Victor 100 ULTRA-CUT Operating Manual

Download

100

™

ULTRA-CUT

PLASMA CUTTING SYSTEM W/AUTOMATED GAS CONTROL

Operating Manual

Art # A-08579_AB

Rev. AL Date: March 13, 2013 Manual # 0-5132 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 worldwide service network. To locate your nearest distributor or service agency call 1-800-426-1888, or visit us on the web at

www.thermal-dynamics.com.

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

YOU ARE IN GOOD COMPANY!

The Brand of Choice for Contractors and Fabricators Worldwide.

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

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

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

WARNINGS

Read and understand this entire Manual and your employer’s safety practices before installing, operating, or servicing the equipment.

While the information contained in this Manual represents the Manufacturer's best judgement, the Manufacturer assumes no liability for its use.

Plasma Cutting Power Supply, Ultra-Cut® 100 Automated Gas Contol, DFC-3000

Operating Manual No. 0-5132 Published by: Thermadyne Corporation 82 Benning Street West Lebanon, New Hampshire, USA 03784 (603) 298-5711

www.thermal-dynamics.com

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

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

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

Publication Date: June 24, 2009 Revision Date: March 13, 2013

Record the following information for Warranty purposes:

Where Purchased: ___________________________________

Purchase Date:______________________________________

Power Supply Serial #:_______________________________

Torch Serial #:_____________________________________

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 .................................................................................................. 1-2

1.04 Note, Attention et Avertissement .................................................................. 1-3

1.05 Precautions De Securite Importantes ........................................................... 1-3

1.06 Documents De Reference ............................................................................. 1-5

1.07 Declaration of Conformity ............................................................................. 1-6

1.08 Statement of Warranty .................................................................................. 1-7

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

3.03 Cables & Leads Identification ....................................................................... 3-3

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

3.05 Remove the Connections Cover ................................................................... 3-5

3.06 Connect Work Cable and Pilot and Negative Leads....................................... 3-8

3.07 Ground Connections ..................................................................................... 3-9

3.08 Connect Coolant Leads ................................................................................3-12

3.09 Connect Control Cables for CNC, Remote Arc Starter, and DMC-3000 ........ 3-13

3.10 Connect TSC-3000 Cable and DMC-3000 Fiber Optic Cable to CCM............ 3-14

3.11 Set Switches on the Command - Control Module ......................................... 3-16

3.12 Height Control Connections ......................................................................... 3-18

3.13 DMC-3000 Gas Manifold Control Installation ................................................ 3-18

3.14 DPC-3000 Gas Pressure Control Installation ............................................... 3-22

3.15 Fiber Optic Cable Installation from CCM to DMC-3000. ............................... 3-25

3.16 Fiber Optic Cable Installation From DMC-3000 to DPC-3000........................ 3-28

3.17 Install TSC-3000 Touch Screen Control ........................................................ 3-30

3.18 Install Remote Arc Starter ...........................................................................3-31

3.19 Connecting Torch ......................................................................................... 3-40

3.20 Install Consumable Torch Parts ....................................................................3-41

3.21 Complete the Installation ............................................................................. 3-45

TABLE OF CONTENTS (continued)

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

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

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

4.03 TSC-3000 Navigation Functions ................................................................... 4-2

4.04 TSC-3000 Initial Setup ONLY ........................................................................ 4-3

4.05 TSC-3000 Selecting New Process ................................................................ 4-4

4.06 TSC-3000 Selecting Recently Used Process ................................................ 4-5

4.07 TSC-3000 Creating a Custom Process ......................................................... 4-6

4.08 Back up and Restoration of Custom Processes. ........................................... 4-8

4.09 Sequence of Operation ................................................................................ 4-11

4.10 Gas Selection .............................................................................................. 4-14

4.11 Power Supply Status Codes ........................................................................ 4-16

4.12 DMC-3000 Status Codes ............................................................................. 4-19

4.13 DPC-3000 Status Codes .............................................................................. 4-21

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

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

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

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

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

5.05 Remote Arc Starter: Service Chart .............................................................. 5-3

5.06 Remote Arc Starter: Spark Gap Adjustment ................................................ 5-4

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

6.01 Main Component / System Replacement ...................................................... 6-1

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

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

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

6.05 Power Supply External Replacement Parts .................................................. 6-10

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

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

6.08 Power Supply Replacement Parts - Right Side ............................................ 6-13

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

6.10 Power Supply Replacement Parts - Front Panel ........................................... 6-15

6.11 Power Supply Replacement Parts - Right Side ............................................ 6-16

6.12 Power Supply Replacement Parts - Rear Panel ............................................ 6-17

6.13 Power Supply Replacement Parts - Right Side ............................................ 6-18

6.14 Power Supply Replacement Parts ................................................................ 6-19

6.15 Power Supply Replacement Parts - Right Side ............................................ 6-20

6.16 Power Supply Replacement Parts ................................................................ 6-21

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

6.18 DFC-3000 Automated Gas Control System Replacement Componants ........6-23

6.19 DMC-3000 Gas Control Module Replacement Parts ..................................... 6-24

6.20 DPC-3000 Gas Control Module Replacement Parts ..................................... 6-25

6.21 TSC-3000 Touch Screen Control Remote and Internal Replacement Parts ... 6-26

6.22 Remote Arc Starter (RAS-1000) Replacement Parts.................................... 6-27

6.23 Remote Arc Starter (RAS-1000) Replacement Parts.................................... 6-28

6.24 Command & Control Module For Auto Gas Control - Replacement Parts ..... 6-29

TABLE OF CONTENTS (continued)

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

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

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

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

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

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

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

APPENDIX 2: DMC-3000 PCB Layout ...................................................................................... A-2

APPENDIX 3: DPC-3000 PCB Layout ...................................................................................... A-3

APPENDIX 4: TSC-3000 PCB Layout ...................................................................................... A-4

APPENDIX 5: CCM Input / Output PCB Layout ........................................................................ A-5

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

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

A7.01 CNC functions ............................................................................................ A-8

A7.02 CNC Input / Output Descriptions................................................................. A-9

A7.03 Simplified CNC Circuit. ............................................................................. A-10

A7.04 CNC Connections. .................................................................................... A-11

APPENDIX 8: SERIAL COMMUNICATIONS ........................................................................... A-12

A8.01 Cables and Switch Settings for 2 and 4 Wire ............................................ A-12

APPENDIX 9: Schematic, 230-460V, Chopper Pilot ................................................................. A-14

APPENDIX 9: Schematic, 230-460V, Chopper Pilot Cont. ........................................................ A-16

APPENDIX 10: Schematic, CCC 400V, w/ Chopper Pilot ......................................................... A-18

APPENDIX 10: Schematic, CCC 400V, w/ Chopper Pilot Cont. ................................................ A-20

APPENDIX 11: Schematic, CE 400V, Chopper Pilot ................................................................ A-22

APPENDIX 11: Schematic, CE 400V, Chopper Pilot Cont. ....................................................... A-24

APPENDIX 12: Schematic, CSA 600V, Chopper Pilot .............................................................. A-26

APPENDIX 12: Schematic, CSA 600V, Chopper Pilot Cont. ..................................................... A-28

APPENDIX 13: Schematic, DFC-3000 Auto Gas Box System ................................................. A-30

APPENDIX 14: PUBLICATION HISTORY................................................................................ A-32

TABLE OF CONTENTS (continued)

NOTE

provided separately.

SECTION 8. TORCH OPERATION, is

ULTRA-CUT 100

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

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

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

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

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

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

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

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

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

• This product, when used for welding or cutting, produces fumes or gases which contain chemicals known to the State of California to cause birth defects and, in some cases, cancer. (California Health & Safety Code Sec. 25249.5 et seq.)

WARNINGS

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

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

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

GASES AND FUMES

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

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

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.

Manual 0-5132

1-1

ULTRA-CUT 100

• 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.

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

NOISE

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

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

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

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

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:

Minimum Protective Suggested

Arc Current Shade No. Shade No.

Less Than 300* 8 9

300 - 400* 9 12

400 - 800* 10 14

* 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.

LEAD WARNING

This product contains chemicals, including lead, or otherwise produces chemicals known to the State of California to cause cancer, birth defects and other reproductive harm. Wash hands after handling. (California Health & Safety Code § 25249.5 et seq.)

1-2

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

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

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

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

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

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

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

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

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

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

12. CSA Standard W117.2, CODE FOR SAFETY IN WELDING AND CUTTING, obtainable from the Canadian Standards Association, Standards Sales, 178 Rexdale Boulevard, Rexdale, Ontario, Canada M9W 1R3

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

Manual 0-5132

THAT HAVE HELD HAZARDOUS SUBSTANCES, obtainable

from the American Welding Society, 550 N.W. LeJeune Rd, Miami, FL 33126

ULTRA-CUT 100

FUMÉE et GAZ

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

1.04 Note, Attention et Avertissement

Dans ce manuel, les mots “note,” “attention,” et “avertissement” sont utilisés pour mettre en relief des informations à caractère important. Ces mises en relief sont classifiées comme suit :

NOTE

Toute opération, procédure ou renseignement général sur lequel il importe d’insister davantage ou qui contribue à l’efficacité de fonctionnement du système.

ATTENTION

Toute procédure pouvant résulter l’endommagement du matériel en cas de non-respect de la procédure en question.

AVERTISSEMENT

Toute procédure pouvant provoquer des blessures de l’opérateur ou des autres personnes se trouvant dans la zone de travail en cas de non-respect de la procédure en question.

1.05 Precautions De Securite Importantes

AVERTISSEMENTS

L’OPÉRATION ET LA MAINTENANCE DU MATÉRIEL DE SOUDAGE À L’ARC AU JET DE PLASMA PEUVENT PRÉSENTER DES RISQUES ET DES DANGERS DE SANTÉ.

La fumée et les gaz produits par le procédé de jet de plasma peuvent présenter des risques et des dangers de santé.

• Eloignez toute fumée et gaz de votre zone de respiration. Gardez votre tête hors de la plume de fumée provenant du chalumeau.

• Utilisez un appareil respiratoire à alimentation en air si l’aération fournie ne permet pas d’éliminer la fumée et les gaz.

• Les sortes de gaz et de fumée provenant de l’arc de plasma dépendent du genre de métal utilisé, des revêtements se trouvant sur le métal et des différents procédés. Vous devez prendre soin lorsque vous coupez ou soudez tout métal pouvant contenir un ou plusieurs des éléments suivants:

antimoine cadmium mercure argent chrome nickel arsenic cobalt plomb baryum cuivre sélénium béryllium manganèse vanadium

• Lisez toujours les fiches de données sur la sécurité des matières (sigle américain “MSDS”); celles-ci devraient être fournies avec le matériel que vous utilisez. Les MSDS contiennent des renseignements quant à la quantité et la nature de la fumée et des gaz pouvant poser des dangers de santé.

• Pour des informations sur la manière de tester la fumée et les gaz de votre lieu de travail, consultez l’article 1 et les documents cités à la page 5.

• Utilisez un équipement spécial tel que des tables de coupe à débit d’eau ou à courant descendant pour capter la fumée et les gaz.

• N’utilisez pas le chalumeau au jet de plasma dans une zone où se trouvent des matières ou des gaz combustibles ou explosifs.

• Le phosgène, un gaz toxique, est généré par la fumée provenant des solvants et des produits de nettoyage chlorés. Eliminez toute source de telle fumée.

• Ce produit, dans le procéder de soudage et de coupe, produit de la fumée ou des gaz pouvant contenir des éléments reconnu dans L’état de la Californie, qui peuvent causer des défauts de naissance et le cancer. (La sécurité de santé en Californie et la code sécurité Sec.

25249.5 et seq.)

