Thermal Dynamics ULTRA-CUT 400 XT, Ultra-Cut 300 XT Operating Instructions Manual

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480V

ULTRA-CUT 400 XT

PLASMA CUTTING SYSTEM

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Operating Manual

Revision: AH Issue Date: May 27, 2015 Manual No.: 0-5275

Thermal-Dynamics.com

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 1-800-752-7622, 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.

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

WARNING

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 400 XT Operating Manual No. 0-5275

Published by: Thermal Dynamics Corporation. 2800 Airport Rd. Denton, Texas 76207

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.

™

Original Publication Date: April 22, 2013 Revision Date: May 27, 2015

Record the following information for Warranty purposes:

Where Purchased: ___________________________________

Purchase Date:______________________________________

Power Supply Serial #:_______________________________

Torch Serial #:_______________________________________

Be sure this information reaches the operator.

You can get extra copies through your supplier.

CAUTION

These INSTRUCTIONS are for experienced operators. If you are not fully familiar with the principles of operation and safe practices for arc welding and cutting equipment, we urge you to read our booklet, “Precautions and Safe Practices for Arc Welding, Cutting, and Gouging,” Booklet 0-5407. Do NOT permit untrained persons to install, operate, or maintain this equipment. Do NOT attempt to install or operate this equipment until you have read and fully understand these instructions. If you do not fully understand these instructions, contact your supplier for further information. Be sure to read the Safety Precautions before installing or operating this equipment.

USER RESPONSIBILITY

This equipment will perform in conformity with the description thereof contained in this manual and accompanying labels and/or inserts when installed, operated, maintained and repaired in accordance with the instructions provided. This equipment must be checked periodically. Malfunctioning or poorly maintained equipment should not be used. Parts that are broken, missing, worn, distorted or contaminated should be replaced immediately. Should such repair or replacement become necessary, the manufacturer recommends that a telephone or written request for service advice be made to the Authorized Distributor from whom it was purchased.

This equipment or any of its parts should not be altered without the prior written approval of the manufacturer. The user of this equipment shall have the sole responsibility for any malfunction which results from improper use, faulty maintenance, damage, improper repair or alteration by anyone other than the manufacturer or a service facility designated by

the manufacturer.

READ AND UNDERSTAND THE INSTRUCTION MANUAL BEFORE INSTALLING OR

PROTECT YOURSELF AN D OTHERS!

OPERATING.

ASSUREZ-VOUS QUE CETTE INFORMATION EST DISTRIBUÉE À L’OPÉRATEUR.

ATTENTION

VOUS POUVEZ OBTENIR DES COPIES SUPPLÉMENTAIRES CHEZ VOTRE FOURNISSEUR.

Les INSTRUCTIONS suivantes sont destinées aux opérateurs qualiés seulement.

Si vous n’avez pas une connaissance approfondie des principes de fonctionnement et des règles de sécurité pour le soudage à l’arc et l’équipement de coupage, nous vous suggérons de lire notre brochure « Precautions and Safe Practices for Arc Welding, Cutting and Gouging, » Brochure 0-5407. Ne permettez PAS aux personnes non

qualiées d’installer, d’opérer ou de faire l’entretien de cet équipement. Ne tentez

PAS d’installer ou d’opérer cet équipement avant de lire et de bien comprendre ces instructions. Si vous ne comprenez pas bien les instructions, communiquez avec votre fournisseur pour plus de renseignements. Assurez-vous de lire les Règles de Sécurité avant d’installer ou d’opérer cet équipement.

RESPONSABILITÉS DE L’UTILISATEUR

Cet équipement opérera conformément à la description contenue dans ce manuel, les étiquettes d’accompagnement

et/ou les feuillets d’information si l’équipement est installé, opéré, entretenu et réparé selon les instructions fournies. Vous

devez faire une vérication périodique de l’équipement. Ne jamais utiliser un équipement qui ne fonctionne pas bien ou n’est

pas bien entretenu. Les pièces qui sont brisées, usées, déformées ou contaminées doivent être remplacées immédiatement. Dans le cas où une réparation ou un remplacement est nécessaire, il est recommandé par le fabricant de faire une demande de conseil de service écrite ou par téléphone chez le Distributeur Autorisé de votre équipement.

Cet équipement ou ses pièces ne doivent pas être modiés sans permission préalable écrite par le fabricant. L’utilisa-

teur de l’équipement sera le seul responsable de toute défaillance résultant d’une utilisation incorrecte, un entretien fautif, des

dommages, une réparation incorrecte ou une modication par une personne autre que le fabricant ou un centre de service

désigné par le fabricant.

ASSUREZ-VOUS DE LIRE ET DE COMPRENDRE LE MANUEL D’UTILISATION AVANT

D’INSTALLER OU D’OPÉRER L’UNITÉ.

PROTÉGEZ-VOUS ET LES AUTRES!

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TABLE OF CONTENTS

SECTION 1: SAFETY ........................................................................................ 1-1

1.01 Safety Precautions - ENGLISH ........................................................................ 1-1

1.02 Précautions de sécurité - FRENCH CANADIAN ............................................... 1-6

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

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

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

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

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

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

2.06 Speciﬁcations & Electrical Requirements ....................................................... 2-1

2.07 Power Supply Dimensions .............................................................................. 2-2

2.08 Power Supply Rear Panel Features ................................................................. 2-3

2.09 Gas Requirements .......................................................................................... 2-4

2.10 Gas Applications ............................................................................................. 2-4

2.11 XT Torch Speciﬁcations ................................................................................. 2-5

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

3.01 Installation Requirements ............................................................................... 3-1

3.02 System Layout ............................................................................................... 3-2

3.03 Recommended Gas Supply Hose .................................................................... 3-3

3.04 Leads and Cables All Amperage ...................................................................... 3-3

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

3.06 Connect Input Power and Ground Cables ....................................................... 3-5

3.07 Connect Work Cable and Pilot and Negative Leads ......................................... 3-6

3.08 Ground Connections ....................................................................................... 3-7

3.09 Connect Coolant Leads ................................................................................. 3-10

3.10 Connect Cables for CNC, Remote Arc Starter, GCM and HE 400 ................... 3-11

3.11 Handling and Installation of Fiber Optics ...................................................... 3-12

3.12 Set Switches on the Command - Control Module ......................................... 3-15

3.13 Height Control Connections .......................................................................... 3-17

3.14 Gas Control Module Installation .................................................................... 3-18

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

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

3.17 HE400XT COOLER ........................................................................................ 3-23

3.18 Install Remote Arc Starter ............................................................................. 3-25

3.19 Torch Valve Installation ................................................................................. 3-32

3.20 Connecting Torch .......................................................................................... 3-34

3.21 Install Consumable Torch Parts .................................................................... 3-35

3.22 Voltage Divider for iHC Torch Height Control ................................................ 3-38

3.23 Complete the Installation .............................................................................. 3-40

TABLE OF CONTENTS

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

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

4.02 System Operation ........................................................................................... 4-2

4.03 Gas Selection .................................................................................................. 4-4

4.04 GCM 2010 Gas Control Module Operation ...................................................... 4-6

4.05 GCM 2010 First Time Operation Matching Gas Control to Lead Length ........ 4-10

4.06 GCM 2010 Sequence Of Operation ............................................................... 4-10

4.07 Power Supply Status Codes .......................................................................... 4-13

4.08 Remote Arc Starter Trouble Shooting ........................................................... 4-21

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

5.01 General Maintenance ...................................................................................... 5-1

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

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

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

6.01 Replacement Power Supply ............................................................................ 6-1

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

6.03 Recommended Gas Supply Hose .................................................................... 6-2

6.04 Leads And Cables All Amperages .................................................................... 6-3

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

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

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

6.08 Power Supply Replacement Parts - Rear Panel .............................................. 6-8

6.09 Power Supply Replacement Parts - Left Side .................................................. 6-9

6.10 Gas Control Module (GCM-2010) Replacement Parts ................................... 6-10

6.11 Gas Control Module (GCM-2010) Replacement Parts ................................... 6-11

6.12 Remote Arc Starter (RAS-1000 XT) Replacement Parts ............................... 6-12

6.13 HE400XT Heat Exchanger - Replacement Parts ............................................ 6-13

6.14 XTL Torch Valve Assembly External Replacement Parts ............................... 6-14

6.15 XTL Torch Valve Assembly Internal Replacement Parts ................................ 6-15

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

7.01 Consumable Removal ..................................................................................... 7-1

7.02 O-Ring Lubrication ......................................................................................... 7-2

7.03 Parts Wear ...................................................................................................... 7-3

7.04 Torch Consumables Installation ...................................................................... 7-4

7.05 Coolant Leak Trouble-Shooting ...................................................................... 7-6

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

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

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

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

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

APPENDIX 6: CNC - Control Module PCB Connections ............................................... A-7

TABLE OF CONTENTS

APPENDIX 7: CNC ......................................................................................... A-8

CNC functions ............................................................................................................... A-8

CNC Input / Output Descriptions ................................................................................. A-10

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

CNC Connections ........................................................................................................ A-14

CNC Cable Color Code ................................................................................................ A-15

APPENDIX 8: CCM CPU PCB Layout ...................................................................A-16

APPENDIX 9: CCM I/O PCB Layout .....................................................................A-18

APPENDIX 10: Pilot PCB Layout ........................................................................A-20

APPENDIX 11: Relay and Interface PCB Layout ......................................................A-22

APPENDIX 12: Display PCB Layout ....................................................................A-24

APPENDIX 13: System Bias PCB Layout ..............................................................A-26

APPENDIX 14: Main Inverter Bottom PCB Layout ....................................................A-28

APPENDIX 15: Main Inverter Top PCB Layout ........................................................ A-30

APPENDIX 16: Control and Fault PCB Layout ........................................................A-32

APPENDIX 17: Cap Bias Bottom PCB Layout .........................................................A-34

APPENDIX 18: Cap Bias Top PCB Layout .............................................................. A-35

APPENDIX 19: Suppressor PCB Layout ................................................................A-36

APPENDIX 20: COOLING DIAGRAM ....................................................................A-37

APPENDIX 21: System Schematic 400A, 480V PG 1 .................................................A-38

APPENDIX 22: System Schematic 400A, 480V PG 2 .................................................A-40

APPENDIX 23: ADVANCED TROUBLESHOOTING .....................................................A-42

APPENDIX 24: SL100 INTERCONNECTION ............................................................A-88

APPENDIX 25: HE 400 XT CONNECTION ..............................................................A-90

APPENDIX 26: SL100 Torch Option ....................................................................A-91

APPENDIX 27: PUBLICATION HISTORY ................................................................A-98

INTERNATIONAL CONTACT INFORMATION ................................................. BACK COVER

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TABLE OF CONTENTS

ULTRA-CUT 400 XT

SECTION 1: SAFETY

1.01 Safety Precautions - ENGLISH

WARNING: These Safety Precautions are for your protection. They summarize precautionary information from the references listed in Additional Safety Information section. Before performing any installation or

operating procedures, be sure to read and follow the safety precautions listed below as well as all other

manuals, material safety data sheets, labels, etc. Failure to observe Safety Precautions can result in injury or death.

PROTECT YOURSELF AND OTHERS -- Some welding, cutting, and gouging processes are noisy and require ear protection. The arc, like the sun, emits ultraviolet (UV) and other radiation and can injure skin and eyes. Hot metal can cause burns. Training in the proper use of the processes and

equipment is essential to prevent accidents. Therefore:

1. Always wear safety glasses with side shields in any work area, even if welding helmets, face shields, and goggles are also required.

2. Use a face shield ﬁtted with the correct ﬁlter and cover plates to protect your eyes, face, neck, and ears from sparks and rays of the arc when operating or observing operations. Warn bystanders not to watch the arc and not to expose themselves to the rays of the electric-arc or hot metal.

3. Wear ﬂameproof gauntlet type gloves, heavy long-sleeve shirt, cufﬂess trousers, high-topped shoes, and a welding helmet or cap for hair protection, to protect against arc rays and hot sparks or hot metal. A ﬂameproof apron may also be desirable as protection against radiated heat and sparks.

4. Hot sparks or metal can lodge in rolled up sleeves, trouser cuffs, or pockets. Sleeves and collars should be kept buttoned, and open pockets eliminated from the front of clothing.

5. Protect other personnel from arc rays and hot sparks with a suitable non-ﬂammable partition or curtains.

6. Use goggles over safety glasses when chipping slag or grinding. Chipped slag may be hot and can ﬂy far. Bystanders should also wear goggles over safety glasses.

FIRES AND EXPLOSIONS -- Heat from ﬂames and arcs can start ﬁres. Hot slag or sparks can also cause ﬁres and explosions. Therefore:

1. Remove all combustible materials well away from the work area or cover the materials with a protective non-ﬂammable covering. Combustible materials include wood, cloth, sawdust, liquid and gas fuels, solvents, paints and coatings, paper, etc.

2. Hot sparks or hot metal can fall through cracks or crevices in ﬂoors or wall openings and cause a hidden smoldering ﬁre or ﬁres on the ﬂoor below. Make certain that such openings are protected from hot sparks and metal.“

3. Do not weld, cut or perform other hot work until the work piece has been completely cleaned so that there are no substances on the work piece which might produce ﬂammable or toxic vapors. Do not do hot work on closed containers. They may explode.

4. Have ﬁre extinguishing equipment handy for instant use, such as a garden hose, water pail, sand bucket, or portable ﬁre extinguisher. Be sure you are trained in its use.

5. Do not use equipment beyond its ratings. For example, overloaded welding cable can overheat and create a ﬁre hazard.

6. After completing operations, inspect the work area to make certain there are no hot sparks or hot metal which could cause a later ﬁre. Use ﬁre watchers when necessary.

7. For additional information, refer to NFPA Standard 51B, “Fire Prevention in Use of Cutting and Welding Processes”, available from the National Fire Protection Association, Battery march Park, Quincy, MA 02269.

Manual 0-5275 SAFETY INSTRUCTIONS 1-1

ULTRA-CUT 400 XT

ELECTRICAL SHOCK -- Contact with live electrical parts and ground can cause severe injury or death. DO NOT use AC welding current in damp areas, if movement is conﬁned, or if there is danger of falling.

1. Be sure the power source frame (chassis) is connected to the ground system of the input power.

2. Connect the work piece to a good electrical ground.

3. Connect the work cable to the work piece. A poor or missing connection can expose you or others to a fatal shock.

4. Use well-maintained equipment. Replace worn or damaged cables.

5. Keep everything dry, including clothing, work area, cables, torch/electrode holder, and power source.

6. Make sure that all parts of your body are insulated from work and from ground.

7. Do not stand directly on metal or the earth while working in tight quarters or a damp area; stand on dry boards or an insulating platform and wear rubber-soled shoes.

8. Put on dry, hole-free gloves before turning on the power.

9. Turn off the power before removing your gloves.

10. Refer to ANSI/ASC Standard Z49.1 (listed on next page) for speciﬁc grounding recommendations. Do not mistake the work lead for a ground cable.

ELECTRIC AND MAGNETIC FIELDS — May be dangerous. Electric current ﬂowing through any conductor causes localized Electric and Magnetic Fields (EMF ). Welding and cutting current creates EMF around welding cables and welding machines. Therefore:

1. Welders having pacemakers should consult their physician before welding. EMF may interfere with some pacemakers.

2. Exposure to EMF may have other health effects which are unknown.

3. Welders should use the following procedures to minimize exposure to EMF:

A. Route the electrode and work cables together. Secure them with tape when possible. B. Never coil the torch or work cable around your body. C. Do not place your body between the torch and work cables. Route cables on the same side of your

body. D. Connect the work cable to the work piece as close as possible to the area being welded. E. Keep welding power source and cables as far away from your body as possible.

FUMES AND GASES -- Fumes and gases, can cause discomfort or harm, particularly in conﬁned

spaces. Do not breathe fumes and gases. Shielding gases can cause asphyxiation.

