Thermal Dynamics Ultra-cut 300, ULTRA-CUT 100 Operating Manual

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300

™

ULTRA-CUT

PLASMA CUTTING SYSTEM

Art # A-04816

Operating Manual

Rev. AG.01 Date: July 10, 2007 Manual # 0-4819 Operating Features:

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 market-leading, dependable products that have stood the test of time. We pride ourselves on technical innovation, competitive prices, excellent delivery, superior customer service and 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, Ultra-Cut® 300 Operting Manual No. 0-4819

Published by: Thermadyne Corporation 82 Benning Street West Lebanon, New Hampshire, USA 03784 (603) 298-5711

www.thermal-dynamics.com

Reproduction of this work, in whole or in part, without written permission of the publisher is prohibited.

The publisher does not assume and hereby disclaims any liability to any party for any loss or damage caused by any error or omission in this Manual, whether such error results from negligence, accident, or any other cause.

Printed in the United States of America

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

Publication Date: July 10, 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

Remote Arc Starter ............................................................................................... 2-1

Gas Control Module .............................................................................................. 2-1

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

Specifications & Electrical Requirements ............................................................. 2-2

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

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

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

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

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

XTTM-300 Torch Specifications ............................................................................ 2-6

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

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

B. Cooling System Requirements ...................................................................... 3-1

C. System Layout ............................................................................................. 3-2

D. Cables & Leads Identification ....................................................................... 3-3

D. Lift the Power Supply .................................................................................... 3-4

E -1. Set Switches on the Command - Control Module (Type 1 Module) ................ 3-5

E -2. Set Switches on the Command - Control Module (Type 2 Module) ................ 3-7

F. Remove the Connections Cover ................................................................... 3-9

G. Connect Work Cable and Pilot and Negative Leads...................................... 3-10

H. Check / Adjust Input Voltage Configuration ..................................................3-11

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

J. Ground Connections .................................................................................... 3-13

K. Connect Coolant Leads ................................................................................ 3-15

L. Connect Control Cables for CNC, Remote Arc Starter, and GCM ................. 3-16

M. Gas Control Module Installation ................................................................... 3-19

N. Fiber Optic Cable Installation .......................................................................3-20

O. Gas Control Module: Control, Input, and Output Connections .......................3-22

P. Install Remote Arc Starter ...........................................................................3-23

Q. Original & XTL Torch Valve Installation.........................................................3-32

R. Connecting Torch .........................................................................................3-33

S. Install Consumable Torch Parts .................................................................... 3-34

T. Complete the Installation .............................................................................3-37

TABLE OF CONTENTS (continued)

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

Power Supply Control Panel .................................................................................. 4-1

Start-Up Sequence ............................................................................................... 4-2

Gas Control Module Operation .............................................................................. 4-3

Sequence Of Operation ........................................................................................ 4-7

Gas Selection ......................................................................................................4-10

Power Supply Status Codes ................................................................................ 4-11

Remote Arc Starter: Service Chart ..................................................................... 4-14

Remote Arc Starter: Spark Gap Adjustment .......................................................4-15

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

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

Internal Coolant Filter Cleaning Procedure ............................................................ 5-2

Coolant Replacement Procedure ........................................................................... 5-2

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

System Layout ..................................................................................................... 6-2

Leads and Cables ................................................................................................. 6-3

Optional Gas Supply Leads .................................................................................. 6-8

Power Supply External Replacement Parts ........................................................... 6-9

Power Supply Replacement Parts - Right Side.....................................................6-10

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

Power Supply Replacement Parts - Right Side.....................................................6-12

Power Supply Replacement Parts - Front Panel ................................................... 6-13

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

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

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

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

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

Power Supply Replacement Parts - Right Side.....................................................6-19

Power Supply Replacement Parts ........................................................................ 6-20

Power Supply Replacement Parts - Right Side.....................................................6-21

Power Supply Replacement Parts - Right Side.....................................................6-22

Gas Control Module (GCM-2010) Replacement Parts .......................................... 6-23

Gas Control Module (GCM-2010) Replacement Parts .......................................... 6-24

Remote Arc Starter (RAS-1000) Replacement Parts ............................................6-25

Remote Arc Starter (RAS-1000) Replacement Parts ............................................6-26

Command & Control Module Type 1- Replacement Parts .................................. 6-27

Command & Control Module Type 2 - Replacement Parts ................................. 6-28

Torch Valve Assembly Replacement Parts ........................................................... 6-29

XTL Torch Valve Assembly External Replacement Parts ...................................... 6-30

XTL Torch Valve Assembly Internal Replacement Parts ....................................... 6-31

TABLE OF CONTENTS (continued)

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

E. Coolant Leak Trouble-Shooting ...................................................................... 7-5

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

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

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

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

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

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

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

APPENDIX 8: CNC - Control Module PCB Connections ............................................................ A-9

CNC functions. ................................................................................................... A-10

CNC Input / Output Descriptions ......................................................................... A-11

Simplified CNC Circuit. ....................................................................................... A-12

APPENDIX 9: Schematic, 230-460V Power Supply.................................................................. A-14

APPENDIX 10: Schematic, CCC 400V Power Supply .............................................................. A-16

APPENDIX 11: Schematic, CE 400V Power Supply ................................................................. A-18

APPENDIX 12: Schematic, CSA 600V Power Supply .............................................................. A-20

APPENDIX 13: Publication History ......................................................................................... A-22

Global Customer Service Contact Information ...................................................... A-2

NOTE:

The Section 8 torch operaton

section is provided separately.

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

OPERATION AND MAINTENANCE OF PLASMA ARC EQUIPMENT CAN BE DANGEROUS AND HAZARDOUS TO YOUR HEALTH.

Plasma arc cutting produces intense electric and magnetic emissions that may interfere with the proper function of cardiac pacemakers, hearing aids, or other electronic health equipment. Persons who work near plasma arc cutting applications should consult their medical health professional and the manufacturer of the health equipment to determine whether a hazard exists.

To prevent possible injury, read, understand and follow all warnings, safety precautions and instructions before using the equipment. Call 1-603-298-5711 or your local distributor if you have any questions.

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. You must be very careful when cutting or welding any metals which may contain one or more of the following:

Antimony Chromium Mercury Beryllium Arsenic Cobalt Nickel Lead Barium Copper Selenium Silver Cadmium Manganese Vanadium

Manual 0-4819 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 State 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. You must protect your ears from loud noise to prevent permanent loss of hearing.

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

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

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

GENERAL INFORMATION 1-2 Manual 0-4819

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 HEALTH IN ARC WELDING AND GAS WELDING AND CUTTING, obtainable from the Superintendent of Documents, U.S. Government Printing Office, Washington, D.C. 20402

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

5. ANSI Standard Z41.1, STANDARD FOR 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 Standard W117.2, CODE FOR SAFETY IN WELDING AND CUTTING, obtainable from the Canadian Standards

Association, Standards Sales, 178 Rexdale Boulevard, Rexdale, Ontario, Canada M9W 1R3

Manual 0-4819 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 0-4819

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 0-4819 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 WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE.

LIMITATION OF LIABILITY: Thermal shall not under any circumstances be liable for special or consequential damages, such as, but not limited

to, damage or loss of purchased or replacement goods, or claims of customers of distributor (hereinafter “Purchaser”) for service interruption. The remedies of the Purchaser set forth herein are exclusive and the liability of Thermal with respect to any contract, or anything done in connection therewith such as the performance or breach thereof, or from the manufacture, sale, delivery, resale, or use of any goods covered by or furnished by Thermal whether arising out of contract, negligence, strict tort, or under any warranty, or otherwise, shall not, except as expressly provided herein, exceed the price of the goods upon which such liability is based.

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

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

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

AutoCut

Parts

and UltraCut© Power Supplies and Components 2 Years 1 Year

Labor

Torch And Leads

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

Repair/Replacement Parts 90 Days 90 Days

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

Effective August 19, 2005

GENERAL INFORMATION 1-6 Manual 0-4819

SECTION 2: SPECIFICATIONS

General Description Of The System

A typical Ultra-Cut® 300 system configuration includes:

• One Power Supply

• Remote Arc Starter

• Gas Control Module

• Torch Valve Assembly

• Precision Plasma Cutting Torch

• Set Of Connecting Leads

• Torch Spare Parts Kit

The components are connected at installation.