Coupant à l’arc au jet de plasma produit de l’énergie électrique haute tension et des émissions magnétique qui peuvent interférer la fonction propre d’un “pacemaker” cardiaque, les appareils auditif, ou autre matériel de santé electronique. Ceux qui travail près d’une application à l’arc au jet de plasma devrait consulter leur membre professionel de médication et le manufacturier de matériel de santé pour déterminer s’il existe des risques de santé.

Il faut communiquer aux opérateurs et au personnel TOUS les dangers possibles. Afin d’éviter les blessures possibles, lisez, comprenez et suivez tous les avertissements, toutes les précautions de sécurité et toutes les consignes avant d’utiliser le matériel. Composez le + 603-298-5711 ou votre distributeur local si vous avez des questions.

Manual 0-5132

CHOC ELECTRIQUE

Les chocs électriques peuvent blesser ou même tuer. Le procédé au jet de plasma requiert et produit de l’énergie électrique haute tension. Cette énergie électrique peut produire des chocs graves, voire mortels, pour l’opérateur et les autres personnes sur le lieu de travail.

• Ne touchez jamais une pièce “sous tension” ou “vive”; portez des gants et des vêtements secs. Isolez-vous de la pièce de travail ou des autres parties du circuit de soudage.

• Réparez ou remplacez toute pièce usée ou endommagée.

• Prenez des soins particuliers lorsque la zone de travail est humide ou moite.

1-3

ULTRA-CUT 100

• Montez et maintenez le matériel conformément au Code électrique national des Etats-Unis. (Voir la page

• Débranchez l’alimentation électrique avant tout travail d’entretien ou de réparation.

• Lisez et respectez toutes les consignes du Manuel de consignes.

INCENDIE ET EXPLOSION

Les incendies et les explosions peuvent résulter des scories chaudes, des étincelles ou de l’arc de plasma. Le procédé à l’arc de plasma produit du métal, des étincelles, des scories chaudes pouvant mettre le feu aux matières combustibles ou provoquer l’explosion de fumées inflammables.

• Soyez certain qu’aucune matière combustible ou inflammable ne se trouve sur le lieu de travail. Protégez toute telle matière qu’il est impossible de retirer de la zone de travail.

• Procurez une bonne aération de toutes les fumées inflammables ou explosives.

• Ne coupez pas et ne soudez pas les conteneurs ayant pu renfermer des matières combustibles.

• Prévoyez une veille d’incendie lors de tout travail dans une zone présentant des dangers d’incendie.

• Le gas hydrogène peut se former ou s’accumuler sous les pièces de travail en aluminium lorsqu’elles sont coupées sous l’eau ou sur une table d’eau. NE PAS couper les alliages en aluminium sous l’eau ou sur une table d’eau à moins que le gas hydrogène peut s’échapper ou se dissiper. Le gas hydrogène accumulé explosera si enflammé.

article 9.)

• Utilisez la nuance de lentille qui est suggèrée dans le recommendation qui suivent ANSI/ASC Z49.1:

Nuance Minimum Nuance Suggerée

Courant Arc Protective Numéro Numéro

Moins de 300* 8 9

300 - 400* 9 12

400 - 800* 10 14

* Ces valeurs s’appliquent ou l’arc actuel est observé clairement. L’experience a démontrer que les filtres moins foncés peuvent être utilisés quand l’arc est caché par moiceau de travail.

BRUIT

Le bruit peut provoquer une perte permanente de l’ouïe. Les procédés de soudage à l’arc de plasma peuvent provoquer des niveaux sonores supérieurs aux limites normalement acceptables. Vous dú4ez vous protéger les oreilles contre les bruits forts afin d’éviter une perte permanente de l’ouïe.

• Pour protéger votre ouïe contre les bruits forts, portez des tampons protecteurs et/ou des protections auriculaires. Protégez également les autres personnes se trouvant sur le lieu de travail.

• Il faut mesurer les niveaux sonores afin d’assurer que les décibels (le bruit) ne dépassent pas les niveaux sûrs.

• Pour des renseignements sur la manière de tester le bruit, consultez l’article 1, page 5.

RAYONS D’ARC DE PLASMA

Les rayons provenant de l’arc de plasma peuvent blesser vos yeux et brûler votre peau. Le procédé à l’arc de plasma produit une lumière infra-rouge et des rayons ultra-violets très forts. Ces rayons d’arc nuiront à vos yeux et brûleront votre peau si vous ne vous protégez pas correctement.

• Pour protéger vos yeux, portez toujours un casque ou un écran de soudeur. Portez toujours des lunettes de sécurité munies de parois latérales ou des lunettes de protection ou une autre sorte de protection oculaire.

• Portez des gants de soudeur et un vêtement protecteur approprié pour protéger votre peau contre les étincelles et les rayons de l’arc.

• Maintenez votre casque et vos lunettes de protection en bon état. Remplacez toute lentille sale ou comportant fissure ou rognure.

• Protégez les autres personnes se trouvant sur la zone de travail contre les rayons de l’arc en fournissant des cabines ou des écrans de protection.

PLOMB AVERTISSEMENT

Ce produit contient des produits chimiques, comme le plomb, ou engendre des produits chimiques, reconnus par l’état de Californie comme pouvant être à l’origine de cancer, de malformations fœtales ou d’autres problèmes de reproduction. Il faut se laver les mains après toute manipulation. (Code de Californie de la sécurité et santé, paragraphe 25249.5 et suivants)

1-4

Manual 0-5132

1.06 Documents De Reference

Consultez les normes suivantes ou les révisions les plus récentes ayant été faites à celles-ci pour de plus amples renseignements :

1. OSHA, NORMES DE SÉCURITÉ DU TRAVAIL ET DE PROTECTION DE LA SANTÉ, 29CFR 1910, disponible auprès du Superintendent of Documents, U.S. Government Printing Office, Washington, D.C. 20402

2. Norme ANSI Z49.1, LA SÉCURITÉ DES OPÉRATIONS DE COUPE ET DE SOUDAGE, disponible auprès de la Société Américaine de Soudage (American Welding Society), 550 N.W. LeJeune Rd., Miami, FL 33126

3. NIOSH, LA SÉCURITÉ ET LA SANTÉ LORS DES OPÉRATIONS DE COUPE ET DE SOUDAGE À L’ARC ET AU GAZ, disponible auprès du Superintendent of Documents, U.S. Government Printing Office, Washington, D.C. 20402

4. Norme ANSI Z87.1, PRATIQUES SURES POUR LA PROTECTION DES YEUX ET DU VISAGE AU TRAVAIL ET DANS LES ECOLES, disponible de l’Institut Américain des Normes Nationales (American National Standards Institute), 1430 Broadway, New York, NY 10018

5. Norme ANSI Z41.1, NORMES POUR LES CHAUSSURES PROTECTRICES, disponible auprès de l’American National Standards Institute, 1430 Broadway, New York, NY 10018

ULTRA-CUT 100

14. Norme AWSF4.1 de l’Association Américaine de Soudage, RECOMMANDATIONS DE PRATIQUES SURES POUR LA PRÉPARATION À LA COUPE ET AU SOUDAGE DE CONTENEURS ET TUYAUX AYANT RENFERMÉ DES PRODUITS DANGEREUX , disponible auprès de la American Welding Society, 550 N.W. LeJeune Rd., Miami, FL 33126

15. Norme ANSI Z88.2, PRATIQUES DE PROTECTION RESPIRATOIRE, disponible auprès de l’American National Standards Institute, 1430 Broadway, New York, NY 10018

6. Norme ANSI Z49.2, PRÉVENTION DES INCENDIES LORS DE L’EMPLOI DE PROCÉDÉS DE COUPE ET DE SOUDAGE, disponible auprès de l’American National Standards Institute, 1430 Broadway, New York, NY 10018

7. Norme A6.0 de l’Association Américaine du Soudage (AWS), LE SOUDAGE ET LA COUPE DE CONTENEURS AYANT RENFERMÉ DES PRODUITS COMBUSTIBLES, disponible auprès de la American Welding Society, 550 N.W. LeJeune Rd., Miami, FL 33126

8. Norme 51 de l’Association Américaine pour la Protection contre les Incendies (NFPA), LES SYSTEMES À GAZ AVEC ALIMENTATION EN OXYGENE POUR LE SOUDAGE, LA COUPE ET LES PROCÉDÉS ASSOCIÉS, disponible auprès de la National Fire Protection Association, Batterymarch Park, Quincy, MA 02269

9. Norme 70 de la NFPA, CODE ELECTRIQUE NATIONAL, disponible auprès de la National Fire Protection Association, Batterymarch Park, Quincy, MA 02269

10. Norme 51B de la NFPA, LES PROCÉDÉS DE COUPE ET DE SOUDAGE, disponible auprès de la National Fire Protection Association, Batterymarch Park, Quincy, MA 02269

11. Brochure GCA P-1, LA MANIPULATION SANS RISQUE DES GAZ COMPRIMÉS EN CYLINDRES, disponible auprès de l’Association des Gaz Comprimés (Compressed Gas Association), 1235 Jefferson Davis Highway, Suite 501, Arlington, VA 22202

12. Norme CSA W117.2, CODE DE SÉCURITÉ POUR LE SOUDAGE ET LA COUPE, disponible auprès de l’Association des Normes Canadiennes, Standards Sales, 178 Rexdale Boulevard, Rexdale, Ontario, Canada, M9W 1R3

13. Livret NWSA, BIBLIOGRAPHIE SUR LA SÉCURITÉ DU SOUDAGE, disponible auprès de l’Association Nationale de Fournitures de Soudage (National Welding Supply Association), 1900 Arch Street, Philadelphia, PA 19103

Manual 0-5132

1-5

ULTRA-CUT 100

1.07 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’ (2006/95 EC) 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.

* CENELEC EN50199 EMC Product Standard for Arc Welding Equipment.

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

* 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 cutting 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,

1-6

England PR6 7BX

Manual 0-5132

ULTRA-CUT 100

1.08 Statement of Warranty

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

THIS WARRANTY IS EXCLUSIVE AND IS IN LIEU OF ANY WARRANTY OF MERCHANT ABILITY OR FITNESS FOR A P ARTICULAR PURPOSE.

LIMIT A 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 INVALID 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 Y ear

Labor

Torch And Leads

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

Repair/Replacement Parts 90 Days 90 Days

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

Effective August 19, 2005

Manual 0-5132

1-7

ULTRA-CUT 100

1-8

Manual 0-5132

ULTRA-CUT 100

SECTION 2: SPECIFICATIONS

2.01 General Description Of The System

A typical Ultra-Cut® 100 system configuration will include:

• One Power Supply

• Remote Arc Starter

• Gas Control Module

• Torch Valve Assembly

• Precision Plasma Cutting Torch

• Set Of Connecting Leads

• Torch Spare Parts Kit

The components are connected at installation.

