Tweco 150 User Manual

150

™

ULTRA-CUT

PLASMA CUTTING SYSTEM

Art # A-04816

Operating Manual

Rev. AJ Date: October 29, 2007 Manual # 0-4800
Operating Features:

WE APPRECIATE YOUR BUSINESS!

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

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

YOU ARE IN GOOD COMPANY!

The Brand of Choice for Contractors and Fabricators Worldwide.

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

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

Above all, we are committed to developing technologically
advanced products to achieve a safer working environment within
the welding industry.

!

WARNINGS

Read and understand this entire Manual and your 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® 150

Operting Manual No. 0-4800
Published by:
Thermadyne Corporation
82 Benning Street
West Lebanon, New Hampshire, USA 03784
[phone]

www.thermal-dynamics.com

© Copyright 2005, 2006,2007 by
Thermadyne Corporation

All rights reserved.

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

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

Printed in the United States of America

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

Publication Date: October 29, 2007

Record the following information for Warranty purposes:

Where Purchased: ___________________________________

Purchase Date:______________________________________

Power Supply Serial #:_______________________________

Torch Serial #:_____________________________________

This page intentionally blank

TABLE OF CONTENTS

SECTION 1:

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

C. Creating An Earth Ground ............................................................................3-16

K. Connect Coolant Leads ................................................................................ 3-17

L. Connect Control Cables for CNC, Remote Arc Starter, and GCM ................. 3-18

M. Gas Control Module Installation ................................................................... 3-21

N. Fiber Optic Cable Installation .......................................................................3-22

O. Gas Control Module: Control, Input, and Output Connections .......................3-25

P. Install Remote Arc Starter ...........................................................................3-26

Q. Original & XTL Torch Valve Installation.........................................................3-35

R. Connecting Torch ......................................................................................... 3-37

S. Install Consumable Torch Parts .................................................................... 3-38

T. Complete the Installation .............................................................................3-41

TABLE OF CONTENTS (continued)

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

TABLE OF CONTENTS (continued)

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

APPENDIX 9: Schematic: 230/460V Unit w/ Chopper Pilot w/ Diode ........................................ A-14

APPENDIX 10: Schematic: 230/460V Unit w/ Resistor Pilot ..................................................... A-16

APPENDIX 11: Schematic: CCC 400V Unit w/ Chopper Pilot ................................................... A-18

APPENDIX 12: Schematic: CE 400V Unit w/ Chopper Pilot ..................................................... A-20

APPENDIX 13: Schematic: CE 400V Unit w/ Resistor Pilot ..................................................... A-22

APPENDIX 14: Schematic: CSA 600V Unit w/ Chopper Pilot ................................................... A-24

APPENDIX 15: PUBLICATION HISTORY ................................................................................ A-26

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

NOTE
Section 8, Torch operation, is provided separately.

TABLE OF CONTENTS (continued)

SECTION 1:

GENERAL INFORMATION

1.01 Notes, Cautions and Warnings

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

NOTE

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

CAUTION

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

WARNING

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

1.02 Important Safety Precautions

WARNINGS

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

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

To prevent possible injury, read, understand and follow all warnings, safety precautions and instructions
before using the equipment. Call 1-603-298-571 1 or your local distributor if you have any questions.

GASES AND FUMES

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

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

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

• The kinds of fumes and gases from the plasma arc depend on the kind of metal being used, coatings on the metal,
and the different processes. Y ou must be very careful when cutting or welding any met als which may contain one
or more of the following:

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

Manual 0-4800 1-1 GENERAL INFORMATION

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

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

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

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

• Phosgene, a toxic gas, is generated from the vapors of chlorinated solvents and cleansers. Remove all sources
of these vapors.

• This product, when used for welding or cutting, produces fumes or gases which contain chemicals known to the
St ate of California to cause birth defects and, in some cases, cancer. (California Health & Safety Code Sec.

25249.5 et seq.)

ELECTRIC SHOCK

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

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

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

• Repair or replace all worn or damaged parts.

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

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

• Disconnect power source before performing any service or repairs.

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

FIRE AND EXPLOSION

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

• Be sure there is no combustible or flammable material in the workplace. Any material that cannot be removed
must be protected.

• Ventilate all flammable or explosive vapors from the workplace.

• Do not cut or weld on containers that may have held combustibles.

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

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

NOISE

Noise can cause permanent hearing loss. Plasma arc processes can cause noise levels to exceed safe limits. Y o u
must protect your ears from loud noise to prevent permanent loss of hearing.

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

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

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

GENERAL INFORMATION 1-2 Manual 0-4800

PLASMA ARC RAYS

Plasma Arc Rays can injure your eyes and burn your skin. The plasma arc process produces very bright ultra violet and
infra red light. These arc rays will damage your eyes and burn your skin if you are not properly protected.

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

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

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

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

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

Arc Current Shade No. Shade No.

Less Than 300* 8 9

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

Minimum Protective Suggested

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

1.03 Publications

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

1. OSHA, SAFETY AND HEALTH STANDARDS, 29CFR 1910, obtainable from the Superintendent of Documents,
U.S. Government Printing Office, Washington, D.C. 20402

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

3. NIOSH, SAFETY AND HEAL TH IN ARC WELDING AND GAS WELDING AND CUTTING, obtainable from the Super­intendent of Documents, U.S. Government Printing Office, Washington, D.C. 20402

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

5. ANSI Standard Z41.1, STANDARD FOR MEN’S SAFETY- TOE FOOTWEAR, obt ainable from the American National
Standards Institute, 1430 Broadway, New York, NY 10018

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

7. AWS Standard A6.0, WELDING AND CUTTING CONTAINERS WHICH HAVE HELD COMBUSTIBLES, obtainable
from American Welding Society, 550 N.W. LeJeune Rd, Miami, FL 33126

8. NFPA Standard 51, OXYGEN-FUEL GAS SYSTEMS FOR WELDING, CUTTING AND ALLIED PROCESSES, ob­tainable from the National Fire Protection Association, Batterymarch Park, Quincy, MA 02269

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

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

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

12.CSA St andard W1 17.2, CODE FOR SAFETY IN WELDING AND CUTTING, obtainable from the Canadian St andards
Association, Standards Sales, 178 Rexdale Boulevard, Rexdale, Ontario, Canada M9W 1R3

Manual 0-4800 1-3 GENERAL INFORMATION

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

14. American Welding Society Standard AWSF4.1, RECOMMENDED SAFE PRACTICES FOR THE PREPARATION
FOR WELDING AND CUTTING OF CONTAINERS AND PIPING THAT HAVE HELD HAZARDOUS SUBSTANCES,
obtainable from the American Welding Society, 550 N.W. LeJeune Rd, Miami, FL 33126

15.ANSI Standard Z88.2, PRACTICE FOR RESPIRATORY PROTECTION, obtainable from American National Stan­dards Institute, 1430 Broadway, New York, NY 10018

GENERAL INFORMATION 1-4 Manual 0-4800

1.04 Declaration of Conformity

Manufacturer: Thermal Dynamics Corporation
Address: 82 Benning Street

West Lebanon, New Hampshire 03784
USA

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

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

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

National Standard and Technical Specifications

The product is designed and manufactured to a number of standards and technical requirements. Among them are:

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

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

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

associated accessories.

* CENELEC EN50199 EMC Product Standard for Arc Welding Equipment

* For environments with increased hazard of electrical shock, Power Supplies bearing the S mark conform to

EN50192 when used in conjunction with hand torches with exposed tips, if equipped with properly installed stand­off guides.

* Extensive product design verification is conducted at the manufacturing facility as part of the routine design and

manufacturing process. This is to ensure the product is safe, when used according to instructions in this manual and
related industry standards, and performs as specified. Rigorous testing is incorporated into the manufacturing
process to ensure the manufactured product meets or exceeds all design specifications.

