Tweco 9-9435 User Manual

82 Benning Street, West Lebanon, NH 03784 USA

[phone] • www.thermal-dynamics.com

Manual 0-4738

Gas Control Module

Model GCM-2000

Catalog # 9-9435

Installation Instructions

General Description

This control Module is for use only with Thermal Dy­namics Auto-Cut® 20O2 and Auto-Cut® 30O2 power
supplies and the Thermal Dynamics XTTM-301 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

Thermal Dynamics

Automated

Plasma Cutting System

9

GAS

16.25"

413 mm

AMPS

SHIELD

9

PRESSURE

FLOW

ENABLE

DISABLE

PLASMA

POWER SUPPLY

H

2

O

MIST

14.25"

362 mm

11"

279 mm

RUN

SET PREFLOW

SET PLASMA

& SHIELD

TEST

MODE

PREFLOW

GCM

2000

O2 - AIR

2

H35 - N

AIR - AIR

2

- H2O

N

GAS

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-07282

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

Scope of Instructions

These instructions cover installation of the gas control
module only. Operational instructions are provided in
the Auto-Cut® 20O2 and Auto-Cut® 30O2 power sup­ply manuals.

© 2006, Thermadyne Corp.

March 6, 2006 1 Manual 0-4738 Rev. AA

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.

Circuit Board

2

M

COM

J56

J57

POWER

LOW

F

E

R

P

A

M

S

LA

P

LD

IE

H

S

2O

H

IELD

H

S

AIR

2O

H

INPUTS

N

2

2

O

Art # A-07287

SUPPLY

TVA

H35

Fiber Optic Cable

PREFLOW

OUT

PLASMA

SHIELD

OUT

OUT

AIR N

O

2

H

INPUTS

2

O

2

3

M

M

O

C

J56

J57

POWER
SUPPLY

TVA

H35

1

Art # A-07285

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

March 6, 2006 2 Manual 0-4738 Rev. AA

Circuit Board

Fiber Optic Cable

Art # A-07286

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

5. Reinstall the cover panel.

March 6, 2006 3 Manual 0-4738 Rev. AA

Supply, Control, and Output Connections

1 Position the module on a flat, horizontal sur-

face.

2. Ensure that the flowmeters are plumb.

3. Fasten the module to the mounting surface.

4. Connect inputs and outputs as shown.

NOTE

Water shield is not used in all applications.

5. Make all other connections as required to the
rear of the module. The connections and cables
are labeled or keyed. Gases must be connected
to the appropriate ports. Air must be connected
when cutting with O2 (oxygen) plasma.

6. 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.

NOTE

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.

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

Ground Stud

COMM

Gas Control Module
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

Art # A-07283

March 6, 2006 4 Manual 0-4738 Rev. AA