2.02 Plasma Power Supply

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

2.03 Remote Arc Starter

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

2.04 Gas Control Module

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

2.05 Precision Plasma Cutting Torch

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

Manual No. 0-5132 2-1 SPECIFICATIONS

ULTRA-CUT 100

2.06 Specifications & Electrical Requirements

Ultra-Cut 100 Specifications & Design Features

Input Power & Current 208/230V - 460V , 1/ 3 ph, 50 / 60 Hz Max OCV (U Minim um Out put Current 10 Amps Max Out put Current 100 Amps Output V oltage 60 - 230 vdc Duty Cy c l e Rati ng 100% @ 100A, 180V Ambi ent Temperature for Dut y Cy cl e Rati ng Operating range 14°F to 122°F (-10°C to + 50°C) Power Factor 0. 70 @ 100 A DC Output Cooling Forced A i r (Class F)

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

Vol tage Freq. 3-Ph 3-Ph Fuse (A mps ) W i re (AWG)

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

208 50/60 23 64 80 230 50/60 24 60 75 40050284050

400 (CE) 50 28 40 50

460 50/60 26 33 40 600 50/60 25 24 30 #8

Line Voltages wit h S ugges ted Circui t P rot ect ion and Wire Si zes

Bas ed on Nati onal E l ec t ri c Code and Canadian Electri cal Code

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

) 380 vdc

104F° (40°C)

Ultra-Cut 100 Power S upply

#4 #4 #6

1 1 1

2.07 System Component Layout

125’ / 38.1 m Maximum Length

Pilot Return

Negative

Coolant Supply

Primary power

CNC

To uch

Screen

Controller

Art # A-09124

Ultra-Cut

Power Supply

Coolant Return

Control Cable

Fiber Optic

Control Cable

Ground Cable

Only When DMC Mounted On Top Of PS

DMC-3000

175’ / 53.3 m Maximum Length

Gas

Console

175’ / 53.3 m Maximum Length

Remote

Starter

Plasma Gas

Fiber Optic

Secondary

Preflow

Control Cable

Water Shield

Marking

Work Cable

DPC-3000

100’ / 30.5 m Maximum Length

Pilot Return

Arc

Gas

Control

Coolant Supply

Coolant Return

Plasma Gas

Shield Gas

Shield

Positioning Tube

Torch

Work

SPECIFICATIONS 2-2 Manual No. 0-5132

2.08 Power Supply Dimensions

41.25 inch 1050 mm

ULTRA-CUT 100

27 inch 680 mm

Art # A-04793

33 inch 840 mm

37.75 inch

960 nm

27.5 inch 700 mm

343 lb / 156 kg

Manual No. 0-5132 2-3 SPECIFICATIONS

ULTRA-CUT 100

2.09 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

SPECIFICATIONS 2-4 Manual No. 0-5132

ULTRA-CUT 100

2.10 Gas Requirements

The customer will provide all gases and pressure regulators. Gases must be of high quality. Pressure regulators shall be double stage. The chart includes gases which may not be used in all applications.

Ultra-Cut 100 Power S uppl y: Gas Pressures, Fl ows, and Qua l i ty Require m ents

Gas Quality Minimum Press ure Flow

(Oxygen)

(Nitrogen)

99.5% Purity

(Liquid rec om mended)

99.5% Purity

(Liquid rec om mended)

<1000 ppm O

ppm H

, <32

120 psi

8.3 bar / 827 k Pa

120 psi

8.3 bar / 827 k Pa

70 scfh (1982 l/h)

200 scfh (5700 l/h)

Compressed

or Bottled Air

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

65% A rgon

Ar (A rg on)

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

: The air sourc e m ust be adequat el y filtered to remove all oil or greas e. Oi l or greas e

Note 1

Clean, Dry ,

Free of Oil (s ee Not e 1)

99.995% P uri ty

(gas recommended)

99-995% Puri ty

(gas rec om m ended)

120 psi

8.3 bar / 827 k Pa

120 psi

8.3 bar / 827 k Pa

80 psi

5.5 bar / 550 k Pa

244 scfh (6910 l/h)

90 scfh (2550 l/h)

21 scfh (600 l/h)

cont am i nation from c ompress ed or bot t l ed ai r can cause fires i n conjunc tion wi t h oxy gen. For filt ering, a coal esc i ng fil t er abl e t o fil ter to 0. 01 m i crons should be placed as close as

possible to the gas inl et s on t he Gas Control M odul e.

: The tap water s ource does not need to be deionized, but in wat er s ys tems wit h extrem el y hi gh

Note 2

mineral content a water s oft ener is rec omm ended. Tap water with hi gh l evels of particulat e m at ter mus t be filtered.

2.11 Gas Applications

Ultra-Cut-100 Gas A ppli c ations

MATERIAL

OPERATION

30A CUT

50 A CUT

70 A CUT

85A CUT

100 A CUT

PREFLOW PLASMA SHIELD PREFLOW PLASMA SHIELD PREFLOW PLASMA SHIELD

MILD ST EEL ST AINL ES S S T EEL ALUMI NUM

GAS TYPEGAS TYPE GAS TYPE

Air

Air Air Air Air Air Air

H20N2N

Air Air Air Air Air Air

H20N2N

Air Air Air Air Air Air

H20N2N

Air Air Air Air

AirO

H35 N

H20N2N

H35 N

H20

Manual No. 0-5132 2-5 SPECIFICATIONS

ULTRA-CUT 100

2.12 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

SPECIFICATIONS 2-6 Manual No. 0-5132

2.74"

69.55 mm

1.57"

39.96 mm

1.49"

37.8 mm

B. Torch Specifications

-300 Torch Rat i ngs

for us e wi th Ul tra-Cu t 100 Powe r Supply Ambient Tempera ture

104° F

40° C Duty Cycl e 100% @ 100 Am ps Maxi m um Current 100 Am ps

Volt age (V

)500V

peak

Arc S t ri k i ng V ol t age 10kV Current

-300 Torc h Gas Speci fic ations

Up to 100 Amps, DC,

Straight Polarity

Compress ed A i r, Plasma Gases:

Oxygen,

Nit rog en, H35

Compress ed A i r, Shield Gases:

Oxygen,

Nitrogen, Water Marking Gas

Argon

ULTRA-CUT 100

Operating P ressure Maxi m um Input P res sure 135 psi / 9.3 bar

C. Leads Lengths

Gas Lead Assemblies

D. Torch Parts (Generic Parts Shown)

125 psi ± 10 ps i

8.6 bar ± 0.7 bar

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 Cup

Manual No. 0-5132 2-7 SPECIFICATIONS

Shield Cap

Shield Gas

Distributor

Plasma Gas

Tip

Distributor

Electrode

Cartridge

ULTRA-CUT 100

E. 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.

F. Type of Cooling

Combination of gas stream through torch and liquid cooling.

SPECIFICATIONS 2-8 Manual No. 0-5132

SECTION 3: INSTALLATION

3.01 Installation Requirements

Electric Supply

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

Ultra-Cut 100 Power S upply

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

Vol tage Freq. 3-Ph 3-Ph Fuse (A mps ) W i re (AWG)

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

208 50/60 23 64 80 230 50/60 24 60 75 40050284050

400 (CE) 50 28 40 50

460 50/60 26 33 40 600 50/60 25 24 30 #8

Line Voltages wit h S ugges ted Circui t P rot ect ion and Wire Si zes

Bas ed on Nati onal E l ec t ri c Code and Canadian Electri cal Code

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

ULTRA-CUT 100

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.

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.

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

7-3580 'Extra-Cool

7-3581 'Ultra-Cool

7-3582 'Ext reme Cool

* For mixing wit h D-I Cool

' Concentrate* -76° F / -60° C

7-3583

Manual No. 0-5132 3-1 INSTALLATION

25 / 75 10° F / -12° C

50 / 50 -27° F / -33° C

ULTRA-CUT 100

3.02 System Layout

Refer to section 3.05 for ground connections and ground cables.

175’ / 53.3 m Maximum Length

Primary power

CNC

To uch

Screen

Controller

Art # A-09124_AC

Pilot Return

Ultra-Cut

Power Supply

Fiber Optic

Control Cable

Ground Cable

Only When DMC Mounted On Top Of PS

125’ / 38.1 m Maximum Length

Negative

Coolant Supply

Coolant Return

Control Cable

DMC-3000

175’ / 53.3 m Maximum Length

Gas

Console

Plasma Gas

Fiber Optic

Shield Gas

Preflow

Control Cable

Water Shield

Marking

Work Cable

100’ / 30.5 m Maximum Length

Pilot Return

Remote

Arc

Starter

DPC-3000

Gas

Control

Shield

Coolant Supply

Coolant Return

Shield

Plasma Gas

Shield Gas

Positioning Tube

To rc h

Work

INSTALLATION 3-2 Manual No. 0-5132

3.03 Cables & Leads Identification

ULTRA-CUT 100

#8 AWG Cable

#1 AWG Cable

Green

Red

Green / Yellow #4 AWG (16 mm2)

Green / Yellow 1/0 (50 mm2)

Green

Red

Pilot Return, Power Supply to Arc Starter

Negative Lead, Power Supply to Arc Starter

Coolant Supply Lead, Power Supply to Arc Starter

Coolant Return Lead, Power Supply to Arc Starter

Control Cable, Power Supply to Arc Starter

Ground Cable

Ground Cable, Remote Arc Starter To Earth Ground

Shielded Torch Lead Assembly, Remote Arc Starter to Torch

Art # A-09125_AC

H, Q, R, T, U

S,V

16 pin

P, W

14/11

1/0 Cable (50 mm2 )

Plasma Gas Lead, Torch Valve to Torch

Shield Gas Lead, Torch Valve to Torch

Control Cable, From Power Supply

Fiber Optic Cable, Power Supply to DMC-3000

For use with DFC-3000

S - Control Cable,

DMC-3000

V - TSC-3000 to PS

Work Cable

P - CNC Cable (14 Wire)

W - CNC Communitcation Cable (11 Wire)

DPC-3000

Manual No. 0-5132 3-3 INSTALLATION

ULTRA-CUT 100

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

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.

INSTALLATION 3-4 Manual No. 0-5132

Art # A-04796

ULTRA-CUT 100

3.05 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. 0-5132 3-5 INSTALLATION

ULTRA-CUT 100

Check / Adjust Input Voltage Configuration for 208/230 and 460V Systems

1. The 208/230 and 460 V 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. Unplug connector

208/230V / 460V

Input Voltage Board

(Shown in 460V Position)

2. Remove bolts.

3. Invert board.

4. Re-install board.

5. Plug in connector.

Art # A-04856_AB

INSTALLATION 3-6 Manual No. 0-5132

ULTRA-CUT 100

Connect Input Power and System Ground Cables

1. Carefully cut back the outer sheath on the primary input power cable to expose the individual wires. Cut back the insulation on the individual wires. Route the cable upward through 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 stripped end of 3 phase wires into the terminal block L1, L2 and L3.

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

CAUTION

The clear connections cover must remain in place.

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

Ground Terminal Block

Connections Cover

Connection Panel

to Remote Arc Starter

AC INPUT

L1 L2 L

PILOT

Art # A-07659_AB

K TORCH

to Remote Arc Starter

Input power cable

System Ground Cable

Input power cable ground

Connections Cover

Support Panel

System Ground Cable

Leads Bracket

Manual No. 0-5132 3-7 INSTALLATION

ULTRA-CUT 100

3.06 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

1 L2

To Remote Arc Starter

Connections Cover Support Panel

Art # A-07660_AB

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

INSTALLATION 3-8 Manual No. 0-5132

Lead Connection Detail

To Cutting Table

Leads Bracket

3.07 Ground Connections

Star Ground on Cutting Table

ULTRA-CUT 100

Remote Arc

Starter (RAS-1000)

To rc h

Cutting Machine / Gantry

Cutting Table

1/0

Ground Cable

(F1)

1/0

Ground Cable

Customer supplied

Earth Ground

Rod

0 - 10 ft (0 - 3 m) Ideal

20 ft (6 m) Maximum

DPC-3000 Gas Control

Primary location

TSC-3000 Remote

(F)

TSC-3000 Internal

#4 AWG

Ground

(F)

1/0 Ground Cable

Power Supply

1/0 Work Cable

‘Star’

Ground

Note: The DMC-3000 gas control can be mounted on top of the power supply. If it is, it should be grounded directly to the power supply with #4 AWG ground, (F). This alternate location requires grounding the power supply to the ‘Star’ ground with the 1/0 Ground Cable (F1).

Art # A-09128

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.

Manual No. 0-5132 3-9 INSTALLATION

ULTRA-CUT 100

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

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

NOTE

Do Not connect the work cable directly to the ground rod. Do not coil up excess ground or power cables. Cut to proper length and reterminate as needed.