Plasma Power Supply

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

Remote Arc Starter

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

Gas Control Module

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

Precision Plasma Cutting Torch

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

Manual No. 0-4819 2-1 SPECIFICATIONS

Specifications & Electrical Requirements

Ultra-Cut 300 Specifications & Design Features

Max OCV (U0) 380 vdc Minimum Output Current 10 Amps Max Output Current 300 Amps Output Voltage 60 - 230 vdc Duty Cycle Rating 100% @ 300A, 180V, (54kW), Ambient Temperature for Duty Cycle Rating Operating range 14°F to 122°F (-10°C to + 50°C) Power Factor 0.70 @ 300 A DC Output Cooling Forced Air (Class F)

Input Power Input Current Suggested Sizes (See Note)

Voltage Freq. 3-Ph 3-Ph Fuse (Amps) Wire (AWG)

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

208 50/60 74 206 260 #3/0 230 50/60 72 181 230 #2/0

400 (Incl. CE) 50/60 75 109 135 #3

460 50/60 89 112 150 #2

Line Voltages with Suggested Circuit Protection and W ire Sizes

Based on National Electric Code and Canadian Electrical Code

104F° (40°C)

Ultra-Cut 300 Power Supply

System Component Layout

125’ / 38.1 m Maximum Length

Pilot Return

Negative Leads

Coolant Supply

Primary power

CNC

Art # A-07234

300-A Power Supply

Coolant Return

Control Cable

Fiber Optic

Cable

Gas Control

Control

Cable

175’ / 53.3 m Maximum Length

Module

Plasma Gas

Shield Gas

Preflow Gas

Control Cable

Water Shield

Work Cables

Remote

Arc

Starter

Torch

Val ve

Assembly

25’ / 7.6 m Maximum Length

Pilot Return

Shield

Coolant Supply

Coolant Return

Shield

Plasma Gas

Shield Gas

Positioning Tube

Torch

Work

Manual No. 0-4819 2-2 SPECIFICATIONS

Power Supply Dimensions

27 inch 680 mm

52.25 inch 1030 mm

27.5 inch 700 mm

Art # A-06939

33 inch 840 mm

37.75 inch 960 mm

535 lb / 243 kg

Manual No. 0-4819 2-3 SPECIFICATIONS

Power Supply Rear Panel Features

Gas Control

Console Connector

CNC Connector

Remote Arc Starter

Connector

Coolant Connections

Coolant Filter

Pilot (Pos) Terminal

Circuit Breaker

Panel

RETURN

SUPPLY

Torch (Neg) Terminal

AC Power Lamp

Input Power

Terminals

Ground Terminals

Terminal Cover

Work Cable Terminal

Terminal Cover

Support Panel

Coolant Tank

Leads Bracket

Art # A-04794

Manual No. 0-4819 2-4 SPECIFICATIONS

Gas Requirements

The customer will provide all gases and pressure regulators. Gases must be of high quality. Pressure regulators shall be double stage and installed within 3 meters from the Gas Console.

Ultra-Cut 300 Power Supply: Gas Pressures, Flows, and Quality Requirements

Gas Quality Minimum Pressure Flow

(Oxygen)

99.5% Purity

(Liquid recommended)

120 psi

8.3 bar / 827 kPa

200 scfh (5700 l/h)

99.5% Purity

(Nitrogen)

Compressed

or Bottled Air

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

65% Argon

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

Note 1

: The air source must be adequately filtered to remove all oil or grease. Oil or grease

(Liquid recommended)

<1000 ppm O

ppm H

, <32

Clean, Dry,

Free of Oil (see Note 1)

99.995% Purity

(gas recommended)

120 psi

8.3 bar / 827 kPa

120 psi

8.3 bar / 827 kPa

120 psi

8.3 bar / 827 kPa

300 scfh (8496 l/h)

450 scfh (12743 l/h)

200 scfh (5664 l/h)

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

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

Note 2

: The tap water source does not need to be deionized, but in water systems with extremely high mineral content a water softener is recommended. Tap water with high levels of particulate matter must be filtered.

Note 3:

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

Gas Applications

ATERIA

PERATIONPREFLOW PLASMA SHIELD PREFLOW PLASMA SHIELD PREFLOW PLASMA SHIELD

30A Cut

50A Cut

70A Cut

85A Cut

100A Cut

150A Cut

300A Cut

Manual No. 0-4819 2-5 SPECIFICATIONS

MILD STEEL STAINLESS STEEL ALUMINUM

GAS TYPE GAS TYPE GAS TYPE

Air O

Air

Air Air Air Air Air Air

H20N2N

Air Air Air Air Air Air

H20N2N

Air Air Air Air Air Air

H20N2N

Air Air Air

Air

Air O

Air

H20N2N

H20

XTTM-300 Torch Specifications

A. Torch Dimensions

Art # A-04897

19.00"

482.68 mm

15.50"

393.78 mm

6.30"

160.10 mm

3.54"

89.87 mm

2.25"

57.15 mm

2.0"

50.8 mm

2.39"

60.81 mm

2.74"

69.55 mm

1.57"

39.96 mm

1.49"

37.8 mm

Manual No. 0-4819 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 30.4 125 38.2 150 45.7 175 53.3

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 of Cooling

Combination of gas stream through torch and liquid cooling.

Manual No. 0-4819 2-7 SPECIFICATIONS

F. XTTM-300 Torch Data (with Ultra-CutTM 300 Power Supply)

-300 Torch Ratings

for use with Ult ra-Cut 300 Power Supply

Ambient Temperature Duty Cycle 100% @ 300 Amps Maximum Current 300 Amps

Voltage (V

)500V

peak

Arc Striking Voltage 10kV

Current

-300 Torch Gas Specification

Plasma Gases:

Shield Gases:

Operating Pressure

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

104° F 40° C

Up to 300 Amps, DC, Straight Polarity

Compressed Air, Oxygen, Nitrogen, H35 Compressed Air, Oxygen, Nitrogen, W ater 125 psi ± 10 psi

8.6 bar ± 0.7 bar

G. Plasma Power Supply Used With:

• Thermal Dynamics Ultra-Cut® 300

Manual No. 0-4819 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.

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:

• 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.

B. Cooling System Requirements

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

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

Coolant Capabilities

Cat. Number and Mixture Mixture Protects To

7-3580 'Extra-Cool

7-3581 'Ultra-Cool

7-3582 'Extreme Cool

* For mixing with D-I Cool

' Concentrate* -65° F / -51° C

7-3583

25 / 75 10° F / -12° C

50 / 50 -27° F / -33° C

Manual No. 0-4819 3-1 INSTALLATION

C. System Layout

Primary power

CNC

Art # A-07118

125’ / 38.1 m Maximum Length

Pilot Return

Negative Leads (2)

300-A

Power

Supply

Fiber

Optic Cable

Control

Cable

175’ / 53.3 m Maximum Length

Coolant Supply

Coolant Return

Control Cable

Ground Cable

Gas Control

Module

Plasma Gas

Shield Gas

Preflow Gas

Control

Cable

Water Shield

Remote

Arc

Starter

Torch

Valve

Assembly

Work Cables (2)

25’ / 7.6 m Maximum Length

Pilot Return

Coolant Supply w/ Negative

Coolant Return

Plasma Gas Shield Gas

Positioning Tube

Shield

Torch

Work

NOTE

Installation requires two negative leads and two work cables.

Manual No. 0-4819 3-2 INSTALLATION

D. Cables & Leads Identification

#8 AWG Cable

#1 AWG Cable

Green

Red

Green / Yellow # 4 AWG

Green / Yellow 1/0 (50 mm )

Green

Red

Pilot Return, Power Supply to Arc Starter

Negative Lead, Power Supply to Arc Starter

Coolant Supply Lead, Power Supply to Arc Starter

Coolant Return Lead, Power Supply to Arc Starter

Control Cable, Power Supply to Arc Starter

Ground Cable

Ground Cable, Remote Arc Starter To Earth Ground

Shielded Torch Lead Assembly, Remote Arc Starter to Torch

Art # A-07473

H, Q, R, S,T

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

Plasma Gas Lead, Torch Valve to Torch

Shield Gas Lead, Torch Valve to Torch

Control Cable, Power Supply to Gas Control Module

Fiber Optic Cable, Power Supply to Gas Control Module

CNC Cable (14 Wire)

Work Cable

Manual No. 0-4819 3-3 INSTALLATION

D. Lift the Power Supply

WARNINGS

Do not touch live electrical parts.

