connection ring inside the module. Slide the leads clamp
over the jacket and fasten the clamp and jacket to the connection ring. Re-install the module top cover.

Manual No. 0-4805 3-20 INSTALLATION

5

Clamp

Inner Shield
Connection

Art # A-04935

Manual No. 0-4805 3-21 INSTALLATION

M. Torch Head Installation and Connection

Install the Torch as follows:

1. Install the torch mounting block on the cutting table (gantry). Fasten the block in place.

2. Leave the end cap in place on the torch leads. Remove and discard the protective end caps from the
Mounting Tube.

3. Install the O-ring in the groove at the upper end of the mounting tube. Slide the torch mounting tube onto
the leads far enough to expose the fittings on the ends of the leads.

4. Connect the Torch Head to the torch leads. Follow the sequence shown. Do not let the leads twist.

End Cap

Shown to illustrate

assembly order only;

parts must remain

secured tightly.

Insulating Paper

O-Ring

Pilot Lead

Plasma Lead

Connector

Positioning Tube

1

2

Coolant Return

Check Valve

and Connector

Shield ('Secondary')

Gas Connector

Insulating Paper

Coolant Supply Connector

Plasma Lead

Positioning Tube

Detail

Torch Leads

O-Ring

Threaded

Holes

Drain Holes

Art # A-06258

Manual No. 0-4805 3-22 INSTALLATION

5. Slide the positioning tube down to the torch head. Hold the torch head stationary. Rotate the positioning
tube onto the torch head. Pull the leads back as needed to ensure a proper fit through the Mounting Tube.
Do not let the torch leads twist.

CAUTION

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

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

7. Fasten the positioning tube into the mounting block. Slide the leads end cap down onto the torch position­ing tube. Ensure that the end cap engages the O-ring at the top of the positioning tube.

8. Install the shield cup, and cartridge assembly (including consumables) onto the torch head.

Manual No. 0-4805 3-23 INSTALLATION

N. Install Consumable Torch Parts

1. Refer to the Torch Speed Charts to select the correct parts for the application. The application will deter­mine which torch parts must be used. Refer to the speed charts for the proper torch parts to install for a
selected application.

CAUTION

Do not interchange parts. Make sure both the tip and electrode in the torch correspond with the plasma and shield
gas in use for the application.

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

NOTE

For 200-Amp consumables, when replacing the shield retainer or the shield cup, assemble these two parts first
before assembling the other consumables.

Shield

Retainer

Assemble First

Shield Cup

Shield Cap

3. Stack the consumable parts together.

Shield Gas

Distributor

Tip

Plasma Gas

Assemble Second

Distributor

Cartridge

Electrode

Art # A-07262

Manual No. 0-4805 3-24 INSTALLATION

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.

Electrode

Plasma Gas
Distributor

Tip

Shield Gas
Distributor

Shield Cap

3: Thread Shield Cup onto Cartridge

1: Stack Parts

O-Ring

on Tip

2: Press Cartridge onto Stacked Parts

No Gaps

Between Parts

Cartridge Covers
O-Ring
on Torch Tip

4: Check Shield Cap Protrusion

Shield Cup

Shield Cap

Shield Cap Protrudes

0.063-0.083" (1.6 - 2.1 mm)

Art # A-04873

5. Use the removal tool to hold the cartridge assembly, while turning the shield cup onto the cartridge
assembly. When this group is fully assembled, the shield should protrude from the front of the shield
cup 0.063" to 0.083" (1.6 - 2.1 mm). Without this protrusion the shield cup is not properly tightened
onto the cartridge assembly.

Manual No. 0-4805 3-25 INSTALLATION

Cartridge Tool

Assembled Cartridge

Art # A-04344

Shield Cup

Installing Shield Cup Onto Cartridge

6. Take the removal tool off the cartridge. Fit the cartridge assembly onto the torch head. The cartridge should
seal to the large O-ring on the torch body as shown. If the cartridge does not seal on the O-ring, the cartridge
is not fully tightened.

CAUTION

Do not force the cartridge if it will not fully tighten. Remove the cartridge and gently clean the threads on the
torch head body with a wire brush. Apply oxygen-compatible lubricant (supplied with the torch) to the threads.

Torch Head

Assembled Cartridge

Art # A-03893

Installing Assembled Cartridge Onto Torch Head

Manual No. 0-4805 3-26 INSTALLATION

7. Confirm proper parts assembly as shown.

Torch Head

0.063 - 0.083"

(1.6 - 2.1 mm)

Protrusion

Torch Head O-Ring

Art # A-07202

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

NOTE

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

Ohmic Clip

A-03393

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

Manual No. 0-4805 3-27 INSTALLATION

O. Complete the Installation

1. 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.