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

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

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

NOTE

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

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

Creating An Earth Ground

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

NOTE

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

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.

INSTALLATION 3-10 Manual No. 0-5132

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

ULTRA-CUT 100

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

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. 0-5132 3-11 INSTALLATION

ULTRA-CUT 100

3.08 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

INSTALLATION 3-12 Manual No. 0-5132

ULTRA-CUT 100

3.09 Connect Control Cables for CNC, Remote Arc Starter, and DMC-

3000

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.

Customer Wiring Access Hole

To DMC-3000

To CNC Control

To Remote Arc Starter

RETURN

SUPPLY

Art # A-09129

Manual No. 0-5132 3-13 INSTALLATION

ULTRA-CUT 100

3.10 Connect TSC-3000 Cable and DMC-3000 Fiber Optic Cable to CCM

1. Remove the plastic plug in the CCM at the rear of the Power Supply labelled GCM/DCM.

To TSC-3000

Fiber Optic To DMC-3000

RETURN

SUPPLY

Art # A-09134

CAUTION

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

2. Remove outer thin nut from through hole protector at one end of Fiber Optic Cable (L) that connects between the CCM portion of the Power Supply and the DMC-3000.

INSTALLATION 3-14 Manual No. 0-5132

ULTRA-CUT 100

3. Feed the Fiber Optic Cable plug and wires through the hole where the plastic plug was removed labelled GCM/DCM and slide the thin nut back over the Fiber Optic Cable.

4. Secure the thin nut on the through hole protector so both nut faces are tight against the sheet metal inside and out.

5. Plug the Fiber Optic Cable into the PCB as shown below. Make sure the locking tabs are engaged.

Fiber Optic Cable Plug

Thin nut securing the through hole protector

Art # A-09136

6. Notice the alignment pin and then connect the TSC-3000 cable (V) to the rear of the CCM as shown below.

TSC-3000 Cable

DMC-3000 Fiber Optic Cable

Art # A-09137

Manual No. 0-5132 3-15 INSTALLATION

ULTRA-CUT 100

3.11 Set Switches on the Command - Control 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

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 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 Reserved for Factory use. SW-5-2: Off Plate Reserved for Factory use.

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

ON = Long (3 s.)

SW 8-2: Remote Current OFF = Disabled (Factory default setting). ON = (Remote Analog Current Control)

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

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

SW1

SW3 SW4

SW5

SW8

O N

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

* SW 8-3 is reserved for

Factory use prior to

Firmware V3.5

Art # A-09166

INSTALLATION 3-16 Manual No. 0-5132

ULTRA-CUT 100

CAUTION

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

SW11

SW6

SW12

SW13

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

SW-11: Analog Current Control. B = from Gas Control (Factory default setting) or A = Remote Analog Source. 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 = ON = 25:1

SW13: Auto Gas Switch positions

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

Only 1 on at a time.

Art # A-09167

Manual No. 0-5132 3-17 INSTALLATION

SW13 (Note positions 3-4 are not yet used)

ULTRA-CUT 100

3.12 Height Control Connections

The terminal strip has Arc Volts (-) connection to power supply negative output TORCH terminal, Arc Volts (+) connection to power supply positive output WORK terminal. These are for a height control that requires connection to the full non-divided arc voltage. Also available on the terminal strip are 120VAC (120,0) and 24 VAC (24, 0). Note that the two 0’s are not common. The allowable current draw is 100ma @ 120VAC and 1Amp @ 24 VAC.

Art # A-08404

NOTE

There is also a hole added in the rear panel above the J55-GCM receptacle for customer wiring. This, rather than the one in the CCM will be the preferred place for customer added wiring (and strain relief) for connections to height controls, etc..

3.13 DMC-3000 Gas Manifold Control Installation

The DMC-3000 Gas Control 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 any 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.

INSTALLATION 3-18 Manual No. 0-5132

Mounting Dimensions

DMC-3000 Proﬁle

Art # A-09138

13.60 in

[345.6 mm]

DMC-3000 Top

7.08 in

[179.8 mm]

5.00 in [127.0 mm]

.30 in

[7.62 mm]

ULTRA-CUT 100

11.44 in

[290.6 mm]

12.18 in

[309.4 mm]

Preparation

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

Remove 2 Screws

Manual No. 0-5132 3-19 INSTALLATION

Art # A-09139

Loosen or remove 2 screws

ULTRA-CUT 100

2. Carefully remove the cover from the module noting the attached wire harness that connects to J1. Remove the wire harness and then set the cover to the side.

Art # A-09140

Cover Removal

3. Attach all hoses and cables to the back of the DMC-3000 except the Fiber Optic cable which will be covered a little later. Avoid turning any fittings already mounted in the unit by placing a wrench on it before tightening the hose fitting to it.

Art # A-09141

If replacing existing fittings in the base: For a secure seal, apply thread sealant to the fitting threads, according to manufacturer’s instructions. Do not use Teflon tape as a thread sealer, as small particles of the tape may break off and block the small air passages in the torch.

INSTALLATION 3-20 Manual No. 0-5132

NOTE

ULTRA-CUT 100

NOTE

All gas fittings are 1/4” and the air fitting is 3/8”.

4. Connect the ground cable to rear of DMC-3000 shown in previous illustration.

5. Connect Control cable from the Power Supply to J56 on the front of the DMC-3000 as shown below. The Fiber Optic cable will be covered a little later.

Art # A-09142

Manual No. 0-5132 3-21 INSTALLATION

ULTRA-CUT 100

3.14 DPC-3000 Gas Pressure Control Installation

The DPC-3000 Gas Control must be installed in a suitable location close to the Torch such as the gantry. The unit must be mounted to a flat horizontal surface. If the Module is mounted to any support subject to vibration or motion, the installer must fasten the module to the support securely.

The Module also comes with non metalic isolation grommets for mounting. These must be used in all four mounting slots to raise the Module so there is nometal to metal contact between the Module and the mounting surface.

Mounting Dimensions

DPC-3000 Proﬁle

10.90 in

[276.86 mm]

Art # A-09143

DPC-3000 Top

6.64in

[168.7mm]

.30 in [7.62mm]

4.00 in

[101.6 mm]

10.45 in

[265.4 mm]

11.00 in

[279.4 mm]

INSTALLATION 3-22 Manual No. 0-5132

Preparation

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

Remove 2 Screws

ULTRA-CUT 100

Art # A-09144

Loosen or remove 2 screws

2. Carefully remove the cover from the module noting the attached wire harness that connects to J4. Remove the wire harness and then set the cover to the side.

Manual No. 0-5132 3-23 INSTALLATION

Art # A-09145

Cover Removal

ULTRA-CUT 100

3. Attach all hoses and cables to the back of the DPC-3000 except the Fiber Optic cable which will be covered a little later. Avoid turning any fittings already mounted in the unit by placing a wrench on it before tightening the hose fitting to it.

Do not connect Fiber Optic cable until later

Art # A-09146

4. Connect hoses from the front of the DMC-3000 where shown below to the torch.

NOTE

One fitting with the notches is left hand thread and the other is standard right hand thread.

INSTALLATION 3-24 Manual No. 0-5132

Art # A-09147

ULTRA-CUT 100

3.15 Fiber Optic Cable Installation from CCM to DMC-3000.

1. Remove outer thin nut from through hole protector at the end of Fiber Optic Cable (L) that is connectsed to

the CCM.

CAUTION

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

2. Ensure that the cable is exposed beyond the through hole protector approximately 1” (as shown below) and secure by hand tightening the wide nut with the rounded end.

3. Feed the Fiber Optic Cable plug and wires through the hole where shown then slide the thin nut back over the Fiber Optic Cable.

Manual No. 0-5132 3-25 INSTALLATION

Art # A-09148

ULTRA-CUT 100

4. Secure the thin nut on the through hole protector so both nut faces are tight against the sheet metal inside and out.

Art # A-09149

5. Plug the Fiber Optic Cable into the PCB as shown below. Make sure the locking tabs are engaged.

Fiber Optic Cable to/from DPC-3000 plugs in here

Fiber Optic Cable to/from CCM plugs in here

INSTALLATION 3-26 Manual No. 0-5132

Art # A-09150

Before

After

ULTRA-CUT 100

Art # A-09151

Manual No. 0-5132 3-27 INSTALLATION

ULTRA-CUT 100

3.16 Fiber Optic Cable Installation From DMC-3000 to DPC-3000

1. Remove outer thin nuts from through hole protector at both ends of Fiber Optic Cable (L) that connects between the DCM-3000 and DPC-3000.

CAUTION

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

2. Ensure that the cable is exposed beyond the through hole protector approximately 1” and secure by hand tightening the wide nut with the rounded end.

3. Feed the Fiber Optic Cable plug and wires through the back of each module (DMC-DPC)where indicated and slide the thin nut back over the Fiber Optic Cable.

Fiber Optic for DMC-3000 goes here

Art # A-09152

Insert Fiber Optic cable here

Art # A-09153

INSTALLATION 3-28 Manual No. 0-5132

ULTRA-CUT 100

4. Secure each of the thin nuts on the through hole protectors so both nut faces are tight against the sheet metal inside and out.

5. Plug the Fiber Optic Cable into the PCB as shown below for the DMC-3000. Make sure the locking tabs are engaged.

Plug Fiber Optic cable to/from DPC-3000 here

Art # A-09154

6. Plug the Fiber Optic Cable into the PCB as shown below for the DPC-3000. Make sure the locking tabs are engaged.

Fiber Optic to/from DMC-3000 plugs in here

Art # A-09155

7. Reinstall the Cover Panels making sure the wireharnesses are attached. Reverse steps 1 and 2 in sub section 3.13 and 3.14

Manual No. 0-5132 3-29 INSTALLATION

ULTRA-CUT 100

3.17 Install TSC-3000 Touch Screen Control

Mounting Dimensions

TSC-3000 Top

1.11 in

[28.2 mm]

2.35 in

[59.69 mm]

5.58 in

[141.7 mm]

.25 in

[6.35 mm]

10.83 in

[275.0 mm]

11.80 in

[299.7 mm]

12.45 in

[316.2 mm]

TSC-3000 Profile

6.99 in

[177.5 mm]

Preparation

1. 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. The TSC-3000 mounting brackets allow for mounting on or under a horizontal surface as well as left or right of a vertical surface. Choose which ever works best for protection against moving equipment and flying metal/cutting debris etc..

Art # A-09156

2. Once the unit has been secured to a flat surface, attach Communication cable (“V” which is already attached to the CCM done in sub section 3.10) and ground cable (“F”) to the rear of the unit.

Art # A-09157

Ground Cable to/from “Star” ground on table

Communication Cable to/from CCM rear of power supply

INSTALLATION 3-30 Manual No. 0-5132

ULTRA-CUT 100

3.18 Install Remote Arc Starter

Site Location

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

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

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

Mounting Dimensions

NOTE

Height not shown is 7.375” ( 187mm )

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”

Art # A-07961

Manual No. 0-5132 3-31 INSTALLATION

37.77mm

1.49”

266.70mm

10.50”

ULTRA-CUT 100

Installation

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

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

NOTE

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

2. Remove the Cover Panel from the Arc Starter.

Upper screws (2 per side)

Cover

Lower screws (2 per side)

Art # A-09625

Cover Removal

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

Ground Wire

INSTALLATION 3-32 Manual No. 0-5132

ULTRA-CUT 100

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-09626

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-09627

Return

Supply

Coolant Supply and Return Hoses (from power supply)

Manual No. 0-5132 3-33 INSTALLATION

ULTRA-CUT 100

Coolant Return (Red)

Art # A-09628

Red

Coolant Supply (Green)

Green

Copper plate

Art # A-09629

Negative Cable from power supply.