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

Manufacturers responsible representative: Steve Ward

Operations Director
Thermadyne Europe
Europa Building
Chorley N Industrial Park
Chorley, Lancashire,
England PR6 7BX

Manual 0-4800 1-5 GENERAL INFORMATION

1.05 Statement of Warranty

LIMITED WARRANTY : Thermal Dynamics® Corporation (hereinafter “Thermal”) warrants that its products will be free of defects in workmanship

or material. Should any failure to conform to this warranty appear within the time period applicable to the Thermal products as stated below ,
Thermal shall, upon notification thereof and substantiation that the product has been stored, installed, operated, and maintained in accordance
with Thermal’s specifications, instructions, recommendations and recognized standard industry practice, and not subject to misuse, repair,
neglect, alteration, or accident, correct such defects by suitable repair or replacement, at Thermal’s sole option, of any components or parts
of the product determined by Thermal to be defective.

THIS WARRANTY IS EXCLUSIVE AND IS IN LIEU OF ANY W ARRANTY OF MERCHANTABILITY OR FITNESS FOR A P ARTICULAR PURPOSE.
LIMITA TION OF LIABILITY : Thermal shall not under any circumstances be liable for special or consequential damages, such as, but not limited

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

THIS WARRANTY BECOMES INV ALID IF REPLACEMENT P ARTS OR ACCESSORIES ARE USED WHICH MA Y IMP AIR THE SAFETY OR
PERFORMANCE OF ANY THERMAL PRODUCT .

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

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

AutoCut

Parts

©

and UltraCut© Power Supplies and Components 2 Years 1 Year

Labor

Torch And Leads

TM

XT

-300 / XTTM-301 T orch (Excluding Consumable Parts) 1 Y ear 1 Year

Repair/Replacement Parts 90 Days 90 Days

Warranty repairs or replacement claims under this limited warranty must be submitted by an authorized Thermal Dynamics® repair facility within
thirty (30) days of the repair. No transport ation costs of any kind will be paid under this warranty . T ransportation charges to send products
to an authorized warranty repair facility shall be the responsibility of the customer. All returned goods shall be at the customer’s risk and
expense. This warranty supersedes all previous Thermal warranties.

Effective August 19, 2005

GENERAL INFORMATION 1-6 Manual 0-4800

SECTION 2: SPECIFICATIONS

General Description Of The System

A typical Ultra-Cut® 150 system configuration includes:

• One Power Supply

• Remote Arc Starter

• Gas Control Module

• Torch Valve Assembly

• Precision Plasma Cutting Torch

• Set Of Connecting Leads

• Torch Spare Parts Kit

The components are connected at installation.

Plasma Power Supply

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

Remote Arc Starter

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

Gas Control Module

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

Precision Plasma Cutting Torch

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

Manual No. 0-4800 2-1 SPECIFICATIONS

Specifications & Electrical Requirements

UItraCut 150 Specifications & Design Fea tures

Max OCV (U0) 380 vdc
Minim um Out put Current 10 Amps
Max Out put Current 150 Amps
Output V oltage 60 - 230 vdc
Duty Cy c l e Rati ng 100% @ 150A, 180V
Ambi ent Temperature
for Dut y Cy cl e Ra ting
Operating range 14°F to 122°F (-10°C to + 50°C)
Power Fac t or 0.70 @ 100 A DC Out put
Cooling Forced A i r (Class F)

Input Power Input Current

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

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

208 60 23 105 125
230602498110
40050285875

400 (CE) 50 28 58 75

46060265775

Line Voltages wi t h S ugges ted Circuit Prot ecti on and W i re S izes

Bas ed on Nati onal E l ectri c Code and Canadian Elec tric al Code

1

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

2

Extra Hard Usage Type G, G-GC, W

104F° (40°C)

Ultr a-Cu t 150

Power Supply

Sugges t ed S i z es (See Not e)

2

#4

2

#4

1

#4

1

#4

1

#4

System Component Layout

125’ / 38.1 m Maximum Length

Pilot Return

Negative

Coolant Supply

Primary power

CNC

Art # A-07233

Power
Supply

P

F

Coolant Return

Control Cable

Fiber
Optic

Cable

Control

Cable

175’ / 53.3 m Maximum Length

L

K

F

Gas Control

Module

175’ / 53.3 m Maximum Length

A

B

Remote

C

D

E

Plasma Gas

Shield Gas

Preflow Gas

Control Cable

Water Shield

Work Cable

H

Q

R

S

T

O

Arc

Starter

Assembly

100’ / 30.5 m Maximum Length

Pilot Return

Shield

Coolant Supply

Coolant Return

F1

Plasma Gas

Torch

Valve

Shield Gas

Shield

I

J

Positioning Tube

Torch

Work

G

Manual No. 0-4800 2-2 SPECIFICATIONS

Power Supply Dimensions

41.25 inch
1050 mm

27 inch
680 mm

Art # A-07182

33 inch
840 mm

37.75 inch
960 mm

27.5 inch
700 mm

433 lb / 196 kg

Manual No. 0-4800 2-3 SPECIFICATIONS

Power Supply Rear Panel Features

Gas Control

Console Connector

CNC Connector

Remote Arc Starter

Connector

Coolant Connections

Coolant Filter

Pilot (Pos) Terminal

Circuit Breaker

Panel

RETURN

SUPPLY

Torch (Neg) Terminal

AC Power Lamp

Input Power

Terminals

Ground Terminals

Terminal Cover

Work Cable Terminal

Terminal Cover

Support Panel

Coolant Tank

Leads
Bracket

Art # A-04794

Manual No. 0-4800 2-4 SPECIFICATIONS

Gas Requirements

The customer will provide all gases and pressure regulators. Gases must be of high quality. Pressure regulators
shall be double stage.

Ultra-Cut 150 Pow er Supply: Gas Pre ssures, Flows, and Qual i ty Require m e nts

Gas Qualit y Mi nim um P res sure Flow

O

(Oxygen)

2

99.5% Purity

(Liquid recommended)

120 psi

8.3 bar / 827 k Pa

70 scfh (1982 l/h)

99.5% Purity

N

(Liquid recommended)

(Nitrogen)

2

Compressed

or Bottled Air

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

65% A rgon

O (Water) See Note 2 50 psi (3. 5 bar) 10 gph (38 lph)

H

2

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

Note 1

<1000 ppm O

ppm H

2

O)

2

, <32

Clea n, Dry,

Free of Oil (see Note 1)

99.995% P urity

(gas recommended)

120 psi

8.3 bar / 827 k Pa

120 psi

8.3 bar / 827 k Pa

120 psi

8.3 bar / 827 k Pa

204 scfh (5777 l/h)

244 scfh (6910 l/h)

90 scfh (2550 l/h)

cont am i nat ion from c om pres sed or bott led ai r c an c ause fires in conjunc t i on wit h oxygen.
For filtering, a coales cing filt er able to filter t o 0. 01 m i c rons should be plac ed as close as

pos sible to the gas inlets on the Gas Control Module.

: The tap water source does not need to be deionized, but in water systems with ex tremely

Note 2

high mineral content a wat er s oftener is recom m ended. Tap water with high l evels of partic ul at e
matter mus t be filtered.

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

Note 3

Gas Applications

Ultra-Cut-150 Gas A ppli cati ons

MATERIAL

OPERATION

PREFLOW PLASMA SHIELD PREFLOW PLASMA SHIELD PREFLOW PLASMA SHIELD

30A CUT

50 A CUT

70 A CUT

85A CUT

100 A CUT

150A CUT

Manual No. 0-4800 2-5 SPECIFICATIONS

MILD STEEL ST AINL ES S S T EEL ALUMI N UM

GAS TYPEGAS TYPE GAS TYPE

Air

Air

Air

O

2

O

2

O

2

O

Air

Air

2

Air Air Air Air Air Air
N

2

N

2

H20N2N
Air Air Air Air Air Air
N

2

N

2

H20N2N
Air Air Air Air Air Air
N

2

N

2

H20N2N

Air Air Air
Air

Air O

N

2

2

AirO

Air

2

N

2

N

2

N

2

H

35

N

2

H

35

N

2

N

2

N

2

H20N2N

N

2

N

2

H20N2N

2

2

2

H

35

2

H

35

2

H20

H20

H20

N

H20

N

H20

2

2

XTTM-300 Torch Specifications

A. Torch Dimensions

End Cap

Art # A-04897

19.00"

482.68 mm

393.78 mm

15.50"

160.10 mm

6.30"

3.54"

89.87 mm

2.25"

57.15 mm

Mounting Tube

2.0"

50.8 mm

2.39"

60.81 mm

2.74"

69.55 mm

1.57"

39.96 mm

1.49"

37.8 mm

Manual No. 0-4800 2-6 SPECIFICATIONS

B. Torch Leads Lengths

Gas Lead Assemblies

C. Torch Parts (Generic Parts Shown)

Length

Feet Meters

10 3.05
15 4.6
25 7.6
35 10.6
50 15.2

75 22.8
100 30.4
125 38.2
150 45.7
175 53.3

Art # A-04741

Shield Gas

Distributor

Shield Cap

Shield Cup

Plasma Gas

Tip

Distributor

Electrode

Cartridge

D. Parts - In - Place (PIP)

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

E. Type of Cooling

Combination of gas stream through torch and liquid cooling.