2. Replace the cap on the tank.

Coolant Capabilit i es

Cat. Number and Mixture Mixture Protects To

7-3580 'Extra-Cool

7-3581 'Ultra-Cool

7-3582 'Ext reme Cool

* For mixing wit h D-I Cool

TM

'

TM

'

TM

' Concent rat e* -65° F / -51° C

TM

7-3583

25 / 75 10° F / -12° C

50 / 50 27° F / -33° 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):

NOTE

Depending on the length of the torch leads, the system may require more coolant after turning the system ON for

Manual No. 0-4805 3-28 INSTALLATION

the first time.

Manual No. 0-4805 3-29 INSTALLATION

SECTION 4: OPERATION

!

Power Supply Indicators

AC Indicator

Temp Indicator

Art # A-04813

AC Power Lamp

Indicates AC power is being supplied to the system when the ON/OFF switch is in ON position. When switch is first set
to ON, the lamp will blink, indicating gas purge at power on.

TEMP Lamp: Normally OFF. Lamp will come ON when the internal temperature sensors detect temperatures

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

Gas Indicator

DC Indicator

Status Indicator

GAS Lamp: Normally ON. Indicates adequate gas pressure for operation in the system

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

Message Center: Show 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 operating software
revision level.

Manual No. 0-4805 4-1 OPERATION

Control Console Features

Plasma Gas

Pressure Gauge

Run / Set Selector

Amperage

GCM

Selector

1000

CUT
OUT

A

Shield

Selector

RUN

SET

SHIELD

GAS

2

O MIST

H

CUT
OUT

A

PLASMA

Plasma Gas Pressure

Control Knob

RUN

SET

SHIELD

PLASMA

GAS

O MIST

2

H

SHIELD

SHIELD

Shield Gas Pressure

Control Knob

Art # A-06802

Shield Gas

Pressure Gauge

H2O MIST

Water Mist (Shield) Flow Meter

and Control Knob

Run / Set Selector: Use SET position to adjust plasma and shield pressures and flows. Once these are set, switch

to RUN position for operation.

Plasma and Shield Gas Pressure Control Knobs: Adjust plasma and shield gas pressures. Turn knobs to set

desired levels.

Plasma and Shield Gas Pressure Gauges: Display plasma and shield gas pressures.

Shield Selector: Selects shield fluid, gas or H2O Mist (water).

Water Shield Mist (H2O) Flowmeter and Control Knob: Controls flow rate of shield water supply.

Amperage Selector: Continuously adjustable up to 200 Amps.

Manual No. 0-4805 4-2 OPERATION

Operating Set-up

Follow this set-up procedure each time the system is operated:

WARNING

Disconnect primary power at the source before assembling or disassembling power supply, torch parts, torch and
leads assemblies or adding coolant.

A. Coolant Level Inspection

Check the coolant level in the coolant tank at the rear of the unit. If the tank is below 3/4 full, add coolant.

B. Torch Parts Selection

Check the torch for proper assembly. Install proper torch parts for the application per the Torch section of the
manual..

C. Input Power

Check the power source for proper input voltage. Make sure that Power Supply is set for the proper voltage. Close main
disconnect switch or plug unit in to supply primary power to the system.

D. Work Cable Connection

Check for a solid and clean work cable connection to the workpiece or cutting table. The connection area must
be free from paint and rust.

E. Torch Connection

Check that the torch is properly connected.

F. Gas Supplies

Connect desired plasma and shield gases. Make sure gas sources meet requirements. Check connections and turn gas
supply on.

Select the desired shield gas as follows:

1. If gas shield is desired, set shield selector switch to GAS position.

2. If Water Mist shield is desired, set shield mode selector switch to ‘H2O MIST’ position. Water must be
connected to the control console at the shield water connection.

NOTES

Tap water should only be used for shield gas.

If tap water pressure is over 100 psi (6.9 bar) there must be a Water Regulator (Catalog No. 8-6118) installed
between the water source and the Power Supply.

Manual No. 0-4805 4-3 OPERATION

H. Plasma Gas Purge

Move the Power Supply ON/OFF switch to the ON position.

An automatic gas purge will remove any condensation that may have accumulated in the torch and leads
while the system was shut down. After the purge is complete, if the RUN/SET switch is in SET position, gases
will flow.

I. Amperage Selection

Select the desired current output amperage.

J. Pressure and Flow Settings

1. Refer to the Torch manual for pressure and flow details according to the material being cut. Move the RUN/SET
switch to SET position. (Gas will flow through the torch). Set gas pressures and flows as follows:

2. To set the Plasma Gas pressure:

a. Pull out the knob on the Plasma Gas pressure control knob.

c. Turn the knob to adjust gas pressure.

d. Push the knob back in to lock the pressure setting.