Negative Cable (from Power Supply rear panel)

INSTALLATION 3-34 Manual No. 0-5132

Pilot Return Cable from Power supply

ULTRA-CUT 100

Art # A-09630

PILOT Return Cable (from Power Supply rear panel)

Art # A-09631

Control Cable from Power Supply rear panel

Manual No. 0-5132 3-35 INSTALLATION

ULTRA-CUT 100

Output Connections

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

For newer leads with only one black wire, it must be connected to the pilot return.There are no inner shield wires.

NOTE

Pilot Lead

Art # A-09632

Pilot Lead Connection Detail

Pilot Return Cable (from Torch Leads)

INSTALLATION 3-36 Manual No. 0-5132

Art # A-09633

Coolant Return Fitting (Tagged with Red)

Coolant Return (Red) from Torch

ULTRA-CUT 100

Some items are removed for clarity.

Coolant Supply Fitting (Tagged with Green)

Coolant Supply (Green) to 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 (2 per side)

Cover

Ground Wire

Lower screws (2 per side)

Manual No. 0-5132 3-37 INSTALLATION

Art # A-09625

ULTRA-CUT 100

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

grounding details.

Art # A-04758

Torch Leads

1 Nut and 1 Washer Remain in Place

Ground Cable

• 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

INSTALLATION 3-38 Manual No. 0-5132

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

ULTRA-CUT 100

Art # A-04801

Remote Arc Starter

Remote Arc Starter Input Connection Panel

Manual No. 0-5132 3-39 INSTALLATION

ULTRA-CUT 100

3.19 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-09198

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.

INSTALLATION 3-40 Manual No. 0-5132

ULTRA-CUT 100

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. Use two wrenches for each connection: one to hold the non hose fitting in place while using the other to tighten the hose fitting.

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. Fold the excess wire in a serpentine shape and tuck inside cover. 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.

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

3.20 Install Consumable Torch Parts

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

Manual No. 0-5132 3-41 INSTALLATION

ULTRA-CUT 100

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

2. Stack the consumable parts together.

Art # A-09200

Shield

Cup

1 - Assemble “B”.

Shield

Shield Gas

Distributor

Tip

Plasma Gas

Distributor

Electrode

2 - Assemble “B” to “C”. 3 - Assemble “A” to “B-C” assembly.

Cartridge

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

4. Use the cartridge tool to hold the cartridge assembly, while turning the shield cup or shield retainer for onto the cartridge assembly. When this group is fully assembled, the shield should protrude from the front of the shield cup or shield retainer. Without this protrusion the shield cup is not properly tightened onto the cartridge assembly.

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

Torch Head

Torch Head O-Ring

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.

INSTALLATION 3-42 Manual No. 0-5132

Art # A-08300_AB

55 - 100 Amp Parts Assembly

ULTRA-CUT 100

Electrode

Plasma Gas Distributor

Tip

Shield Gas Distributor

Shield Cap

3: Thread Shield Cup onto Cartridge

1: Stack Parts

O-Ring

on Tip

2: Press Cartridge onto Stacked Parts

No Gaps

Between Parts

Cartridge Covers O-Ring on Torch Tip

4: Check Shield Cap Protrusion

Shield Cup

Shield Cap Protrudes

0.063-0.083" (1.6 - 2.1 mm)

Installing Assembled Cartridge Onto Torch Head

Shield Cap

Art # A-04873

Manual No. 0-5132 3-43 INSTALLATION

ULTRA-CUT 100

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

Ohmic Clip

sensing.

Art # A-03393_AB

NOTE

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

INSTALLATION 3-44 Manual No. 0-5132

ULTRA-CUT 100

3.21 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

' Concentrate* -76° F / -60° C

7-3583

25 / 75 10° F / -12° C

50 / 50 -27° F / -33° C

Fill Range

Coolant Tank

COOLANT

RETURN

SUPPLY

RETURN

SUPPLY

Art # A-04803

Manual No. 0-5132 3-45 INSTALLATION

ULTRA-CUT 100

2. After the complete system has been installed, check that the coolant has been pumped through the system as follows (see NOTE):

Depending on the length of the torch leads, the system may require more coolant after turning the system ON for the first time.

a. Place the ON/OFF Switch to ON.

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

c. Place the ON/OFF switch to OFF.

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

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

torch leads this sequence may need to be done three to five times and coolant may need to be added.

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

from the coolant lines before using the system.

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

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

NOTE

INSTALLATION 3-46 Manual No. 0-5132

SECTION 4: OPERATION

4.01 Power Supply Control Panel

ULTRA-CUT 100

AC Indicator

Temp Indicator

Art # A-04862

AC Power Indicator

Indicates AC power is being supplied to the inverters when the ON/OFF switch is in ON position. When switch is first set to ON, the indicator stays off until the inrush cycle is complete and the correct voltage is confirmed.

TEMP Indicator: Normally OFF. Indicator turns ON when the internal temperature sensors detect tempera-

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

Gas Indicator

DC Indicator

Status Indicator

GAS Indicator: Normally ON when gas is flowing. The indicator blinks when the gas control is not ready,

such as during the purge cycle or when the gas control is not in the RUN mode or when there is a communication error. Indicator is off when there is no call for gas flow.

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

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

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

Manual No. 0-5132 4-1 OPERATION

ULTRA-CUT 100

4.02 Start-Up Sequence

1. Connect system to primary input power.

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

turns ON after about 5 seconds.

POWER

OFF

Art # A-04812

3. Check the AC indicator. If the inverter modules are correctly configured for the input voltage and the switch is ON, then voltage has been applied to the inverter modules (input contactors are ON). If the indicator does not light after a few seconds disconnect power and check that each inverter is correctly configured for the input voltage and all 3 phases are present. Check Status Indicator for any codes that can help. Once it is determined that input is OK, it is necessary to select and load a process.

OFF

4.03 TSC-3000 Navigation Functions

SAMPLE

System Sta tus: IDLE

BACK BUT TON

REVERSES TO THE PREVIOUS PAGE

DISPLAYS SYSTEM STATUS IN ALL SCREENS

PAGE HEADER

- +

INCR EMENTS

SELECTED VALUE

DECREMENTS THE

Art # A-09158

SELECTION NAVIGATION

MOVES CURSOR / SELECTION UP

AND DOWN ON THE PAGE OR

SC R OLLS TE XT IN D IALOG BOX

OK /NEXT BUTTON :

ACCEPTS ENTRIES AND MOVES TO THE

WINDOW

OPERATION 4-2 Manual No. 0-5132

ULTRA-CUT 100

4.04 TSC-3000 Initial Setup ONLY

Initial steps required before First operation only. Note 400 Amp system requires a Height

Controller with Elevation Height (EH) feature.

When power is turned on TSC 3000 goes to the Home screen. For new installation it is required to perform initial SETUP. Press SETUP button (1). Enter Initial default PASSWORD 00000 (2)

Select language and measurement units.

Enter SYSTEM UTILITY (3).

Enter XT lead (DPC to Torch); only 4’ current allowed. Enter DFC 3000 lead length (DMC to DPC);

HOME

SETUP

UTILITY 1 of 3

ENTER/CHANGE PASSWORD

To change Password press SET PASSWORD enter new 5 digit password (1a). Press green arrow to accept new password and return to SETUP screen (2).

Elevation Height Feature is required for the Ultra-Cut 400

Utility Screen 2 is for information only. Displays Device and Cutchart IDs, setting of options switches etc.

Utility screen 3 (5) allows viewing consumable statistics, Starts, Hours, Errors.

Manual No. 0-5132 4-3 OPERATION

UTILITY 2 of 3

Return to Home Screen.

UTILITY 3 of 3

Art # A-09656

ULTRA-CUT 100

4.05 TSC-3000 Selecting New Process

Select new standard process by material; thickness; amperage (1) or enter process # using pop-up number pad (2).

HOME

Material –

Scroll to select, Thickness – Scroll to select,

Accept & advance (1).

SELECT MATERIAL, THICKNESS

SELECT PROCESS NUMBER

TORCH CONSUMABLES

Select process by # (2) or by name (3). If by name, first select process type; best cut, fastest, MAX Pierce, etc. Then press

To accept &

advance to Torch Consumables. (4

Confirm the listed torch consumables are installed in the torch.

Go to THC / CNC settings for cutting (5).

SELECT PROCESS

THC / CNC Settings (Cutting)

THC / CNC Settings (Marking)

Now you are ready to start cutting. Displayed Amps Demand is the output current

setting, not the actual current.

As soon as Start is applied Process Monitor shows output voltage, gas pressures, status of Start, OK to Move and Gas On signals. Here you can toggle between Plasma Marking with the selected consumables and cutting.

OPERATION 4-4 Manual No. 0-5132

PROCESS MONITOR

Toggle between Cut & Marking settings (6).

Proceed to Process Monitor (7).

Art # A -09160

4.06 TSC-3000 Selecting Recently Used Process

Home screen shows some of the most recently used processes with the last one used highlighted. Select the highlighted process by pressing the Green arrow or scroll with up/down arrows to select another recent process then press the green arrow.

ULTRA-CUT 100

HOME

If you already know the settings and consumables you can go directly to Process Monitor using CUT MONITOR button. (1a).

THC / CNC Settings

Check that you have the correct torch consumables. (1)

Use SHOW CUTTING & SHOW MARKING to toggle between views of cutting & marking settings.

Proceed to Cut Monitor (3)

TORCH CONSUMABLES

Go to THC / CNC Setting to see recommended Torch Height Control and CNC settings; (2)

Art # A-09161

CUT MONITOR

Now you are ready to start cutting. Displayed Amps Demand is the output current

setting, not the actual current.

Manual No. 0-5132 4-5 OPERATION

ULTRA-CUT 100

4.07 TSC-3000 Creating a Custom Process

Considerable effort has been made to define the best parameters for each cutting and marking process. However for various reasons, variations in material composition, variations in cutting table performance, user preferences, etc. you may desire to modify one or more processes. Or perhaps you want to keep the same cutting current and gas pressures but save different THC / CNC parameters such as cutting speed, arc voltage, pierce height, etc. That will still be treated as a custom process.

Creating a Custom Process starts with an existing standard process. From there you may adjust the cutting current and the gas pressures. It’s up to you to determine and enter the correct values. There no limits in these values, if you change too far it may cause faults.

You may also change the values displayed on THC/CNC Settings screen. THC / CNC settings on the TSC-3000 at this time are for information only. They do not connect to the THC or CNC so do not automatically modify setting in those devices. Still, when you determine the correct values for your modified (custom) process you may want to record them here.

The custom process will have the same name as the standard base process but it will be automatically assigned a new number and the whole name and number will be in red text wherever it appears.

You cannot change the gas type. If you want a different gas types find a standard process that uses those types and edit it.

First step is to select a standard process. Usually you want a process that is for the same metal type and thickness that you want to cut. From the HOME screen you may select a recent process (sect 4.06, Selecting Recently Used Process) or a new process (sect 4.05, Selecting New Process).

OPERATION 4-6 Manual No. 0-5132

ULTRA-CUT 100

HOME

SELECT MATERIAL/THICKNESS

SELECT CUT

Customize Recent Cut. Highlight the process closest to what you want to use then press CUSTOM CUTS button.

Or Select NEW CUT then MATERIAL & THICKNESS.

Select value to change using UP/DN arrows. Change value with +/- buttons.

Shows List of consumables to use.

If the custom process requires different setting, speed, arc voltage, etc., edit it here.

Editing the THC / CNC SETTING is for reference only, does not change the actual THC or CNC setting. That must be done on the THC or CNC.

CUSTOM PROCESS SETUP

TORCH CONSUMABLES LIST

CUSTOM THC/CNC SETTINGS

Going to the Cut Monitor loads the new custom process with its name/number in red. Following purging of the new process you are ready to cut. Your custom process will appear in the recent cuts menu in red.