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

FALLING EQUIPMENT can cause serious personal injury and equipment damage.

Use all four lifting eyes when using lifting straps to lift the power supply.

Use a forklift, crane, or hoist to lift the unit off the shipping pallet as shown. Keep the power supply steady and vertical. Do not lift it any further than necessary to clear the shipping pallet.

Art # A-04796

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

Manual No. 0-4819 3-4 INSTALLATION

E -1. Set Switches on the Command - Control Module (Type 1 Module)

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

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

CAUTION

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

O N

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

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)

SW 8-3, SW 8-4: Reserved for Factory use.

SW1

SW3

SW4

SW5

SW8

Future Use

O N

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

Art # A-04819

Manual No. 0-4819 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

Art # A-07673

SW13

SW6: OK-to-Move: Contact closure, 120VAC @ 1A (Factory default setting) or DC Volts (16-18vdc@ up to 100 ma.) SW11: Analog Current Control. B = from Gas Control (Factory default setting) or A = from CNC. Position A requires that SW-8-2 be ON.

SW12-1/2/3/4: Divided Arc signal

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

SW13: TVA and XTL Switch positions

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

Only 1 on at a time.

TVA XTL TVA

SW13

Manual No. 0-4819 3-6 INSTALLATION

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

Compare the command - control module to the illustration. Follow instructions in this section for a module without an external connection cover.

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

CAUTION

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

Future Use

SW1

O N

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)

SW 8-3, SW 8-4: Reserved for Factory use.

SW3

SW4

SW5

SW8

O N

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

Art # A-06791

Manual No. 0-4819 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: TVA and XTL Switch positions

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

Only 1 on at a time.

Art # A-06792

TVA XTL TVA

SW13

Manual No. 0-4819 3-8 INSTALLATION

F. Remove the Connections Cover

The primary power cable must be supplied by the end user and connected to the power supply.

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

Connections Cover (Removed)

Connection Panel

Art # A-04797

Manual No. 0-4819 3-9 INSTALLATION

G. Connect Work Cable and Pilot and Negative Leads

1. Pass the ends of the work cable and pilot and negative leads upward through the leads bracket and then upward through openings in the connections cover support panel.

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

CAUTIONS

The clear connections cover must remain in place.

There are two work cables and two negative leads to be connected.

Pilot

Connections Cover

Torch

Work

PILOT WORK TORCH

Work Lead

Pilot Lead To Remote Arc Starter

Connection Panel

Torch Lead -

AC INPUT

L1 L2 L3

To Remote Arc Starter

Connections Cover Support Panel

Lead Connection Detail

Art # A-07661

To Cutting Table

Leads Bracket

Manual No. 0-4819 3-10 INSTALLATION

H. Check / Adjust Input Voltage Configuration

1. The power supply includes a voltage configuration board which must be positioned to match the primary input voltage. Remove the power supply left side panel and locate the voltage configuration board. The input voltage configuration is shown at the top of the board.

2. If necessary, disconnect the jumper at the top right corner of the board, remove the board and re-install it with the correct input voltage shown at the top of the board.

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

Inverter Module

1. 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. 0-4819 3-11 INSTALLATION

I. 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 leads bracket and through the connections cover support panel on the rear panel of the power supply.

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

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

CAUTION

The clear connections cover must remain in place.

4. Pass a system ground cable through the leads bracket and 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

Connections Cover

Connection Panel

to Remote Arc Starter

WORK TORCH

PILOT

to Remote Arc Starter

Art # A-07658

AC INPUT

L1 L2 L3

Input power cable

System Ground Cable

Input power cable ground

Connections Cover

Support Panel

System Ground Cable

Leads Bracket

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

Manual No. 0-4819 3-12 INSTALLATION

J. Ground Connections

A. Electromagnetic Interference (EMI)

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

B. Grounding

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

NOTE

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

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

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

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

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

NOTE

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

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

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

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

NOTE

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

7. The plasma control cable should be shielded with the shield connected only at the cutting machine end. Connecting the shield at both ends will allow ground loop currents which may cause more interference than with no shield at all.

Manual No. 0-4819 3-13 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.

Manual No. 0-4819 3-14 INSTALLATION

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.

K. Connect Coolant Leads

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

Coolant Connections

Art # A-04800

COOLANT

RETURN

RED

SUPPLY

GREEN

RETURN

SUPPLY

To Remote Arc Starter

Manual No. 0-4819 3-15 INSTALLATION

L. Connect Control Cables for CNC, Remote Arc Starter, and GCM

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

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

3. The CNC cable shield must be attached to ground at the CNC end of the cable. Do not ground to the Plasma Power Supply.

To Gas Control Module

To CNC

To Remote Arc Starter

RETURN

SUPPLY

Art # A-04802

Manual No. 0-4819 3-16 INSTALLATION

A. Connect Fiber Optic Cable (Type 1 internal control module)

CAUTION

Check the type of internal control module. Use this section for connections to an internal control module with an external connections cover. Use the following section for connections to an internal control module without an external connections cover.

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

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

relief dome nut from the strain relief.

b. Pass the cable connector through the appropriate opening on the connections cover. Slide the strain

relief securing nut onto the cable. Make a loop of the cable; carefully press the cable connector into the appropriate receptacle on the power supply rear panel.

c. Slide the strain relief assembly onto the connections cover; fasten it in place with the strain relief

securing nut. Fasten the strain relief dome nut onto the strain relief; do not overtighten.

Power Supply Right Side Panel

Connection Cover Side Panel

Power Supply Rear Panel

To Gas Control Module

Connection Cover

To Slave Power Supply (if installed)

Strain Relief Securing Nut

To Remote HMI (if installed)

Connection Cover Side Panel

Art # A-04805

Strain Relief

Strain Relief Dome Nut

Fiber Optic Cable

Fiber Optic Cable Connector

Profile Detail, Fiber Optic Cable Installation

Manual No. 0-4819 3-17 INSTALLATION

B. Connect Fiber Optic Cable (Type 2 internal control module)

CAUTION

Check the type of internal control module. Use this section for connections to an internal control module without an external connections cover. Use the preceding section for connections to an internal module with an external connections cover.

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

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

relief dome nut from the strain relief.

b. Pass the cable connector through the appropriate opening. Slide the strain relief securing nut onto the

cable. Make a loop of the cable; carefully press the cable connector into the appropriate receptacle on the internal control module.

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

Cable Receptacles

Profile Detail, Fiber Optic Cable Installation

To Gas Control Module

To Remote HMI (if installed)

To Slave Power Supply (if installed)

Art # A-06793

Manual No. 0-4819 3-18 INSTALLATION

M. Gas Control Module Installation

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

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

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

Mounting Dimensions

Gas Box

7.14mm

0.28”

279.40mm

11.00”

410.97mm

16.18”

347.47mm

13.68”

215.90mm

8.50”

Art # A-07962

NOTE

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

Manual No. 0-4819 3-19 INSTALLATION

Preparation

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

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

Gas Control Module Cover

Remove Ground Wire

Do not remove

Art # A-06882

Cover Removal

N. Fiber Optic Cable Installation

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

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

CAUTION

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

Manual No. 0-4819 3-20 INSTALLATION

Art # A-04772

Fiber Optic Cable

PREFLOW

OUT

PLASMA

SHIELD

OUT

AIR N

Circuit Board

INPUTS

LOW

PREF

SMA

PLA

SHIELD

AIR N

SHIE

COMM

J56

J57

POWER SUPPLY

TVA

H35

COMM

J56

J57

POWER

SUPPL

H35

INPUTS

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

Manual No. 0-4819 3-21 INSTALLATION

Circuit Board

Fiber Optic Cable

Art # A-04773

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

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

Manual No. 0-4819 3-22 INSTALLATION

O. Gas Control Module: Control, Input, and Output Connections

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

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

3. Ensure that the Flowmeters are plumb.

4. Secure the Module to the mounting surface.

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

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

SHIELD PLASMA

H O

SHIELD

To Torch Valve Assembly

H O

PREFLOW

To Torch Valve Assembly

J57

When Cutting With O2 Plasma

Air MUST BE Connected

AIR

INPUTS

H35

Gas & Water Inputs (Check Valves)

TVA

To Power Supply

J56

POWER SUPPLY

Ground Stud

COMM

Gas Control Box Rear Panel

J56

Connection Panel

SHIELD PLASMA

H O

SHIELD

H O

PREFLOW

When Cutting With O2 Plasma

Air MUST BE Connected

INPUTS

AIR

J57

TVA

H35

COMM

POWER SUPPLY

Art # A-06881

Manual No. 0-4819 3-23 INSTALLATION

P. Install Remote Arc Starter

Site Location

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

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

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

Mounting Dimensions

304.80mm

12.00”

12.70mm .50”

Arc Starter Box

6.35mm D.250”

3 PLACES

203.20mm

8.00”

50.80mm

2.00”

190.83mm

7.51”

37.77mm

Art # A-07961

1.49”

266.70mm

10.50”

Installation

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

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

NOTE

The cover is grounded to the Arc Starter base through a wire shown below. This wire must remain in place.