Manual No. 0-4800 2-7 SPECIFICATIONS

F. XTTM-300 Torch Data (with Ultra-CutTM 150 Power Supply)

TM

XT

-300 Torch Ratings

for use with Ul tra-Cut 15 0 P o wer Suppl y

Ambient
Tempera ture
Duty Cy c l e 100% @ 150 Am ps
Maxi m um Current 150 Amps

Volt age (V

)500V

peak

Arc Striking Voltage 10kV
Current

TM

-300 Torch Gas Specifications

XT

Plasma Gases:

Shield Gases:

Operating Pres sure
Maxi m um Input P res s ure 135 psi / 9. 3 bar

Gas flow 10 - 300 s cfh

104° F
40° C

Up to 150 Amps, DC,
Straight Polarity

Compress ed Ai r, Oxygen,
Nitrogen, H35
Compress ed Ai r, Oxygen,
Nitrogen, Wat er
125 ps i ± 10 psi

8.6 bar ± 0.7 bar

G. Plasma Power Supply Used With:

• Thermal Dynamics UltraCut®150

Manual No. 0-4800 2-8 SPECIFICATIONS

SECTION 3: INSTALLATION

A. Installation Requirements

1. Electric Supply

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

Ultr a-Cu t 150

Input Power Input Current

Power Supply

Sugges t ed S i z es (See Not e)

Volt age Freq. 3-Ph 3-Ph Fus e (A m ps ) Wire (A WG)

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

208 60 23 105 125
230602498110
40050285875

400 (CE) 50 28 58 75

46060265775

#4
#4
#4
#4
#4

2
2
1
1
1

Line Voltages wi t h S ugges ted Circuit Prot ecti on and Wire Si zes

Bas ed on Nati onal E l ectri c Code and Canadian Electri c al Code

1

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

2

Extra Hard Usage Type G, G-GC, W

CAUTION

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

2. Gas Supply

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

• Reduced cutting speed

• Poor cut quality

• Poor cutting precision

• Reduced consumables life.

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

B. Cooling System Requirements

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

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

Coolant Capabilit i es

Cat. Number and Mixture Mixture Protects To

TM

7-3580 'Extra-Cool

7-3581 'Ultra-Cool

7-3582 'Ext reme Cool

* For mixing wit h D-I Cool

'

TM

'

TM

' Concent rate* -65° F / -51° C

TM

7-3583

Manual No. 0-4800 3-1 INSTALLATION

25 / 75 10° F / -12° C

50 / 50 -27° F / -33° C

C. System Layout

175’ / 53.3 m Maximum Length

Primary power

CNC

Art # A-07233

125’ / 38.1 m Maximum Length

Pilot Return

Negative

Coolant Supply

Power
Supply

P

F

Coolant Return

Control Cable

Fiber
Optic

Cable

Control

Cable

175’ / 53.3 m Maximum Length

L

Gas Control

K

F

Module

Plasma Gas

Shield Gas

Preflow Gas

Control Cable

Water Shield

Work Cable

A

B

Remote

C

D

E

H

Q

R

S

T

O

Arc

Starter

Torch

Assembly

100’ / 30.5 m Maximum Length

Pilot Return

Shield

Coolant Supply

Coolant Return

F1

Valve

Shield

Plasma Gas

Shield Gas

Positioning Tube

I

J

G

Torch

Work

Manual No. 0-4800 3-2 INSTALLATION

D. Cables & Leads Identification

B

D

E

F

F1

#8 AWG Cable

A

#1 AWG Cable

C

14

G

Green

Red

Green / Yellow # 4 AWG

Green / Yellow 1/0 (50 mm )

Green

Red

2

Pilot Return, Power Supply
to Arc Starter

Negative Lead, Power Supply
to Arc Starter

Coolant Supply Lead,
Power Supply to Arc Starter

Coolant Return Lead,
Power Supply to Arc Starter

Control Cable, Power Supply
to Arc Starter

Ground Cable

Ground Cable,
Remote Arc Starter
To Earth Ground

Shielded Torch Lead
Assembly, Remote
Arc Starter to Torch

Art # A-07473

I

J

K

L

H, Q,
R, S,T

O

P

37

14

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

Plasma Gas Lead,
Torch Valve to Torch

Shield Gas Lead,
Torch Valve to Torch

Control Cable,
Power Supply to
Gas Control Module

Fiber Optic Cable,
Power Supply to
Gas Control Module

2

CNC Cable (14 Wire)

Work Cable

Manual No. 0-4800 3-3 INSTALLATION

D. Lift the Power Supply

WARNINGS

Do not touch live electrical parts.

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

FALLING EQUIPMENT can cause serious personal injury and equipment damage.

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

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

Art # A-04796

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

Manual No. 0-4800 3-4 INSTALLATION

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

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

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

CAUTION

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

O
N

SW-1-1: Auto Pilot Restart. 1 = ON = Auto Pilot Function enabled.
1 = OFF = Auto Pilot Function disabled (Factory default setting).
SW-1-2: Pilot Delay 2 = OFF, 3 = OFF, 4 = OFF: 0 Seconds (Factory default setting).
SW-1-3: Pilot Delay 2 = ON, 3 = OFF, 4 = OFF: 0.1 Seconds
SW-1-4: Pilot Delay 2 = OFF, 3 = ON, 4 = OFF: 0.2 Seconds
2 = ON, 3 = ON, 4 = OFF: 0.4 Seconds
2 = OFF, 3 = OFF, 4 = ON: 0.8 Seconds
2 = ON, 3 = OFF, 4 = ON: 1.0 Seconds
2 = OFF, 3 = ON, 4 = ON: 1.5 Seconds
2 = ON, 3 = ON, 4 = ON: 2.0 Seconds

SW-3: Gas Preflow Time 1 = OFF, 2 = OFF: 2 Seconds (Factory default setting).
1 = ON, 2 = OFF: 4 Seconds
1 = OFF, 2 = ON: 6 Seconds
1 = ON, 2 = ON: 8 Seconds
SW-4: Postflow Time 1 = OFF, 2 = OFF: 10 Seconds (Factory default setting).
1 = ON, 2 = OFF: 20 Seconds
1 = OFF, 2 = ON: 5 Seconds
1 = ON, 2 = ON: 0 Seconds

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

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

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

SW 8-2: Remote Current 1 = ON (Remote Analog Current Control)

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

SW1

1

3

2

SW3

1

4

2

1

SW4

SW5

1

2

2

SW8

4

1

3

2

Future Use

O
N

1

2

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

Art # A-04819

Manual No. 0-4800 3-5 INSTALLATION

CAUTION

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

SW11

SW6

SW12

Art # A-07673

SW13

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

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

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

SW13: TVA and XTL Switch positions

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

Only 1 on at a time.

1

2

TVA XTL TVA

SW13

1

2

Manual No. 0-4800 3-6 INSTALLATION

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

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

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

CAUTION

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

Future Use

2

SW1

3

O
N

1

SW-1-1: Auto Pilot Restart. 1 = ON = Auto Pilot Function enabled.
1 = OFF = Auto Pilot Function disabled (Factory default setting).
SW-1-2: Pilot Delay 2 = OFF, 3 = OFF, 4 = OFF: 0 Seconds (Factory default setting).
SW-1-3: Pilot Delay 2 = ON, 3 = OFF, 4 = OFF: 0.1 Seconds
SW-1-4: Pilot Delay 2 = OFF, 3 = ON, 4 = OFF: 0.2 Seconds
2 = ON, 3 = ON, 4 = OFF: 0.4 Seconds
2 = OFF, 3 = OFF, 4 = ON: 0.8 Seconds
2 = ON, 3 = OFF, 4 = ON: 1.0 Seconds
2 = OFF, 3 = ON, 4 = ON: 1.5 Seconds
2 = ON, 3 = ON, 4 = ON: 2.0 Seconds

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

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

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

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

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

SW 8-2: Remote Current 1 = ON (Remote Analog Current Control)

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

SW3

1

4

2

1

SW4

SW5

1

2

2

SW8

4

1

3

2

1

O
N

2

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

Art # A-06791

N.