Manual No. 0-5132 4-7 OPERATION

CUT MONITOR

Art # A -09162

ULTRA-CUT 100

4.08 Back up and Restoration of Custom Processes.

Users can create their own custom cut processes. These can be lost by accidentally deleting them on the TDC 3000 or they can be over written when updating programs. They can also be lost if the DSC 3000 should be replaced. We recommend you back up your custom processes every time a new one is created. To back up you will need a USB Flash drive.

Backing Up Custom Process:

1. For the remotely mounted DSC 3000 insert the flash drive in the USB connector on the back. If using the TSC 3000 mounted in the plasma supply front panel the USB connector is in the front under the clear plastic protective screen.

2. Go to the HOME screen. Select SETUP. Enter the 5 digit password (00000) unless you’ve changed it.

3. Press button “Back Up Custom>USB”

4. Very quickly, depending on how many custom processes there are, you should see along the bottom of the screen the message “Copy to D:\TD\CustomFiles\Complete” at which point you can remove the flash drive.

Art # A-09234_AB

OPERATION 4-8 Manual No. 0-5132

ULTRA-CUT 100

Restoring Custom Processes:

During file backup (see previous process) a folder and sub folders called “TD” were placed on your flash drive. You should copy this folder with its subfolders to some secure place. Making more than one copy is advised. If the need arises to restore from this backup, place the entire TD folder in the root directory (not in another folder) on a USB flash drive and plug it into the USB port on the TDC 3000.

2. Go to the HOME screen. Select SETUP. Enter the 5 digit password (00000) unless you’ve changed it.

3. Press the “Restore Custom <USB.

Art # A-09235_AB

4. Shortly, almost instantly if only a few files, you should see at the bottom “Status: Copy to .\Files\Custom/ Complete” then you can remove the USB flash drive.

Manual No. 0-5132 4-9 OPERATION

ULTRA-CUT 100

Renaming Custom Files

You cannot rename the files while on the TSC 3000 but once you backup a file on the flash drive you can use a computer to rename the file on the flash drive and perform the restore to put the renamed file back on the TSC 3000.

1. Use Windows Explorer to find the folder TD in the root directory of the flash drive. Then find and open the folder CustomFiles. Here you will find all the custom processes saved.

Art # A-09236

2. Use Windows Rename to change the file name to whatever you want. Do not change the file extension (.cus) or the file number in the brackets! Suggest not making the name too long as the TSC 3000 screen is limited in the

number characters on one line. Here I’ve renamed the top file.

Art # A-09237

3. Now put the flash drive with the renamed file back into the TSC 3000 and perform the file restore.

4. Go back to the Home screen. You will find your new file name (John Doe’s) and the old name with the same file number [20392]. They are the same process, either one will work. You can delete the file with the old name if you don’t want both of them showing.

OPERATION 4-10 Manual No. 0-5132

ULTRA-CUT 100

4.09 Sequence of Operation

Ultracut with DFC 3000 using TSC 3000

The purpose of this section is to explain the steps an operator should follow when using the DFC 3000 with the TSC 3000 touch screen control panel for a specific cutting process. Also included are steps to follow for changing torch consumables.

NOTE

For units not using the TSC 3000 where control is embedded into the cutting table controller most of this sequence still applies except for the parts that are specific to the TSC 3000. For those sections refer to the cutting table controller documentation.

This assumes the system setup; language and units, lead lengths, etc., have already been performed by the installer and the system is confirmed as operational.

1. Before Applying power:

a) Ensure that the required gasses are connected to the DMC 3000 inlet and gasses are turned on and set

for required inlet pressure.

b) Ensure you have a torch cartridge with consumables installed on the torch.

If you don’t know what consumables you need to use and need to select the cutting process in order to read the consumables list on the TSC 3000, you can start up with Plasma Disabled. In this case the operation sequence will skip to step 3.

c) Set Plasma Enable SW on the TSC 3000 to Enabled.

2. Turn on 3 phase power at the main disconnect (Plasma Enable on TSC 3000 on). Turn on the power supply ON/Off switch on the front panel.

a) The AC indicator on the front panel will come on and the inverter fans will start after an initial 4-5

second self check.

b) After another 5 seconds the DC indicator will blink twice indicating this is an Ultracut.

c) Immediately following this the Temp, Gas, DC & Status indicators will blink the CCM firmware version.

Example, version 4.1 will blink 4 times followed by a short space then blink once more.

d) At the same time the DMC & DPC, both Green & Red LEDs, also blink their firmware version in the same

fashion.

e) Following the firmware version indication, while CCM establishes communication with the gas control

(Step e.), the coolant pump and fans come on to “prime” the system. The “gas” indicator on the front panel blinks until correct coolant flow is detected. Normally this takes only a few seconds but can last up to 4 minutes if there is a problem. Should there be a problem with priming the coolant system the Status indicator will flash code 4-4 and the pump will stop until you rectify the problem and recycle the power.

NOTE

If communication is not established in step e. the Gas indicator will not blink at this time, also pump shuts off after 15 sec and shows code 4-2.

f) Once communication with the DFC components is established the Green power indicator on both DMC

& DPC will be on and their Red indicator will be off.

g) Skip to step 4.

Manual No. 0-5132 4-11 OPERATION

ULTRA-CUT 100

3. Turn on 3 phase power at the main disconnect (Plasma Enable on TSC 3000 Disabled).

a) AC indicator on front panel does not come on, pump and fans do not start.

b) Approximately 10 sec after power up the front panel DC indicator will blink twice indicating this is an

Ultracut.

c) Immediately following this the Temp, Gas, DC & Status indicators will blink the CCM firmware version.

Example, version 4.1 will blink 4 times followed by a short space then blink once more.

d) At the same time the DMC & DPC, both Green & Red LEDs, also blink their firmware version in the same

fashion.

e) After blinking the CCM firmware version on the front panel indicators the CCM establishes communi-

cation with the DMC & DPC. Once communication is established the Green LEDs are on steady and the Red LEDs should be off.

4. At power on while all the items in step 2 (or 3) are going on the TSC 3000 has been starting up Windows XP™ which takes about 2 ¼ minutes. Another 15 sec the application starts and displays the HOME screen.

5. Now you must select the cutting (and plasma marking) process. Refer to sections 4.05, 4.06 and 4.07 for step by step instructions in selecting New, Recently Used or Creating Custom Processes.

6. During process selection you will come to the “Torch Consumables” screen. At this point if you have not installed correct consumables and “Plasma” is not already disabled, shut off (disable) the Plasma Enable SW. Install the consumables, Set the Plasma Enable SW to “Enable”.

a) Coolant Pump and fan start up to prime the torch cooling system. The “Gas” indicator on the front

panel blinks until correct coolant flow is detected. Normally only a few seconds. See step 2.d. for full details.

7. The next screen following Torch Consumables is a table of recommended CNC and THC (Torch Height Control) settings. You may toggle between cutting and marking settings using the “Show Marking / Show Cutting” button. Set your cutting table controller and height control to the recommended setting.

a) If you prefer other settings for cutting you can create a “Custom” process where you edit the cutting

CNC/THC setting if you want. Currently, modifying the marking CNC/THC settings is not allowed. A custom process does not have to change the cutting current or gas pressures unless you want to. You can use customs to modify the recommended CNC/THC settings as well.

8. Continue the process selection until you reach the Cut Monitor screen.

a) Purging of the gasses used for the selected process begins. Depending on your lead length and consum-

able type this can take some time.

Purge times for different lead lengths have been set to allow time to fully pressurize the leads and to remove any coolant that gets into the consumables during a parts change. Make sure that during setup the correct lead length has been selected, the default time is for max lead length and may be longer than you require.

9. Once purge is complete you are ready to start cutting.

a) If marking is desired press button “Go to Marking”. The screen will show recommended CNC/THC

setting. Green arrow takes you back to the Cut Monitor set up for Marking.

b) To return to cutting on the Cut Monitor press button “Got to Cutting”. Same as with the marking this

takes you to the CNC/THC screen except this displays the cutting settings.

OPERATION 4-12 Manual No. 0-5132

ULTRA-CUT 100

10. Changing torch consumables:

Following a consumables change or inspection the system will initiate a purge of the gas. This serves two purposes:

a) Remove the coolant that gets into the consumables when they have been removed.

b) If the gas type has changed “Purge” removes the old gas from the lines and replaces it with the new

gas. If the gas type has changed from a fuel gas like H35 to an oxidizing gas like oxygen or air the purge inserts a buffer of inert gas, nitrogen, so the H35 and oxygen don’t mix.

You can change consumables by removing power or using the “Plasma Disable” SW.

If you remove power the system does not remember what gasses were last used so it will do a complete purge including nitrogen buffer even if you do not change gas types.

With “Plasma Disable” the system remembers what was used last and does only the amount of purge necessary possibly saving time.

11. Use “Plasma Disable”.

a) You may use the Plasma Disable when removing the torch cartridge to change or inspect consumables.

Plasma disable stops coolant pump, shuts off all gas solenoids, removes power from the inverter (power supply) and pilot circuits, inhibits the arc starter ignition (HF) circuit. It does not remove power from the TSC 3000 or the systems logic and communications circuits so you do not need to go through as long a power up process after replacing the consumables.

b) If changing to a process with a different gas type you may want to select it before enabling the plasma

otherwise it will start purging the old process and when you do select the new one it will purge again taking more time.

c) If you are not changing gas type you may want to turn on the Enable first to start the purge while you

enter the process.

12. Shutting off power.

a) If you chose to shut off power for inspecting or changing consumables, or any other purpose, the system

does not remember what you were doing last so you will have to go through the complete sequence from the beginning starting with step 1.

Manual No. 0-5132 4-13 OPERATION

ULTRA-CUT 100

4.10 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 and reduced weldability on ferrous 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.

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

• Recommended for 1/2 inch (12 mm) and thicker nonferrous materials. H17 is not normally used for thinner nonferrous materials because less expensive gases can achieve similar cut quality.

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

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

• Poor cut quality on ferrous materials.

6. Marking Gas

•Argon is required for Marking.

OPERATION 4-14 Manual No. 0-5132

B. Shield Gases

1. Compressed Air Shield

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

• Improves cut quality on some ferrous materials.

• Inexpensive - reduces operating costs.

2. Nitrogen (N2) Shield

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

• Provides smooth finishes on nonferrous materials.

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

3. Water Shield

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

• Normally used with nitrogen.

• Provides very smooth cut surface.

• Reduces smoke and heat input to the workpiece.

• Effective up to 3/4 inch (19.1 mm) maximum material thickness.

• Tap water provides low operating expense.

ULTRA-CUT 100

Manual No. 0-5132 4-15 OPERATION

ULTRA-CUT 100

4.11 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.

CCM Status Code

Code Message Remedy / Comments

Group 1 -- Plasma Process

Plasma Disabled or

1-1

Missing AC Input Phase

1-2 Pilot Ignition Failure

1-3 Lost Pilot

1-4 Transfer Lost

1-5 Off the Plate Function not currently enabled

Pilot Timeout, no

1-6

Transfer

1-7 Reserved No information available; Contact customer service

Plasma Enable Off ; External Disable / E-Stop Activated or CCM TB11&2 jumper missing; Control cable to DMC not connected; Missing AC Phase.

Pilot did not start within 15 seconds. Ensure process loaded agrees with torch parts installed; Torch consumable parts worn; Defective Arc Starter. Defective chopper (100-300A unit); Defective #2 inverter (400A unit).

Pilot went out while CNC Start active Ensure process loaded agrees with torch parts installed; If custom process cut current too low or preflow pressure too high. Torch consumable parts worn

Arc was transferred to work for more than 50 ms and then went out while CNC Start still active. Standoff too high; Ensure process loaded agrees with torch parts installed; If custom process current set too low or wrong plasma pressure.