Manual No. 0-4819 3-24 INSTALLATION

2. Remove the Cover Panel from the Arc Starter.

Upper screws (4 per side)

Cover

Lower screws

Art # A-07029

Ground Wire

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

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

Minimum 2

Art # A-04749

Input Connections

1. Refer to the illustrations. Make the following input connections to the Arc Starter.

• Coolant Supply and Return Hoses (from power supply). Hoses and connectors are color-coded; Red

for Return, Green for Supply.

Manual No. 0-4819 3-25 INSTALLATION

Art # A-04750

Coolant Supply and Return Hoses (from power supply)

Green

Red

Coolant

Return

(Red)

Coolant Supply (Green)

Art # A-04751

Coolant Return (Red)

Manual No. 0-4819 3-26 INSTALLATION

Negative Cable

from power supply

Art # A-04752

Art # A-04754

Negative Cable

(for > 150 Amps)

Negative Cables (from Power Supply rear panel)

Manual No. 0-4819 3-27 INSTALLATION

Art # A-04753

Pilot Return Cable

from Power supply

PILOT Return Cable (from Power Supply rear panel)

Art # A-04755

Control Cable from Power Supply rear panel

Manual No. 0-4819 3-28 INSTALLATION

Output Connections

1. Refer to the illustrations. Make the following output connections to the Arc Starter.

Inner Shield Lead

Pilot Lead

Inner Shield Connection Detail

Art # A-04933

Pilot Lead Connection Detail

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

Art # A-04757

Some items are removed for clarity.

Coolant Return Fitting (Tagged with Red)

Coolant Supply Fitting (Tagged with Green)

Coolant Supply (Green) to Torch

Coolant Return (Red) from Torch

Coolant Supply and Return Hoses (from Torch)

Manual No. 0-4819 3-29 INSTALLATION

Reinstall the Arc Starter Cover. Ensure that the hardware at the cover grounding area is arranged as shown.

Upper screws (4 per side)

Cover

Ground Wire

Lower screws

Art # A-07029

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

grounding details.

Art # A-04758

Torch Leads

1 Nut and 1 Washer Remain in Place

Ground Cable

Manual No. 0-4819 3-30 INSTALLATION

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

Art # A-04759

Torch Leads Shield

Shield Clamp

Coolant and Pilot Leads to Torch Valve Assembly

Manual No. 0-4819 3-31 INSTALLATION

Connect Control Cable

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

Power Supply Rear Panel

RETURN

SUPPLY

COOLANT

RETURN

SUPPLY

Art # A-04801

Remote Arc Starter

Remote Arc Starter Input Connection Panel

Manual No. 0-4819 3-32 INSTALLATION

Q. Original & XTL Torch Valve Installation

General Information

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

Mounting

113.03 mm

4.450”

6.63 mm

.261” Dia.

36.83 mm

1.450”

Art # A-07648

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

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

Do not remove brass plugs Front and side

Outlet Side

Art # A-07645

Left-hand Thread:

To Torch Plasma Gas fitting

Right-hand Thread:

To Torch Shield Gas fitting

Manual No. 0-4819 3-33 INSTALLATION

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

Exhaust Muffler

Plasma Gas Inlet

Control Cable

Water Inlet

Shield Gas Inlet

Preflow Gas Inlet

Art # A-07646

CAUTION

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

R. Connecting Torch

Connect the Torch as follows:

Manual No. 0-4819 3-34 INSTALLATION

Leads Cover

Torch Leads End Cap

Groove for O-Ring

Coolant Supply, Coolant Return, and Pilot Leads

Shield Gas

(Right Hand Thread)

O-Ring

Mounting Tube

Torch Head Assembly

Pilot Lead

Coolant Supply

Power Lead (-)

Pilot Lead Connector

Plasma Gas

(Left Hand Thread)

Art # A-04746

To Torch Valve

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

2. Hold the Torch Leads End Cap stationary. Pull approximately 18" (0.5 m) of leads through the End Cap.

3. Remove and discard the protective end caps from the Mounting Tube.

4. Install the O-ring in the groove at the upper end of the Mounting Tube.

5. Install the Mounting Tube as follows:

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

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

c. Press the upper end of the Mounting Tube into the lower end of the Torch Leads End Cap. Ensure that

the O-Ring on the Tube engages the mating groove inside the Torch Leads End Cap.

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

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

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

b. Plasma and secondary gas connections to the Torch Head are threaded differently; the plasma gas

connection is left-hand thread, the shield gas connection is right-hand thread.

c. Hold the Torch Head leads connectors stationary; turn the leads fittings with a wrench to secure the

leads to the Torch Head. Do not overtighten.

CAUTION

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

Manual No. 0-4819 3-35 INSTALLATION

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

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

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

CAUTION

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

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

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

S. Install Consumable Torch Parts

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

WARNINGS

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

Art # A-03887

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

2. Stack the consumable parts together.

3. 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.

4. 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.

5. 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.

Manual No. 0-4819 3-36 INSTALLATION

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.

Manual No. 0-4819 3-37 INSTALLATION

Electrode

Plasma Gas Distributor

Tip

1: Stack Parts

Upper 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 Upper O-Ring on Torch Tip

Art # A-04716

Manual No. 0-4819 3-38 INSTALLATION

Torch Head

0.063 - 0.083"

(1.6 - 2.1 mm)

Protrusion

Installing Assembled Cartridge Onto Torch Head

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

Torch Head O-Ring

Art # A-07202

Ohmic Clip

A-03393

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

NOTE

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

Manual No. 0-4819 3-39 INSTALLATION

T. Complete the Installation

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

Coolant Capabilities

Cat. Number and Mixture Mixture Protects To

7-3580 'Extra-Cool

7-3581 'Ultra-Cool

7-3582 'Extreme Cool

* For mixing with D-I Cool

' Concentrate* -65° F / -51° C

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 the first time.

a. Place the ON/OFF Switch to ON.

b. After about 30 seconds the system may shut down if the leads are not full of coolant.

c. Place the ON/OFF switch to OFF.

d. After 10 seconds place the ON/OFF switch to ON again.

e. Repeat steps ‘b’ through ‘d’ until the system no longer shuts down. Depending on the length of the torch

leads this sequence may need to be done three to five times.

f. After the system stays operational allow the pump to operate for ten minutes to properly purge any air

from the coolant lines before using the system.

3. Re-fill the reservoir and re-install the filler cap.

4. Purge coolant from the torch before firing the torch. Ensure there are no leaks before use. If leaks are evident, consult the coolant leak trouble-shooting guide in the maintenance section of this manual.

Intentionally Blank

SECTION 4: OPERATION

Power Supply Control Panel

AC Indicator

Temp Indicator

Art # A-04862

AC Power Indicator

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 indicator will blink, indicating gas purge at power on.

TEMP Indicator: Normally OFF. Indicator turns ON when the internal sensors detect temperatures above

normal limits. Let the unit cool before continuing operation.

Gas Indicator

DC Indicator

Status Indicator

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

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

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

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

Manual No. 0-4819 4-1 OPERATION

Start-Up Sequence

1. Connect system to primary input power.

2. Turn ON/OFF switch to ON (up) position. AC Indicator turns ON.

POWER

OFF

Art # A-04812

3. Check the AC indicator. If indicator does not light, reverse two phases of primary input power cable. If indicator is ON, system is ready to operate (pending fault checks by internal circuitry).