Therefore:

1. Always provide adequate ventilation in the work area by natural or mechanical means. Do not weld, cut, or gouge on materials such as galvanized steel, stainless steel, copper, zinc, lead, beryllium, or cadmium unless positive mechanical ventilation is provided. Do not breathe fumes from these materials.

2. Do not operate near degreasing and spraying operations. The heat or arc rays can react with chlorinated hydrocarbon vapors to form phosgene, a highly toxic gas, and other irritant gases.

3. If you develop momentary eye, nose, or throat irritation while operating, this is an indication that ventilation is not adequate. Stop work and take necessary steps to improve ventilation in the work area. Do not continue to operate if physical discomfort persists.

4. Refer to ANSI/ASC Standard Z49.1 (see listing below) for speciﬁc ventilation recommendations.

5. WARNING: This product contains chemicals, including lead, known to the State of California to cause birth defects and other reproductive harm. Wash hands after handling.

1-2 SAFETY INSTRUCTIONS Manual 0-5275

ULTRA-CUT 400 XT

CYLINDER HANDLING -- Cylinders, if mishandled, can rupture and violently release gas. Sudden rupture of cylinder, valve, or relief device can injure or kill. Therefore:

1. Use the proper gas for the process and use the proper pressure reducing regulator designed to operate from the compressed gas cylinder. Do not use adaptors. Maintain hoses and ﬁttings in good condition. Follow manufacturer’s operating instructions for mounting regulator to a compressed gas cylinder.

2. Always secure cylinders in an upright position by chain or strap to suitable hand trucks, undercarriages, benches, walls, post, or racks. Never secure cylinders to work tables or ﬁxtures where they may become part of an electrical circuit.

3. When not in use, keep cylinder valves closed. Have valve protection cap in place if regulator is not connected. Secure and move cylinders by using suitable hand trucks. Avoid rough handling of cylinders.

4. Locate cylinders away from heat, sparks, and ﬂames. Never strike an arc on a cylinder.

5. For additional information, refer to CGA Standard P-1, “Precautions for Safe Handling of Compressed Gases in Cylinders”, which is available from Compressed Gas Association, 1235 Jefferson Davis Highway, Arlington, VA 22202.

EQUIPMENT MAINTENANCE -- Faulty or improperly maintained equipment can cause injury or death. Therefore:

1. Always have qualiﬁed personnel perform the installation, troubleshooting, and maintenance work. Do not perform any electrical work unless you are qualiﬁed to perform such work.

2. Before performing any maintenance work inside a power source, disconnect the power source from the incoming electrical power.

3. Maintain cables, grounding wire, connections, power cord, and power supply in safe working order. Do not operate any equipment in faulty condition.

4. Do not abuse any equipment or accessories. Keep equipment away from heat sources such as furnaces, wet conditions such as water puddles, oil or grease, corrosive atmospheres and inclement weather.

5. Keep all safety devices and cabinet covers in position and in good repair.

6. Use equipment only for its intended purpose. Do not modify it in any manner.

ADDITIONAL SAFETY INFORMATION -- For more information on safe practices for electric arc welding and cutting equipment, ask your supplier for a copy of “Precautions and Safe Practices for Arc Welding,

Cutting and Gouging”, Form 52-529.

The following publications, which are available from the American Welding Society, 550 N.W. LeJuene Road, Miami, FL 33126, are recommended to you:

1. ANSI/ASC Z49.1 - “Safety in Welding and Cutting”.

2. AWS C5.1 - “Recommended Practices for Plasma Arc Welding”.

3. AWS C5.2 - “Recommended Practices for Plasma Arc Cutting”.

4. AWS C5.3 - “Recommended Practices for Air Carbon Arc Gouging and Cutting”.

5. AWS C5.5 - “Recommended Practices for Gas Tungsten Arc Welding“.

6. AWS C5.6 - “Recommended Practices for Gas Metal Arc Welding”.

7. AWS SP - “Safe Practices” - Reprint, Welding Handbook.

8. ANSI/AWS F4.1, “Recommended Safe Practices for Welding and Cutting of Containers That Have Held Hazardous Substances.”

9. CSA Standard - W117.2 = Safety in Welding, Cutting and Allied Processes.

Manual 0-5275 SAFETY INSTRUCTIONS 1-3

ULTRA-CUT 400 XT

DANGER

CAUTION

WARNING

CAUTION

Meaning of symbols - As used throughout this manual: Means Attention! Be Alert! Your safety is involved.

Means immediate hazards which, if not avoided, will result in immediate, serious personal injury or loss of life.

Means potential hazards which could result in personal injury or loss of life.

Means hazards which could result in minor personal injury.

Enclosure Class

The IP code indicates the enclosure class, i.e. the degree of protection against penetration by solid objects or water. Protection is provided against touch with a ﬁnger, penetration of solid objects greater than 12mm and against spraying water up to 60 degrees from vertical. Equipment marked IP21S may be stored, but is not intended to be used outside during precipitation unless sheltered.

This product is solely intended for plasma cutting. Any other use may result in personal injury and / or equipment damage.

If equipment is placed on a surface that slopes more than 15°, toppling over may occur. Personal injury and / or signicant damage to equipment is possible.

15°

Art# A-12726

To avoid personal injury and/or equipment damage, lift using method and attachment points shown here.

1-4 SAFETY INSTRUCTIONS Manual 0-5275

Art# A-12736

ULTRA-CUT 400 XT

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Manual 0-5275 SAFETY INSTRUCTIONS 1-5

ULTRA-CUT 400 XT

1.02 Précautions de sécurité - FRENCH CANADIAN

AVERTISSEMENT : Ces règles de sécurité ont pour but d’assurer votre protection. Ils récapitulent les informations de précaution provenant des références dans la section des Informations de sécurité sup-

plémentaires. Avant de procéder à l’installation ou d’utiliser l’unité, assurez-vous de lire et de suivre les précautions de sécurité ci-dessous, dans les manuels, les ﬁches d’information sur la sécurité du matériel et sur les étiquettes, etc. Tout défaut d’observer ces précautions de sécurité peut entraîner des blessures graves ou mortelles.

PROTÉGEZ-VOUS -- Les processus de soudage, de coupage et de gougeage produisent un niveau de bruit élevé et exige l’emploi d’une protection auditive. L’arc, tout comme le soleil, émet des rayons

ultraviolets en plus d’autre rayons qui peuvent causer des blessures à la peau et les yeux. Le métal incandescent peut causer des brûlures. Une formation reliée à l’usage des processus et de l’équipement est essentielle pour prévenir les accidents. Par conséquent:

1. Portez des lunettes protectrices munies d’écrans latéraux lorsque vous êtes dans l’aire de travail, même si vous devez porter un casque de soudeur, un écran facial ou des lunettes étanches.

2. Portez un écran facial muni de verres ﬁltrants et de plaques protectrices appropriées aﬁn de protéger vos yeux, votre visage, votre cou et vos oreilles des étincelles et des rayons de l’arc lors d’une opération ou lorsque vous observez une opération. Avertissez les personnes se trouvant à proximité de ne pas regarder l’arc et de ne pas s’exposer aux rayons de l’arc électrique ou le métal incandescent.

3. Portez des gants ignifugiés à crispin, une chemise épaisse à manches longues, des pantalons sans rebord et des chaussures montantes aﬁn de vous protéger des rayons de l’arc, des étincelles et du métal incandescent, en plus d’un casque de soudeur ou casquette pour protéger vos cheveux. Il est également recommandé de porter un tablier ininﬂammable aﬁn de vous protéger des étincelles et de la chaleur par rayonnement.

4. Les étincelles et les projections de métal incandescent risquent de se loger dans les manches retroussées, les rebords de pantalons ou les poches. Il est recommandé de garder boutonnés le col et les manches et de porter des vêtements sans poches en avant.

5. Protégez toute personne se trouvant à proximité des étincelles et des rayons de l’arc à l’aide d’un rideau ou d’une cloison ininﬂammable.

6. Portez des lunettes étanches par dessus vos lunettes de sécurité lors des opérations d’écaillage ou de meulage du laitier. Les écailles de laitier incandescent peuvent être projetées à des distances considérables. Les personnes se trouvant à proximité doivent également porter des lunettes étanches par dessus leur lunettes de sécurité.

INCENDIES ET EXPLOSIONS -- La chaleur provenant des ﬂammes ou de l’arc peut provoquer un incendie. Le laitier incandescent ou les étincelles peuvent également provoquer un incendie ou une explosion. Par conséquent :

1. Éloignez sufﬁsamment tous les matériaux combustibles de l’aire de travail et recouvrez les matériaux avec un revêtement protecteur ininﬂammable. Les matériaux combustibles incluent le bois, les vêtements, la sciure, le gaz et les liquides combustibles, les solvants, les peintures et les revêtements, le papier, etc.

2. Les étincelles et les projections de métal incandescent peuvent tomber dans les ﬁssures dans les planchers ou dans les ouvertures des murs et déclencher un incendie couvant à l’étage inférieur Assurez-vous que ces ouvertures sont bien protégées des étincelles et du métal incandescent.

3. N’exécutez pas de soudure, de coupe ou autre travail à chaud avant d’avoir complètement nettoyé la surface de la pièce à traiter de façon à ce qu’il n’ait aucune substance présente qui pourrait produire des vapeurs inﬂammables ou toxiques. N’exécutez pas de travail à chaud sur des contenants fermés car ces derniers pourraient exploser.

4. Assurez-vous qu’un équipement d’extinction d’incendie est disponible et prêt à servir, tel qu’un tuyau d’arrosage, un seau d’eau, un seau de sable ou un extincteur portatif. Assurez-vous d’être bien instruit par rapport à l’usage de cet équipement.

1-6 SAFETY INSTRUCTIONS Manual 0-5275

ULTRA-CUT 400 XT

5. Assurez-vous de ne pas excéder la capacité de l’équipement. Par exemple, un câble de soudage surchargé peut surchauffer et provoquer un incendie.

6. Une fois les opérations terminées, inspectez l’aire de travail pour assurer qu’aucune étincelle ou projection de métal incandescent ne risque de provoquer un incendie ultérieurement. Employez des guetteurs d’incendie au besoin.

7. Pour obtenir des informations supplémentaires, consultez le NFPA Standard 51B, “Fire Prevention in Use of Cutting and Welding Processes”, disponible au National Fire Protection Association, Batterymarch Park, Quincy, MA 02269.

CHOC ÉLECTRI QUE -- Le contact avec des pièces électriques ou les pièces de mise à la terre sous tension peut causer des blessures graves ou mortelles. NE PAS utiliser un courant de soudage c.a. dans un endroit humide, en espace restreint ou si un danger de chute se pose.

1. Assurez-vous que le châssis de la source d’alimentation est branché au système de mise à la terre de l’alimentation d’entrée.

2. Branchez la pièce à traiter à une bonne mise de terre électrique.

3. Branchez le câble de masse à la pièce à traiter et assurez une bonne connexion aﬁn d’éviter le risque de choc électrique mortel.

4. Utilisez toujours un équipement correctement entretenu. Remplacez les câbles usés ou endommagés.

5. Veillez à garder votre environnement sec, incluant les vêtements, l’aire de travail, les câbles, le porteélectrode/torche et la source d’alimentation.

6. Assurez-vous que tout votre corps est bien isolé de la pièce à traiter et des pièces de la mise à la terre.

7. Si vous devez effectuer votre travail dans un espace restreint ou humide, ne tenez vous pas directement sur le métal ou sur la terre; tenez-vous sur des planches sèches ou une plate-forme isolée et portez des chaussures à semelles de caoutchouc.

8. Avant de mettre l’équipement sous tension, isolez vos mains avec des gants secs et sans trous.

9. Mettez l’équipement hors tension avant d’enlever vos gants.

10. Consultez ANSI/ASC Standard Z49.1 (listé à la page suivante) pour des recommandations spéciﬁques concernant les procédures de mise à la terre. Ne pas confondre le câble de masse avec le câble de mise à la terre.

CHAMPS ÉLECTRIQUES ET MAGNÉTIQUES — comportent un risque de danger. Le courant électrique qui passe dans n’importe quel conducteur produit des champs électriques et magnétiques localisés. Le soudage et le courant de coupage créent des champs électriques et magnétiques autour des câbles

de soudage et l’équipement. Par conséquent :

1. Un soudeur ayant un stimulateur cardiaque doit consulter son médecin avant d’entreprendre une opération de soudage. Les champs électriques et magnétiques peuvent causer des ennuis pour certains stimulateurs cardiaques.

2. L’exposition à des champs électriques et magnétiques peut avoir des effets néfastes inconnus pour la santé.

3. Les soudeurs doivent suivre les procédures suivantes pour minimiser l’exposition aux champs électriques et magnétiques :

A. Acheminez l’électrode et les câbles de masse ensemble. Fixez-les à l’aide d’une bande adhésive lorsque

possible. B. Ne jamais enrouler la torche ou le câble de masse autour de votre corps. C. Ne jamais vous placer entre la torche et les câbles de masse. Acheminez tous les câbles sur le même

côté de votre corps. D. Branchez le câble de masse à la pièce à traiter le plus près possible de la section à souder. E. Veillez à garder la source d’alimentation pour le soudage et les câbles à une distance appropriée de

votre corps.

Manual 0-5275 SAFETY INSTRUCTIONS 1-7

ULTRA-CUT 400 XT

LES VAPEURS ET LES GAZ -- peuvent causer un malaise ou des dommages corporels, plus particulièrement dans les espaces restreints. Ne respirez pas les vapeurs et les gaz. Le gaz de protection risque de causer l’asphyxie.

Par conséquent :

1. Assurez en permanence une ventilation adéquate dans l’aire de travail en maintenant une ventilation naturelle ou à l’aide de moyens mécanique. N’effectuez jamais de travaux de soudage, de coupage ou de gougeage sur des matériaux tels que l’acier galvanisé, l’acier inoxydable, le cuivre, le zinc, le plomb, le berylliym ou le cadmium en l’absence de moyens mécaniques de ventilation efﬁcaces. Ne respirez pas les vapeurs de ces matériaux.

2. N’effectuez jamais de travaux à proximité d’une opération de dégraissage ou de pulvérisation. Lorsque la chaleur ou le rayonnement de l’arc entre en contact avec les vapeurs d’hydrocarbure chloré, ceci peut déclencher la formation de phosgène ou d’autres gaz irritants, tous extrêmement toxiques.

3. Une irritation momentanée des yeux, du nez ou de la gorge au cours d’une opération indique que la ventilation n’est pas adéquate. Cessez votre travail aﬁn de prendre les mesures nécessaires pour améliorer la ventilation dans l’aire de travail. Ne poursuivez pas l’opération si le malaise persiste.

4. Consultez ANSI/ASC Standard Z49.1 (à la page suivante) pour des recommandations spéciﬁques concernant la ventilation.

5. AVERTISSEMENT : Ce produitcontient des produits chimiques, notamment du plomb, reconnu par l’Étatde la Californie pour causerdes malformations congénitaleset d’autresdommages touchant le système reproductif.

MANIPULATION DES CYLINDRES -- La manipulation d’un cylindre, sans observer les précautions nécessaires, peut produire des ﬁssures et un échappement dangereux des gaz. Une brisure soudaine du cylindre, de la soupape ou du dispositif de surpression peut causer des blessures graves ou mortelles.

Par conséquent :

Se laver les mainsaprès manipulation.

1. Utilisez toujours le gaz prévu pour une opération et le détendeur approprié conçu pour utilisation sur les cylindres de gaz comprimé. N’utilisez jamais d’adaptateur. Maintenez en bon état les tuyaux et les raccords. Observez les instructions d’opération du fabricant pour assembler le détendeur sur un cylindre de gaz comprimé.