Manual No. 0-4800 3-7 INSTALLATION

CAUTION

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

SW11

SW6

No external
connection cover

SW12

SW13

SW-6: OK-to-Move: Contact closure, 120VAC @ 1A (Factory default setting) or
DC Volts (16-18vdc@ up to 100 ma.)

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

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

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

SW13: TVA and XTL Switch positions

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

Only 1 on at a time.

Art # A-06792

1

2

TVA XTL TVA

SW13

1

2

Manual No. 0-4800 3-8 INSTALLATION

F. Remove the Connections Cover

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

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

Connections Cover
(Removed)

Connection Panel

Art # A-04797

Manual No. 0-4800 3-9 INSTALLATION

G. Connect Work Cable and Pilot and Negative Leads

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

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

CAUTION

The clear connections cover must remain in place.

Pilot

Connections Cover

Torch

Work

PILOT WORK TORCH

Work Lead

Pilot Lead ­To Remote Arc Starter

Connection Panel

Torch Lead -

AC INPUT

L1 L2 L3

To Remote Arc Starter

Connections Cover
Support Panel

Lead Connection Detail

Art # A-07660

To Cutting Table

Leads Bracket

Manual No. 0-4800 3-10 INSTALLATION

H. Check / Adjust Input Voltage Configuration

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

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

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

Inverter Module

1. Disconnect jumper

208/230V / 460V

Input Voltage Board

(Shown in 460V Position)

2. Remove bolts.

3. Invert board.

4. Re-install board.

5. Connect jumper.

Art # A-04856

Manual No. 0-4800 3-11 INSTALLATION

I. Connect Input Power and System Ground Cables

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

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

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

CAUTION

The clear connections cover must remain in place.

4. Pass a system ground cable through the same opening in the connections cover support panel as the input
power cable. Connect the cable to the ground terminal block on the power supply rear panel. Refer to the
Ground Connections Section for full details and procedures on proper system grounding.

Ground Terminal Block

Connections Cover

Connection Panel

AC INPUT

to Remote Arc Starter

L2 L3

L1

PILOT

Art # A-07659

WORK TORCH

to Remote Arc Starter

L3

L2

L1

Input power cable

System Ground Cable

Input power cable ground

Connections Cover
Support Panel

System Ground Cable

Leads Bracket

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

Manual No. 0-4800 3-12 INSTALLATION

J. Ground Connections

A. Electromagnetic Interference (EMI)

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

B. Grounding

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

NOTE

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

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

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

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

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

NOTE

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

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

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

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

NOTE

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

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

Manual No. 0-4800 3-13 INSTALLATION

Star Ground on Cutting Table

Ultra-Cut

or

Auto-Cut O2

Remote Arc

Starter (RAS-1000)

Cutting Machine / Gantry

Cutting Table

1/0

Ground Cable

Ground Cable

Earth Ground

Rod

Torch

1/0

0 - 10 ft (0 - 3 m) Ideal

20 ft (6 m) Maximum

CNC

Device

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

Gas Control Module

Primary location

#4 AWG
Ground

1/0 Work Cable

1/0 Ground Cable

Power Supply

Gas Control Module

Alternate location

#4 AWG Ground

Note: The gas control module
can be mounted on top of the power
supply. If it is, it should be grounded
directly to the power supply with
#4 AWG ground.

‘Star’

Ground

Remote Arc

Starter (RAS-1000)

Cutting Machine / Gantry

Cutting Table

1/0

Ground Cable

Ground Cable

Earth Ground

Rod

Torch

1/0

0 - 10 ft (0 - 3 m) Ideal

20 ft (6 m) Maximum

CNC

Device

Gas Control Module

Power Supply

1/0 Work Cable

1/0 Ground Cable

‘Star’

Ground

#4 AWG Ground

(Factory Installed)

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

Art # A-08253

Manual No. 0-4800 3-14 INSTALLATION

Auto-Cut Basic System

Without RAS

Cutting Machine / Gantry

Cutting Table

Ground Cable

Earth Ground

Rod

Torch

1/0

0 - 10 ft (0 - 3 m) Ideal

20 ft (6 m) Maximum

CNC

Device

Auto-Cut

Power Supply

1/0 Work Cable

1/0 Ground Cable

(F1)

‘Star’

Ground

GCM-1000

Gas Control Module

#4 AWG Ground

(Factory Installed)

Art # A-08254

Manual No. 0-4800 3-15 INSTALLATION

C. Creating An Earth Ground

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

NOTE

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

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

shown.

CAUTION

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

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

NEUTRAL
Earth Grounded

NEUTRAL
PROBE

WARNING

Use extreme caution. This

test uses live voltage.

HOT

100W Incandescent
light bulb*

HOT
PROBE

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

Ground Rod
with other
connections removed

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

VAC

On 230V AC Line:

1.5VAC = 3 ohms

0.5VAC = 1 ohm

Art # A-07252

Ground Testing

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

D. Routing Of Torch Leads

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

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

Manual No. 0-4800 3-16 INSTALLATION

K. Connect Coolant Leads

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

COOLANT

RETURN

SUPPLY

RETURN

SUPPLY

Coolant Connections

RED

GREEN

To Remote Arc Starter

Art # A-04800

Manual No. 0-4800 3-17 INSTALLATION

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

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

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

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

To Gas Control Module

To CNC

To Remote Arc Starter

.

RETURN

SUPPLY

Art # A-04802

Manual No. 0-4800 3-18 INSTALLATION

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

CAUTION

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

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

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

relief dome nut from the strain relief.

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

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

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

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

Power Supply
Right Side Panel

Connection Cover
Side Panel

1

Power Supply
Rear Panel

To Gas Control Module

Connection Cover

To Slave Power Supply
(if installed)

Strain Relief Securing Nut

23

To Remote HMI
(if installed)

Connection Cover
Side Panel

Art # A-04805

Strain Relief

Strain Relief Dome Nut

Fiber Optic Cable

Fiber Optic
Cable Connector

Profile Detail, Fiber Optic Cable Installation

Manual No. 0-4800 3-19 INSTALLATION

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

CAUTION

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

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

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

relief dome nut from the strain relief.

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

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

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

Cable Receptacles

Profile Detail, Fiber Optic Cable Installation

To Gas Control Module

To Remote HMI
(if installed)

To Slave Power
Supply
(if installed)

Art # A-06793

Manual No. 0-4800 3-20 INSTALLATION

M. Gas Control Module Installation

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

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

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

Mounting Dimensions

Gas Box

7.14mm

0.28”

279.40mm

11.00”

410.97mm

16.18”

347.47mm

13.68”

215.90mm

8.50”

Art # A-07962

NOTE

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

Manual No. 0-4800 3-21 INSTALLATION

Preparation

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

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

Gas Control Module Cover

Remove Ground
Wire

Do not remove

Art # A-06882

Cover Removal

N. Fiber Optic Cable Installation

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

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

CAUTION

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

Manual No. 0-4800 3-22 INSTALLATION

Art # A-04772

Fiber Optic Cable

PREFLOW

OUT

PLASMA

SHIELD

OUT

OUT

AIR N

O

2

H

Circuit Board

INPUTS

O

2

LOW

PREF

SMA

PLA

SHIELD

AIR N

O

2

H

O

2

H

LD

SHIE

2

3

COMM

J56

J57

POWER
SUPPLY

F5

TVA

H35

2

1

COMM

J56

J57

POWER

Y

SUPPL

F5

A

TV

H35

2

INPUTS

O

2

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

Manual No. 0-4800 3-23 INSTALLATION

Circuit Board

Fiber Optic Cable

Art # A-04773

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

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

Manual No. 0-4800 3-24 INSTALLATION

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

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

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

3. Ensure that the Flowmeters are plumb.

4. Secure the Module to the mounting surface.

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

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

SHIELD PLASMA

H O

2

SHIELD

To Torch Valve Assembly

H O

2

PREFLOW

To Torch Valve Assembly

J57

When Cutting With O2 Plasma

Air MUST BE Connected

AIR

INPUTS

N2

O2

H35

Gas & Water Inputs (Check Valves)