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

1-8 Possible Shorted Torch

Part Process not

1-9

configured

1-10 Device Locked Process loading, wait until finished

OPERATION 4-16 Manual No. 0-5132

Tip voltage too close to electrode voltage. Plasma supply pressure too low; Leak in Plasma hose to torch; Ensure process loaded agrees with torch parts installed; If custom process, plasma pressure may be too low or cut current too high. Torch consumable parts worn; Shorted torch body

CNC Start applied without a process loaded. Select process and send to plasma system

CCM Status Code

Code Message Remedy / Comments

Group 2 -- Plasma Power Supply

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

Inverter(s) not configured correctly for input voltage;

2-2 Wrong input voltage

Inverter Over

2-3

Temperature Power Supply not

2-4

Ready

2-5 DC Output Low

2-6 Inverter input fault

2-7 Unexpected current

Unexpected current in

2-8

pilot circuit

Unexpected current in

2-9

work lead

2-10

2-11

3-10 DPC-fault Check DPC status indicator for specific problem 3-11 DPC valve control fault Check DPC status indicator for specific problem 3-12 DMC fault Check DMC status indicator for specific problem

Output Current Too High

Output Current Too Low

Gas Control

3-1

Communication fault.

3-2 Gas Control reply fault.

Gas Supply Pressure

3-3

out of range.

3-4 Gas Control Purging

Gas Control Protocol

3-5

Error

3-6 Reserved No information available; Contact customer service

Gas Control

3-7

sequencing error

Gas Cont rol Type

3-8

Mismatch

Gas Control Command

3-9

fault

Poor power quality (brownouts, dropouts); Input power capacity / wiring too small causing voltage drop; broken or loose power cable connections. Ambient above 40 deg C. (104 F); Blocked airflow.Failed fan; Defective inverter.

Defective inverter; PCB4; PCB7; defective input contactor.

Less than 60 VDC; Defective inverter, shorted output; CCM voltage sense (J6) wire open or disconnected. Negative lead short to gnd. Shorted chopper (100-300A only).

Capacitor bank voltage im bal ance (400-460-600V onl y) or inverter primary swit ching circ ui t overcurrent. If occasional m ay be line voltage s urge; remove power to reset . If persis t s defecti ve invert er; LE D on in verter indic ate whic h one.

Current above 20A in work or pilot leads before pilot ignition; Possible shorted torch; Defective current sensor. Current above 5A in pilot circuit; wrong or mismatched consumables; Pilot lead shorted to negative in torch tube; Possible shorted torch Current above 5A in work lead; Short to chassis in RAS; Negative lead short to ground. Current greater than 20% above process setting. Measure current of each inverter, only one high likely defective inverter. All high likely defective PCB5, CCM. Current more than 20% below process setting. Measure current of each inverter, only one low likely defective inverter. All low likely defective PCB5, CCM.

Group 3 -- Gas Controller Status & Protocol

Cannot establish Communication with gas control. DMC to DPC Control Cable not connected or Fiber-optic cable not properly connected, dirty or defective; DPC power supply or Control PCB defective. DMC Control PCB defective; CCM defective, replace.

Connection was established but Gas Control did not reply to the CCM in the allowed time (15 ms.). Dirt on fiber ends or in connectors, blow out with clean dry air. Fiber not locked into connector; sharp bends in fiber; fiber defective. If it's determined the fiber is OK then DPC or DMC Control or Power Supply PCB likely defective, replace board. DPC has detected a pressure error, Check DPC status indicator for specific problem. The time to purge depends on Lead Length, previous fluids used, and current process fluids selected. Wait until finished.

Verify Firmware revison for compatiblity with DMC and DPC

CCM must be Ultracut type with USB for use with Auto Gas Control (DFC-3000) Verify Firmware revison for compatiblity with DMC and DPC; Elctromagentic interference with Arc Starter; inspect grounding; bonding; and isolation

ULTRA-CUT 100

Manual No. 0-5132 4-17 OPERATION

ULTRA-CUT 100

Code Message Remedy / Comments

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

4-2

4-3

4-4 Coolant System not ready.

4-5 Low Coolant Level Warning

5-1 CANBUS Acknowledge fault.

5-2 CANBUS Off

5-3 CANBUS Errors Warning.

5-4 Reserved No information available; Contact customer service

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

6-3 Coolant Flow too High

6-4 CCM Data Memory error Replace CCM 6-5 CCM Program memory fault Replace CCM 6-6 +5V Logic supply low Replace CCM 6-7 CCM processor over temp Reduce ambient tempurature; Defective CCM; replace

6-8

Group 4 -- Torch Coolant System

Low coolant flow

Coolant overheated

Group 5 -- Gas Control Communications Port

5V supply for RS 485/422 communication low.

CCM Status Code

Fault response time: Process Never started since last power cyle: Below 0.7 GPH for 15 Seconds. Else below 0.5 GPH no delay or after 3 seconds if below 0.7 GPH Possible cause: Suction leak introducing air into coolant, suspect rear panel filter seal; clogged filter; defective pump.

Coolant return temperature exceeded 70 degrees Celcius (158F). Coolant fan failed; radiator fins clogged with dirt; operating with side panel loose or removed. Ambient temperature > 40 deg C.

Proper coolant flow of 0.7 GPH was not obtained during up to 4 minutes of Priming. New installation can require additional Priming cycle(s) to fill hoses with coolant; cylce power to restart Priming; Suction leak introducing air into coolant; suspect rear panel filter seal; Clogged coolant filter; Damaged torch coolant tube; Defective pump assembly.

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

Message sent over CANBUS (Fiber-optic) was not acknowledged as received by DMC. CCM to DMC Fiberoptic cable not properly connected, dirty or defective; DMC power supply or Control PCB defective; CCM defective. Excessive communication errors resulted in communication with DMC to turn off. Dirt on fiber ends or in connectors, blow out with clean dry air; fiber not locked into connector; sharp bends in fiber; fiber defective; Communication with DMC has required a signifcant number of message retries due to communication errors. Dirt on fiber ends or in connectors, blow out with clean dry air; fiber not locked into connector; sharp bends in fiber; fiber defective;

Group 6 -- CCM

Flow greater than 2.7 gal/min Torch coolant tube broken or missing; CCM fault, replace CCM

Replace CCM

OPERATION 4-18 Manual No. 0-5132

ULTRA-CUT 100

4.12 DMC-3000 Status Codes

Status Code indicators:

1. At power up, RED & GREEN indicators flash program firmware revision number in a 2 digit code as explained below. Following the revision code

2. Green indicator

· On steady = OK, communication established.

· Blinking = no communication established with CCM

3. Red indicator

· Off = Status OK

· Rapid blinking = downloading new program

· Blinking 2 digit code = Status (table below)

Status Indicators on the DMC & DPC modules flash a 2-part code. Both green and red flash the firmware version at power up. Only the red flashes for a fault.

First part of the code indicates a code group, the second part a particular condition within that group. DMC and DPM may flash codes at the same time and they may be different codes. For example, a power supply fault, such as 1-3, in the DMC could prevent communicating with the DPM so the DPC would flash one it’s group 2 codes. You have to consider the codes in all the modules, CCM, DMC & DPC before determining which hardware has the fault.

The 2 digit code is separated by a 1.2 second space between digits and a 4 second space before the sequence repeats or flashes another code group. Codes displayed may be currently active or may represent a fault that shut the process down but is no longer active. If the fault that shut down the process is no longer active the first blink of the first digit is extra long.

Example: Indicator flashes 1 long followed by 3 shorter blinks the condition is in group 4. After 1.2 seconds delay, the indicator blinks 3 times; the condition code is 4-3 (the first long blink counts as part of the first digit), indicating the DMC has detected a DPC time-out error and it is not currently active. After a 4 second delay, the indicator repeats the sequence until the condition is corrected.

Manual No. 0-5132 4-19 OPERATION

ULTRA-CUT 100

DMC Status Code Ke

Code Message Cause/Remedy

Group 1 - DMC

1-1 Plasma Disabled Enable Plasma; Defective DMC Power Supply (E-Stop relay)

1-2 24 VDC fault

1-3 5 VDC fault Check /replace DMC power supply; Replace DMC control PCB 1-4 No gas process selected Select and send process from TSC 3000 or CNC; 1-5 DMC is locked Process loading, wait until finished 1-6 Gas not Purged DPC fault prevented purge from occuring, see DPC fault status

2-1 DPC Acknowledge error

2-2 DPC Bus off error

2-3 Reserved No information available; Contact customer service

3-1 CCM Acknowledge error

3-2 CCM Bus off error

3-3 Reserved No information available; Contact customer service

4-1 CCM Connection loss

4-2 CCM Timeout

4-3 DPC Timeout

4-4 DPC error

4-5 Reserved No information available; Contact customer service 4-6 Reserved No information available; Contact customer service

5-1 Sol 1 – H35 Plasma Replace solenoid; Shorted wire harness; Defective DMC Control PCB 5-2 Sol 2 – Oxygen Plasma Replace solenoid; Shorted wire harness; Defective DMC Control PCB 5-3 Sol 3 – Air Plasma Replace solenoid; Shorted wire harness; Defective DMC Control PCB 5-4 Sol 4 – Nitrogen Plasma Replace solenoid; Shorted wire harness; Defective DMC Control PCB 5-5 Sol 5 – Aux Plasma Replace solenoid; Shorted wire harness; Defective DMC Control PCB 5-6 Sol 6 – Oxygen Shield Replace solenoid; Shorted wire harness; Defective DMC Control PCB 5-7 Sol 7 – Air Shield Replace solenoid; Shorted wire harness; Defective DMC Control PCB 5-8 Sol 8 – Nitrogen Shield Replace solenoid; Shorted wire harness; Defective DMC Control PCB 5-9

Sol 9 – H 5-10 Sol 10 – Oxygen Preflow Replace solenoid; Shorted wire harness; Defective DMC Control PCB 5-11 Sol 11 – Air Preflow Replace solenoid; Shorted wire harness; Defective DMC Control PCB 5-12 Sol 12 – Nitrogen Preflow Replace solenoid; Shorted wire harness; Defective DMC Control PCB 5-13 Sol 13 – Argon Marking Replace solenoid; Shorted wire harness; Defective DMC Control PCB 5-14 Sol 14 – Air Marking Replace solenoid; Shorted wire harness; Defective DMC Control PCB 5-15 Sol 15 – Nitrogen Marking Replace solenoid; Shorted wire harness; Defective DMC Control PCB

* Communication faults shown on the DMC can be caused by the device on the other end of the communication line. Before assuming the DMC is at fault see if either the CCM or the DPC are showing any codes that might indicate they are at fault instead.

O Shield

Check /replace DMC power supply fuse (F2); Replace DMC Power Supply; Replace DMC control PCB

Group 2 - DPC Communication Port *

Check DMC to DPC fiber optic cable and connections; Dirty or defective fiber-optic;DPC power supply, fuse or Control PCB. DMC Control PCB

Check DMC to DPC fiber optic cable and connections; Dirty or defective fiber-optic;DPC power supply, fuse or Control PCB. DMC Control PCB.

Group 3 - CCM Communication Port *

Check DMC to CCM fiber optic cable and connections; Dirty or defective fiber-optic; Replace DMC Control PCB; Replace CCM. Check DMC to CCM fiber optic cable and connections; Dirty or defective fiber-optic; Replace DMC Control PCB; Replace CCM.

Group 4 - Gas Controller Status and Protocal Errors

Loss of communication with either DPC or DMC; check for dirty or defective fiber optic to either DPC or CCM; See DPC and CCM status codes

Loss of communication with either DPC or DMC, check for dirty or defective fiber-optic to either DPC or CCM. See DPC and CCM status codes.