2. Fixez les cylindres dans une position verticale, à l’aide d’une chaîne ou une sangle, sur un chariot manuel, un châssis de roulement, un banc, un mur, une colonne ou un support convenable. Ne ﬁxez jamais un cylindre à un poste de travail ou toute autre dispositif faisant partie d’un circuit électrique.

3. Lorsque les cylindres ne servent pas, gardez les soupapes fermées. Si le détendeur n’est pas branché, assurez-vous que le bouchon de protection de la soupape est bien en place. Fixez et déplacez les cylindres à l’aide d’un chariot manuel approprié. Toujours manipuler les cylindres avec soin.

4. Placez les cylindres à une distance appropriée de toute source de chaleur, des étincelles et des ﬂammes. Ne jamais amorcer l’arc sur un cylindre.

5. Pour de l’information supplémentaire, consultez CGA Standard P-1, “Precautions for Safe Handling of Compressed Gases in Cylinders”, mis à votre disposition par le Compressed Gas Association, 1235 Jefferson Davis Highway, Arlington, VA 22202.

ENTRETIEN DE L’ÉQUIPEMENT -- Un équipement entretenu de façon défectueuse ou inadéquate peut causer des blessures graves ou mortelles. Par conséquent :

1. Efforcez-vous de toujours conﬁer les tâches d’installation, de dépannage et d’entretien à un personnel qualiﬁé. N’effectuez aucune réparation électrique à moins d’être qualiﬁé à cet effet.

2. Avant de procéder à une tâche d’entretien à l’intérieur de la source d’alimentation, débranchez l’alimentation électrique.

3. Maintenez les câbles, les ﬁls de mise à la terre, les branchements, le cordon d’alimentation et la source d’alimentation en bon état. N’utilisez jamais un équipement s’il présente une défectuosité quelconque.

1-8 SAFETY INSTRUCTIONS Manual 0-5275

ULTRA-CUT 400 XT

DANGER

MISE EN GARDE

AVERTISSEMENT

MISE EN GARDE

4. N’utilisez pas l’équipement de façon abusive. Gardez l’équipement à l’écart de toute source de chaleur, notamment des fours, de l’humidité, des ﬂaques d’eau, de l’huile ou de la graisse, des atmosphères corrosives et des intempéries.

5. Laissez en place tous les dispositifs de sécurité et tous les panneaux de la console et maintenez-les en bon état.

6. Utilisez l’équipement conformément à son usage prévu et n’effectuez aucune modiﬁcation.

INFORMATIONS SUPPLÉMENTAIRES RELATI VES À LA SÉCURITÉ -- Pour obtenir de l’information supplémentaire sur les règles de sécurité à observer pour l’équipement de soudage à l’arc électrique et le

coupage, demandez un exemplaire du livret “Precautions and Safe Practices for Arc Welding, Cutting and

Gouging”, Form 52-529. Les publications suivantes sont également recommandées et mises à votre disposition par l’American Welding

Society, 550 N.W. LeJuene Road, Miami, FL 33126 :

1. ANSI/ASC Z49.1 - “Safety in Welding and Cutting”.

2. AWS C5.1 - “Recommended Practices for Plasma Arc Welding”.

3. AWS C5.2 - “Recommended Practices for Plasma Arc Cutting”.

4. AWS C5.3 - “Recommended Practices for Air Carbon Arc Gouging and Cutting”.

5. AWS C5.5 - “Recommended Practices for Gas Tungsten Arc Welding“.

6. AWS C5.6 - “Recommended Practices for Gas Metal Arc Welding”.

7. AWS SP - “Safe Practices” - Reprint, Welding Handbook.

8. ANSI/AWS F4.1, “Recommended Safe Practices for Welding and Cutting of Containers That Have Held Hazardous Substances.”

9. CSA Standard - W117.2 = Safety in Welding, Cutting and Allied Processes.

SIGNIFICATION DES SYMBOLES - Ce symbole, utilisé partout dans ce manuel, signie “Attention” ! Soyez

vigilant ! Votre sécurité est en jeu.

Signie un danger immédiat. La situation peut entraîner des blessures graves ou mortelles.

Signie un danger potentiel qui peut entraîner des blessures graves ou mortelles.

Signie un danger qui peut entraîner des blessures corporelles mineures.

Classe de protection de l’enveloppe

L’indice de protection (codiﬁcation IP) indique la classe de protection de l’enveloppe, c’est-à-dire, le degré de protection contre les corps solides étrangers ou l’eau. L’enveloppe protège contre le toucher, la pénétration d’objets solides dont le diamètre dépasse 12 mm et contre l’eau pulvérisée à un angle de jusqu’à 60 degrés de la verticale. Les équipements portant la marque IP21S peuvent être entreposés à l’extérieur, mais ne sont pas conçus pour être utilisés à l’extérieur pendant une précipitation à moins d’être à l’abri.

Ce produit a été conçu pour la découpe au plasma seulement. Toute autre utilisation pourrait causer des blessures et/ou endommager l’appareil.

Manual 0-5275 SAFETY INSTRUCTIONS 1-9

ULTRA-CUT 400 XT

MISE EN GARDE

L’équipement pourrait basculer s’il est placé sur une surface dont la pente dépasse 15°. Vous pourriez vous blesser ou endommager l’équipement de façon importante.

15°

Art# A-12726

Soulevez à l’aide de la méthode et des points d’attache illustrés an d’éviter de vous blesser ou d’endommager l’équipement.

Art# A-12736

1-10 SAFETY INSTRUCTIONS Manual 0-5275

ULTRA-CUT 400 XT

SECTION 2: SPECIFICATIONS

2.01 General Description Of The System

A typical Ultra-Cut XT™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.

2.02 Plasma Power Supply

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

2.03 Remote Arc Starter

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

2.04 Gas Control Module

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

2.05 Precision Plasma Cutting Torch

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

2.06 Speciﬁcations & Electrical Requirements

Ultra-Cut 400 XT™ Speciﬁcations & Design Features

Max OCV (U0) 425 vdc Minimum Output Current 5 Amps Max Output Current 400 Amps Output Voltage 60 - 200 vdc

400 Amp System

Duty Cycle Rating 100% @ 400A, 200V, (80kW), Ambient Temperature

for Duty Cycle Rating Operating range 14°F to 122°F (-10°C to + 50°C) Power Factor 0.94 @ 400 A DC Output Cooling Coolant and Forced Air (Class F)

104F° (40°C)

Input Power Input Current Suggested Sizes (See Note)

Voltage Freq. 3-Ph 3-Ph Fuse (Amps) Wire (AWG) Wire (mm2)

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

480 50/60 93 114 175 #3 35

Manual 0-5275 SPECIFICATIONS 2-1

Ultra-Cut 400 XT™ Power Supply

ULTRA-CUT 400 XT

NOTE!

* Suggested wire size based on United States NFPA 70 National Electrical Code 2011 edition published by the National Fire Prevention Association. Listings are from table 400.5(A)(2) for ﬂexible cord of certain types rated for 75 deg C in ambient temperatures up to 30 deg C. Using wires of lower temperature rating or different insulation type may require larger wire size. De rate for higher ambient. These are suggestions only. Always refer to your local and national codes that apply to your region for ﬁnal determination of correct wire type and size.

2.07 Power Supply Dimensions

27.6 inch 701 mm

35.97 inch 914 mm

Art # A-11982

47.77 inch 1213 mm

400A 580 lb / 263 kg

2-2 SPECIFICATIONS Manual 0-5275

ULTRA-CUT 400 XT

2.08 Power Supply Rear Panel Features

GCM Connector

CNC Connector

C.C.M.

Arc Starter Connector

H.E. Connector

Fuse

Customer Optional Ports

TSC/Comm

J55 - GCM

USER INPUT

J15 - CNC

HEIGHT CONTROL

J54 - TSC /COMM

J59 - RAS

CB2 - 5A 120 VAC

CB3 - 5A 24 VAC

J70 - HE

CB4 - 5A 120 VAC

F1 - 8A SB 230 VAC F2 - 8A SB 230 VAC

Circuit Breakers

Coolant Return

Coolant Supply

AC Power Lamp

Pilot Lead

Work Lead

Negative Return

Coolant Filter

Input Power

Ports

Art # A-11842_AB

Manual 0-5275 SPECIFICATIONS 2-3

ULTRA-CUT 400 XT

2.09 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 400 XT™ Power Supply: Gas Pressures, Flows, and Quality Requirements

Gas Quality Minimum Pressure Flow

O2 (Oxygen) 99.5% Purity

(Liquid recommended)

N2 (Nitrogen) 99.5% Purity

(Liquid recommended)

<1000 ppm O2, <32 ppm

H2O)

Compressed

or Bottled Air

H35 (Argon-Hydrogen)

H35 = 35% Hydrogen,

Clean, Dry,

Free of Oil (see Note 1)

99.995% Purity

(gas recommended)

65% Argon

H17 17.5% Hydrogen

32.5% Argon

99.995% Purity

(gas recommended)

50% Nitrogen

H2O (Water) See Note 2 55 psi (3.8 bar) 10 gph (0.6 lpm)

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

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

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

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

120 psi

8.3 bar / 827 kPa

200 scfh (95 lpm)

120 psi

8.3 bar / 827 kPa

120 psi

8.3 bar / 827 kPa

300 scfh (141.6 lpm)

500 scfh (236 lpm)

120 psi

8.3 bar / 827 kPa 200 scfh (95 lpm)

120 psi

8.3 bar / 827 kPa 200 scfh (95 lpm)

2.10 Gas Applications

MATERIAL MILD STEEL STAINLESS STEEL ALUMINUM

GAS TYPE GAS TYPE GAS TYPE

OPERATION PREFLOW PLASMA SHIELD PREFLOW PLASMA SHIELD PREFLOW PLASMA SHIELD

30A Cut

50A Cut

70A Cut

100A Cut

150A Cut

200A Cut

250A Cut Air O

300A Cut

400A Cut

Air O

2 2

2-4 SPECIFICATIONS Manual 0-5275

Air Air Air Air Air Air Air

Air N

Air Air N

Air N

Air Air Air Air Air Air N

2 2

H35 N

H17 N

H20 N

2 2

H35 N

H17 N

H20

ULTRA-CUT 400 XT

2.11 XT Torch Speciﬁcations

A. Torch Dimensions

Basic 400 Amp torch dimensions

Basic 100 Amp torch dimensions

2”

50.8 mm

168.5 mm

6.6”

4.3”

109.1 mm

2.4”

61 mm

70°

1.4”

34.5 mm

.5”

12.7 mm

Art # A-09534

2.25"

End Cap

19"

57.15 mm

482.7 mm

Mounting Tube

2.0"

50.8 mm

15.5"

393.8 mm

6.3"

160.1 mm

2.4" 61 mm

3.98"

101.1 mm

2.7"

69.6 mm

1.6"

40. mm

1.49"

37.8 mm

Manual 0-5275 SPECIFICATIONS 2-5

ULTRA-CUT 400 XT

Cartridge

Shield Cup

Art # A-04741

Electrode

Tip

Plasma Gas

Distributor

Shield Gas

Distributor

Shield Cap

B. Torch Leads Lengths

Torch Lead Assembly

Lengths

Feet Meters

10 3.05 15 4.6 25 7.6 50 15.2

C. Torch Parts (Generic Parts Shown)

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.

F. XT Torch Data

for use with Ultra-Cut 400 XT™ Power Supply

Ambient Temperature

Duty Cycle 100% @ 400 Amps Maximum Current 400 Amps Voltage (Vpeak) 500V Arc Striking Voltage 10kV Current Up to 400 Amps, DC,

XT Torch Gas Speciﬁcations

Plasma Gases: Compressed Air, Oxygen,

Shield Gases: Compressed Air, Oxygen,

Operating Pressure 125 psi ± 10 psi

Maximum Input Pressure 135 psi / 9.3 bar Gas ﬂow 10 - 500 scfh

XT Torch Ratings

104° F 40° C

Straight Polarity

Nitrogen, H35, H17,

Nitrogen, Water, H35

8.6 bar ± 0.7 bar

2-6 SPECIFICATIONS Manual 0-5275

ULTRA-CUT 400 XT

SECTION 3: INSTALLATION

3.01 Installation Requirements

Electric Supply

The electrical supply network, the gas and water supply system must meet local safety standards. This conformity shall

be checked by qualiﬁed personnel.

Ultra-Cut 400 XT™ Power Supply

Input Power Input Current Suggested Sizes (See Note)

Voltage Freq. 3-Ph 3-Ph Fuse (Amps) Wire (AWG) Wire (mm2)

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

480 50/60 93 114 175 #3 35

NOTE!

* Suggested wire size based on United States NFPA 70 National Electrical Code 2011 edition published by the National Fire Prevention Association. Listings are from table 400.5(A)(2) for ﬂexible cord of certain types rated for 75 deg C in ambient temperatures up to 30 deg C. Using wires of lower temperature rating or different insulation type may require larger wire size. Derate for higher ambient. These are suggestions only. Always refer to your local and national codes that apply to your region for ﬁnal determination of correct wire type and size.

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resinconjunctionwithoxygen.

Cooling System Requirements

Coolant must be added to the system on installation. The amount required varies with torch leads length. Victor 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™’ 25 / 75 10° F / -12° C

7-3581 ‘Ultra-Cool™’ 50 / 50 -27° F / -33° C

7-3582 ‘Extreme Cool™’ Concentrate* -76° F / -60° C

* For mixing with D-I Cool™ 7-3583

Manual 0-5275 INSTALLATION 3-1

ULTRA-CUT 400 XT

3.02 System Layout

Refer to section 3.04 for ground connections and ground cables.

175’ / 53.3 m Maximum Length

Primary power

CNC

Art # A-11940

Pilot Return #8

Coolant Supply 10’

Coolant Return 10’

Control Cable

Ultra-Cut

XT Power

Supply

Fiber Optic

Cable

Control

Cable

125’ / 38.1 m Maximum Length

Negative Cable

Control Cable

HE 400

Heat Exchanger

Gas Control

Module

Coolant Supply

Coolant Return

Plasma Gas

Shield Gas

Preflow Gas

Control

Cable

Water Shield

Remote

Torch

Valve

Assembly

Work Cable

50’ / 15.25 m Maximum Length

Pilot Return

Arc

Starter

Coolant Supply

Coolant Return

Plasma Gas Shield Gas

Shield

Positioning Tube

Torch

Work

175’ / 53.3 m Maximum Length

3-2 INSTALLATION Manual 0-5275

ULTRA-CUT 400 XT

3.03 Recommended Gas Supply Hose

Item # Qty Description Catalog #

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

3.04 Leads and Cables All Amperage

E,Y 14/7

Green

Red

#8 AWG Cable

3/0 AWG Cable (95 mm

Green / Yellow # 4 AWG

Green / Yellow 1/0 (50 mm )

Pilot Return, Power Supply to Arc Starter

)

Green

Red

Negative Lead, Power Supply to Arc Starter

Coolant Supply Lead, Power Supply to Arc Starter

Coolant Return Lead, Power Supply to Arc Starter

E - Control Cable, Power Supply to Arc Starter

Y - Control Cable to Heat Exchanger

Ground Cable

Ground Cable, Remote Arc Starter To Earth Ground

Shielded Torch Lead Assembly, Remote Arc Starter to Torch

Art # A-11873_AB

H, Q, R, S,T

3/0 (95 mm ) Cable

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

Work Cable

CNC Cable (37 Wire)

Manual 0-5275 INSTALLATION 3-3

ULTRA-CUT 400 XT

3.05 Lift the Power Supply

WARNING

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 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. Ensure all panels and screws are secure prior to lifting.

Art # A-11531_AC

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.

3-4 INSTALLATION Manual 0-5275

ULTRA-CUT 400 XT

3.06 Connect Input Power and Ground Cables

Connect Input Power and System Ground Cables

1. Remove the input power cover to the right of the coolant ﬁlter at the rear of the power supply. To do this remove the two screws then lift up and pull away.