TVA

To Power Supply

J56

POWER
SUPPLY

F5

Ground Stud

COMM

Gas Control Box
Rear Panel

J56

Connection Panel

SHIELD PLASMA

H O

2

SHIELD

H O

2

PREFLOW

When Cutting With O2 Plasma

Air MUST BE Connected

INPUTS

AIR

N2

J57

TVA

H35

O2

COMM

POWER
SUPPLY

F5

Art # A-06881

Manual No. 0-4800 3-25 INSTALLATION

P. Install Remote Arc Starter

Site Location

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

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

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

Mounting Dimensions

304.80mm

12.00”

12.70mm
.50”

Arc Starter Box

6.35mm
D.250”

3 PLACES

203.20mm

8.00”

50.80mm

2.00”

190.83mm

7.51”

37.77mm

1.49”

Art # A-07961

Manual No. 0-4800 3-26 INSTALLATION

266.70mm

10.50”

Installation

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

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

NOTE

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

2. Remove the Cover Panel from the Arc Starter.

Upper screws (4 per side)

Cover

Ground Wire

Lower screws

Art # A-07029

Cover Removal

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

Manual No. 0-4800 3-27 INSTALLATION

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

Minimum 2

Art # A-04749

Input Connections

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

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

for Return, Green for Supply.

Art # A-04750

Coolant Supply and Return Hoses
(from power supply)

Manual No. 0-4800 3-28 INSTALLATION

Art # A-04751

Green

Coolant Supply (Green)

Coolant Return (Red)

Red

Coolant

Return

(Red)

Art # A-04752

Negative Cable

from power supply

Negative Cable (from Power Supply rear panel)

Manual No. 0-4800 3-29 INSTALLATION

Art # A-04753

Pilot Return Cable
from Power supply

PILOT Return Cable (from Power Supply rear panel)

Art # A-04755

Control Cable from Power Supply rear panel

Manual No. 0-4800 3-30 INSTALLATION

Output Connections

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

Inner Shield Lead

Pilot Lead

Inner Shield
Connection Detail

Art # A-04933

Pilot Lead
Connection Detail

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

Manual No. 0-4800 3-31 INSTALLATION

Art # A-04757

Some items are removed
for clarity.

Coolant Return Fitting
(Tagged with Red)

Coolant Supply Fitting
(Tagged with Green)

Coolant Supply
(Green) to Torch

Coolant Return (Red)
from Torch

Coolant Supply and Return Hoses (from Torch)

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

Upper screws (4 per side)

Cover

Ground Wire

Lower screws

Art # A-07029

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

grounding details.

Manual No. 0-4800 3-32 INSTALLATION

Art # A-04758

Torch Leads

1 Nut and 1 Washer
Remain in Place

Ground Cable

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

Art # A-04759

Torch Leads Shield

Shield Clamp

Coolant and Pilot Leads
to Torch Valve Assembly

Manual No. 0-4800 3-33 INSTALLATION

Connect Control Cable

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

Power Supply Rear Panel

RETURN

SUPPLY

COOLANT

RETURN

SUPPLY

Art # A-04801

Remote Arc Starter

Remote Arc Starter ­Input Connection Panel

Manual No. 0-4800 3-34 INSTALLATION

Q. Original & XTL Torch Valve Installation

General Information

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

Mounting

113.03 mm

4.450”

6.63 mm

.261” Dia.

36.83 mm

1.450”

Art # A-07648

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

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

Do not remove brass plugs
Front and side

Outlet Side

Art # A-07645

Left-hand Thread:

To Torch Plasma Gas fitting

Right-hand Thread:

To Torch Shield Gas fitting

Manual No. 0-4800 3-35 INSTALLATION

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

Exhaust Muffler

Plasma Gas Inlet

Control Cable

Water Inlet

Shield Gas Inlet

Preflow Gas Inlet

Art # A-07646

CAUTION

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

Manual No. 0-4800 3-36 INSTALLATION

R. Connecting Torch

Connect the Torch as follows:

Leads Cover

Torch Leads End Cap

Groove for O-Ring

Coolant Supply,
Coolant Return,

and Pilot Leads

Shield Gas

(Right Hand Thread)

O-Ring

Mounting Tube

Torch Head Assembly

Pilot Lead

Coolant Supply

&

Power Lead (-)

Pilot Lead Connector

Plasma Gas

(Left Hand Thread)

Art # A-04746

To Torch Valve

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

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

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

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

5. Install the Mounting Tube as follows:

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

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

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

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

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

Manual No. 0-4800 3-37 INSTALLATION

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

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

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

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

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

leads to the Torch Head. Do not overtighten.

CAUTION

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

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

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

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

CAUTION

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

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

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

S. Install Consumable Torch Parts

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

WARNINGS

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

Art # A-03887

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

2. Stack the consumable parts together.

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

Manual No. 0-4800 3-38 INSTALLATION

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

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

CAUTION

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

Manual No. 0-4800 3-39 INSTALLATION

Electrode

Plasma Gas
Distributor

Tip

1: Stack Parts

Upper O-Ring

on Tip

2: Press Cartridge onto Stacked Parts

No Gaps

Between Parts

Shield Gas
Distributor

Shield Cap

3: Thread Shield Cup onto Cartridge

4: Check Shield Cap Protrusion

Shield Cup

Shield Cap

Shield Cap Protrudes

0.063-0.083" (1.6 - 2.1 mm)

Cartridge Covers
Upper O-Ring
on Torch Tip

Art # A-04716

Manual No. 0-4800 3-40 INSTALLATION

Torch Head

0.063 - 0.083"

(1.6 - 2.1 mm)

Protrusion

Installing Assembled Cartridge Onto Torch Head

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

Torch Head O-Ring

Art # A-07202

Ohmic Clip

A-03393

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

NOTE

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

T. Complete the Installation

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

Coolant Capabilit i es

Cat. Number and Mixture Mixture Protects To

7-3580 'Extra-Cool

7-3581 'Ultra-Cool

7-3582 'Ext reme Cool

* For mixing wit h D-I Cool

TM

'

TM

'

TM

' Concent rate* -65° F / -51° C

TM

7-3583

25 / 75 10° F / -12° C

50 / 50 27° F / -33° C

Manual No. 0-4800 3-41 INSTALLATION

Intentionally Blank

SECTION 4: OPERATION

Power Supply Control Panel

AC Indicator

Temp Indicator

Art # A-04862

AC Power Indicator

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

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

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

Gas Indicator

DC Indicator

Status Indicator

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

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

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

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

Manual No. 0-4800 4-1 OPERATION

Start-Up Sequence

1. Connect system to primary input power.

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

turns ON.

POWER

I

OFF

O

O

Art # A-04812

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

ON

OFF

Manual No. 0-4800 4-2 OPERATION

Gas Control Module Operation

Functional Overview

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

O2 - AIR

MODE

RUN

SET PREFLOW

SET PLASMA

& SHIELD

TEST

MODE

PREFLOW

GAS

RUN

SET PREFLOW

SET PLASMA

& SHIELD

TEST

O2 - AIR

O2 - O2

H35 - N2

F5 - N2

AIR - AIR

N2 - H20

N2 - N2

PLASMA

O2 - O2

H35 - N2

F5 - N2

AIR - AIR

N2 - H20

N2 - N2

GAS

ENABLE

DISABLE

H20

MIST

PLASMA
POWER
SUPPLY

AMPERAGE

SET-UP

9

SHIELD

9

ENABLE

DISABLE

PLASMA

POWER SUPPLY

AMPERAGE

SET-UP

PRESSURE

GAS

FLOW

GCM

2010

PRESSURE

GAS

FLOW

Art # A-04771

Manual No. 0-4800 4-3 OPERATION

Gas Control Module: Controls & Indicators

1. MODE Selection Switch

MODE

O2 - AIR

SET PREFLOW

SET PLASMA

& SHIELD

O2 - O2

2 - H2O

N

2 - N2

N

GAS

PLASMA

RUN

TEST

MODE

PREFLOW

H35 -N
F5 - N2
AIR - AIR

2

RUN

SET PREFLOW

SET PLASMA

TEST

High Precision

Plasma Cutting System

9

& SHIELD

AMPERAGE

SHIELD

SET-UP

ENABLE

DISABLE

PLASMA

POWER SUPPLY

9

H

2

O

MIST

GCM

2010

GAS

PRESSURE

FLOW

Art # A-04765

• Normally in the RUN position during torch operation.