3. To set the Shield Gas pressure: Set the Shield Mode Selector switch to the GAS or H

O MIST position.

2

For Gas Shield:

a. Pull out the Shield Gas Pressure Control Knob.

c. Turn the knob to adjust gas pressure.

d. Push the knob back in to lock the pressure setting.

For H2O MIST Shield:

a. Turn the Water Mist Control Knob to adjust pressure.

b. Push the knob back in to lock the pressure setting.

NOTE

Unless the installation includes gas selection equipment between the gas supplies and the control console, switch­ing between gases requires disconnecting the gas supply line(s) from the control console rear panel and connecting
the appropriate input gases. Water input can remain connected permanently because the shield selector switch
disables and enables the flow of water for H2O Mist shield.

4. Place the RUN/SET switch to the RUN position.

Manual No. 0-4805 4-4 OPERATION

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

Cut Surface

Left Side

Cut Angle

Right Side

Cut Angle

A-00512

Cut Surface

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

Bevel Angle

Top

Spatter

Build-Up

Dross

Cut Surface

Drag Lines

Bevel Angle

Top Edge
Rounding

A-00007

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.

Manual No. 0-4805 4-5 OPERATION

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.

Left Side

Cut Angle

Right Side

Cut Angle

A-00512

Clockwise

Scrap

Counter-

Clockwise

Scrap

Workpiece

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 Sensing

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

Manual No. 0-4805 4-6 OPERATION

System Operation

This section contains operating information which is specific to the power supply.

WARNINGS

Frequently review the safety precautions in Section 1.

Disconnect primary power at the source before assembling or disassembling power supply, torch parts, or torch
and leads assemblies, or adding coolant.

It is not enough to simply move the ON/OFF switch on the unit to OFF position when cutting operations have been
completed. Always open the power supply disconnect switch five minutes after the last cut is made.

1. Connect system to primary input power.

2. Turn ON/OFF switch to ON (up) position. AC Lamp
is a start-up purge of gas through the system.

turns ON. Fan and coolant pump turn on. There

POWER

I

OFF

O

Art # A-04842

3. Check the AC lamp. If lamp is ON, AC input power is present in the power supply.

Circuitry in the power supply monitors the status of various conditions. If the circuitry detects a situation
requiring operator attention, the status lamp 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: Lamp flashes 4 times; the condition is in group 4. After a 1.2 second delay, the lamp blinks 3 times;
the status code is 4-3. After a 4-second delay, the lamp repeats the sequence until the condition is corrected.

ON

O

OFF

Some conditions can be active indefinitely, while others are momentary. The power supply latches momentary
conditions; some momentary errors can shut down the system. The lamp may show multiple conditions in
sequence; it is important to recognize all possible conditions that may be displayed. The Error Code section
provides explanations of status codes.

Manual No. 0-4805 4-7 OPERATION

4. Place RUN/SET switch to SET mode.

a. Gases flow to set pressures.

5. Place RUN/SET switch to RUN mode.

a. Gas flow stops.

6. Protect eyes and start torch.

a. Gas pre-flows starts.

7. After gas pre-flow:

a. Power supply enabled. DC lamp turns ON.

8. Pilot arc is established.

9. Move Torch within transfer distance of workpiece.

a. Main arc transfers to the workpiece. Pilot arc shuts off.

10. Complete cutting operation.

11. Stop the torch.

a. Main arc stops.

12. Gas will flows briefly (‘post-flow’).

a. Gas solenoid closes; gas flow stops:

13. Set the ON/OFF power switch on the front panel of the unit to OFF.

a. AC Power lamp turns OFF.

b. Fan and pump turn OFF.

14. Place the main power disconnect to open.

a. Main AC power is removed from the system.

Manual No. 0-4805 4-8 OPERATION

Operational Suggestions

1. Wait five minutes before setting the ON/OFF switch to OFF after operation. This allows the cooling fan to run
to dissipate operating heat from the power supply.

2. For maximum parts life, do not operate the pilot arc any longer than necessary.

3. Use care in handling torch leads and protect them from damage.

4. When using water as the shield note the following:

• Use clean drinking quality tap water to help prevent particulate build-up within the system water shield
plumbing.

• Particulate contamination and bulid-up can cause reduced consumable parts life and premature torch
failure.

• A cartridge type particulate water filter may help achieve optimum cutting performance.

Manual No. 0-4805 4-9 OPERATION

Note

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

Faul t Code Key

Error

Code Error Remedy / Comme nts

External E-Stop Activated

1-1

Plasma Enable Switch OFF

1-2 P i l ot Ignit i on Fail ure Pil ot does not s t art > 15 s ec onds.
1-3 P i l ot Out Pil ot s hut off without shutoff si gnal.