OFF

Manual No. 0-4819 4-2 OPERATION

Gas Control Module Operation

Functional Overview

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

O2 - AIR

MODE

RUN

SET PREFLOW

SET PLASMA

& SHIELD

TEST

PREFLOW

GAS

RUN

SET PREFLOW

SET PLASMA

& SHIELD

TEST

O2 - AIR

O2 - O2

H35 - N2

F5 - N2

AIR - AIR

N2 - H20

N2 - N2

PLASMA

O2 - O2

H35 - N2

F5 - N2

AIR - AIR

N2 - H20

N2 - N2

GAS

ENABLE

DISABLE

H20

MIST

PLASMA POWER SUPPLY

AMPERAGE

SET-UP

SHIELD

ENABLE

DISABLE

PLASMA

POWER SUPPLY

AMPERAGE

SET-UP

PRESSURE

GAS

FLOW

GCM

2010

PRESSURE

GAS

FLOW

Art # A-04771

Manual No. 0-4819 4-3 OPERATION

Gas Control Module: Controls & Indicators

1. MODE Selection Switch

MODE

O2 - AIR

SET PREFLOW

SET PLASMA

& SHIELD

O2 - O2

2 - N2

GAS

PLASMA

RUN

TEST

MODE

PREFLOW

2 - H2O

H35 -N F5 - N2 AIR - AIR

Plasma Cutting System

RUN

SET PREFLOW

SET PLASMA

& SHIELD

TEST

High Precision

SHIELD

AMPERAGE

SET-UP

ENABLE

DISABLE

PLASMA

POWER SUPPLY

MIST

GCM

2010

GAS

PRESSURE

FLOW

Art # A-04765

• Normally in the RUN position during torch operation.

• In the SET PREFLOW position, Air or N2 travels to the torch. The Preflow valve remains open for 2 minutes to allow the operator to adjust flow pressure.

• In the SET PLASMA & SHIELD position, gases travel to the torch. The Preflow valve at the torch remains open for 2 minutes to allow the operator to adjust flow pressures and rates.

• In the TEST position, gases fill the torch leads. The display shows the pressure of the plasma gas while flowing. After 1 minute the Module shuts off the valves at the torch.

Manual No. 0-4819 4-4 OPERATION

2. GAS Selection Switch

Selects combinations of plasma and shield gases.

O2 - AIR

O2 - O2

GAS

RUN

SET PREFLOW

SET PLASMA

& SHIELD

TEST

MODE

PREFLOW

GCM

2010

H35 -N

F5 - N2

AIR - AIR

2 - H2O

2 - N2

O2 - AIR

O2 - O2

H35 -N F5 - N2 AIR - AIR

2 - H2O

2 - N2

PLASMA

High Precision

Plasma Cutting System

GAS

SHIELD

PRESSURE

FLOW

GAS

Art # A-04766

AMPERAGE

SET-UP

ENABLE

DISABLE

PLASMA

POWER SUPPLY

MIST

Manual No. 0-4819 4-5 OPERATION

3. Amperage / Set-Up Knob

Adjusts the output amperage of the torch.

High Precision

Plasma Cutting System

O2 - AIR

SET PREFLOW

SET PLASMA

& SHIELD

O2 - O2

H35 -N

F5 - N

AIR - AIR

2 - H2

2 - N2

PLASMA

High Precision

Plasma Cutting System

GAS

MODE

RUN

TEST

PREFLOW

GCM

2010

SHIELD

PRESSURE

GAS

FLOW

AMPERAGE

SET-UP

AMPERAGE

SET-UP

ENABLE

DISABLE

PLASMA

POWER SUPPLY

MIST

Art # A-04767

4. Plasma Power Supply Enable / Disable Switch

In the DISABLE position, stops the system from starting a pilot arc at the torch, while the operator selects and adjusts gases, or changes torch parts. The DISABLE position also stops coolant and gas flow. In the ENABLE position, allows normal operation (under control of the CNC device).

5. PREFLOW Control Knob and Pressure Gauge

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

6. PLASMA and SHIELD Control Knobs, Pressure Gauges, and Flow Meters

Used to set plasma and shield gas pressures and flows. MODE switch must be in SET PLASMA & SHIELD position.

7. H2O Mist Control Knob and Flow Meter

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

NOTES

Water mist is not used in all applications.

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

Manual No. 0-4819 4-6 OPERATION

Sequence Of Operation

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

DANGER

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

a. Change the torch parts if necessary.

b. Set the Plasma Power Supply Enable / Disable switch (on the Gas Control Module) to Enable. The

Module performs purges of 15 seconds, 11 seconds, and another 11 seconds. This removes water from the torch parts.

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

3. Set the preflow gas pressure.

a. Set the MODE switch to SET PREFLOW.

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

settings.

c . Use the AMPERAGE SET-UP control knob to set the desired pre-charge pressure set point.

Press the control knob for 2 seconds without rotating. Then rotate the knob to adjust pressure.

4. Set the plasma and shield gas pressures and flows.

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

b. Use the PLASMA and SHIELD control knobs, pressure gauges, and flow meters to set plasma and

shield gas pressures and flows. Refer to the torch manual for pressure settings.

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

Refer to the torch manual for flow rates.

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

6. Place the MODE switch to the RUN position.

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

NOTE

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

CAUTION

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

Manual No. 0-4819 4-7 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

Top

Spatter

Build-Up

Dross

Cut Surface

Drag Lines

Bevel Angle

Top Edge Rounding

A-00007

Cut Surface

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

Bevel Angle

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

Top-Edge Rounding

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

Dross Build-up and Top Spatter

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

Kerf Width

The width of material removed during the cut.

Nitride Build-up

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

Manual No. 0-4819 4-8 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 sensing is not recommended with water shield. Water on the plate interferes electrically with the ohmic sensing circuit.

Marking

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

Manual No. 0-4819 4-9 OPERATION

Gas Selection

A. Plasma Gases

1. Air Plasma

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

• Air plasma is normally used with air shield.

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

• Provides satisfactory results on nonferrous materials.

2. Argon/Hydrogen (H35) Plasma

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

• Poor cut quality on ferrous materials.

• Provides faster cutting speeds and high cut quality on thicker materials to offset the higher cost.

• A 65% argon / 35% hydrogen mixture should be used.

3. Oxygen (O2) Plasma

• Oxygen is recommended for cutting ferrous materials.

• Provides faster cutting speeds.

• Provides very smooth finishes and minimizes nitride build-up on cut surface (nitride build-up can cause difficulties in producing high quality welds if not removed).

4. Nitrogen (N2) Plasma

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

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

• Provides much better parts life than air.

• A good clean welding grade nitrogen should be used.

B. Shield Gases

1. Compressed Air Shield

• Air shield is normally used when operating with air plasma.

• Improves cut quality on some ferrous materials.

• Inexpensive - reduces operating costs.

2. Nitrogen (N2) Shield

• Nitrogen shield is used with Ar/H2 (H35) plasma.

• Provides smooth finishes on nonferrous materials.

• May reduce smoke when used with Ar/H2 plasma.

3. Water Shield

• Water shield should be used only in mechanized applications - never in hand cutting!

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

• Provides very smooth cut surface.

• Reduces smoke and heat input to the workpiece.

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

• Tap water provides low operating expense.

Manual No. 0-4819 4-10 OPERATION

Power Supply Status Codes

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

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

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

Note

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

Fault Code Key

Error

Code Error Remedy / Comments

Plasma Enable Off ; External E-Stop Activated or CCM TB1-1&2 jumper missing; Missing AC Phase;

System not Enabled or

1-1

Missing AC Input Phase

1-2 Pilot Ignition Failure

1-3 Lost Pilot

1-4 Loss of Transfer

1-5 Off the Plate Function not currently enabled

1-6 Pilot Timed out w/o Transfer

1-7 Tip Saver Function not currently enabled.

1-8 Possible Shorted Torch

No power to GCM 2000 or 2010 Gas Control, c heck GCM control cable connected, reset CP4 or CP5 circuit breaker in power supply, blown fuse F19 in GCM. Pilot did not start within 15 seconds. Preflow pressure too high; Defective Arc Starter

Pilot went out without shutoff signal; Preflow pressure too high; cut current set too low for consumables.

Arc transfer (>50 ms.) then arc lost with START still on. Standoff too high; Current set too low.

