Tweco 7-4000 User Manual

82 Benning Street, West Lebanon, NH 03784 USA

[phone] • www.thermal-dynamics.com

Manual 0-4739

Gas Control Module

Model GCM-2010

Catalog # 7-4000

Installation Instructions

General Description

This control Module is for use only with Thermal Dy­namics UltraCut® power supplies and the Thermal Dy­namics XTTM-300 torch. Do not use this module with
any other equipment.

The Control Module includes front panel selector
switches and flow and pressure controls and gauges.
All connections to the module are made to the rear
panel.

Specifications

High Precision

9

16.25"

413 mm

SHIELD

PRESSURE

GAS

FLOW

AMPERAGE

SET-UP

9

ENABLE

DISABLE

PLASMA

POWER SUPPLY

2

O

H

MIST

14.25"

362 mm

11"

279 mm

RUN

SET PREFLOW

SET PLASMA

& SHIELD

TEST

MODE

PREFLOW

GCM

2010

O2 - AIR

O2 - O2

H35 -N

2

F5 - N2
AIR - AIR

N

2 - H2O

2 - N2

N

GAS

Plasma Cutting System

PLASMA

Installation

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

All gas inputs and two control cables attach to the rear
panel. A fiber-optic control cable passes through the
rear panel and connects to a printed circuit board in­side the module. There must be adequate space be­hind the module for these hose and cable connections
without crimping.

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 any
other support subject to vibration or motion, the in­staller must fasten the module to the support securely.

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

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

NOTE

40 lb / 18 kg

Art # A-04764

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

© 2005, Thermadyne Corp.

January 4, 2006 1 Manual 0-4739

Preparation

Fiber Optic Cable Installation

1. Remove the screws securing the cover panel to
the Module.

2. Remove the Cover from the Module.

Gas Control Module Cover

Do not remove

1. Remove the securing nut from the through-hole
protector supplied on the cable. Pass the cable
and the through-hole protector into the hole in
the connection panel on the back of the mod­ule. Fasten the through-hole protector in place
with the securing nut. Do not tighten the pro­tector.

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

CAUTION

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

M

M

O

C

J56

J57

POWER

W

FLO

PRE

PLASMA

ELD

SHI

O

2

H

O

2

H

SHIELD

AIR

INPUTS

N

O

2

TVA

H35

2

Art # A-07062

Y

SUPPL

F5

January 4, 2006 2 Manual 0-4739

Art # A-04772

Fiber Optic Cable

PREFLOW

OUT

PLASMA

SHIELD

OUT

OUT

AIR N

O

2

H

Circuit Board

INPUTS

O

2

W

O
L
F

E

R

P

T
U

O

A

M

S

A

L

P

T
U

O

IR

A

O

2

H

D

L

IE

H

S

T

U

O

Circuit Board

Fiber Optic Cable

2

3

M

M

O

C

J56

J57

POWER
SUPPLY

F5

TVA

H35

2

1

M

M

O

C

6

5

J

7

5

J

R

E

W

O

P

Y
L
P

P

5

U

F

S

A

V

T

5

3

H

S

T

2

U

P

IN

O

2

N

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

Art # A-04773

4. Tighten the through-hole protector for the fiber­optic cable.

5. Reinstall the cover panel.

January 4, 2006 3 Manual 0-4739

Supply, Control, and Output Connections

4. Fasten the module to the mounting surface.

1 Make all other connections as required to the

rear of the module. The connections are labeled.
The module must be grounded; the grounding
terminal is marked

. Use #10 AWG (or thicker)
wire for grounding. Keep the ground wire as
short as possible.

2. Position the module on a flat, horizontal sur­face.

3. Ensure that the flowmeters are plumb.

SHIELD PLASMA

H O

2

SHIELD

H O

2

PREFLOW

When Cutting With O2 Plasma

Air MUST BE Connected

INPUTS

AIR

5. Connect inputs and outputs as shown.

Water shield is not used in all applications.

Every effort has been made to provide com­plete and accurate information in this
manual. However, the publisher does not
and hereby disclaims any liability to any
party for any loss or damage caused by er­rors or omissions in this manual, whether
such errors arise from negligence, accident,
or any other cause.

To Torch Valve Assembly

J57

H35

N2

O2

TVA

NOTE

NOTE

To Power Supply

J56

F5

COMM

POWER
SUPPLY

To Torch Valve Assembly

Gas Control Box
Rear Panel

Connection Panel

SHIELD PLASMA

H O

2

SHIELD

Gas & Water Inputs (Check Valves)

J56

J57

TVA

F5

H35

O2

H O

2

PREFLOW

When Cutting With O2 Plasma

Air MUST BE Connected

INPUTS

AIR

N2

COMM

POWER
SUPPLY

Ground Stud

Art # A-06881

January 4, 2006 4 Manual 0-4739