1-4 Los s of Transfer

1-5 Off the Pl ate

or

Check and c orrec t.

Arc t ransferred (>50 ms) t hen shut off
without signal.

Torch moved past edge of met al (0nly wit h Off Plate
enabled and Aut o P il ot Rest art di sabled. )

Transfer Timeout (Fail ure t o

1-6

trans fer in allowed t im e)

1-7 Tip Saver

1-8 S hort ed Torch
2-1 M i s sing P hase 1 of 3 input AC phas es m i ss ing.

2-2 Input voltage out of toleranc e Test and c orrec t .
2-3 P ower Suppl y O verheated Inverter module or pilot modul e overheated.
2-4 P ower Suppl y Not ready
2-5 DC Out put Low < 60 vdc .
2-6 A C Input over Current Fault Turn off power to reset.

2-7 Unwanted Current

Unwanted Pi l o t

2-8

Current Signal

2-9 Unwanted Transfer

Must transfer from pilot to cutting arc
in 85 ms . (S w 8-1 off) or 3 s ec (S W 8 -1 on ).

(If enabled; act ive during ramping and cutt i ng.
Pos sibl e double arc .
Elect rode to tip voltage <50v
w/ inverter on.

Pos sibl e s hort ed torch. Current i n pil ot l ead or work
lead before pilot arc st art s.

Current in pilot circuit before starting pilot.
Current i n work l ead before

starti ng pil ot .

Manual No. 0-4805 4-10 OPERATION

g

Faul t Code Key

Error Code Error Rem edy / Com m ents

3-1
3-3 Pl asma P res sure Low
4-1

4-2

4-3

4-4

4-5

6-1

6-2
6-3
6-4

Gas Cont rol Conn Fault ­Connection missing or lost

Coolant Level Low
(before arc s tart)
Low or Mi ssi ng Coo l ant F lo w
(> 15 seconds when arc off,

ASAP when flow <0.35 gal/min
during a c ti ve arc,

when flow is 0.35 - 0.7
Coolant Overheated
(over 158° F [70° C] )

Cooling Sys t em Not Ready.
Pum p has run >30 sec w/ o
reaching minimum flow
requirement.

Low Coolant W arning
(during cut)

CCM Analog V oltage Error
CCM Analog to Digital Coverter
Coolant Fl ow Circui t E rror
CCM Data Mem o ry E r ror

or

or

al/min

Check coolant l evel in t ank, add as needed.

Check coolant l evel in t ank, add as needed.

Coolant t em perature m us t drop by 9° F (5° C)
to clear overtemp condition

Recy cle power or cy cl e plas m a enable / E-S top.

W arning does not stop cut . St op c ut , shut off input
power, add coolant to t ank .

Contac t Thermal Dynam ics .
Contac t Thermal Dynam ics .
Contac t Thermal Dynam ics .
Contac t Thermal Dynam ics .

Manual No. 0-4805 4-11 OPERATION

SECTION 5: MAINTENANCE

Perform the following checks periodically to ensure proper system performance.

Pow e r S upply Ma i nte na nce S chedul e

Daily

Check c ool ant level; add coolant as needed.
Check gas hos e connections and pres s ures .
Check c ool ing fan; clean as needed.

M onthly

Check c ool ing fan and radiator; clean as needed.
Check gas hos es for cracks , leak s, or abrasi on.
Replace as neede d.
Check all elect rical c onnec tions for cracks or
abras i on . Rep l ace as neede d.

Clean water filter (if using H

Six Months

Replace cool ant fil ter.
Clean coolant t ank .
Vac uum out any dus t bui l dup ins i de power supply.

O Mis t)

2

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 system from main input power.

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. 0-4805 5-1 MAINTENANCE

Water Filter Cleaning Procedure

NOTE This procedure is only required in installations using water as a shield.

Clean the filter as follows:

1. Disconnect system from main input power.

2. Unscrew and remove the filter bowl by hand. Be sure to keep the gasket.

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

4. Turn the system on and check for leaks.

Water Filter Assembly

Screen

Water Filter

Art # A-04936

Gasket

Cup

Manual No. 0-4805 5-2 MAINTENANCE

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.

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.

Manual No. 0-4805 5-3 MAINTENANCE

Arc Starter Service

e

S

g

A rc St arter Service Chart

Symptom Cause Check Remedy

Use conductivity meter

Use capacit a nc e met er Reconnec t or r ep lac e.

Capacitance meter Replace.

V isual inspection Reconnect.

V isual inspection Reconnect.

Visual inspection Replace c oo lant line( s).