2. Carefully cut back the outer sheath on the primary input power cable to expose the individual wires. Cut back the insulation on the individual wires. Route the cable upward through Input Power Port at the bottom of the panel. There are 2 extra plates included at the cable entrance. Discarding one or both allows changing the opening size for larger cable/ strain relief.

3. Install stripped end of 3 phase wires into the terminal block L1, L2 and L3 and connect the individual cables as shown.

4. Connect the power cable ground wire to the ground terminal block.

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

Art # A-11970

Ground Terminals

F1 Ground

Input Power

Manual 0-5275 INSTALLATION 3-5

ULTRA-CUT 400 XT

3.07 Connect Work Cable and Pilot and Negative Leads

1. Remove the output power cover to the left of the coolant ﬁlter at the rear of the power supply. To do this remove the two screws then lift up and pull away.

2. Route the ends of the work cable, pilot and negative/torch leads upward through the leads strain relief at the bottom edge of the left rear panel.

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

Pilot

Work Cable

Torch

Art # A-11533

4. Reinstall the cover on the power supply. Snug the hardware securely by hand. Do not overtighten.

3-6 INSTALLATION Manual 0-5275

ULTRA-CUT 400 XT

3.08 Ground Connections

Star Ground on Cutting Table

Remote Arc

Starter (RAS-1000)

Cutting Machine / Gantry

Cutting Table

1/0

Ground Cable

(F1)

Ground Cable

Customer supplied

Earth Ground

Rod

A good ground will be less than 3 ohm. Ideal 1.

Torch

1/0

0 - 10 ft (0 - 3 m) Ideal

20 ft (6 m) Maximum

See

Manufacturer

CNC

Device

Gas Control Module

Primary location

#4 AWG

Ground

(F)

3/0 Work Cable

1/0 Ground Cable

Power Supply

‘Star’

Ground

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

Art # A-11875.AB

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 automation (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 less 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. Do not coil up excess ground or power cables. Cut to proper length and reterminate as needed.

Manual 0-5275 INSTALLATION 3-7

ULTRA-CUT 400 XT

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.

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.

D. Low Cost Ground Rod Tester

1. A key component of reduced EMI is a good low resistance earth ground rod. There are several very expensive instruments to measure the ground but cost from several hundred to a few thousand dollars. Below is a low cost alternative which can be constructed by qualiﬁed personnel familiar with established electrical construction and safety practices. Previously suggested method using an incandescent light bulb will not work with GFCI outlets which are increasingly being used and the bulbs are becoming obsolete.

2. This method, as well as the light bulb method and some of the expensive instruments, assumes the utility ground is perfect, Zero ohms. It connects the rod being tested in series with the utility ground and measures the resistance of both in series. If the utility ground is not zero ohms, no matter how good your rod is, you won’t get a low reading due the higher resistance of the utility ground. Fortunately this is rare. Also if your rod is right next to another earth grounded structure you may get a false lower reading of only resistance between that structure and your rod rather than to gnd.

NOTE!

In the United States most standard AC outlets are 120 VAC 60 Hz. Elsewhere most outlets are 220 VAC 50Hz.

3. Obtain a transformer rated for at least 25 VA with primary voltage and frequency matching your standard outlets. The transformer should have an isolated secondary of either 220 VAC (220 -240 is OK) or 120 VAC (110-120 is OK) and be rated for at least 100 ma. The transformer could also have dual 115VAC primaries wired in series for 220V or in parallel for 120 VAC. An example is Triad N-68X, shown below, rated 50VA, 50/60 Hz.

Obtain a power resistor of either 1200 (1.2K) ohms, 15-25W min, if using a 120V secondary or 2200 (2.2K) ohms, 25 -30W

for a 220V secondary.

4. Assemble the transformer and power resistor in a metal box. Connect a 3 wire (w/gnd) power cord with ground wire attached to the metal box for safety. If a plastic box is used instead, connect the transformer core and the resistor mounts to the power cord ground wire. There should be a fuse ¼ - ½ A, in series with the transformer primary. From the transformer secondary connect one wire to the utility safety ground. This could be the cutting table frame, the ground terminal of the 120 or 220 VAC outlet or the test box if grounded as indicated.

3-8 INSTALLATION Manual 0-5275

ULTRA-CUT 400 XT

An excellent ground measures 1 ohm or less. Up to 3 ohms is often acceptable, higher reduces the effectiveness of the EMI

suppression.

R = 1.2K, 15W

Triad N-68X

115 VAC 115 VAC

(2.2K, 25W for 220 VAC)

Triad N-68X

115 VAC

Ground Rod with other

connecons removed

GND

220 VAC

115 VAC

GND

120 VAC

Utility (building) GND

Art # A-12710

0.1 VAC = 1 OHM,

0.3 VAC = 3 OHM,

etc.

5. 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. You may also try a chemical ground rod devise. When these methods are used, periodic checking of the ground resistance is required to make sure the ground is still good.

E. Routing Of Torch Leads

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

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

Manual 0-5275 INSTALLATION 3-9

ULTRA-CUT 400 XT

3.09 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.

J55 - GCM

USER INPUT

J15 - CNC

HEIGHT CONTROL

J54 - TSC /COMM

J59 - RAS

CB2 - 5A 120 VAC

CB3 - 5A 24 VAC

J70 - HE

CB4 - 5A 120 VAC

F1 - 8A SB 230 VAC F2 - 8A SB 230 VAC

COOLANT

RETURN SUPPLY

Coolant Connections

RED

GREEN

To HE-400 Heat Exchanger

Art # A-11992

3-10 INSTALLATION Manual 0-5275

ULTRA-CUT 400 XT

3.10 Connect Cables for CNC, Remote Arc Starter, GCM and HE 400

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.

J55 - GCM

J55 To GCM

J15 To CNC Control

J59 To Remote Arc Starter

USER INPUT

J15 - CNC

HEIGHT CONTROL

J54 - TSC /COMM

J59 - RAS

CB2 - 5A 120 VAC

CB3 - 5A 24 VAC

J70 - HE

CB4 - 5A 120 VAC

F1 - 8A SB 230 VAC F2 - 8A SB 230 VAC

J54 TSC/ Comm

J70 To Heat Exchanger

Art # A-11971

Manual 0-5275 INSTALLATION 3-11

ULTRA-CUT 400 XT

Hose

Strain Relief

Fiber

Connector with Latch

Protective End Covers

Art # A-09416

3.11 Handling and Installation of Fiber Optics

General Information

This kit is for proper handling and installation of Fiber Optic Cables used in Thermal Dynamics Ultra-Cut® and Auto-Cut O2® automated gas boxes and Gas Control Modules.

Fiber Optic cable is used in place of wire because it offers far superior immunity to electrical noise but it is more delicate and requires careful handling. With ﬁber optics, electrical signals are converted to light with a transmitter LED. The light passes down the ﬁber where it is converted back to an electrical signal at the receiver end. Any damage to the ﬁber from sharp bends or pulling that stretches the ﬁber can reduce it’s ability to transmit light. We run the ﬁber inside a hose for most of its length to protect it from abrasion, burning from hot metal or sharp bends but the ends are exposed and must be handled with care.

Remove ﬁber optic end covers and plugs.

WARNING

Disconnect primary power at the source.

Art # A-12015

3-12 INSTALLATION Manual 0-5275

ULTRA-CUT 400 XT

Art # A-09417

Art # A-09418

Avoid the following:

1. If you need to pull the cable through a power track do not fold the ﬁber back on itself making a sharp bend where it exits the hose.

2. Don’t hook onto the ﬁber to pull on the cable.

3. Once the ﬁber cable is installed in the CCM or gas control make sure the strain relief nut is securely tightened onto the hose so the hose can’t pull out of it like this:

Hose not secured in the Strain Relief

Art # A-09677_AB

Manual 0-5275 INSTALLATION 3-13

ULTRA-CUT 400 XT

Art # A-09420

bends

Correct installation:

Correct way to pull the cable is to use a snake or a wire or another cable and attach it securely to the hose behind the strain relief. Then secure the ﬁber connector to the pulling device leaving some slack in the ﬁber. Keep the protective end covers on the ﬁber until you are ready to connect it to the PCB in the CCM or gas control.

Correct installation in CCM or Gas Control leaves a loop of ﬁber so there is no stress on the ﬁber where it exits the connector or the hose.

CCM

No Sharp

sharp

Bends

Art # A-12014

3-14 INSTALLATION Manual 0-5275

ULTRA-CUT 400 XT

3.12 Set Switches on the Command - Control Module

Remove the power supply upper right side. Set switches on the CCM (Command-Control Module) per the illustrations. Switch settings and connection details are provided in the Appendix. Any changes made require a restart of the power supply.

CAUTION

O N

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

1 = ON = Long (3 s.)

SW 8-2: Remote Current 1 = OFF = Disabled (Factory default setting). 1 = ON = (Remote Analog Current Control) Also set SW11 to “A” position

*SW 8-3: Auto Transfer Retry1 = OFF = Enabled Up to 3 tries (Factory default setting).

1 = ON = Disabled SW 8-4: OFF = Disabled (Factory default setting). ON = Remote Marking SW Enabled at TB3-1&2

SW-1-1: Auto Pilot Restart. 1 = ON = Auto Pilot Function enabled. 1 = OFF = Auto Pilot Function disabled (Factory default setting). SW-1-2: Pilot Delay 2 = OFF, 3 = OFF, 4 = OFF: 0 Seconds (Factory default setting). SW-1-3: Pilot Delay 2 = ON, 3 = OFF, 4 = OFF: 0.1 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-5-1: Tip Saver Reserved for Factory use. SW-5-2: Off Plate Reserved for Factory use.

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

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 SW3SW4SW5SW8

Switches shown in OFF position

SW9

USB

O N

Actual orientation

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

Art # A-11890_AB

Switches shown in OFF position

SW1 SW3SW4SW5SW8

SW9

Manual 0-5275 INSTALLATION 3-15

ULTRA-CUT 400 XT

CAUTION

Printed circuit boards in the Command - Control Module are static

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

SW11

SW6

SW12

SW13

SW-6: OK-to-Move: Contact closure, 120VAC @ 1A (Factory default setting) or DC Volts (16-18vdc@ up to 100 ma.) SW-11: Set “B” position, (up) for default SW-11: Set “A” position (down) for remote analog current control. SW-8-2 must be set to “ON”.

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

1 = ON = 16.6:1 2 = ON = 30:1 3 = ON = 40:1 4 = ON = 25:1

SW13: Ultra-Cut Switch positions

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

Only 1 on at a time.

Art # A-12016_AB

3-16 INSTALLATION Manual 0-5275

ULTRA-CUT 400 XT

3.13 Height Control Connections

The terminal strip provides connections to negative Arc Volts (Torch or electrode), Tip Volts (Pilot) and Work. These are for a height control that requires connection to the full non-divided arc voltage. Also available on the terminal strip are 120VAC and 24 VAC. The allowable current draw is 100ma @ 120VAC and 1Amp @ 24 VAC.

Art # A-11900

TB4

NOTE!

1 2 3 4 5 6 7

24 VAC

@ 1A

Art # A-11954

120 VAC

@ 100 ma.

Work

Tip Volts

(Pilot)

Arc Volts

(Torch)

There are holes added in the rear panel for customer wiring. This, rather than the one in the CCM will be the preferred place for customer added wiring (and strain relief) for connections to height controls, etc..

Manual 0-5275 INSTALLATION 3-17

ULTRA-CUT 400 XT

Art # A-07962

8.50”

215.90mm

0.28”

7.14mm

11.00”

279.40mm

16.18”

410.97mm

13.68”

347.47mm

Gas Box

3.14 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 as far away as possible from the Arc Starter due to electromagnetic interference. It is acceptable to locate the control cable in the same track as the cables from the Arc Starter.

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

Mounting Dimensions

NOTE

Height not shown is 14.125” (359 mm)

3-18 INSTALLATION Manual 0-5275

NOTE!

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

ULTRA-CUT 400 XT

Art # A-06882

Gas Control Module Cover

Do not remove

Remove Ground Wire

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.

Cover Removal

Manual 0-5275 INSTALLATION 3-19

ULTRA-CUT 400 XT

Circuit Board

Art # A-04772

Fiber Optic Cable

COMM

PLASMA

OUT

PREFLOW

OUT

J57

J56

SHIELD

OUT

INPUTS

TVA

POWER SUPPLY

H35

AIR N

COMM

J57

J56

INPUTS

TVA

POWER SUPPLY

H35

AIR N

SHIELD

PLASMA

PREFLOW

SHIELD

3.15 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.

3-20 INSTALLATION Manual 0-5275

ULTRA-CUT 400 XT

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

Cable must snap into place.

Circuit Board

Fiber Optic Cable

Art # A-04773

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

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

Manual 0-5275 INSTALLATION 3-21

ULTRA-CUT 400 XT

Gas & Water Inputs (Check Valves)

Connection Panel

To Torch Valve Assembly

To Power Supply

SHIELD PLASMA

PREFLOW

H O

SHIELD

H O

AIR

H35

TVA

POWER SUPPLY

COMM

J57

J56

INPUTS

When Cutting With O2 Plasma

Air MUST BE Connected

Ground Stud

SHIELD PLASMA

PREFLOW

H O

SHIELD

H O

AIR

H35

TVA

POWER SUPPLY

COMM

J57

J56

INPUTS

When Cutting With O2 Plasma

Air MUST BE Connected

Gas Control Box Rear Panel

Art # A-06881

3.16 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’.

3-22 INSTALLATION Manual 0-5275

ULTRA-CUT 400 XT

3.17 HE400XT COOLER

Used in series with the existing cooling system of the Ultra-Cut XT™ series power supplies, the HE400XT Cooler provides additional cooling when ambient temperatures exceed the units rated temperature. The HE400XT fan is thermally controlled to operate whenever the Ultra-Cut fan and pump is on and the coolant temperature is above a predetermined level. It may come on anytime while the main pump is operating.

WARNING

Locate the Cooler so that there is adequate ventilation in front of and behind the unit and do not place or stack anything on top of the unit.

Do not disassemble the Cooler with the power applied or the coolant ﬂowing. Dangerous 220 AC voltages and high pressure liquid are present.

3” 76 mm

Manual 0-5275 INSTALLATION 3-23

2’ (0.6 m)

3” 76 mm

2’ (0.6 m)

Art # A-12813

NOTE!

Ensure the four coolant lines described below are connected and leak free before connecting power to J71.

ULTRA-CUT 400 XT

Art # A-09624_AB

Included with the HE400XT are two 10’ hoses, supply (green) and return (red), that are to be connected to the matching colors on left side of the HE400XT and to the supply and return ﬁttings on the rear of the Ultra-Cut XT power supply. Hoses to the RAS1000XT connect on the right side of the HE400XT.

CAUTION

Attach and tighten all #6 JIC ﬁttings with 11/16” (18mm) wrench. Do not overtighten as it will strip the ﬁtting threads and will cause a leak. Do not start the Ultra-Cut XT™ without coolant in the reservoir. An additional gallon (3.78l) of coolant is required to compensate for the HE400XT being attached to the system. Monitor the ﬂuid level while ﬁlling the Ultra-Cut XT. Do not allow the coolant reservoir level to drop below minimum.

Attach the cable from J70 on the power supply to J71 on the HE400XT after the Cooler and coolant lines have been determined to be leak free.

Do NOT cross the coolant lines as this will not provide cooling for the XT™ plasma torch as designed and void the warranty.

Under low power plasma cutting the HE400XT may not come on. This is normal operation. Periodically check obstructions in the radiator and remove them by vacuuming the ﬁns. Do not use cleaners or ﬂuids to remove

debris, they may affect the radiator integrity.

3-24 INSTALLATION Manual 0-5275

ULTRA-CUT 400 XT

3.18 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 con-

nections without excessive kinking or bending.

Mounting Dimensions

NOTE!