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

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

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

Manual No. 0-4800 4-4 OPERATION

2. GAS Selection Switch

Selects combinations of plasma and shield gases.

O2 - AIR

O2 - O2

GAS

RUN

SET PREFLOW

SET PLASMA

& SHIELD

TEST

MODE

PREFLOW

GCM

2010

H35 -N

2

F5 - N2

AIR - AIR

N

2 - H2O

2 - N2

N

O2 - AIR

O2 - O2

H35 -N

2

F5 - N2
AIR - AIR

N

2 - H2O

N

2 - N2

PLASMA

High Precision

Plasma Cutting System

9

GAS

SHIELD

PRESSURE

FLOW

GAS

Art # A-04766

AMPERAGE

SET-UP

9

ENABLE

DISABLE

PLASMA

POWER SUPPLY

H

2

O

MIST

Manual No. 0-4800 4-5 OPERATION

3. Amperage / Set-Up Knob

Adjusts the output amperage of the torch.

High Precision

Plasma Cutting System

O2 - AIR

SET PREFLOW

SET PLASMA

& SHIELD

O2 - O2

2

H35 -N

F5 - N

2

AIR - AIR

N

2 - H2

O

2 - N2

N

PLASMA

High Precision

Plasma Cutting System

9

GAS

MODE

RUN

TEST

PREFLOW

GCM

2010

SHIELD

PRESSURE

GAS

FLOW

AMPERAGE

SET-UP

9

AMPERAGE

SET-UP

ENABLE

DISABLE

PLASMA

POWER SUPPLY

H

2

O

MIST

Art # A-04767

4. Plasma Power Supply Enable / Disable Switch

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

5. PREFLOW Control Knob and Pressure Gauge

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

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

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

7. H2O Mist Control Knob and Flow Meter

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

NOTE

Water mist is not used in all applications.

Manual No. 0-4800 4-6 OPERATION

Sequence Of Operation

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

DANGER

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

a. Change the torch parts if necessary.

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

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

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

3. Set the preflow gas pressure.

a. Set the MODE switch to SET PREFLOW.

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

settings.

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

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

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

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

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

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

c . In installations using water shield, use the H

O MIST control knob and flow meter to set water flow rate.

2

Refer to the torch manual for flow rates.

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

6. Place the MODE switch to the RUN position.

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

NOTE

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

CAUTION

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

Manual No. 0-4800 4-7 OPERATION

Cut Quality

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

Kerf Width

Cut Surface

Left Side

Cut Angle

Right Side

Cut Angle

A-00512

Top

Spatter

Build-Up

Dross

Cut Surface

Drag Lines

Bevel Angle

Top Edge
Rounding

A-00007

Cut Surface

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

Bevel Angle

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

Top-Edge Rounding

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

Dross Build-up and Top Spatter

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

Kerf Width

The width of material removed during the cut.

Nitride Build-up

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

Marking

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

Manual No. 0-4800 4-8 OPERATION

Direction of Cut

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

Left Side

Cut Angle

Right Side

Cut Angle

A-00512

Clockwise

Scrap

Counter-

Clockwise

Scrap

Workpiece

Art # A-04182

Swirl Effect on Side Characteristics Of Cut

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

Underwater Cutting

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

Ohmic Sensing

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

Manual No. 0-4800 4-9 OPERATION

Gas Selection

A. Plasma Gases

1. Air Plasma

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

• Air plasma is normally used with air shield.

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

• Provides satisfactory results on nonferrous materials.

2. Argon/Hydrogen (H35) Plasma

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

• Poor cut quality on ferrous materials.

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

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

3. Oxygen (O2) Plasma

• Oxygen is recommended for cutting ferrous materials.

• Provides faster cutting speeds.

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

4. Nitrogen (N2) Plasma

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

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

• Provides much better parts life than air.

• A good clean welding grade nitrogen should be used.

B. Shield Gases

1. Compressed Air Shield

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

• Improves cut quality on some ferrous materials.

• Inexpensive - reduces operating costs.

2. Nitrogen (N2) Shield

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

• Provides smooth finishes on nonferrous materials.

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

3. Water Shield

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

• Provides very smooth cut surface.

• Reduces smoke and heat input to the workpiece.

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

• Tap water provides low operating expense.

Manual No. 0-4800 4-10 OPERATION

Power Supply Status Codes

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

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

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

Note

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

Faul t Code Key

Error

Code Error Remedy / Comme nts

Plasma Enable Off ; External E-Stop Activated or
CCM TB1-1&2 jumper mi s sing; M iss i ng A C Phase;

Sy st em not Enabled or

1-1

Missing AC Input Phase

1-2 Pil ot Ignit i on Fai lure

1-3 Lost P i l ot

1-4 Loss of Transfer
1-5 Off the Plat e Function not c urrent ly enabled

1-6 Pil ot Timed out w/ o Transfer

1-7 Tip Saver Function not c urrent ly enabled.

1-8 Pos sible S hort ed Torch

No power to GCM 2000 or 2010 Gas Control, chec k
GCM c ont rol cable c onnec t ed, reset CP 4 or CP5
circ ui t breaker i n powe r suppl y, bl own fuse F 19 i n
GCM.
Pilot did not start within 15 seconds.
Preflow press ure t oo high; Defect i ve Arc S t art er

Pil ot went out without shutoff signal ; P reflow pressure
too high; cut c urrent set too low for consum abl es .

Arc transfer (>50 ms.) then arc lost with START still
on. S t andoff too high; Current s et too low.

Must transfer from Pilot to Cutting Arc in 85 ms.
(SW8-1 O F F ) or 3 sec. (S W8-1 ON). Standoff t oo
high or void in work under torch; cut current too low
for consum ables; Preflow pressure t oo low.

Detec t ed t i p voltage too c l ose to elect rode voltage.
Plasma flow/pressure too low; Plasma leak; cut
current too high; shorted t orc h body; consum abl e
parts worn out.

Manual No. 0-4800 4-11 OPERATION

Fault Code Key

Error

Code E rror Remedy / Comments

2-1 Missing Phase B low n fuse, B r o k en or loose connec tion on power cable

Inverter(s) not configured correctly for input v oltage;

2-2 W r ong i nput vol tage

Invert er or Pilot Regul ator Over

2-3

Temperature

2-4 Power S upply not Rea dy Defective invert er
2-5 DC Output Low

2-6 Pr imary over curr ent fault

2-7 Unexpecte d c ur rent

Unexpected c urrent in pilot

2-8

circuit
Unexpected c urrent in wor k

2-9

lead
Gas Cont r o l Communicatio n

fault, Cannot establish

3-1

Communication with gas
control.

Gas Cont r o l Communicatio n
reply fault , connecti on was

3-2

established but CCM did
receive a reply t o a process
request.

3-3 Gas Pressure Low

3-4 Gas Control no t ready Purging; not in RUN mode; Gas Cont r ol faulty, replac e P CB.
3-5 Gas Control P rotocol Fault Applic a tion error o r firmware compatibilit y f ault

Inv alid Current Control level

3-6

from GCM
Gas Control returns wrong

3-7

command sequence
CCM and Gas Control t ype

3-8

(Autocut-Ultr ac u t) mismatch
Gas Cont r o l Communicatio n

3-9

reply fault
Warning. -- Gas Control

3-10

fir mware need s updat e

Poor power quality (brownouts, dropouts); Input power capacity / wiring
too small causing v oltage drop; br ok en or l oose power cable
connections.