V i sual Inspection of col or- c ode d
connections

Loosen fit t i ng slightly and check
for coolant flow

V isual inspection of lead
attachment t o Arc St ar ter

V i sual inspection of gr ou nd wir e
to Arc Starter

Visual inspection / capa c itor
mea surement

No Pilot ignition:

Spark in Arc Starter

but no ignition

No Pilot ignition:

No Spar k

in A r c S t a rter

No cooling o r

insuff ic ien t cool ing:

Leaks coolant

No cooling o r

insuff ic ien t cool ing:

No Coolant Flow

Erratic System

Behavior

(EMI I nterference)

Coolant has become conductiv
Pilot return wir e not conne c ted Visual inspection Connect W ir e.

Spar k g ap set too c lose Check with feeler gauge Set to 0. 063 " ±0. 002"
High Frequency cap (C4)
possibly open
Brok en or missing ferr ites Visual inspection Replace.

Shor t acr oss in induct or (L1) Visual inspection
Spar k g ap bus caps

(C1, C2, C3)
broken or defective
Negat ive supply not
connected correctly
Spar k g ap set too lar ge Check with feeler gauge Set to 0.063" ±0 .002"
Faulty transformer Resistance measurement Replac e.

No 120V supply Che c k in put voltage at EMI fi lter
No/ loose conn ec tion

to spark gap
Faulty EMI filt er Volt a ge/ Resistor measurement Replace.
Loose fitting( s) Visual inspection Tigh t en fit tings.
Failure to braze joints (L1) Visual inspection Replace HF Coil.
Damaged or punctured
coolant line(s).

Supply & return hose rev ersed

Blockage in co il or
supply / r eturn hoses

hield Drain / Tor c h le ad inne r
shield connector
missin

Missing or loose
ground co nnec t i on

Cap C5 not connected,
open or loose

or loose.

Flush sy st em,
replac e co olant.

Remove short;
increase coil gaps.

Make connections ;
replac e harn ess.

Match coolant c onnect ion colors
to arc starter fitting colors.

Flush sy st em.

Reconnec t / ti ghten
lead connectors.

Make or t ighten
connections to
good ground.

Replace PCB.

Manual No. 0-4805 5-4 MAINTENANCE

Arc Starter Spark Gap Adjustment

1. Shut off input power. Remove the top console cover.

2. Adjust the spark gap as shown. Re-install the top cover.

0.063" ± 0.002"

1.6 ± 0.05 mm

Art # A-04835

Manual No. 0-4805 5-5 MAINTENANCE

This page is blank intentionally.

Manual No. 0-4805 5-6 MAINTENANCE

Section 6: Replacement Assemblies & Parts

Complete Unit / Component Catalog Numbers Catalog Number

Auto-Cut 200 Power Supply, 208/230V 3-9112-1

Auto-Cut 200 Power Supply, 460V 3-9112-2

Auto-Cut 200 Power Supply, 400V 3-9112-3

Auto-Cut 200 Power Supply, 400V (CE) 3-9112-4

OPTIONAL EQUIPMENT:

Wheel Kit 9-9379

Manual No. 0-4805 6-1 Parts List

Leads and Cables

Ground Cables

Key

A,B,C,D,E

A

B
C
D

E

F

F1

G

K
O

P

Arc Starter /

Gas Control Module

(GCM-1000)

Pilot Return

Negative

Coolant Supply

Power Supply

Coolant Return

Control Cable

CNC

CNC Cable

Leads Catal og Numbers ; Aut oCut 200 P ower Supply, XT-301 Torch

Description
Supply Lead Set
Pilot Return Cable (only) (4 ft / 1.2 m)
Negat ive Cable (only )
Hose, Coolant Supply (only)
Hose, Coolant Ret ur n ( only)
Control Cable ( only), P ower Supply
to Arc Starter (4 ft / 1.2 m)

Gr oun d Wire ( only), P owe r S up ply to
Gas Cont r o l Module, , 4 ft / 1.2 m

Gr oun d Ca ble, G as Cont rol Module
to Earth
Tor c h Lead Assembly
Control Cable, Power S u pply
to Gas Control Module
Work Cable
Contr ol Cable, CNC
to Power Supply

Maximum Length 100’ / 30.5 m

Ground

Auto-Cut

Cable

Control

Cable

Torch Lead Set, Shielded

- Coolant Supply w/ Negative

- Coolant Return

- Pilot Return

- Plasma Gas

- Shield Gas

Primary power

Positioning

Tube

Torch

Work Cable

Work

Art # A-07231

Leads Length

3 ft

10 ft

1 m

3.05 m

4-3027
9-4890
9-4892
9-4886
9-4888

9-4941

9-4923

9-4923 9-4924 9-4925 9-4926 9-4927 9-4928 9-4929

9-9331

9-9300 9-9301 9-9302 9-9303 9-9304 9-9305 9-9306 9-9307

15 ft

4.5 m

25 ft

7.6 m

35 ft

10.6 m

50 ft

15.2 m

75 ft

22.8 m

4-3044 4-30 45 4-3046 4-3047 4-3048

9-8312 9-8313 9-8315 9-8316 9-8317

100 ft

30.5 m

125 ft

38.1 m

NOTE :

Supply lead set includes Pilot Return Cable, Negative Cable, Coolant Supply & Return Hoses, and Control Cable.