Height not shown is 7.375” ( 187mm )

38.10mm

1.50in

190.50mm

7.50in

50.80mm

2.00in

203.20mm

8.00in

Art # A-12058

50.80mm

2.00in

38.10mm

1.50in

Manual 0-5275 INSTALLATION 3-25

ULTRA-CUT 400 XT

Installation

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

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

the Cover Panel to the Arc Starter.

NOTE!

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

2. Remove the Cover Panel from the Arc Starter.

Upper screws (2 per side)

Cover

Ground Wire

Lower screws (2 per side)

Art # A-12059

Cover Removal

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-12060

3-26 INSTALLATION Manual 0-5275

ULTRA-CUT 400 XT

Input Connections

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

• CoolantSupplyandReturnHoses(fromHE-400HeatExchanger).Hosesandconnectorsarecolor-coded;Redfor

Return, Green for Supply.

Art # A-12061

Supply

Return

Coolant Supply and Return Hoses (from power supply)

Art # A-12062

Coolant Return (Red)

Coolant Supply (Green)

Red

Green

Manual 0-5275 INSTALLATION 3-27

ULTRA-CUT 400 XT

2. Refer to illustration. Connect the Pilot wire and Negative cables using a star washer on each.

NOTE!

* Slave and Master refer to only those set ups using two power supplies in parrallel. Slave is not used in single system operations.

*Negative (Slave)

*Negative (Master) Torch Lead

Pilot

Art # A-12063_AB

Negative Master, Negative Slave and Pilot Cables (from Power Supply )

Art # A-12064

Control Cable from Power Supply rear panel

3-28 INSTALLATION Manual 0-5275

ULTRA-CUT 400 XT

Output Connections

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

Pilot Lead

Coolant Return (Red)

Coolant Supply (Green)

Red

Art # A-12065

Green

Pilot Return Cable, Coolant Supply and Return Hoses (from Torch)

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

Upper screws (2 per side)

Cover

Manual 0-5275 INSTALLATION 3-29

Ground Wire

Lower screws (2 per side)

Art # A-12059

ULTRA-CUT 400 XT

Ground Cable

Art # A-04758

1 Nut and 1 Washer Remain in Place

To rch Leads

Art # A-04759

Coolant and Pilot Leads to Torch Valve Assembly

Torch Leads Shield

Shield Clamp

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

details.

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

3-30 INSTALLATION Manual 0-5275

ULTRA-CUT 400 XT

Connect Control Cable

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

J55 - GCM

USER INPUT

J15 - CNC

HEIGHT CONTROL

J54 - TSC /COMM

J59 - RAS

CB2 - 5A 120 VAC

CB3 - 5A 24 VAC

J70 - HE

CB4 - 5A 120 VAC

F1 - 8A SB 230 VAC F2 - 8A SB 230 VAC

Art # A-12067

Manual 0-5275 INSTALLATION 3-31

ULTRA-CUT 400 XT

1.450”

36.83 mm

4.450”

113.03 mm

.261” Dia.

6.63 mm

Art # A-07648

Art # A-07645

Do not remove brass plugs Front and side

Right-hand Thread:

To Torch Shield Gas fitting

Left-hand Thread:

To To rch Plasma Gas fitting

Outlet Side

3.19 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

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.

3-32 INSTALLATION Manual 0-5275

ULTRA-CUT 400 XT

Control Cable

Plasma Gas Inlet

Shield Gas Inlet

Preflow Gas Inlet

WMS™ Inlet

Art # A-07646

Exhaust Muffler

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.

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.

Manual 0-5275 INSTALLATION 3-33

ULTRA-CUT 400 XT

Art # A-09198

Pilot Lead Connector

Torch Head Assembly

Mounting Tube

O-Ring

Torch Leads End Cap

Plasma Gas

(Left Hand Thread)

Shield Gas

(Right Hand Thread)

Coolant Supply

Power Lead (-)

Pilot Lead

Coolant Supply, Coolant Return, and Pilot Leads

Leads Cover

Groove for O-Ring

To Torch Valve

3.20 Connecting Torch

Connect the Torch as follows:

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.

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ULTRA-CUT 400 XT

Art # A-03887

WARNINGS

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

Shield

Retainer

Shield

Shield Gas

Distributor

Tip

Plasma Gas

Distributor

Electrode

Cartridge

Art # A-12789

B C

1 - Assemble “A” 200 A only. 2 - Assemble “B”. 3 - Assemble “B” to “C”. 4 - Assemble “A” to “B-C” assembly.

CAUTION

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.

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.

The gas and coolant leads include compression ﬁttings. Do not use sealant on these connections. Slowly apply pressure to the gas lines. Check for leaks at all connections before continuing. If there are no leaks, shut off the gas supplies and continue with installation.

CAUTION

Ensure that the leads do not twist within the mounting tube. Leads

must lie as shown in the installation sketch.

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.

3.21 Install Consumable Torch Parts

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

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

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

3. Stack the consumable parts together.

Manual 0-5275 INSTALLATION 3-35

ULTRA-CUT 400 XT

To rch Head O-Ring

Torch Head

Art # A-08300_AB

0.063 - 0.083" (1.6 - 2.1 mm)

Protrusion

Ohmic Clip

4. Insert the stack of consumable parts into the cartridge. Ensure that the large O-ring on the torch tip ﬁts completely into the cartridge. If any part of the O-ring protrudes from the cartridge, the parts are not seated properly.

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

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

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

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

Installing Assembled Cartridge Onto Torch Head

Art # A-03393_AB

NOTE!

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

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ULTRA-CUT 400 XT

Cartridge Covers O-Ring on Torch Tip

Shield Cap Protrudes

0.063-0.083" (1.6 - 2.1 mm)

Electrode

Plasma Gas Distributor

Tip

Shield Gas Distributor

Shield Cap

O-Ring

on Tip

1: Stack Parts

2: Press Cartridge onto Stacked Parts

4: Check Shield Cap Protrusion

Art # A-04873

No Gaps

Between Parts

3: Thread Shield Cup onto Cartridge

Shield Cap

Shield Cup

30 - 100 Amp Parts Assembly

Installing Assembled Cartridge Onto Torch Head

Manual 0-5275 INSTALLATION 3-37

ULTRA-CUT 400 XT

Space for V-D Board Ohmic clip cable port

V-D Board connection

V-D Board installed

Art # A-12079

3.22 Voltage Divider for iHC Torch Height Control

For best plasma cutting performance it is necessary to maintain a constant height (standoff) above the metal while cutting. Cutting tables use a Torch Height Control (THC), also called a Z axis control, most of which use feedback from the arc voltage to control the height. Several of these, including the iHC, part of the Victor Technologies XT CNC Controller, come with a Voltage Divider Printed Circuit Board that has to be installed inside the plasma power supply to divide the high arc voltage down to lower levels for use with control circuits.

There is a space for mounting the V-D Board located on the upper portion of an internal vertical panel near the rear of the power supply. Predrilled holes for mounting the iHT V-D board as well as another popular height control are provided.

CAUTION

Install the V-D Board.

1. Locate the V-D Board which should be with the iCNC.

2. Inside the Power Supply, locate and remove the mounting panel’s 2 screws and panel.

3. Install the V-D board standoffs and the V-D Board from the XT iCNC then reattach the panel with the 2 screws, securing the V-D board in place. If using another V-D Board, follow the instructions provided mounting it in this same location.

If using another board that doesn’t align with the existing holes, remove the panel if possible before drilling. If not possible then every precaution must be taken to keep metal ﬁlings from being deposited inside the power supply.

V-D Board shown with optional wire harness for iHC controller

Control Cable.

The iHC board can be supplied with a wire harness and connector (shown in previous image), to be installed in the rear panel hole labeled “Height Control” . The connector mates with a cable from the iHC. For other height control V-D boards a strain relief can be installed in this hole for those cables. Refer to Appendix for wiring diagram.

J55 - GCM

USER INPUT

J15 - CNC

HEIGHT CONTROL

J54 - TSC /COMM

J59 - RAS

CB2 - 5A 120 VAC

CB3 - 5A 24 VAC

J70 - HE

CB4 - 5A 120 VAC

F1 - 8A SB 230 VAC F2 - 8A SB 230 VAC

Ohmic clip cable port

V-D Board connection

Art # A-12080

3-38 INSTALLATION Manual 0-5275

ULTRA-CUT 400 XT

Arc Voltage Connections.

The XT plasma supplies provide a terminal strip, TB4, on the right side ahead of the CCM module for connections to Arc V- (Torch); Tip V (Pilot); Arc V + (Work). If the V-D board requires separate power, 24 VAC and 120 VAC is available on the terminal strip TB4. Refer to the wiring diagram in the Appendix for more information.

TB4

Art # A-11954

1 2 3 4 5 6 7

24 VAC

@ 1A

120 VAC

@ 100 ma.

Work

Tip Volts

(Pilot)

Arc Volts

(Torch)

“Ohmic” or Shield (cup) cable.

Some height controls including the iHC ﬁnd the plate using an electrical or resistance measurement, thus “ohmic”, contact between the conductive end of the torch and the metal or “plate” being cut. A wire, usually a single highly ﬂexible wire that withstands the reﬂective heat from the arc, is connected between the V-D board and the torch shield cup. The XT torch includes a metal spring clip which slips into a groove in the shield cup allowing easy removal for parts change. The Ohmic wire can be connected to this clip with a ¼” female push-on terminal.

Signiﬁcant amounts of high frequency (HF) energy causing electromagnetic interference (EMI) can be conducted along this wire due to it’s close coupling to the torch. This is the reason for mounting the V-D board away from the CCM and close to the rear panel where the Ohmic wire does not need to pass near other sensitive electronics. It is especially recommended that the Ohmic wire not be routed near the CCM module or along the torch leads.

Refer to Appendix for wiring diagram.

Ferrite cores.

It is recommended that the Ohmic Sensing wire be wrapped through a ferrite core with several turns, at least 3 but more is better, to reduce the energy conducted to the V-D board and into the plasma supply. The ferrite core should be located on the wire where it enters the plasma supply. A second ferrite core added several feet (couple of meters) from the torch will further reduce the conducted EMI that may couple to other cable/wires and cause interference.

Refer to Appendix for wiring diagram.

Manual 0-5275 INSTALLATION 3-39

ULTRA-CUT 400 XT

3.23 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-CoolTM’ 25 / 75 10° F / -12° C

7-3581 ‘Ultra-CoolTM’ 50 / 50 27° F / -33° C

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

* For mixing with D-I CoolTM 7-3583

Coolant Tank

Fill Range

Art # A-11536

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 4 minutes the system may shut down if the leads are not full of coolant.

c. Place the ON/OFF switch to OFF. Add more coolant if needed 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 repeated.

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

ant lines before using the system.

3. Reﬁll the reservoir and reinstall 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 troubleshooting guide in the maintenance section of this manual.

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ULTRA-CUT 400 XT

SECTION 4: OPERATION

4.01 Power Supply Control Panel

AC Indicator

Gas Indicator

Status Indicator

Temp Indicator

Art # A-11541_AB

AC Power Lamp

Indicates unit has passed the input power tests and AC power is being supplied to the inverter modules via the input contactor when the ON/OFF switch is in ON position.

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

limits. Let the unit cool before continuing operation.

GAS Lamp: Flashing during start up gas purge/pump priming, then steady whenever gas is ﬂowing. Indicates adequate gas

pressure and coolant ﬂow for operation.

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

DC Indicator

Refer to Section 4.07 and Status Code Section for details.

Indicates AC power is present inside the unit

Status Indicator: Shows CCM code version on start up followed by the Current Control setting and system status.

Rear Panel AC Power Lamp

Manual 0-5275 OPERATION 4-1

ULTRA-CUT 400 XT

4.02 System Operation

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

WARNING

Review the safety precautions in Section 1. If the power supply cord has a plug or is not permanently connected to power, be sure the power to the outlet is disconnected when inserting the plug into the outlet. Disconnect primary power at the source before assembling or disassembling power supply, torch parts, or torch and leads assemblies, or adding coolant. It is not enough to simply move the ON/OFF switch on the unit to OFF position when cutting operations have been completed. Always open the power supply disconnect switch ﬁve minutes after the last cut is made.

NOTE!

Prior to starting the system determine the process to be used. The process is determined by the type and thickness of the metal to be cut. Select and install the required consumables, connect the required gasses to the system.

1. Connect system to primary input power. An indicator will light on the rear panel when AC power is applied to the unit. On the GCM 2010 place switch (upper right corner) in the “Enable Plasma” position.

2. Turn ON/OFF switch to ON (up) position. System goes through the “Start up Sequence”.

• Forabout10secondsthedecimalpointsofthe4digitdisplayblinkfromrighttoleft.

• Nextthe4rectangularLEDindicatorsandthe4statusdisplaydigitsilluminateallsegmentsasatest.

• Thenforabout6secondsthedisplayshowstheletter“C”(code)followedbytheCCMcodeversion.Example“C1.2.0”

. During this time various input voltage tests are being performed. If a fault is found its code is displayed and the start up sequence halts. Faults will show “E” or “L”. If Plasma hasn’t been Enabled by this point, E101 will be displayed and the startup sequence will not proceed.

• Thecoolantpumpstarts,theGasindicatorblinksandthedisplayshowsthecurrentcontrolsetting(fromtheGCM

2010) alternating with the Status code which will be E304, for as long as the gas purge lasts. Once the purge ends the display shows only the amperage without any letter, for example, “100” for 100 amps. Purge time varies with the torch lead length and the cutting process. See section 4.05 for setting lead length on the GCM 2010. If the GCM 2010 is not in RUN mode E304 will continue to be displayed along with the amperage setting until the GCM 2010 is set to RUN.

• Oncecoolantowisdetected,usuallywithin5secondsafterthepumpstarts,theinputcontactor(s)W1(W2)close

and the AC indicator lights.

When the Gas Control has completed the gas purge code E304 will go away and the Gas LED stops blinking however

if correct coolant ﬂow was not obtained the contactors will not close and the Gas LED will continue blinking until required coolant ﬂow has been obtained. The Gas LED will blink for up to 4 minutes after which code E404 will be displayed indicated proper coolant ﬂow was not established.

4-2 OPERATION Manual 0-5275

ULTRA-CUT 400 XT

POWER

Art # A-11542

OFF

3. Set Gas Pressure GCM 2010 a. Place Mode switch in SET PREFLOW mode. Adjust Preﬂow pressure as required for the cutting process. b. Set Mode Switch in SET PLASMA & SHIELD position. Adjust plasma and shield pressure regulators to correct pres-

sure. c. Set plasma and shield ( if process calls for setting shield ﬂow) ﬂow meters to correct ﬂow. d. Return Mode Switch to RUN position.

4. Set cutting current. a. Set cutting current using the AMPERAGE SET_UP knob and LCD display on the GCM 2010.

5. Prepare to cut. a. Protect your eyes and ears. b. Position the Torch to the proper transfer distance above the work piece.

6. Apply START.

• Gasindicatorlights;Gaspre-owstarts.

• Duringgaspre-owpowersupplyisenabled.DClampturnsON.

7. Pilot Arc

• Attheendofpre-ow,ignitionoccurs(arcstarterres)andthePilotArcisestablished.

8. Transfer

• Almostimmediately,ifthetorchispositioned correctly,thepilotarc transferstotheworkandbecomesa cutting

(transferred) arc.

• CurrentquicklyrampsuptothelevelsetbytheCurrentControlandthearcpiercesthroughthemetal.

• OKtoMovesignalbecomesactiveandthetorchismovedtoperformthecut.

9. End of Cut

• STARTsignalisremoved;currentrampsdownandgoesout.

• GasescontinuetoowfortheselectedPost-owtimethenstops.

• Pumpandfanwillrunfor4minutesthenshutoff.