Fail ed fan; Ambient abo ve 40 deg C. ( 104 F); B loc ked airflow

Output less t han 60 VDC; D efective inverter, shorted output ; Shorte d pilot
regulator (chopper ); CCM voltage sense (J6) w ir e o pen or disconnected.

Over cur r ent detect ed in invert er pr imary circui t , remove power to reset ;
defe c tive in vert er ; v oltage surge;
Curr ent >20A in work or pil ot leads befo r e p ilot ignition; Possible short ed
torch; Def ective current sensor.

Curr ent > 5A in pilot cir c u it; wrong or mismatc hed consumables; P ilot
lead shorted to negative in torch tube; Possible shorted torch

Curr ent > 5A in work lead; Short to chassis in RAS; Negativ e lead short to
ground.

If GCM 1000: Control cable not c onne c ted or Basic I D signal open.
GCM 2010 & 2000: Dirt on fiber ends or in connectors, blow out with
clean dr y air; fiber not locked int o c onne c tor; sharp bends in f iber ; fiber
defe c tive; Gas Contr ol P C B defective, r ep lac e. CCM defective, r epl ac e .

Gas Control did not reply to signal from CCM in allowed time. Dirt on
fibe r end s or in c onne c tors, blo w out with clean dr y air; fiber not locked
into c onne c tor; sharp bends in f iber; fiber de fective. If problem persists
Gas Cont rol PCB likely defective, replac e board.

If GCM 1000, Plasma < 15 PS I; f aulty or disconnected pressure SW.
If GCM2010_AG, GCM2000_A C or later or G as Cont rol has been
updat ed w ith 19X221 9_AG or later PC B : Plasma or Shield input out of
range 105-135.
If GCM2010_AG, GCM2000_A C or later or G as Cont rol has been
updat ed w ith 19X221 9_AG or later PC B : Plasma or Shield input out of
range 105-135 PSI; Unplugged or F aul ty pr e ssure sensor.

GCM sent output curr ent lev e l outside the r ang e of the power supply,
Check firmware compatibility

Check firmware compatibility

Install correc t CCM or Gas Cont rol fo r syst em

Reply not compat ible with request; Check firmware c ompati bil ity
System will function but control may no t be optimiz ed for best

performance / consumable life

Manual No. 0-4800 4-12 OPERATION

Fault Code Key

Error

Code

E rror Remedy / Comment s

4-1 Coolant Level low fau lt C hec k coolant level, a dd as needed.

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

4-2

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

Coolant ov erheated (>70 deg.

4-3

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

4-4

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

4-5 Low Coolant Level - Warning

CANBUS Failure to

5-1

Acknowledge fault.
CANBUS Off due to excessiv e

5-2

data e r r ors;
CANBUS data error warning.

5-3

Errors increasing, will soon
fault.

5-4 CCM Message not sent

6-1 CCM Analog Voltage Er ro r Replace CCM
6-2 CCM ADC or DAC error Replac e CCM

Coolant F low too High error,

6-3

flow > 2. 7 gal/min

6-4 CCM Da ta Me mory erro r Replac e CCM

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

Coolant fan failed; radiator fins clogged with dirt; Ambient temperature > 40 d eg
C.
If new installation recycle power to restart pump, may take a few times to fill
hoses;
Damaged torch coolant tube; Suction leak introducing air into coolant, suspect rear
panel filter seal; clogged filter; defective pump.

Whil e c utting detected low c oolan t level, does not st op cut.
Add coolant a s requir ed.
If GCM 1000, Basic ID signal missing; Other gas cont r o ls, Fiber
disconnected or broken, Transceiver (what fiber plugs int o) fault, r eplace
Gas control PCB or CC M
Dirt on fiber ends or in c on nec tors, blow out with clean dry air; fiber not
lock ed in to connect or ; sharp bends in f ibe r ; fiber defective;

Dirt on fiber ends or in c on nec tors, blow out with clean dry air; fiber not
lock ed in to connect or ; sharp bends in f ibe r ; fiber defective;

Dirt on fiber ends or in c on nec tors, blow out with clean dry air; fiber not
lock ed in to connect or ; sharp bends in f ibe r ; fiber defective; CANBUS
hardware error (CCM or G as Contr ol P CB )

Torch c oolant tube br ok en o r missing; CCM fa ult, replac e CCM

Manual No. 0-4800 4-13 OPERATION

Remote Arc Starter: Service Chart

e

S

g

A rc S t arter Serv ice Chart

Symptom Cause Check Remedy

Use conductivity meter

Use capacitance meter Reconnect or replace.

Capacit a nce meter R eplace.

V isual inspect ion Reconnec t.

V isual inspect ion Reconnec t.

Visual inspection Replac e c oo lant line(s).

Visual Inspection of color -coded
connections

Loosen fit ting slight ly and chec k
for coolant flow

Visual inspection o f lead
attachment to Arc Starter

V isual inspection of ground wire
to Arc Starter

Visual inspection / capacitor
me asurement

No Pilot ignition:

Spark in Arc Starter

but no ignition

No Pilot ignition:

No Spark

in Arc Starter

No cooling or

insufficient cooling:

Leaks coolant

No cooling or

insufficient cooling:

No Coolant Flow

Erratic System

Behavior

(EMI Interference)

Coolant ha s become conduc tiv
Pilot return w ir e no t connect ed Visual inspectio n Connect Wire.

Spar k gap set too close Check wi th feeler gaug e Set t o 0.063" ±0. 002"
High Frequency cap (C4)
possibly open
Brok en or missing fe r r ites Visual inspect ion Replac e.

Shor t across in inductor (L1) Visual inspect io n
Spar k gap bus caps

(C1, C2, C3)
broke n or defect ive
Negative supply not
connec t ed c or r ec t ly
Spar k gap set too large Check with feeler g auge Set to 0.063" ±0.002"
Faulty transformer Resistanc e measurement Replace.

No 120V supply Check i nput vol tage at EMI filter
No/ loo se connect i on

to spark gap
Faulty E MI filter V oltage/ Resistor measurement Replac e.
Loose fit t in g(s) Visual inspect io n Tighten fittings.
Failu r e to braze joints (L1) Visual inspectio n Replace HF Coil.
Damaged or punctured
coolant lin e( s).

Supply & return hose reversed

Blockage in coil or
supply / return hoses

hield Drain / Torch lead in ner
shield connector
missin

Missing or loose
ground c onne c tion

Cap C5 not connected,
open or loose

or loose.

Flush syst em,
replac e coo lant.

Remove short;
incre ase coil gap s.

M ake connections;
replac e harn ess.

Match co olan t connect ion colors
to arc starter fitting colors.

Flush syst em.

Reconnec t / t ighten
lead connec t o r s.

Make or tighten
connec tions to
good ground.

Replace P CB.

Manual No. 0-4800 4-14 OPERATION

Remote Arc Starter: Spark Gap

Adjustment

0.063" ± 0.002"

1.6 ± 0.05 mm

Art # A-04857

Manual No. 0-4800 4-15 OPERATION

This page intentionally blank

Manual No. 0-4800 4-16 OPERATION

SECTION 5: MAINTENANCE

Perform the following checks periodically to ensure proper system performance.

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

Daily

Check c ool ant level; add coolant as needed.
Check gas hos e connect i ons and pres s ures .

M onthly

Check c ool ing fan and radiator; clean as needed.
Check gas hos es for cracks , leaks , or abrasi on.
Replace as needed.
Check all electri c al c onnec tions
for crack s or abrasion. Replac e as needed.