Manual No. 0-4805 6-2 Parts List

#8 AWG Cable

A

Pilot Return, Power Supply
to Arc Starter

D

E

F1

#1 AWG Cable

B

C

Green

Green

Negative Lead, Power Supply
to Arc Starter

Coolant Leads, Power Supply

Red

Red

to Arc Starter

Control Cable, Power Supply

14

F

Green / Yellow #10 AWG

Green / Yellow 1/0 (50 mm )

2

to Arc Starter

Ground Cable

Ground Cable,
Arc Starter
To Earth Ground

G

Torch Lead Set

Control Cable,

K

37

Power Supply to
Gas Control Module

O

1/0 (50 mm ) Cable

P

2

Work Cable

CNC Cable (14 Wire)

4’ / 1.3 m

Q

Ground Cable, Gas Control Module
to Power Supply. Factory Installed.

#4 AWG

Art # A-07103

Manual No. 0-4805 6-3 Parts List

Optional Gas Supply Leads

HOS E AS SEMBL IES

Lengt h (F e et) 10' 15' 25' 35' 50' 75' 100 '
Length (Meters) 3.05 4.6 7.6 10.6 15.2 22.9 30.4

Inert B (RH) 9-2146 9-5061 9-50 73 9-50 85 9-50 97 9-5109 9-51 21

1/4"

3/8"

SYNFLEX HOSE FITTINGS

ID

1/4" 9-3743 9-3556 9-2776 9-2775 8-5518 8-5015 8-0327 8-0266 8-0384
3/8" 9-3616 8-6473 N/A N/A N/A 8-6617 N/A 8-0271 8-0384
1/2" 9-2551 8-6470 N/A N/A 8-0267 9-3831

O2 B (RH) 9-9008 9-900 9 9-9010 9-9011

JIC 9-6956 9-6957 9-6959 9-6961 9-6963 9-6964 9-6965

Inert B (RH)

Inert B (LH) 9-9012 9-9013 9-9014 9-9015

JIC 9-6985 9-6986 9-6988 9-6996 9-6992 9-6993 9-6994

CATALOG#

per foot

NUT NUT NIPPLE NUT NUT NIPPLE JIC CLAMP

Inert B

(LH)

Inert B

(RH) Inert

FUEL B

(LH)

O2 B
(RH)