10. To make another cut repeat steps 5-9. A second cut can be started anytime after completing the ﬁrst cut.

Manual 0-5275 OPERATION 4-3

ULTRA-CUT 400 XT

11. Shut off the system. a. Set the ON/OFF power switch on the front panel of the unit to OFF.

WARNING

AC power is still present inside the unit.

• Fansandpumpaswellasallindicatorsturnoff.

• Thedisplaymayshowafaultcodeforamoment,thisisanormalpartofshuttingoffpoweranddoesnotindicatea

fault.

b. Open (turn off) the main power disconnect. All power is now removed from the unit.

• RearpanelACindicatorturnsOFF.

Operational Suggestions

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

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

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

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

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

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

• Acartridgetypeparticulatewaterltermayhelpachieveoptimumcuttingperformance.

4.03 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nishesandminimizesnitridebuilduponcutsurface(nitridebuildupcancausedifcultiesin

producing high quality welds if not removed).

4-4 OPERATION Manual 0-5275

ULTRA-CUT 400 XT

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.

• Agoodcleanweldinggradenitrogenshouldbeused.

• Whenusedwithawatermistsecondaryitproducessuperiorcutspeedsandcutqualityonstainlesssteelandalumi-

num.

5. H17 Plasma (17.5% Hydrogen / 32.5% Argon / 50% Nitrogen)

•Recommendedfor1/2inch(12mm)andthickernonferrousmaterials.H17isnotnormallyusedforthinnernonferrous

materials because less expensive gases can achieve similar cut quality.

•AlternativetoH35Plasma.Yieldsslightlyhighercutspeedsandsimilarcutquality.

•WhenusingH17,thegasshouldbesuppliedtothegassupplyportmarked“H35”.

•Poorcutqualityonferrousmaterials.

B. Shield Gases

1. Compressed Air Shield

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

• Improvescutqualityonsomeferrousmaterials.

• Inexpensive-reducesoperatingcosts.

2. Nitrogen (N2) Shield

• Nitrogenshieldisusedwithnitrogen(N2)orAr/H2(H35)plasma.

• Providessmoothnishesonnonferrousmaterials.

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

3. Water Shield

• Normallyusedwithnitrogen.

• Providesverysmoothcutsurface.

• Reducessmokeandheatinputtotheworkpiece.

• EffectivewhenusedwithN2upto2inch(50mm)maximummaterialthickness.

• Tapwaterprovideslowoperatingexpense.

Manual 0-5275 OPERATION 4-5

ULTRA-CUT 400 XT

ENABLE

DISABLE

PLASMA POWER SUPPLY

SHIELD

FLOW

GAS

PRESSURE

MODE

GAS

GCM

2010

PLASMA

PREFLOW

O2 - AIR

O2 - O2

H35 - N2

F5 - N2

AIR - AIR

N2 - H20

N2 - N2

Art # A-04771_AC

MODE

GAS

O2 - AIR

O2 - O2

H35 - N2

F5 - N2

AIR - AIR

N2 - H20

N2 - N2

ENABLE

DISABLE

PLASMA

POWER SUPPLY

FLOW

GAS

PRESSURE

H20

MIST

RUN

SET PREFLOW

SET PLASMA

& SHIELD

TEST

RUN

SET PREFLOW

SET PLASMA

& SHIELD

TEST

AMPERAGE

SET-UP

AMPERAGE

SET-UP

4.04 GCM 2010 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.

4-6 OPERATION Manual 0-5275

ULTRA-CUT 400 XT

MODE

RUN

SET PREFLOW

SET PLASMA

& SHIELD

TEST

PREFLOW

MIST

PLASMA

SHIELD

PRESSURE

PLASMA

POWER SUPPLY

GAS

FLOW

High Precision

Plasma Cutting System

ENABLE

DISABLE

GAS

MODE

RUN

SET PREFLOW

SET PLASMA

& SHIELD

TEST

O2 - AIR

O2 - O2

H35 -N

F5 - N

AIR - AIR

2 - H2

2 - N2

Art # A-04765_AB

GCM

2010

GCM 2010 Gas Control Module: Controls & Indicators

1. MODE Selection Switch

• NormallyintheRUNpositionduringtorchoperation.

• IntheSETPREFLOWposition,PreoworPilotinggas(AirorN2) ﬂows to the torch allowing the operator to adjust

pressure. Gas automatically shuts off after 2 minutes if left in the SET PREFLOW position.

• IntheSETPLASMA&SHIELDposition,selectedcuttinggases,Plasma&Shield,owtothetorchtoallowoperator

to set the pressure (regulator & gauge) and ﬂow (knob at top of ﬂowmeter). Gases automatically shut off after 2 minutes if left in the SET PLASMA & SHIELD position. GCM 2010 gas control revision AG or later includes inlet pressure sensors. In SET PLASMA & SHIELD position the LCD display shows alternately the plasma an shield inlet pressure. If either gas pressure is outside the acceptable range, the display shows “PSI low (or high), the actual pressure and the limit it is below (or above).

• IntheTESTposition,selectedcuttinggasses,Plasma&Shield,alsoowtothetorch.ThePlasmaoutletpressure

(pressure going to the torch), is displayed.

• ForGCM2010gascontrolrevisionAGorlatertheModeSelectionSwitchincludesahiddenfunctionusedatinitial

setup to conﬁgure the gas control for the gas lead length. See Sequence of Operation, initial setup.

Manual 0-5275 OPERATION 4-7

ULTRA-CUT 400 XT

GAS

O2 - AIR

O2 - O2

H35 -N

F5 - N

AIR - AIR

2 - H2

2 - N2

PREFLOW

MIST

PLASMA

SHIELD

PRESSURE

PLASMA

POWER SUPPLY

GAS

FLOW

High Precision

Plasma Cutting System

ENABLE

DISABLE

GAS

MODE

RUN

SET PREFLOW

SET PLASMA

& SHIELD

TEST

O2 - AIR

O2 - O2

H35 -N

F5 - N

AIR - AIR

2 - H2

2 - N2

Art # A-04766_AB

GCM

2010

2. GAS Selection Switch

Selects combinations of plasma and shield gases.

3. LCD Display

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

^E4 = CANBus error unacknowledged message.

^E5 = CANBus error Bus off

^E6 = CANBus error communication timed out.

4-8 OPERATION Manual 0-5275

ULTRA-CUT 400 XT

High Precision

Plasma Cutting System

PREFLOW

MIST

PLASMA

SHIELD

PRESSURE

PLASMA

POWER SUPPLY

GAS

FLOW

High Precision

Plasma Cutting System

ENABLE

DISABLE

GAS

MODE

RUN

SET PREFLOW

SET PLASMA

& SHIELD

TEST

O2 - AIR

O2 - O2

H35 -N

F5 - N2

AIR - AIR

2 - H2O

2 - N2

Art # A-04767_AC

GCM

2010

AMPERAGE

SET-UP

AMPERAGE

SET-UP

4. Current Control

Adjusts the output current of the power supply.

5. Plasma Power Supply Enable / Disable Switch

6. PREFLOW Control Knob and Pressure Gauge

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

8. Gas Pressure Flow Switch

9. H2O Mist Control Knob and Flow Meter

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

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

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

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

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

NOTE!

Water mist is not used in all applications.

Manual 0-5275 OPERATION 4-9

ULTRA-CUT 400 XT

4.05 GCM 2010 First Time Operation Matching Gas Control to Lead Length

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

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

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

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

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

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

6. Set the Mode Switch back to Run.

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

4.06 GCM 2010 Sequence Of Operation

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

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

DANGER

Always shut off input power to the system

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.

4. Set the plasma and shield gas pressures and ﬂows. a. Set the MODE switch to SET PLASMA & SHIELD.

before changing or inspecting torch parts.

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

sures 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 / Disableswitch (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.

4-10 OPERATION Manual 0-5275

ULTRA-CUT 400 XT

Right Side

Cut Angle

Left Side

Cut Angle

A-00512

Kerf Width

Cut Surface Bevel Angle

Top Edge

Rounding

Cut Surface

Drag Lines

Dross

Build-Up

Top

Spatter

A-00007

NOTE!

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

CAUTION

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.

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

Cut 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 0-5275 OPERATION 4-11

ULTRA-CUT 400 XT

Right Side

Cut Angle

Left Side

Cut Angle

A-00512

Scrap

Clockwise

Counter-

Clockwise

Art # A-04182

Workpiece

Scrap

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.

Swirl Effect on Side Characteristics Of Cut

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

Underwater Cutting

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

Ohmic Height Sensing

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

4-12 OPERATION Manual 0-5275

ULTRA-CUT 400 XT

4.07 Power Supply Status Codes

NOTE!

See the Appendix for Advanced Troubleshooting

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 display on the front panel shows a 3 digit number code preceded by either letter “E” (currently active fault) or letter “L” (last or latched fault) meaning a fault occurred stopping the process but is not currently active.

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!

There are no Group 5 (500) numbered status codes with the GCM 2010 system. These tables cover units up to 400A, Lower current units won’t have all the inverter sections referred to in the Group 2. However codes for those sections should not appear.

CCM Status Code

Code

101 Plasma Disabled

102 Pilot Ignition Failure

103 Lost Pilot

104 Transfer Lost

105 Not used Reserved for legacy product

106 Pilot Timeout, no Transfer

107 Tip Saver Fault Tip remained in contact with work in excess of 15 seconds. ( Pak200i).

Message

Remedy / Comments

Group 1 -- Plasma Process

Plasma Enable Off ; Disable activated on GCM 2010 or external SW disabled (CNC); CCM TB1-1&2 jumper missing; 40 circuit ribbon cable from Relay PCB to CCM disconnected or defective;

Pilot did not start within 15 seconds. Torch consumable parts worn? Ensure correct process selected or manual setting including current control setting matches consumables; Plasma pressure too high; Defective Arc Starter; Defective Pilot PCB; defective Inverter section 1A. Ribbon cables reversed on INV1 sections 1A and 1B.

Pilot went out while Start active. Torch consumable parts worn? Ensure cut process or current control setting setting matches consumables; Plasma pressure too high;

Arc was transferred to work then went out while Start still active. Arc lost contact with work (run off edge, over hole, etc.); Standoff too high; Ensure cut process or manual settings (current control, gas pressures) matches consumables;

Must transfer from Pilot to Cutting Arc in 0.085 seconds (SW8-1 OFF) or 3 sec. (SW8-1 ON). Standoff too high or void in work under torch; Wrong cut process selected or wrong manual settings (current control set too low or wrong gas pressure).

108 Tip to Electrode voltage fault.

109 Part process not conﬁgured.

110 Devise Locked DFC 3000: Process loading; wait until ﬁnished

Manual 0-5275 OPERATION 4-13

Tip voltage too close to electrode voltage; Torch consumable parts worn out; Wrong consumables installed causing tip to electrode short; Wrong process selected or wrong manual setting of plasma gas or cutting current.; Leak in Plasma hose to torch; Defective Pilot PCB; Shorted torch body .

Applies only to DFC 3000 Auto Gas Control. Select and load a cutting process.

ULTRA-CUT 400 XT

CCM Status Code

Code Message Remedy / Comments

Group 2 -- Plasma Power Supply

201 Missing AC Phase

202 Not used Reserved for legacy product 203 Not used Reserved for legacy product 204 Not used Reserved for legacy product

205 DC Output Low

206 Not used Reserved for legacy product

207

208

209 Not used Reserved for legacy product

210

211 Work Current Too Low

Unexpected current in work lead

Unexpected current in pilot circuit

Work Current Too High

Blown wall fuse, Blown unit fuse F1 or F2 or rear panel, Bad power cable connection; Defective System Bias PCB.

Less than 60 VDC; Negative lead short to work or ground; Defective inverter (output shorted); CCM voltage sense (J24) disconnected or wire broken; Defective CCM.

Current above 8A in work lead prior to pilot ignition or transfer. Negative lead short to ground or arcstarter chassis; Defective HCT1 work lead current sensor; Defective Relay PCB.

Current above 6A in pilot circuit prior to ignition. Wrong or mismatched consumables causing tip - electrode short; Pilot lead shorted to negative in torch tube; Defective Relay PCB; Defective Pilot PCB; Possible shorted torch.

Work lead current detected greater than 16% above process setting. Possible defective HCT1 Work lead current sensor or Relay PCB; Defective CCM.

Work current detected more than 16% below process setting. Possible defective HCT1 Work lead current sensor or Relay PCB; Possible defective pilot PCB (shorted IGBT);

212

213

214

215

216

217

218

219

220

221

Inverter 1A Output Current Low

Inverter 1B Output Current Low

Inverter 2A Output Current Low

Inverter 2B Output Current Low

Inverter 3A Output Current Low

Inverter 3B Output Current Low

Inverter 1A Output Current High

Inverter 1B Output Current High

Inverter 2A Output Current High

Inverter 2B Output Current High

Plasma work current low during cutting and attributed to Inverter Module 1 Section A output low; Inverter output disconnected; Possible defective ribbon cable; If problem persists replace Inverter Module 1

Plasma work current low during cutting and attributed to Inverter Module 1 Section B output low; Inverter output disconnected; Possible defective ribbon cable; If problem persists replace Inverter Module 1

Plasma work current low during cutting and attributed to Inverter Module 2 Section A output low; Inverter output disconnected; Possible defective ribbon cable; If problem persists replace Inverter Module 2

Plasma work current low during cutting and attributed to Inverter Module 2 Section B output low; Inverter output disconnected; Possible defective ribbon cable; If problem persists replace Inverter Module 2

Plasma work current low during cutting and attributed to Inverter Module 3 Section A output low; Inverter output disconnected; Possible defective ribbon cable; If problem persists replace Inverter Module 3

Plasma work current low during cutting and attributed to Inverter Module 3 Section B output low; Inverter output disconnected; Possible defective ribbon cable; If problem persists replace Inverter Module 2

Plasma work current high during cutting and attributed to Inverter Module 1 Section A output high; If problem persists replace Inverter Module 1

Plasma work current high during cutting and attributed to Inverter Module 1 Section B output high; If problem persists replace Inverter Module 1

Plasma work current high during cutting and attributed to Inverter Module 2 Section A output high; If problem persists replace Inverter Module 2

Plasma work current high during cutting and attributed to Inverter Module 2 Section B output high; If problem persists replace Inverter Module 2

4-14 OPERATION Manual 0-5275

ULTRA-CUT 400 XT

CCM Status Code

Code Message

222

223

224 Inverter 1 Not Found

225

226

227

228

229

230

Inverter 3A Output Current High

Inverter 3B Output Current High

Inverter 1A Incompatible Revision

Inverter 1B Incompatible Revision

Inverter 2A Incompatible Revision

Inverter 2B Incompatible Revision

Inverter 3A Incompatible Revision

Inverter 3B Incompatible Revision

Plasma work current high during cutting and attributed to Inverter Module 3 Section A output high; If problem persists replace Inverter Module 3

Plasma work current high during cutting and attributed to Inverter Module 3 Section B output high; If problem persists replace Inverter Module 3

Inverter Module 1 Section A required for Piloting; Bad ribbon cable connection to CCM J31 to Inverter Module 1 Section A.