Six M onths

Clean or replace ext ernal coolant fil t er.
Clean coolant t ank .
Vac uum out any dus t bui l dup ins i de power supply.
Check internal coolant filter

External Coolant Filter Cleaning Procedure

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

Clean the coolant filter as follows:

1. Disconnect the system from main input power.

Filter Screen

Filter Holder

Art # A-04811

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

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

4. Turn the system on and check for leaks.

Manual No. 0-4800 5-1 MAINTENANCE

Internal Coolant Filter Cleaning Procedure

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

Coolant Replacement Procedure

Replace coolant as follows:

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

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

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

COOLANT

RETURN

Fill Range

Coolant Tank

SUPPLY

RETURN

SUPPLY

Art # A-04803

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

Manual No. 0-4800 5-2 MAINTENANCE

SECTION 6: REPLACEMENT ASSEMBLIES & PARTS

Complete Unit / Component Catalog Number

Ultra-Cut®150 Power Supply, 208/230V 3-9117-1

UltraCut®150 Power Supply, 460V 3-9117-2

Ultra-Cut®150 Power Supply, 400V 3-9117-3

Ultra-Cut®150 Power Supply, 400V, (CE) 3-9117-4

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

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

Original Torch Valve Assembly Only 4-3049

XTL Torch Valve Assembly Only 4-3054

Remote Arc Starter (RAS-1000) 3-9130

OPTIONAL EQUIPMENT:

Wheel Kit 9-9379

Manual No. 0-4800 6-1 Power Supply Parts List

System Layout

175’ / 53.3 m Maximum Length

Primary power

CNC

Art # A-07233

125’ / 38.1 m Maximum Length

Pilot Return

Negative

Coolant Supply

Power
Supply

P

F

Coolant Return

Control Cable

Fiber
Optic

Cable

Control

Cable

175’ / 53.3 m Maximum Length

L

Gas Control

K

F

Module

Plasma Gas

Shield Gas

Preflow Gas

Control Cable

Water Shield

Work Cable

A

B

Remote

C

D

E

H

Q

R

S

T

O

Arc

Starter

Torch

Assembly

100’ / 30.5 m Maximum Length

Pilot Return

Shield

Coolant Supply

Coolant Return

F1

Valve

Shield

Plasma Gas

Shield Gas

Positioning Tube

I

J

G

Torch

Work

Manual No. 0-4800 6-2 Power Supply Parts List

Leads and Cables

B

D

E

F

F1

#8 AWG Cable

A

#1 AWG Cable

C

14

G

Green

Red

Green / Yellow # 4 AWG

Green / Yellow 1/0 (50 mm )

Green

Red

2

Pilot Return, Power Supply
to Arc Starter

Negative Lead, Power Supply
to Arc Starter

Coolant Supply Lead,
Power Supply to Arc Starter

Coolant Return Lead,
Power Supply to Arc Starter

Control Cable, Power Supply
to Arc Starter

Ground Cable

Ground Cable,
Remote Arc Starter
To Earth Ground

Shielded Torch Lead
Assembly, Remote
Arc Starter to Torch

Art # A-07473

I

J

K

L

H, Q,
R, S,T

O

P

37

14

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

Plasma Gas Lead,
Torch Valve to Torch

Shield Gas Lead,
Torch Valve to Torch

Control Cable,
Power Supply to
Gas Control Module

Fiber Optic Cable,
Power Supply to
Gas Control Module

2

CNC Cable (14 Wire)

Work Cable

Manual No. 0-4800 6-3 Power Supply Parts List

Key Description Catalog #

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

NOTE 1:

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

Manual No. 0-4800 6-4 Power Supply Parts List

Key Description Catalog #

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Manual No. 0-4800 6-5 Power Supply Parts List

Key Description Catalog #

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

NOTE 2:

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

Manual No. 0-4800 6-6 Power Supply Parts List

Key Description Catalog #

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

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

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

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

O Work Cable, 10’ / 3.05 m 9-9300

O Work Cable, 15’ / 4.5 m 9-9301

O Work Cable, 25’ / 7.6 m 9-9302

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

O Work Cable, 50’ / 15.2 m 9-9304

O Work Cable, 75’ / 22.9 m 9-9305

O Work Cable, 100’ /30.5 m 9-9306

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

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

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

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

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

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

Manual No. 0-4800 6-7 Power Supply Parts List

Optional Gas Supply Leads

HOS E AS SEMBL IES

Length

1/4"

3/8"

HOSE FI TTI NGS

ID

1/4" 9-3743 9-3556 9-2776 9-2775 8-5518 8-5015 8-0327 8-0266 8-0384
3/8" 9-3616 8-6473 20x962 N/A N/A 8-6617 N/A 8-0271 8-0384
1/2" 9-2551 8-6470 20x884 N/A 8-0267 9-3831

ADAPT ER F ITTI NGS

1/4 " NPT

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

Meters 3. 05 4. 6 7.6 10.6 15. 2 22.9 30.4

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

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

Inert B (RH)

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

CATALOG#

per foot

Inert B (RH) 8-0330

Inert B (LH) 8-0329

O2 B (RH) 8-026 0
FUEL B (LH)
FUEL B (LH)

1/4" B arb 8-4264

(Catalog number)

JIC 9-6956 9-6957 9-6959 9-6961 9-6963 9-6964 9- 696 5

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

(Catalog number)

NUT NUT NIPPLE NUT NUT NIPPLE JIC CLAMP

Inert B

(LH)

Cata l o g #

Inert B

(RH)

Inert

FUEL B

(LH)

O2 B
(RH)

Manual No. 0-4800 6-8 Power Supply Parts List

Power Supply External Replacement Parts

Item # Qty Description Catalog #

1 Power Supply Front Panel 9-9380

1 Power Supply Rear Panel 9-9381

1 Power Supply Top Panel 9-9382

1 Power Supply Right Side Panel 9-9383

1 Power Supply Left Side Panel 9-9384

1 Louver Panel 9-9385

1 Power Supply Connections Cover 9-9386

1 Lifting Eye 9-9373

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

9-9386

9-9384

9-9373

9-9382

9-9380

9-9381

9-9385

9-9385

9-9385

9-9383

Art # A-04931

Manual No. 0-4800 6-9 Power Supply Parts List

Power Supply Replacement Parts - Right Side

Item # Qty Description Ref. Des. Catalog #

1 1 Heat Exchanger Fan FAN1 9-9338

2 1 Radiator 9-9339

Manual No. 0-4800 6-10 Power Supply Parts List

Power Supply Replacement Parts - Right Side

Item # Qty Description Ref. Des. Catalog #

3 1 Resistor R6 9-9340

4 1 Output Filter PCB PCB8 9-9341

5 1 Sensor HCT1 9-9342

Manual No. 0-4800 6-11 Power Supply Parts List

Power Supply Replacement Parts - Right Side

Item # Qty Description Ref. Des. Catalog #

5 1 Sensor HCT1 9-9342

6 1 Contactor MC2 9-9343

Manual No. 0-4800 6-12 Power Supply Parts List

Power Supply Replacement Parts - Front Panel

Item # Qty Description Ref. Des. Catalog #

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

Manual No. 0-4800 6-13 Power Supply Parts List

Power Supply Replacement Parts - Front Panel

Item # Qty Description Ref. Des. Catalog #

11 1 Display PC Board PCB6 9-9347

Manual No. 0-4800 6-14 Power Supply Parts List

Power Supply Replacement Parts - Right Side

Item # Qty Description Ref. Des. Catalog #

19 1 Resistor R1-5 9-9353

20 1 Resistor R1-5 9-9353
21 1 Resistor R1-5 9-9353

1 Chopper Module 9-9389

Manual No. 0-4800 6-15 Power Supply Parts List

Power Supply Replacement Parts - Rear Panel

Item # Qty Description Ref. Des. Catalog #

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

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

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

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

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

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

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

1 Coolant Tank 9-5948

1 Tank Cap 8-5142

CIRCUIT

Tank Cap

COOLANT

RETURN

SUPPLY

12

13

14

15

16

17

18

J55

G
C
M

J15

C
N
C

J59

R
A
S

BREAKERS

RAS

120V 5A

CCM

24V3 15A

GCM

24V 10A

GCM

120V2 5A

GCM

15V2 5A

PUMP

200V 5A

FAN

24V 15A

CP2

CP3

CP4

CP5

CP6

CP7

CP8

Art # A-06017

Coolant Tank

Art # A-04932

Manual No. 0-4800 6-16 Power Supply Parts List

Power Supply Replacement Parts - Right Side

Item # Qty Description Ref. Des. Catalog #

23 1 Transformer T1 9-9355

Manual No. 0-4800 6-17 Power Supply Parts List

Power Supply Replacement Parts

Item # Qty Description Catalog #

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

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

Art # A-04786

Manual No. 0-4800 6-18 Power Supply Parts List