ADAPT ER F IT T INGS

Inert B (RH) 8-0330

1/4 " NPT

Inert B (LH) 8-0329

O2 B (RH) 8-02 60

1/4" B arb 8-4264

Cata l o g #

Manual No. 0-4805 6-4 Parts List

Power Supply External Replacement Parts

Item # Qty Description Catalog #

1 Power Supply Front Panel 9-9380

1 Power Supply Rear Panel 9-9381

1 Power Supply Top Panel 9-9382

1 Power Supply Right Side 9-9383

1 Power Supply Left Side 9-9384

1 Louver Panel 9-9385

1 Power Supply Connections Cover 9-9386

1 Lifting Eye 9-9373

1 Touch-Up Paint (Not Shown) 9-9388

9-9381

9-9386

9-9384

9-9373

9-9382

9-9380

9-9385

9-9385

9-9385

9-9383

Art # A-04931

Manual No. 0-4805 6-5 Parts List

Power Supply Replacement Parts - Right Side

Item # Qty Description Ref. Des. Catalog #

1 1 Heat Exchanger Fan FAN1 9-9338

2 1 Radiator 9-9339

Manual No. 0-4805 6-6 Parts List

Power Supply Replacement Parts - Right Side

Item # Qty Description Ref. Des. Catalog #

3 1 Resistor R6 9-9340

4 1 PCB PCB8 9-9341

5 1 Sensor HCT1 9-9342

Manual No. 0-4805 6-7 Parts List

Power Supply Replacement Parts - Right Side

Item # Qty Description Ref. Des. Catalog #

5 1 Sensor HCT1 9-9342

6 1 Contactor MC2 9-9343

Manual No. 0-4805 6-8 Parts List

Power Supply Replacement Parts - Front Panel

Item # Qty Description Ref. Des. Catalog #

7 1 Main Power Switch CP1 9-9344

Manual No. 0-4805 6-9 Parts List

Power Supply Replacement Parts - Front Panel

Item # Qty Description Ref. Des. Catalog #

11 1 PCB, LED PCB6 9-9347

Manual No. 0-4805 6-10 Parts List

Power Supply Replacement Parts - Right Side

Item # Qty Description Ref. Des. Catalog #

19 1 Resistor R1-5 9-9353

20 1 Resistor R1-5 9-9353

21 1 Resistor R1-5 9-9353

1 Chopper Module 9-9389

Manual No. 0-4805 6-11 Parts List

Power Supply Replacement Parts - Rear Panel

Item # Qty Description Ref. Des. Catalog #

12 1 Circuit Breaker CP2 9-9348

13 1 Circuit Breaker CP3 9-9349

14 1 Circuit Breaker CP4 9-9350

15 1 Circuit Breaker CP5 9-9348

16 1 Circuit Breaker CP6 9-9348

17 1 Circuit Breaker CP7 9-9351

18 1 Circuit Breaker CP8 9-9352

1 Coolant Tank 9-5948

1 Tank Cap 8-5142

Tank Cap

Coolant Tank

COOLANT

RETURN

SUPPLY

12

13

14

15

16

17

18

J55

G
C
M

J15

C
N
C

J59

R
A
S

CIRCUIT

BREAKERS

120V 5A

24V3 15A

24V 10A

120V2 5A

15V2 5A

200V 5A

24V 15A

CP2

RAS

CP3

CCM

CP4

GCM

CP5

GCM

CP6

GCM

CP7

PUMP

CP8

FAN

Art # A-06017

Art # A-04932

Manual No. 0-4805 6-12 Parts List

Power Supply Replacement Parts - Right Side

Item # Qty Description Ref. Des. Catalog #

23 1 Transformer T1 9-9355

Manual No. 0-4805 6-13 Parts List

Power Supply Replacement Parts

Item # Qty Description Catalog #

29 2 Inverter Module 208/230V 9-9360D

2 Inverter Module 400V CE and 400V Non CE 9-9482D
2 Inverter Module 600V 9-9485D

Art # A-04786

Manual No. 0-4805 6-14 Parts List

Power Supply Replacement Parts - Right Side

Item # Qty Description Ref. Des. Catalog #

30 1 Sensor (Thermistor) TH1 9-9361

Manual No. 0-4805 6-15 Parts List

Power Supply Replacement Parts

Item # Qty Description Ref. Des. Catalog #

31 1 PC Board PCB1 9-9362

32 1 Resistor R7 9-9363

33 1 Magnetic Contactor MC1 9-9364

34 1 PC Board PCB3 9-9365

Manual No. 0-4805 6-16 Parts List

Power Supply Replacement Parts - Right Side

Item # Qty Description Ref. Des. Catalog #

8 1 Rectifier (Diode) D1 9-9345

10 1 PC Board PCB5 9-9346

23 1 Transformer T1 9-9355

35 1 PC Board PCB7 9-9366

Manual No. 0-4805 6-17 Parts List

Power Supply Replacement Parts - Right Side

Item # Qty Description Ref. Des. Catalog #

22 1 Sensor (Level Switch) LSW1 9-9354

24 1 Motor M 9-9381

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

26 1 Bypass Valve (part of assembly)

27 1 Pump (part of assembly)