Unsupported Inverter Revision; Ribbon cable CCM J31 to Inverter Module 1 Section A damaged; CCM code version incompatible with Inverter revision or model

Unsupported Inverter Revision; Ribbon cable CCM J32 to Inverter Module 1 Section B damaged ; CCM code version incompatible with Inverter revision or model

Unsupported Inverter Revision; Ribbon cable CCM J33 to Inverter Module 2 Section A damaged; CCM code version incompatible with Inverter revision or model

Unsupported Inverter Revision; Ribbon cable CCM J34 to Inverter Module 2 Section B damaged; CCM code version incompatible with Inverter revision or model

Unsupported Inverter Revision; Ribbon cable CCM J35 to Inverter Module 3 Section A damaged; CCM code version incompatible with Inverter revision or model

Unsupported Inverter Revision; Ribbon cable CCM J36 to Inverter Module 3 Section B damaged; CCM code version incompatible with Inverter revision or model

Remedy / Comments

231

232

233

234

235

236

237

238 BIAS VAC Invalid

239 AC Voltage High

240 AC Voltage Low

Inverter 1A VAC Mismatch

Inverter 1B VAC Mismatch

Inverter 2A VAC Mismatch

Inverter 2B VAC Mismatch

Inverter 3A VAC Mismatch

Inverter 3B VAC Mismatch

Too Few Inverters Found

Inverter AC Voltage rating incompatible with Power Supply voltage rating; Bad ribbon cable connection CCM J31 to Inverter Module 1 Section A; Wrong voltage Inverter Module 1 installed; Defective Inverter module

Inverter AC Voltage rating incompatible with Power Supply voltage rating; Bad ribbon cable connection CCM J32 to Inverter Module 1 Section B; Wrong voltage Inverter Module 1 installed; Defective Inverter module

Inverter AC Voltage rating incompatible with Power Supply voltage rating; Bad ribbon cable connection CCM J33 to Inverter Module 2 Section A; Wrong voltage Inverter Module 2 installed; Defective Inverter module

Inverter AC Voltage rating incompatible with Power Supply voltage rating; Bad ribbon cable connection CCM J34 to Inverter Module 2 Section B; Wrong voltage Inverter Module 2 installed; Defective Inverter module

Inverter AC Voltage rating incompatible with Power Supply voltage rating; Bad ribbon cable connection CCM J35 to Inverter Module 3 Section A; Wrong voltage Inverter Module 3 installed; Defective Inverter module

Inverter AC Voltage rating incompatible with Power Supply voltage rating; Bad ribbon cable connection CCM J36 to Inverter Module 3 Section B; Wrong voltage Inverter Module 3 installed; Defective Inverter module

Two or more Inverter Sections required to operate; Ribbon cable from CCM to Inverter Section damaged or disconnected;

Invalid AC Voltage Selection; Damaged or loose connection at J61 of System Bias Supply; Defective System Bias PCB

System Bias PCB detected AC Voltage is higher than Power Supply rated Voltage; System Bias Supply J61 Voltage Selection connection damaged or disconnected; Defective System Bias PCB; Defective CCM

System Bias PCB detected AC Voltage is lower than Power Supply rated Voltage; System Bias Supply J61 Voltage Selection connection damaged or disconnected; Defective System Bias PCB; Defective CCM

Manual 0-5275 OPERATION 4-15

ULTRA-CUT 400 XT

CCM Status Code

Code Message

Inverter Input Voltage fault; voltage out of range or missing phase at AC Input of In-

241

242

243

Inverter 1A Input Voltage Error

Inverter 1B Input Voltage Error

Inverter 2A Input Voltage Error

verter Module 1 Section A; Poor AC Power Quality; Defective W1 contactor; Loose or open connection between input terminals and W1 contactor or contactor and input of Inverter Section; Defective Inverter module

Inverter Input Voltage fault; voltage out of range or missing phase at AC Input of Inverter Module 1 Section B; Poor AC Power Quality; Defective W1 contactor; Loose or open connection between input terminals and W1 contactor or contactor and input of Inverter Section; Defective Inverter module

Inverter Input Voltage fault; voltage out of range or missing phase at AC Input of Inverter Module 2 Section A; Poor AC Power Quality; Defective W1 contactor; Loose or open connection between input terminals and W1 contactor or contactor and input of Inverter Section; Defective Inverter module

Remedy / Comments

244

245

246

247

248

249

250

251

252

253 Inverter 1A Over Temp

254 Inverter 1B Over Temp

Inverter 2B Input Voltage Error

Inverter 3A Input Voltage Error

Inverter 3B Input Voltage Error

Inverter 1A Circuit Fault Inverter Module 1 Section A detected a circuit fault; Damaged Inverter Module 1

Inverter 1B Circuit Fault Inverter Module 1 Section B detected a circuit fault; Damaged Inverter Module 1

Inverter 2A Circuit Fault Inverter Module 2 Section A detected a circuit fault; Damaged Inverter Module 2

Inverter 2B Circuit Fault Inverter Module 2 Section B detected a circuit fault; Damaged Inverter Module 2

Inverter 3A Circuit Fault Inverter Module 3 Section A detected a circuit fault; Damaged Inverter Module 3

Inverter 3B Circuit Fault Inverter Module 3 Section B detected a circuit fault; Damaged Inverter Module 3

Inverter Input Voltage fault; voltage out of range or missing phase at AC Input of Inverter Module 2 Section B; Poor AC Power Quality; Defective W2 contactor; Loose or open connection between input terminals and W2 contactor or contactor and input of Inverter Section; Defective Inverter module

Inverter Input Voltage fault; voltage out of range or missing phase at AC Input of Inverter Module 3 Section A; Poor AC Power Quality; Defective W2 contactor; Loose or open connection between input terminals and W2 contactor or contactor and input of Inverter Section; Defective Inverter module

Inverter Input Voltage fault; voltage out of range or missing phase at AC Input of Inverter Module 3 Section B; Poor AC Power Quality; Defective W2 contactor; Loose or open connection between input terminals and W2 contactor or contactor and input of Inverter Section; Defective Inverter module

Inverter Module 1 Section A is over temperature; Operating with side panels removed, Check for restricted air ﬂow, clogged radiator; Defective fan; If problem persists replace inverter module.

Inverter Module 1 Section B is over temperature; Operating with side panels removed, Check for restricted air ﬂow, clogged radiator; Defective fan; If problem persists replace inverter module.

Inverter Module 2 Section A is over temperature; Operating with side panels re-

255 Inverter 2A Over Temp

256 Inverter 2B Over Temp

4-16 OPERATION Manual 0-5275

moved, Check for restricted air ﬂow, clogged radiator; Defective fan; If problem persists replace inverter module.

Inverter Module 2 Section B is over temperature; Operating with side panels removed, Check for restricted air ﬂow, clogged radiator; Defective fan; If problem persists replace inverter module.

ULTRA-CUT 400 XT

CCM Status Code

Code Message

257 Inverter 3A Over Temp

258 Inverter 3B Over Temp

259

260

261

262

263

264

265

266

267

268

269

270

271

Inverter 1A Over Temp Ambient

Inverter 1B Over Temp Ambient

Inverter 2A Over Temp Ambient

Inverter 2B Over Temp Ambient

Inverter 3A Over Temp Ambient

Inverter 3B Over Temp Ambient

Inverter 1A No Input Power

Inverter 1B No Input Power

Inverter 2A No Input Power

Inverter 2B No Input Power

Inverter 3A No Input Power

Inverter 3B No Input Power

Inverter ID reading fault

Inverter Module 3 Section A is over temperature; Operating with side panels removed, Check for restricted air ﬂow, clogged radiator; Defective fan; If problem persists replace inverter module.

Inverter Module 3 Section B is over temperature; Operating with side panels removed, Check for restricted air ﬂow, clogged radiator; Defective fan; If problem persists replace inverter module.

Inverter circuitry is over temperature likely cause is ambient greater than 40 deg C; Reduce power supply cutting Duty Cycle; Reduce ambient air temperature; Add auxiliary cooler.

Inverter section may have no input power. Contactor W1 not closed; Defective contactor or CB4 tripped; Inverter section input not connected; Defective Inverter.

Inverter section may have no input power. Contactor W2 not closed; Defective contactor or CB4 tripped; Inverter section input not connected; Defective Inverter.

CCM found ID values inconsistant during reading. CCM to an Inverter section ribbon damaged or disconnected; Inproper ribbon cable routing.

Remedy / Comments

Manual 0-5275 OPERATION 4-17

ULTRA-CUT 400 XT

CCM Status Code

Code Message Remedy / Comments

Group 3 -- Gas Controller Status & Protocol

301

302 Gas Control reply fault

303

304 Gas Control Purging Normal following power up or returning from Plasma Disable. Wait for purge to ﬁnish. 305 Gas Control protocol error 306 Not used Reserved for other future use. 307 Gas Control sequencing error Verify Firmware revision for compatibility with GCM 2010 308 Gas Control Type Mismatch Wrong CCM (Auto-Cut or Pak 200 type?) for Ultra-Cut; Install correct CCM

309 Gas Control command fault

310 * DPC fault Check DPC status indicator for speciﬁc problem 311 * DPC valve control fault Check DPC status indicator for speciﬁc problem 312 * DMC fault Check DMC status indicator for speciﬁc problem 313 * Gas Controller not conﬁgured. DMC or DPC not conﬁgured for a process or locked; See DMC and DPC status

* Applies to DFC 3000 (Auto Gas) only

Gas control communication fault

Gas Supply Pressure out of range.

Problem with ﬁber optic cable to GCM 2010; Dirt on ﬁber ends or in connectors; blow out with clean dry air. Fiber not locked into connector; Sharp bends in ﬁber cable; Fiber defective; GCM 2010 circuit board defect;

GCM 2010 inlet plasma or shield pressure low or defective pressure sensors PS3 & PS4; Defective GCM 2010 PCB.

Verify Firmware revision for compatibility with GCM 2010

Verify Firmware revision for compatibility with GCM 2010; Electromagnetic interference with Arc Starter; inspect grounding; bonding; and isolation

CCM Status Code

Code Message Remedy / Comments

Group 4 -- Torch Coolant System

401

402

403

404

405

406

Coolant Level low

Low coolant ﬂow

Coolant overheated

Coolant System not ready.

Low Coolant Level Warning

Coolant Flow Low Warning.

Check coolant level, add as needed. Defective or disconnected level sensor.

Coolant ﬂow as measured by ﬂow switch FS1 is less than 0.7 gpm (0.25 for Pak200i); Clogged ﬁlter; Restriction in torch lead or head; Wrong style consumables; Bad O-ring on the torch check valve; broken or defective torch coolant tube/check valve; Defective pump or bypass valve. 402 code along with 104 code is probably a low ﬂow problem.

Coolant supply temperature exceeded 75 degrees Celcius (167F). Operating with side panel loose or removed; Air ﬂow blocked at air inlet or exit of power supply; Coolant fan failed; radiator ﬁns clogged with dirt.

Proper coolant ﬂow of 0.7 gpm as measured by ﬂow switch FS1 was not obtained during up to 4 minutes of Priming. New installation can require additional Priming cycle(s) to ﬁll hoses with coolant; cylce power to restart Priming; Coolant hoses or torch hoses reversed; Clogged coolant ﬁlter; Restriction in torch lead or head; Wrong style consumables; broken or defective torch coolant tube/check valve; Defective or disconnected FS1 ﬂow SW; Defective pump or bypass valve.

Low coolant level during cut, does not stop cut. Add coolant as required.

This is a warning, does not stop system operation. Coolant ﬂow rate lower than expected. Can be caused by gas bubbles being introduced into the coolant or wrong or mismatched or worn consumable parts; Failed seals in torch cartridge or torch body; Clogged coolant ﬁlter; Restriction in torch lead or head; defective or disconnected FL1 ﬂow sensor.

Coolant over-

407

4-18 OPERATION Manual 0-5275

heated, high ambient.

Coolant supply temperature exceeded 75 degrees Celsius (167 Fahrenheit) likely cause ambient greater than 40 degrees Celsius (104 Fahrenheit); Reduce cutting duty cycle; Reduce ambient temperature; Add separate coolant cooler.

ULTRA-CUT 400 XT

No Group 5 (500) status codes with GCM 2010 system.

CCM Status Code

Code Message Remedy / Comments

Group 6 -- CCM

601 Analog Voltage Error Defective CCM, replace. 602 ADC or DAC error Defective CCM, replace. 603 Reserved No information available; Contact customer service 604 Data Memory error Defective CCM, replace. 605 Program memory fault Defective CCM, replace. 606 +5V Logic supply low Defective CCM, replace. 607 Processor over temperature Reduce ambient temperature; Defective CCM; replace

608

609 Firmware Update Device Error Defective CCM; replace 610 Firmware Update Protocol Error Defective CCM; replace 611 USB Controller Fault Defective CCM; replace

612

613

614

615

616

617 618 ADC Calibration Fault Error too large calibrating ADC; Fault persists defective CCM; 619 Flow Switch Fault Flow switch reporting coolant ﬂow when pump off;

620

621 USB Format Fault

622 CCM Code Execution Fault

5V supply for RS 485/422 communication low.

USB Power Fault

USB Log Creation Fault

No USF File

No CCM Update File

DPC Update Fault

DMC Update Fault

Non Volatile Memory Error

Defective CCM, replace.

Faulty USB device plugged into USB port, remove; Defective CCM Unable to create Log ﬁle on USB Flash drive last ﬁrmware update at-

tempt; Use different USB Flash Drive or Reformat File VTCCMFW.USF missing from Flash Drive; Add proper ﬁles to Flash

Drive for Firmware Update; Use different USB Flash Drive or Reformat CCM Firmware ﬁle speciﬁed in VTCCMFW.USF not found ; Add proper

ﬁles to Flash Drive for Firmware updating Fault occurred attempting to update DPC ﬁrmware; Add proper ﬁles to

USB Flash drive for Firmware updating; Refer to CCM_LOG.TXT on Flash Drive for details

Fault occurred attempting to update DMC ﬁrmware; Add proper ﬁles to USB Flash drive for Firmware updating; Refer to CCM_LOG.TXT on Flash Drive for details

Non Volatile Memory Storage Corrupted and Erased; Fault persists defective CCM.

A USB ﬂash drive was detected but could not be read by CCM. Backup any ﬁles currently on ﬂash drive, reformat the USB ﬂash drive to a FAT or FAT32 ﬁle system, replace only the CCM update ﬁles and try again. Use different USB ﬂash drive formatted with FAT or FAT32 ﬁle system.

Possible EMI noise problem or code fault. Check for proper grounding and bonding of equipment and routing of torch leads and cables to reduce Electromagnetic Emission Interference onto CCM module. If problem persists, verify CCM code version is the latest supported revision. Replace CCM module.

Manual 0-5275 OPERATION 4-19

ULTRA-CUT 400 XT

CCM Status Code

Code Message Remedy / Comments

Group 7 -- Options

1 Torch isolation contactor W5 appears closed when expected to be

701 Isolation Contactor Fault

702 Contact Start consumable fault

703

704 Contact Start pressure fault

705 Contact Start Cartridge fault

Contact Start detection circuit fault

open. Contacts may fused or, W5 could be energized, 24 VAC on it's coil, when it should not be due to faulty Relay PCB.

Prior to 1 torch preﬂow there should be continuity from the electrode, through the start cartridge, to the tip. Failure may be due to worn or missing consumable or Start Cartridge. Inspect, clean or replace.

In the 1 Torch module K201 should energize when W5 does. Either it failed to energize or the pressure switch PS2 is failed closed.

Pressure switch PS2 detects less than 35 PSI. Normal pressure is 75-85 PSI. No air connected to the 1 Torch module inlet or it's too low pressure; if using optional single stage ﬁlter the element may need cleaning or replacement, refer to maintance section. ;1 Torch pressure regulator set too low; 1 torch module solenoid SOL4 has failed; Relay PCB does not apply 24 VAC to SOL4.

Air pressure should seperate the Start Cartridge from the tip to initiate pilot. Failure may be stuck or damaged cartridge or consumables. Clean or replace. Or no DC output from inverters, front panel DC LED does not come on.

4-20 OPERATION Manual 0-5275

ULTRA-CUT 400 XT

4.08 Remote Arc Starter Trouble Shooting

Arc Starter Trouble Shooting

Symptom Cause Check Remedy

Pilot return wire not connected

No Pilot ignition

Neon indicator on

Cap board lights

but no ignition.

No Pilot ignition:

Neon indicator

not illuminated.

Coolant Leaks

No cooling or

insuf¬ﬁcient cool-

ing: No Coolant

Flow

Erratic System

Behavior(EMI

Interference

at torch head or broken in torch lead

Coolant has become conductive Use conductivity meter

High Frequency cap (C4 on Cap PCB) possibly open wires disconnected.