Must transfer from Pilot to Cutting Arc in 85 ms. (SW 8-1 OFF) or 3 sec. (SW8-1 ON). Standoff too high or void in work under torch; cut current too low for consumables; Preflow pressure too low.

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

Manual No. 0-4819 4-11 OPERATION

Fault Code Key

Error

Code Err or Rem e dy / Com ments

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

Inverter(s ) not configured correctly for input voltage;

2-2 Wrong input voltage

Inverter or Pilot Regulator Over

2-3

Temperature

2-4 Power Supply not Ready Defective inverter

2-5 DC Output Low

2-6 Primary over current fault

2-7 Unexpected current

Unexpected current in pilot

2-8

circuit

Unexpected current in work

2-9

lead

Gas Control Communication fault, Cannot establish

3-1

Communication with gas control.

Gas Control Communication reply fault, connection was

3-2

established but CCM did receive a reply to a process request.

3-3 Gas Pressure Low

3-4 Gas Control not ready Purging; not in RUN mode; Gas Control faulty, replace PCB.

3-5 Gas Control Protocol Fault Application error or firmware compatibility fault

Invalid Current Control level

3-6

from GCM Gas Control returns wrong

3-7

command sequence CCM and Gas Control type

3-8

(Autocut-Ultracut) mismatch

Gas Control Communication

3-9

reply fault Warning. -- Gas Control

3-10

firmware needs update

Poor power quality (brownouts, dropouts); Input power capacity / wiring too small causing voltage drop; broken or loose power cable connections.

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

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

Over current detected in inverter primary circuit, remove power to reset; defective inverter; voltage surge; Current >20A in work or pilot leads before pilot ignition; Possible shorted torch; Defective current sensor.

Current > 5A in pilot circuit; wrong or mismatched consumables; Pilot lead s horted to n egative in torch tube; Pos sible s horted torch

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

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

Gas Co ntro l did n ot re ply to s ignal from C CM in allowed time. Dirt on fiber ends or in connectors, blow out with clean dry air; fiber not locked into connector; sharp bends in fiber; fiber defective. If problem persists Gas Control PCB likely defective, replace board.

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

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

Check firm ware compatibility

Install correct CCM or Gas Control for system

Reply not compatible with request; Check firmware compatibility

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

Manual No. 0-4819 4-12 OPERATION

Fault Code Key

Error

Code

Error Remedy / Comments

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

Low coolant flow after power on purge. Not cutting: < 0.7 gal/min for 15

4-2

sec; Cutting: flow between 0.35 to 0.7 gal/min for 3 sec. or immediately if < 0.35gal/min;

Coolant overheated (>70 deg.

4-3

C, 158 deg F) Coolant System not ready. During power on purge / priming,

4-4

flow did not reach 0.35 gal/min for at least 5 seconds

4-5 Low Coolant Level - Warning

CANBUS Failure to

5-1

Acknowledge fault.

CANBU S Off due to e xces sive

5-2

data errors; CANBUS data error warning.

5-3

Errors increasing, will s oon fault.

5-4 CCM Message not sent

6-1 CCM Analog Voltage Error Replace CCM 6-2 CCM ADC or DAC error Replace CCM

Coolant Flow too High error,

6-3

flow > 2.7 gal/min

6-4 CCM Data Memory error Replace CCM

Suction leak introducing air into coolant , susp ect rear p anel filter seal; clogged filter; defective pump.

Coolant fan failed; radiator fins clogged with dirt; Ambient temperature > 40 deg C. If new installation recy cle p ower to rest art pump, may take a few t imes t o fill hoses; Damaged t orch coolant tube; Suct ion leak introducing air into coolant , s uspect rear panel filt er seal; clogged filter; defect ive p ump.

While cutting detected low coolant level, does not stop cut. Add coolant as required. If GCM 100 0, Ba sic ID si gnal missi ng; Other gas controls , Fiber disconnected or broken, Transceiver (what fiber plugs into) fault, replace Gas control PCB or CCM Dirt on fiber ends or in connectors, blow out with clean dry air; fiber not locked into connector; sharp bends in fiber; fiber defective;

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

Dirt on fiber ends or in connectors, blow out with clean dry air; fiber not locked into connector; sharp bends in fiber; fiber defective; CANBUS hardware error (CCM or Gas Control PCB)

Torch coolant tube broken or miss ing; CCM fault, replace CCM

Manual No. 0-4819 4-13 OPERATION

Remote Arc Starter: Service Chart

Arc Starter Service Chart

Symptom Cause Check Remedy

Use conductivity meter

Use capacitance meter Reconnect or replace.

Capacitance meter Replace.

Vis ual ins pection Reconnect.

Visual inspection Replace coolant line(s).

Visual Inspection of color-coded connections

Loosen fitting slightly and check for cool ant flow

Vis ual ins pection of lead attachment to Arc Starter

Visual inspection of ground wire to Arc Starter

Visual inspection / capacitor measurement

No Pilot ignition:

Spark in Arc Starter

but no ignition

No Pilot ignition:

No Spark

in Arc Starter

No cooling or

insufficient cooling:

Leaks coolant

No cooling or

insufficient cooling:

No Coolant Flow

Erratic System

Behavior

(EMI Interference)

Coolant has become conductiv

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

Short across in inductor (L1) Visual inspection

Spark gap bus caps (C1, C2, C3) broken or defective Negative supply not connected correctly Spark gap set too large Check with feeler gauge Set to 0.063" ±0.002" Faulty transformer Resistance measurement Replace.

No 120V supply Check input voltage at EMI filter

No/ loose connection to spark gap Faulty EMI filter Voltage/ Resistor measurement Replace. Loose fitting(s) Visual inspection Tighten fittings. Failure to braze joints (L1) Visual inspection Replace HF Coil. Damaged or punctured coolant line(s).

Supply & return hose reversed

Blockage in coil or supply/return hoses

hield Drain / Torch lead inner shield connector missin

Missing or loose ground connection

Cap C5 not connected, open or loose

or loose.

Flush system, replace coolant.

Remove short; increase coil gaps.

Make connections; replace harness.

Match coolant connection colors to arc starter fitting colors.

Flush system.

Reconnect / tighten lead connectors.

Make or tighten connections to good ground.

Replace PCB.

Manual No. 0-4819 4-14 OPERATION

Remote Arc Starter: Spark Gap

Adjustment

0.063" ± 0.002"

1.6 ± 0.05 mm

Art # A-04857

Manual No. 0-4819 4-15 OPERATION

This page intentionally blank

Manual No. 0-4819 4-16 OPERATION

SECTION 5: MAINTENANCE

Perform the following checks periodically to ensure proper system performance.

Power Supply Maintenance Schedule

Daily

Check coolant level; add coolant as needed. Check gas hose connections and pressures.

Monthly

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

Six Months

Clean or replace external coolant filter. Clean coolant tank. Vacuum out any dust buildup inside power supply. Check internal coolant filter

External Coolant Filter Cleaning Procedure

Periodic cleaning of the coolant filter ensures maximum coolant flow efficiency. Poor coolant flow causes inefficient torch parts cooling with consequent faster consumable wear.

Clean the coolant filter as follows:

1. Disconnect the system from main input power.

Filter Screen

Filter Holder

Art # A-04811

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

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

4. Turn the system on and check for leaks.

Manual No. 0-4819 5-1 MAINTENANCE

Internal Coolant Filter Cleaning Procedure

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

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

Fill Range

Coolant Tank

SUPPLY

RETURN

SUPPLY

Art # A-04803

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

Manual No. 0-4819 5-2 MAINTENANCE

SECTION 6: REPLACEMENT ASSEMBLIES & PARTS

Complete Unit / Component Catalog Number

Ultra-Cut® 300 Power Supply, 208/230V 3-9118-1 Ultra-Cut® 300 Power Supply, 460V 3-9118-2

Ultra-Cut® 300 Power Supply, 400V 3-9118-3

Ultra-Cut

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

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

Original Torch Valve Assembly Repair Part Only 4-3049

XTL Torch Valve Assembly Only 4-3054

Remote Arc Starter (RAS-1000) 3-9130

OPTIONAL EQUIPMENT:

300 Power Supply, 400V, (CE) 3-9118-4

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

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

GCM 2010 Firmware version 3.1 or higher)

Wheel Kit 9-9379

Manual No. 0-4819 6-1 Power Supply Parts List

System Layout

Primary power

CNC

Art # A-07118

125’ / 38.1 m Maximum Length

Pilot Return

Negative Leads (2)

300-A Power Supply

Fiber

Optic

Cable

Control

Cable

175’ / 53.3 m Maximum Length

Coolant Supply

Coolant Return

Control Cable

Ground Cable

Gas Control

Module

Plasma Gas

Shield Gas

Preflow Gas

Control

Cable

Water Shield

Remote

Arc

Starter

Torch

Valve

Assembly

Work Cables (2)

25’ / 7.6 m Maximum Length

Pilot Return

Coolant Supply w/ Negative

Coolant Return

Plasma Gas Shield Gas

Positioning Tube

Shield

Torch

Work

NOTE

Installation requires two negative leads and two work cables.