28 1 Sensor (Flow Indicator) F1 9-9359

28

26

Art # A-08236

25

27

24

22

Manual No. 0-4805 6-18 Parts List

Arc Starter & Gas Control Module (GCM-1000) Replacement Parts

Item # Qty Description Catalog #

1 1 GCM-1000, Gas Box/Arc Starter 9-4997

2 1 Base 9-4979

3 1 Front Panel 9-4980

4 1 Lid (not shown) 9-4981

5 1 Gas Bulkhead 9-4982

6 1 Bulkhead 9-4983

7 1 Solenoid Mount 9-4984

8 1 Lid Bracket 9-4985

9 1 Bracket, Flotometer H2O 9-4987

10 1 Bulkhead 9-4988

11 1 Bulkhead, Gas Box/Arc Starter 9-4989

12 1 Mount, Neg Lead Attach 9-4990

13 1 Bracket, Gas Box/Arc Starter 9-4991

14 1 Bracket, Filter, Water Mist 9-4992

15 1 Hose Package 9-4993

16 1 Harness, Gas Controls 9-4994

17 1 Harness, Arc Starter 9-4995

18 1 Wire List, Arc Starter (Not shown) 9-4996

19 1 Water Filter Assembly 8-3460

20 1 Flotometer, H2O 9-7762

Art # A-04852

11

8

Left Side

5

2

6

3

20

9

14

7

19

10

15

13

Right Side

12

16

17

Manual No. 0-4805 6-19 Parts List

Command & Control Module Type 1 - Replacement Parts

Item # Qty Description Catalog #

1 1 Harness, CCM I/O Board 9-4946

2 1 Plate, CCM Face 9-4947

3 1 Panel, CCM Mount Not Available

4 1 Bracket, CCM Strain Relief 9-4949

5 1 Cover, CCM Strain Relief 9-4950

6 1 Assembly, CCM (Auto-Cut) 9-9330

NOTE

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

6

2

4

3

5

1

Art # A-04850

Manual No. 0-4805 6-20 Parts List

Command & Control Module Type 2 - Replacement Parts

Item # Qty Description Catalog #

1 1 Assembly, CCM (Auto-Cut) 9-9418

2 1 Plate, CCM Face 9-9419

3 1 Panel, CCM Mount Not Available

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

NOTE

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

2

3

1

4

Art # A-06798

Manual No. 0-4805 6-21 Parts List

This page is blank intentionally.

Manual No. 0-4805 6-22 Parts List

SECTION 7: Torch Maintenance

A. Consumable Removal

1. Use the removal 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

Shield Cup

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

Cartridge Tool

Cartridge Assembly

Art # A-04345

Manual 0-4805 7-1 TORCH MAINTENANCE

B. 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.

Inner O-Ring (Cat. No. 8-0545)

O-Rings

Torch Head

Location (Under Locking Ring)

Cat. No. 9-9041

O-Ring, Cat. No. 8-0544

O-Ring, Cat. No. 8-0540

Cartridge Assembly

Cat. No. 8-0539

Cat. No. 8-3487

Cat. No. 8-0530

Snap Ring

Art # A-04071

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.

C. Parts Wear

Art # A-04066

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-04861

TORCH MAINTENANCE 7-2 Manual 0-4805

D. Torch Consumables Installation

1. Install the consumables as follows:

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

NOTE

For 200-Amp consumables, when replacing the shield retainer or the shield cup, assemble these two parts first before
assembling the other consumables.

Shield

Retainer

Assemble First

Shield Cup

Shield Cap

Shield Gas

Distributor

Tip

Plasma Gas

Assemble Second

Distributor

Cartridge

Electrode

Art # A-07262

Manual 0-4805 7-3 TORCH MAINTENANCE

Electrode

Plasma Gas
Distributor

Tip

1: Stack Parts

O-Ring

on Tip

2: Press Cartridge onto Stacked Parts

No Gaps

Between Parts

Shield Gas
Distributor

Shield Cap

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)

Cartridge Covers
O-Ring
on Torch Tip

Art # A-04873

TORCH MAINTENANCE 7-4 Manual 0-4805

2, Remove the Removal 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

0.063 - 0.083"
(1.6 - 2.1 mm)

Protrusion

Torch Head O-Ring

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.

NOTE

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

Ohmic Clip

A-03393

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

Manual 0-4805 7-5 TORCH MAINTENANCE

This sheet is blank intentionally.

TORCH MAINTENANCE 7-6 Manual 0-4805

Appendix 1: Control Cable Pinouts

Power Supply J55 to Gas Control Console J56

4 Ground

14 E-Stop

15 E-Stop

19

20

21

22

33 Ground

28

27

7 Ground

8 Ground

13

26

9

37

32

35 120VAC Ret

36

3

2

1

6 Pot Wiper

5 + 10 vdc

12

11 Gas On

10 Gas On

18

17 24 VAC Ret

16 24VAC

23

24 24 VAC Ret

25

29

30

31

34 120VAC

POWER SUPPLY J55

ARC STARTER / GAS CONTROL MODULE J56

1 Jumper to 2

6 Current Control Pot

5 Current Control Pot

12

11 Run / Set Sw

10

18

17

16

23 Jumper to 15

24 Sol 1

2 Jumper to 1

25

29

30

31

3 Run / Set Sw

35

34

4 Gas Pr Sw (SW1)

7 Current Control Pot

8 Jumper to 9

9 Jumper to 8

13

36

37

33 Ground

32

14 Run / Set Sw

15 Jumper to 23

19 Ground

20
21

22

28

27

26

Art # A-04848

Manual 0-4805 A-1 APPENDIX

Appendix 2: Control Cable Pinouts

Power Supply J59 to Arc Starter / Gas Control Console J58

Art # A-04849

2: Ground

7 - 120 VAC

7 - 120 VAC

11

10

3

6

14

1

3

8

13

ARC STARTER / GAS CONTROL MODULE J58

4

1 - Jumpered to 4

5

4 - Jumpered to 1

8

9: 120 VAC RET

12

POWER SUPPLY J59

2: Ground

5

6

10

9: 120 VAC RET

11

12

15

16

14

13

Manual 0-4805 A-2 APPENDIX