Negative supply cable not connected correctly

Pilot return wire not connected or loose in arcstarter.

No 120V supply, CB4 of plasma rear panel tripped

Electronic Ignition module shorted input

No 120V supply, CB4 not tripped

Faulty Electronic Ignition module

Loose ﬁtting(s) Visual inspection Tighten ﬁttings. Damaged or punctured coolant

line(s).

Supply & return hose reversed

Blockage in supply/return hoses

Missing or loose ground connection

Torch Lead Shield not connected or loose. F1 gnd cable not connected.

Cap board ground screw not tight or missing.

Cap C5 or C7 (on Cap PCB) open or disconnected wires to Cap board.

Visual inspection, continuity check Connect Wire or replace leads.

Flush system, replace coolant.

Use capacitance meter Reconnect or replace.

Visual inspection Reconnect

Visual inspection Connect Wire.

Reset breaker, check for 120 VAC at the module’s 115V terminals during ignition time.

Resistance measurement, good module measures about 45 ohms

check for 120 VAC at the plasma supply’s rear panel connector J597 & 9 during ignition time.

Check for 120 VAC at the modules 115V terminals during pilot ignition time

Visual inspection Replace Coolant Lines

Visual Inspection of color-coded connections

Loosen ﬁtting slightly and check for coolant ﬂow

Visual inspection of ground wire to Arc Starter

Visual inspection of lead shield attachment to Arc Starter

Visual inspection Tighten or replace.

Visual inspection / capacitor measurement

Check for shorted cable, defective circuit breaker, shorted ignition module input. (see next symptom)

Replace bad module

120V present - open control cable, 120V not present - fault in plasma power supply

If 120 VAC is present but neon not illuminated, module is defective, replace module

Match coolant connection colors to arc starter ﬁtting colors.

Flush system or replace blocked hose.

Make or tighten connections to good ground.

Reconnect / tighten lead connectors.

Replace PCB.

Manual 0-5275 OPERATION 4-21

ULTRA-CUT 400 XT

This Page Intentionally Blank

4-22 OPERATION Manual 0-5275

ULTRA-CUT 400 XT

SECTION 5: MAINTENANCE

5.01 General Maintenance

Perform the following checks periodically to ensure proper system performance.

Power Supply Maintenance Schedule

Daily

Check coolant level; add coolant as needed.

Check gas hose connections and pressures.

Check cooling fan; clean as needed.

Weekly

Check O-Rings in Torch and Cartridge

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.

Clean water lter (if using H2O Mist)

Six Months

Clean or replace coolant lter.

Clean coolant tank.

Vacuum out any dust buildup inside power supply.

5.02 External Coolant Filter Cleaning Procedure

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

Clean the coolant ﬁlter as follows:

1. Disconnect system from main input power.

2. Unscrew and remove the ﬁlter canister by hand. Large canister located at the back of the power supply. Be sure to keep the O-ring.

3. Inspect and replace ﬁlter as needed. Re-install the canister, tightening it by hand. Be sure the O-ring is in place.

4. Turn the system on and check for leaks.

Manual 0-5275 MAINTENANCE 5-1

ULTRA-CUT 400 XT

5.03 Coolant Replacement Procedure

Replace coolant as follows:

1. Disconnect the system from main input power.

2. Remove the two right side panels.

3. Locate the coupling in the coolant line that comes from the bottom of the coolant tank, #1 in the following illustration. Disconnect the coolant line at this ﬁtting and drain the coolant into a disposable container of sufﬁcient size. Remember you will be draining more than the contents of the coolant reservoir.

4. Once coolant is draining, disconnect the gray hose coupling #2 in the illustration below. Allow excess coolant to drain, then apply a maximum of 5psi to clear the lines.

CAUTION

Applying more than 5 psi air pressure to the cooling system will result in damage. Extra caution must be used when performing this task.

Art # A11689

5. Reconnect those two ﬁttings and then remove the ﬁlter bowl from the canister at the rear of the power supply. Pour this remaining coolant into the container and replace the ﬁlter bowl.

NOTE!

If you also need to replace the coolant still in the leads, disconnect the leads from the power supply and manually drain them.

6. Fill the tank with fresh coolant until the right level is reached checking for leaks.

7. Turn system on, let it run for a few minutes and check coolant level, reﬁll as needed. Refer to Section 3:22 Complet the Installation on the procedure for this.

8. Install the side panels.

5-2 MAINTENANCE Manual 0-5275

ULTRA-CUT 400 XT

SECTION 6: REPLACEMENT ASSEMBLIES & PARTS

6.01 Replacement Power Supply

Complete Unit / Component Catalog Number

Ultra-Cut 400 XT™ Power Supply, 480V +10 -15% 3-8120-2

Ultra-Cut 400 XT™ Power Supply, 480V +10 -15% with SL100 interface 3-8120-2T

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

(Requires GCM 2010 Firmware version 3.1 or higher)

Remote Arc Starter (RAS-1000 XT) 3-9130E

OPTIONAL EQUIPMENT:

Wheel Kit 9-7378

Manual 0-5275 REPLACEMENT PARTS 6-1

ULTRA-CUT 400 XT

6.02 System Layout

Refer to section 3.05 for ground connections and ground cables.

175’ / 53.3 m Maximum Length

Primary power

CNC

Art # A-11940

Pilot Return #8

Coolant Supply 10’

Coolant Return 10’

Control Cable

Ultra-Cut

XT Power

Supply

Fiber

Optic

Cable

Control

Cable

125’ / 38.1 m Maximum Length

Negative Cable

Control Cable

HE 400

Heat Exchanger

Gas Control

Module

Coolant Supply

Coolant Return

Plasma Gas

Shield Gas

Preflow Gas

Control

Cable

Water Shield

Remote

Torch

Valve

Assembly

Work Cable

50’ / 15.25 m Maximum Length

Pilot Return

Arc

Starter

Coolant Supply

Coolant Return

Plasma Gas Shield Gas

Shield

Positioning Tube

Torch

Work

175’ / 53.3 m Maximum Length

6.03 Recommended Gas Supply Hose

Item # Qty Description Catalog #

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

6-2 REPLACEMENT PARTS Manual 0-5275

ULTRA-CUT 400 XT

6.04 Leads And Cables All Amperages

#8 AWG Cable

Pilot Return, Power Supply to Arc Starter

Art # A-11873_AB

E,Y 14/7

Green

Red

3/0 AWG Cable (95 mm

Green / Yellow # 4 AWG

Green / Yellow 1/0 (50 mm )

)

Green

Red

Negative Lead, Power Supply to Arc Starter

Coolant Supply Lead, Power Supply to Arc Starter

Coolant Return Lead, Power Supply to Arc Starter

E - Control Cable, Power Supply to Arc Starter

Y - Control Cable to Heat Exchanger

Ground Cable

Ground Cable, Remote Arc Starter To Earth Ground

Shielded Torch Lead Assembly, Remote Arc Starter to Torch

Plasma Gas Lead, Torch Valve to Torch

H, Q, R, S,T

3/0 (95 mm ) Cable

Shield Gas Lead, Torch Valve to Torch

Control Cable, Power Supply to Gas Control Module

Fiber Optic Cable, Power Supply to Gas Control Module

Work Cable

CNC Cable (37 Wire)

Manual 0-5275 REPLACEMENT PARTS 6-3

ULTRA-CUT 400 XT

H,Q,R,S,T Gas Lead Set (Note 2) 4-3035 4-3036 4-3037 4-3051 4-3038 4-3039 4-3040 4-3041 4-3042 4-3043

Q Shield Gas Hose 9-7277 9-7278 9-7279 9-7280 9-7281 9-7282 9-7283 9-7284 9-7285 9-7286

H Plasma Gas Hose 9-7103 9-7104 8-0149 9-7270 9-7271 9-7272 9-7273 9-7274 9-7275 9-7276

R Pilot Gas/Pre-Flow Hose 9-6956 9-6957 9-6958 9-6959 9-6960 9-6961 9-6962 9-6963 9-6964 9-7080 9-7081 9-4876 9-4877

S Control Cable 9-4878 9-4753 9-4755 9-4756 9-4757 9-4758 9-4759 9-4760 9-4761 9-4879 9-4880 9-4881

T Water Shield 9-6985 9-6986 9-6988 9-6996 9-6992 9-6993 9-7073 9-7074 9-7075 9-7076

NOTE 1: Supply lead sets inslude Pilot Return Cable, Negative Cable, Coolant Supply & Return Hoses and Control Cable.

NOTE 2: Gas lead sets include Plasma Gas Hose, Shield Gas Hose and Preow Gas Hose not combined.

O Work Cable 9-7350 9-7351 9-7352 9-7353

Control Cable, CNC to

L Control Cable Fiber Optic 9-4898 9-4899 9-4900 9-9335 9-4901 9-4902 9-4903 9-4904 9-4905 9-4906

Control Cable, PS to

GCM

J Shield Lead 9-3334

I Plasma Lead 9-3333

G Assembly, Torch Lead 4-5200 4-5201 4-5202 4-5203 4-5204 4-5205 4-5206 4-5207 4-3016

to Earth

Ground Wire, Remote AS

F Ground Wire, PS to GCM 9-4923 9-4924 9-4925 9-4926 9-4927 9-4928 9-4929 9-4930

Starter

Control Cable to Arc

C Hose, Coolant Supply 9-4805 9-4887 9-4806 9-4807 9-9424 9-4808 4-3202 9-4809 9-4810 9-4812

D Hose, Coolant Return 9-4813 9-4889 9-4814 9-4815 9-9425 9-4816 4-3203 9-4817 9-4818 9-4820

B Negative Cable 9-7356 9-7357 9-7358 9-7359 9-7360 9-7361 4-3201 9-7362 9-7363 9-7364

A Pilot Return Cable 9-4890 9-4891 9-4790 9-4791 9-9426 9-4792 4-3200 9-4793 9-4794 9-4796

A,B,C,D,E Supply Lead Set (Note 1) 4-3096 4-3097 4-3098 4-3099 4-3100 4-3101 4-3105 4-3102 4-3103 4-3104

Key Description

9-7368 9-7369 9-7370 9-7371 9-7372

9-4907 9-4908 9-4909 9-9332 9-4910 9-4911 9-4912 9-4913 9-4914

9-4931 9-4932 9-4933 9-4934 9-4935 9-4936 9-4937 9-4938

9-4941 9-4916 9-4917 9-4918 9-9428 9-4942 4-3205 9-4943 9-4944 9-4922

1.2 m 4 ft

3.05 m 10 ft

4.5 m

15 ft

20 ft

6 m

7.6 m

25 ft

9.1 m

30 ft

10.6 m 35 ft

12 m

40 ft

15.2 m 50 ft

Ultra-Cut XT Leads

18.3 m 60 ft

22.8 m 75 ft

30.5 m

100 ft

38.1 m

125 ft

45.7 m

150 ft

53.3 m

175 ft

6-4 REPLACEMENT PARTS Manual 0-5275

ULTRA-CUT 400 XT

6.05 Power Supply External Replacement Parts

Item # Qty Description Catalog #

1 1 Power and Leads Cable Cover 9-7346

2 1 Top Panel, 9-7300

3 1 Upper Side Covers 9-7301

4 1 Lower Left Side Panel 9-7304

5 1 Lower Right Side Panel (300A/400A) 9-7344

6 1 Lifting Eye 9-9373

Art # A-11968

3 3

Manual 0-5275 REPLACEMENT PARTS 6-5

ULTRA-CUT 400 XT

6.06 Power Supply Replacement Parts - Upper Right Side

Item # Qty Description Ref. Des. Catalog #

1 1 System Bias PCB 9-9253

2 1 Pilot PCB 9-9250

3 1 CCM Assembly 9-7335

4 1 Relays, Pump / Fan MC3 / MC2 9-7314

5 1 Relay, Inrush Control K1 9-7336

6 1 Relay, Inrush MC1 9-7337

7 1 Resistor, Inrush R2 9-7376

8 1 Display PCB 9-9252

9 1 Auxiliary Transformer T1 9-7315

10 1 On/Off Switch Breaker CB1 9-7316

11 1 Relay and Interface PCB 9-9251

7 6

6-6 REPLACEMENT PARTS Manual 0-5275

Art # A-11546_AB

ULTRA-CUT 400 XT

Art # A-11984_AB

6.07 Power Supply Replacement Parts - Lower Right Side

Item # Qty Description Ref. Des. Catalog #

1 1 Coolant Tank, Cap 8-5124

2 1 Coolant Tank 9-7306

3 1 Sensor, Coolant level 9-7307

4 1 Pump, Coolant, Assembly (with motor) 9-7309

1 Pump, Coolant, Assembly (no motor) 9-7422

5 1 Motor, Pump (motor only) 9-7424

6 1 Heat Exchanger Fan 9-7348

7 1 Radiator 9-7349

8 1 Flow, Switch (Not shown) FS1 9-7310

9 1 Bubble (ﬂow) Sensor (Not shown) FL1 9-9297

10 1 Current Transducer, 300A (Not shown) HCT1 W7005324

Manual 0-5275 REPLACEMENT PARTS 6-7

ULTRA-CUT 400 XT

6.08 Power Supply Replacement Parts - Rear Panel

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

1 1 Coolant Filter Assy 9-7320

2 1 Coolant Filter 9-7321

3 1 Fuse, 8A SB 500 VAC 9-7377

J55 - GCM

J15 - CNC

USER INPUT

HEIGHT CONTROL

J54 - TSC /COMM

J59 - RAS

J70 - HE

F1 - 8A SB 500 VAC F2 - 8A SB 500 VAC

CB2 - 5A 120 VAC

CB3 - 5A 24 VAC

CB4 - 5A 120 VAC

Art # A-11549_AC

6-8 REPLACEMENT PARTS Manual 0-5275

ULTRA-CUT 400 XT

6.09 Power Supply Replacement Parts - Left Side

Item # Qty Description Ref. Des. Catalog #

1 1 AC Suppresion PCB 9-9254

2 1 Main Contactor (2 total) W1, W2 9-7318

3 1 Inverter Module, Full 480 VAC (3 total) 9-7330

Art # A11990

Manual 0-5275 REPLACEMENT PARTS 6-9

ULTRA-CUT 400 XT

Art # A-07030_AB

6.10 Gas Control Module (GCM-2010) Replacement Parts

Item # Qty Description Catalog #

1 6 7W Solenoid for O2 use 9-9393 2 1 Gas Selection Manifold Assembly 9-9391 3 1 Check Valve, 1/4 NPT .5 PSI 9-9390 4 1 Mode Switch Assembly 9-9406 5 1 Gas Selection Switch Assembly 9-9403 6 1 LCD Interface PC Board 9-9408 7 1 Rotary Encoder (Switch) 9-9398 8 1 Toggle Switch 9-3426 9 1 Solenoid / Logic PC Board 9-9409 10 1 Cover 9-9410 11 3 Gauge, 0-160 psi 8-6800 12 1 Regulator 8-3223 13 1 Pressure Transducer and wire harness 100 PSI 9-9407 14 2 Pressure Transducer and wire harness 250 PSI 9-9508

NOT SHOWN: 1 Torch Valve Assembly Wire Harness (J13 to J57) 9-9399 1 Power Supply Connection Wire Harness (J3 & J5 to J56) 9-9400 1 LCD Interface PC Board Wire Harness 9-9401 1 Rotary Encoder (Switch) Wire Harness 9-9402 1 Solenoid Drive A Wire Harness (J12 to Solenoids 1-6) 9-9404 1 Solenoid Drive B Wire Harness (J1 to Solenoids 7-12) 9-9405

6-10 REPLACEMENT PARTS Manual 0-5275

Thermal Dynamics ULTRA-CUT 400 XT, Ultra-Cut 300 XT Operating Instructions Manual

Specifications and Main Features

Frequently Asked Questions

User Manual