Manual No. 0-4819 6-2 Power Supply Parts List

Leads and Cables

#8 AWG Cable

#1 AWG Cable

Green

Red

Green / Yellow # 4 AWG

Green / Yellow 1/0 (50 mm )

Green

Red

Pilot Return, Power Supply to Arc Starter

Negative Lead, Power Supply to Arc Starter

Coolant Supply Lead, Power Supply to Arc Starter

Coolant Return Lead, Power Supply to Arc Starter

Control Cable, Power Supply to Arc Starter

Ground Cable

Ground Cable, Remote Arc Starter To Earth Ground

Shielded Torch Lead Assembly, Remote Arc Starter to Torch

Art # A-07473

H, Q, R, S,T

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

Plasma Gas Lead, Torch Valve to Torch

Shield Gas Lead, Torch Valve to Torch

Control Cable, Power Supply to Gas Control Module

Fiber Optic Cable, Power Supply to Gas Control Module

CNC Cable (14 Wire)

Work Cable

Manual No. 0-4819 6-3 Power Supply Parts List

Key Description Catalog #

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

A,B,C,D,E Supply Lead Set, 10’ / 3.05 m (See Note 1) 4-3028

A,B,C,D,E Supply Lead Set, 15’ / 4.5 m (See Note 1) 4-3029

A,B,C,D,E Supply Lead Set, 25’ / 7.6 m (See Note 1) 4-3030

A,B,C,D,E Supply Lead Set, 35’ / 10.6 m (See Note 1) 4-3050

A,B,C,D,E Supply Lead Set, 50’ / 15.2 m (See Note 1) 4-3031

A,B,C,D,E Supply Lead Set, 75’ / 22.9 m (See Note 1) 4-3032

A,B,C,D,E Supply Lead Set, 100’ / 30.5 m (See Note 1) 4-3033

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

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

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

A Pilot Return Cable (only), 15’ / 4.5 m 9-4790

A Pilot Return Cable (only), 25’ / 7.6 m 9-4791

A Pilot Return Cable (only), 35’ / 10.6 m 9-9426

A Pilot Return Cable (only), 50’ / 15.2 m 9-4792

A Pilot Return Cable (only), 75’ /22.8 m 9-4793

A Pilot Return Cable (only), 100’ /30.5 m 9-4794

A Pilot Return Cable (only), 125’ /38.1m 9-4796

B Negative Cable (only), 3’ / 1 m 9-4892

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

B Negative Cable (only), 15’ / 4.5 m 9-4798

B Negative Cable (only), 25’ / 7.6 m 9-4799

B Negative Cable (only), 35’ / 10.6 m 9-9427

B Negative Cable (only), 50’ / 15.2 m 9-4800

B Negative Cable (only), 75’ / 22.8 m 9-4801

B Negative Cable (only), 100’ / 30.5 m 9-4802

B Negative Cable (only), 125’ / 38.1 m 9-4804

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

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

C Hose, Coolant Supply, (only), 15’ / 4.6 m 9-4780

C Hose, Coolant Supply, (only), 20’ / 6 m 9-4781

C Hose, Coolant Supply, (only), 25’ / 7.6 m 9-4782

C Hose, Coolant Supply, (only), 30’ / 9.1 m 9-4783

C Hose, Coolant Supply, (only), 35’ / 10.6 m 9-4784

C Hose, Coolant Supply, (only), 40’ / 12 m 9-4785

NOTE 1:

Supply lead sets include Pilot Return Cable, Negative Cable, Coolant Supply & Return Hoses, and Control Cable.

Manual No. 0-4819 6-4 Power Supply Parts List

Key Description Catalog #

C Hose, Coolant Supply, (only), 50’ / 15.2 m 9-4786

C Hose, Coolant Supply, (only), 75’ / 23 m 9-4787

C Hose, Coolant Supply, (only), 100’ / 30.5 m 9-4788

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

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

D Hose, Coolant Return, (only), 15’ / 4.6 m 9-4762

D Hose, Coolant Return, (only), 20’ / 6 m 9-4763

D Hose, Coolant Return, (only), 25’ / 7.6 m 9-4764

D Hose, Coolant Return, (only), 30’ / 9.1 m 9-4765

D Hose, Coolant Return, (only), 35’ / 10.6 m 9-4766

D Hose, Coolant Return, (only), 40’ / 12 m 9-4767

D Hose, Coolant Return, (only), 50’ / 15.2 m 9-4768

D Hose, Coolant Return, (only), 75’ / 23 m 9-4769

D Hose, Coolant Return, (only), 100’ / 30.5 m 9-4770

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

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

E Control Cable (only), Power Supply to Arc Starter 15’ / 4.5 m 9-4917

E Control Cable (only), Power Supply to Arc Starter 25’ / 7.6 m 9-4918

E Control Cable (only), Power Supply to Arc Starter 50’ / 15.2 m 9-4942

E Control Cable (only), Power Supply to Arc Starter 75’ / 22.9 m 9-4943

E Control Cable (only), Power Supply to Arc Starter 100’ / 30.5 m 9-4944

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

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

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

F Ground Wire, Power Supply to Gas Control Module, 25’ / 7.6 m 9-4925

F Ground Wire, Power Supply to Gas Control Module, 50’ / 15.2 m 9-4926

F Ground Wire, Power Supply to Gas Control Module, 75’ / 22.9 m 9-4927

F Ground Wire, Power Supply to Gas Control Module, 100’ / 30.5 m 9-4928

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

F Ground Wire, Power Supply to Gas Control Module, 150’ / 45.7 m 9-4930

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

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

F1 Ground Wire, Remote Arc Starter to Earth, 25’ / 7.6 m 9-4933

F1 Ground Wire, Remote Arc Starter to Earth, 50’ / 15.2 m 9-4934

F1 Ground Wire, Remote Arc Starter to Earth, 75’ / 22.9 m 9-4935

F1 Ground Wire, Remote Arc Starter to Earth, 100’ / 30.5 m 9-4936

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

F1 Ground Wire, Remote Arc Starter to Earth, 150’ / 45.7 m 9-4938

Manual No. 0-4819 6-5 Power Supply Parts List

Key Description Catalog #

G Assembly, Coolant Return Hose, 10’ / 3.05 m 9-4882

G Assembly, Pilot Return, 3’ / 1 m 9-4945

G Assembly, Pilot Return, 10’ / 3.05 m 9-4883

G Assembly, Negative/Coolant Supply, 10’ / 3.05 m 9-4939

G Assembly, Torch Lead, 3’ / 1 m 9-4884

G Assembly, Torch Lead, 10’ / 3.05 m 9-4885

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

H,Q,R,S, T Gas Lead Set, 15’ / 4.5 m (See Note 2) 4-3036

H,Q,R,S, T Gas Lead Set, 25’ / 7.6 m (See Note 2) 4-3037

H,Q,R,S, T Gas Lead Set, 35’ / 10.6 m (See Note 2) 4-3051

H,Q,R,S, T Gas Lead Set, 50’ / 15.2 m (See Note 2) 4-3038

H,Q,R,S, T Gas Lead Set, 75’ / 22.9 m (See Note 2) 4-3039

H,Q,R,S, T Gas Lead Set, 100’ / 30.5 m (See Note 2) 4-3040

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

H,Q,R,S, T Gas Lead Set, 150’ / 45.7 m (See Note 2) 4-3042

H,Q,R,S, T Gas Lead Set, 175’ / 53.3 m (See Note 2) 4-3043

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

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

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

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

L Control Cable, Fiber Optic, 25’ / 7.6 m 9-4900

L Control Cable, Fiber Optic, 35’ / 10.6 m 9-9335

L Control Cable, Fiber Optic, 50’ / 15.2 m 9-4901

L Control Cable, Fiber Optic, 75’ / 22.9 m 9-4902

L Control Cable, Fiber Optic, 100’ / 30.5 m 9-4903

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

L Control Cable, Fiber Optic, 150’ / 45.7 m 9-4905

L Control Cable, Fiber Optic, 175’ / 53.3 m 9-4906

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

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

K Control Cable, Power Supply to Gas Control Module, 25’ / 7.6 m 9-4909

K Control Cable, Power Supply to Gas Control Module, 35’ / 10.6 m 9-9332

K Control Cable, Power Supply to Gas Control Module, 50’ / 15.2 m 9-4910

K Control Cable, Power Supply to Gas Control Module, 75’ / 22.9 m 9-4911

NOTE 2:

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

Manual No. 0-4819 6-6 Power Supply Parts List

Key Description Catalog #

K Control Cable, Power Supply to Gas Control Module, 100’ / 30.5 m 9-4912

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

K Control Cable, Power Supply to Gas Control Module, 150’ / 45.7 m 9-4914

O Work Cable, 10’ / 3.05 m 9-9300

O Work Cable, 15’ / 4.5 m 9-9301

O Work Cable, 25’ / 7.6 m 9-9302

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

O Work Cable, 50’ / 15.2 m 9-9304

O Work Cable, 75’ / 22.9 m 9-9305

O Work Cable, 100’ / 30.5 m 9-9306

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

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

P Control Cable, CNC to Power Supply, 50’ / 15.2 m 9-8313

P Control Cable, CNC to Power Supply, 75’ / 22.9 m 9-8315

P Control Cable, CNC to Power Supply, 100’ / 30.5 m 9-8316

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

Manual No. 0-4819 6-7 Power Supply Parts List

Optional Gas Supply Leads

HOSE ASSEMBLIES

Length

1/4"

3/8"

HOSE FITTINGS

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 20x962 N/A N/A 8-6617 N/A 8-0271 8-0384 1/2" 9-2551 8-6470 20x884 N/A 8-0267 9-3831

ADAPTER FITTINGS

1/4" NPT

Feet 10' 15' 25' 35' 50' 75' 100'

Meters 3.05 4.6 7.6 10.6 15.2 22.9 30.4

Inert B (RH) 9-2146 9-5061 9-5073 9-5085 9-5097 9-5109 9-5121

O2 B (RH) 9-9008 9-9009 9-9010 9-9011

Inert B (RH)

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

CATALOG#

per foot

Inert B (RH) 8-0330 Inert B (LH) 8-0329

O2 B (RH) 8-0260 FUEL B (LH) FUEL B (LH)

1/4" Barb 8-4264

(Catalog number)

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

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

(Catalog number)

NUT NUT NIPPLE NUT NUT NIPPLE JIC CLAMP

Inert B

(LH)

Catalog #

Inert B

(RH)

Inert

FUEL B

(LH)

O2 B (RH)

Manual No. 0-4819 6-8 Power Supply Parts List

Power Supply External Replacement Parts

Item # Qty Description Catalog #

1 Power Supply Front Panel

1 Power Supply Rear Panel

1 Power Supply Top Panel 9-9382

1 Power Supply Right Side Panel

1 Power Supply Left Side Panel

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

9-9386

9-9373

9-9382

Art # A-06888

Manual No. 0-4819 6-9 Power Supply 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. 0-4819 6-10 Power Supply Parts List

Power Supply Replacement Parts - Right Side

Item # Qty Description Ref. Des. Catalog #

3 1 Resistor R6 9-9340

4 1 Output Filter PCB PCB8 9-9341

5 1 Sensor HCT1 9-9342

Manual No. 0-4819 6-11 Power Supply 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. 0-4819 6-12 Power Supply Parts List

Power Supply Replacement Parts - Front Panel

Item # Qty Description Ref. Des. Catalog #

7 1 Main Power Switch (‘Circuit Protector’) CP1 9-9344

Manual No. 0-4819 6-13 Power Supply Parts List

Power Supply Replacement Parts - Front Panel

Item # Qty Description Ref. Des. Catalog #

11 1 Display PC Board PCB6 9-9347

Manual No. 0-4819 6-14 Power Supply 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. 0-4819 6-15 Power Supply Parts List

Power Supply Replacement Parts - Rear Panel

Item # Qty Description Ref. Des. Catalog #

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

13 1 Circuit Breaker (’TDC’, 24V, 3.25A) CP3 9-9349

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

15 1 Circuit Breaker (AGC, 120V, 2.5A) CP5 9-9348

16 1 Circuit Breaker (AGC, 15V, 2.5A) CP6 9-9348

17 1 Circuit Breaker (Pump, 200V, 5A) CP7 9-9351

18 1 Circuit Breaker (Fan, 24V, 15A) CP8 9-9352

1 Coolant Tank 9-5948

1 Tank Cap 8-5142

CIRCUIT

Tank Cap

COOLANT

RETURN

SUPPLY

J55

G C M

J15

C N C

J59

R A S

BREAKERS

24V3 15A

120V2 5A

RAS

120V 5A

CCM

GCM

24V 10A

GCM

15V2 5A

PUMP

200V 5A

FAN

24V 15A

CP2

CP3

CP4

CP5

CP6

CP7

CP8

Art # A-06017

Coolant Tank

Art # A-04932

Manual No. 0-4819 6-16 Power Supply Parts List

Power Supply Replacement Parts - Right Side

Item # Qty Description Ref. Des. Catalog #

23 1 Transformer T1 9-9355

Manual No. 0-4819 6-17 Power Supply Parts List

Power Supply Replacement Parts

Item # Qty Description Catalog #

29 3 Inverter Module 208/230V 9-9360D

3 Inverter Module 400V CE and 400V Non CE 9-9482D 3 Inverter Module 600V 9-9485D

Art # A-04786

Manual No. 0-4819 6-18 Power Supply Parts List

Thermal Dynamics Ultra-cut 300, ULTRA-CUT 100 Operating Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

1.01 Notes, Cautions and Warnings

1.02 Important Safety Precautions

1.03 Publications

1.04 Declaration of Conformity

1.05 Statement of Warranty

SECTION 2: SPECIFICATIONS

General Description Of The System

Plasma Power Supply

Remote Arc Starter

Gas Control Module

Precision Plasma Cutting Torch

Specifications & Electrical Requirements

System Component Layout

Power Supply Dimensions

Power Supply Rear Panel Features

Gas Requirements

Gas Applications

XTTM-300 Torch Specifications

SECTION 3: INSTALLATION

A. Installation Requirements

B. Cooling System Requirements

C. System Layout

D. Cables & Leads Identification

D. Lift the Power Supply

E -1. Set Switches on the Command - Control Module (Type 1 Module)

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

F. Remove the Connections Cover

G. Connect Work Cable and Pilot and Negative Leads

H. Check / Adjust Input Voltage Configuration

I. Connect Input Power and System Ground Cables

J. Ground Connections

K. Connect Coolant Leads

L. Connect Control Cables for CNC, Remote Arc Starter, and GCM

M. Gas Control Module Installation

N. Fiber Optic Cable Installation

SECTION 4: OPERATION

Power Supply Control Panel

Start-Up Sequence

Gas Control Module Operation

Sequence Of Operation

Gas Selection

Power Supply Status Codes

Remote Arc Starter: Service Chart

SECTION 5: MAINTENANCE

External Coolant Filter Cleaning Procedure

Internal Coolant Filter Cleaning Procedure

Coolant Replacement Procedure

SECTION 6: REPLACEMENT ASSEMBLIES & PARTS

System Layout

Leads and Cables

Optional Gas Supply Leads

Power Supply External Replacement Parts

Power Supply Replacement Parts - Right Side

Power Supply Replacement Parts - Right Side

Power Supply Replacement Parts - Right Side

Power Supply Replacement Parts - Front Panel

Power Supply Replacement Parts - Front Panel

Power Supply Replacement Parts - Right Side

Power Supply Replacement Parts - Rear Panel

Power Supply Replacement Parts - Right Side

Power Supply Replacement Parts