Loss of communication with DPC, check for dirty or defective fiber-optic to DPC. See DPC status code. Loss of communication with DPC, check for dirty or defective fiber-optic to DPC. See DPC status code.

Group 5 - Shorted Solenoid Faults

Replace solenoid; Shorted wire harness; Defective DMC Control PCB

OPERATION 4-20 Manual No. 0-5132

4.13 DPC-3000 Status Codes

Code Message Cause/Remedy

Enable Plasma; DMC Power Supply input fuse F1 blown (no lights on

1-1 Plasma Disabled

1-2 24 VDC fault

1-3 +12 VDC fault Check /replace DPC power supply; Replace DPC control PCB 1-4 -12 VDC fault Check /replace DPC power supply; Replace DPC control PCB 1-5 5 VDC fault Check /replace DPC power supply; Replace DPC control PCB 1-6 Analog Reference fault Replace DPC Control PCB 1-7 ADC voltage fault Replace DPC Control PCB 1-8 Reserved 1-9 Valve not configured Resend process from TSC 3000 / CNC

1-10 DPC is locked Process loading, wait until finished

2-1 Acknowledge error Fiber optic cable; DPC Control PCB

2-2 Timeout

2-3 Protocol Program firmware fault, consult factory 2-4 Bus off Fiber optic cable; DPC Control PCB 2-5 Physical Fiber optic cable; DPC Control PCB

3-1 Plasma Gas High (>145 PSI) Reduce pressure from gas supply; defective pressure sensor (PS4). 3-2 Pilot Gas High (>145 PSI) Reduce pressure from gas supply; defective pressure sensor 3-3 Shield Gas High (>145 PSI) Reduce pressure from gas supply; defective pressure sensor (PS1). 3-4 Shield H2O High (>145 PSI) Reduce pressure from gas supply; defective pressure sensor (PS2).

Group 4 - Proportional Valves & Solenoids Electrical Faults

4-1 Plasma High (V5) shorted Check for shorted wire harness; Replace valve 4-2 Plasma Low (V4) shorted Check for shorted wire harness; Replace valve 4-3 Pilot (V3) shorted Check for shorted wire harness; Replace valve 4-4 Shield Gas (V1) shorted Check for shorted wire harness; Replace valve 4-5 Shield H2O (V2) shorted Check for shorted wire harness; Replace valve 4-6 Vent (SOL2) shorted Check for shorted wire harness; Replace valve 4-7 Cut (SOL3) shorted Check for shorted wire harness; Replace valve 4-8 Mark (SOL1) shorted Check for shorted wire harness; Replace valve

4-9 Vent (SOL2) open Check for open connection; Replace valve. 4-10 Cut (SOL3) open Check for open connection; Replace valve. 4-11 Mark (SOL1) open Check for open connection; Replace valve.

Group 5 - Plasma High Proportional Valve (V5)

5-1 Valve open Check for open connection; Replace valve.

DPC inlet Supply pressure

5-2

low

5-3 Outlet pressure too low

5-4 Outlet pressure low

5-5 Outlet pressure too high.

5-6 Outlet pressure high.

DMC); Defective DMC Power Supply (E-Stop relay). Defective DPC Power Supply (E-Stop relay). Defective DPC control PCB Check /replace DPC power supply output fuse (F2); Defective DPC power supply; Replace DPC control PCB

Group 2 - Control Communication

Communication loss: Check DMC codes; if DMC 2-1 check DPC to DMC Fiber optic cable, DMC 4-2 check DMC to CCM fiber-optic cable.; DPC Control PCB; DMC Control PCB; CCM.

Group 3 - Inlet Pressure Faults

Raise plasma inlet pressure; check for DMC valve not open; restriction in gas supply / hoses. Valve full open. Leak in plasma hose to torch; defective control valve (V5); defective pressure sensor (PS6); DPC Control PCB Tracking error Leak in plasma hose to torch; defective control valve (V5); defective pressure sensor (PS6); DPC Control PCB Valve at minimun setting. Restriction in plasma hose, torch, DPC manifold; defective control valve (V5); defective pressure sensor (PS6); DPC Control PCB Tracking error. Restriction in plasma hose, torch, DPC manifold; defective control valve (V5); defective pressure sensor (PS6); DPC Control PCB

ULTRA-CUT 100

DPC Status Code Key

Group 1 - DPC

(PS3).

Manual No. 0-5132 4-21 OPERATION

ULTRA-CUT 100

Code Message Cause/Remedy

6-1 Valve open Check for open connection; Replace valve.

DPC in l et S upp l y

6-2

pressure lo w Outlet pressure too low

6-3

Outl et pressu re l ow

6-4

Outl et pres sure Too high

6-5

Outl et pres sure hi gh

6-6

7-1 Valve open Check for open connection; Replace valve.

DPC in l et S upp l y

7-2

pressure lo w Outlet pressure too low

7-3

Outl et pressu re l ow

7-4

Outl et pres sure Too

7-5

high Outl et pres sure hi gh

7-6

8-1 Valve open Check for open connection; Replace valve.

DPC in l et S upp l y

8-2

pressure lo w Outlet pressure too low

8-3

Outl et pressu re l ow

8-4

Outl et pres sure Too high

8-5

DPC Status Code Key

Group 6 - Plasma Low Proportional Valve (V4)

Raise plasma inlet pressure; check for DMC valve not open; restriction in gas supply/hoses. Valve full open but pressure still too low. Leak in plasma hose to torch; Defective control valve (V4); Defective pressure sensor (PS6); DPC Control PCB

Tracking error. Leak in plasma hose to torch; Defective control valve (V4); Defective pressure sensor (PS6); DPC Control PCB Valve at minimum setting but pressure still too high. Restriction in plasma hose to torch; torch or DPC manifold; Defective control valve (V4); Defective pressure sensor (PS6); DPC Control PCB Tracking error. Restriction in plasma hose; torch or DPC manifold; Defective control valve (V4); Defective pressure sensor (PS6); DPC Control PCB

Group 7 - Pilot Proportional Valve (V3)

Raise plasma inlet pressure; check for DMC valve not open; restriction in gas supply/hoses.

Valve full open but pressure still too low. Leak in plasma hose to torch; defective control valve; defective pressure sensor (PS6); DPC Control PCB

Tracking error. Leak in plasma hose to torch; defective control valve; defective pressure sensor (PS6); DPC Control PCB

Valve at minimum setting but pressure still too high. Restriction in plasma hose, torch, DPC manifold; defective control valve; defective pressure sensor (PS6); DPC Control PCB

Tracking error. Restriction in plasma hose, torch, DPC manifold; defective control valve; defective pressure sensor (PS6); DPC Control PCB

Group 8 - Shield Gas Proportional Valve (V1)

Raise plasma inlet pressure; check for DMC valve not open; restriction in gas supply/hoses.

Valve full open but pressure still too low. Leak in plasma hose to torch; defective control valve; defective pressure sensor (PS5); DPC Control PCB

Tracking error. Leak in plasma hose to torch; defective control valve; defective pressure sensor (PS5); DPC Control PCB

Valve at minimum setting but pressure still too high. Restriction in plasma hose, torch, DPC manifold; defective control valve; defective pressure sensor (PS5); DPC Control PCB

Outl et pres sure hi gh

8-6

9-1 Valve open Check for open connection; Replace valve.

DPC in l et S upp l y

9-2

pressure lo w Outlet flow too low

9-3

Outlet flow low

9-4

Outl et flow Too high

9-5

Outlet flow high

9-6

Tracking error. Restriction in plasma hose, torch, DPC manifold; defective control valve; defective pressure sensor (PS5); DPC Control PCB

Raise plasma inlet pressure; check for DMC valve not open; restriction in gas supply/hoses.

Valve full on but pressure still too low. Leak in shield hose to torch; Defective control valve (V2); Defective pressure sensor (PS5) or flow sensor (FS-1) if equiped; DPC Control PCB

Tracking error, outlet pressure too low. Leak in shield hose to torc; Defective control valve (V2). Defective pressure sensor (PS5) or flow sensor (FS-1) if equiped; DPC Control PCB

Valve set to minimum but valve outlet pressure still too high. Mineral build up or other restriction in control valve (V2), DPC manifold, shield hose or torch; Defective control valve (V2)/ Defective pressure sensor (PS5) or flow sensor (FS-1) if equiped; DPC Control PCB

Tracking error, outlet pressure too high. Mineral build up or other restriction in control valve (V2), DPC manufold, shield hose or torch; Defective control valve (V2); Defective pressure sensor (PS5) or flow sensor (FS-1) if equiped; DPC Control PCB

OPERATION 4-22 Manual No. 0-5132

Group 9 - Shield H2O Proportional Valve (V2)

SECTION 5: MAINTENANCE

5.01 General 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 connections and pressures.

M onthly

Check c ool ing fan and radiator; clean as needed. Check gas hos es for cracks , l eak s, or abrasion. Replace as needed. Check all electri cal c onnec t i ons 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 int ernal coolant filt er

ULTRA-CUT 100

5.02 External Coolant Filter Cleaning Procedure

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

Clean the coolant filter as follows:

1. Disconnect 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. 0-5132 5-1 MAINTENANCE

ULTRA-CUT 100

5.03 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. Make sure the sealing O-ring is in place.

5.04 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.

MAINTENANCE 5-2 Manual No. 0-5132

5.05 Remote Arc Starter: Service Chart

Arc Starter Service Chart

Symptom Cause Check Remedy

Coolant has become conductive Use conductivity meter

Pilot return wire not connected Visual inspection Connect Wire. Spark gap set too close Check with feeler gauge Set to 0.063" ±0.002"

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)

High Frequency cap (C4) possibly open Broken or missing ferrites Visual inspection Replace.

Short across in inductor (L1) Visual inspection

Spark gap bus caps (C1, C2, C3) broken or defective

Negative supply not connected correctly Spark gap set too large Check with feeler gauge Set to 0.063" ±0.002" Faulty transformer Resistance measurement Replace.

No 120V supply Check input voltage at EMI filter

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

Supply & return hose reversed

Blockage in coil or supply/return hoses

Shield Drain / Torch lead inner shield connector missing or loose.

Missing or loose ground connection

Cap C5 not connected, open or loose

Use capacitance meter Reconnect or replace.

Capacitance meter Replace.

Visual inspection Reconnect.

Visual inspection Replace coolant line(s).

Visual Inspection of color-coded connections

Loosen fitting slightly and check for coolant flow

Visual inspection of lead attachment to Arc Starter

Visual inspection of ground wire to Arc Starter

Visual inspection / capacitor measurement

ULTRA-CUT 100

Flush system, replace coolant.

Remove short; increase coil gaps.

Make connections; replace harness.

Match coolant connection colors to arc starter fitting colors.

Flush system.

Reconnect / tighten lead connectors.

Make or tighten connections to good ground.

Replace PCB.

Manual No. 0-5132 5-3 MAINTENANCE

ULTRA-CUT 100

5.06 Remote Arc Starter: Spark Gap Adjustment

0.063" ± 0.002"

1.6 ± 0.05 mm

Art # A-04857

MAINTENANCE 5-4 Manual No. 0-5132

ULTRA-CUT 100

SECTION 6: REPLACEMENT ASSEMBLIES & PARTS

6.01 Main Component / System Replacement

Complete Unit / Component Catalog Number

Ultra-Cut

Ultra-Cut® 100 Power Supply, 460V 3-9116-2

Ultra-Cut® 100 Power Supply, 400V 3-9116-3

Ultra-Cut® 100 Power Supply, 400V (CE) 3-9116-4

Ultra-Cut® 100 Power Supply, 600V 3-9116-5

Remote Arc Starter (RAS-1000) 3-9130

OPTIONAL EQUIPMENT:

Wheel Kit 9-9379

100 Power Supply, 208/230V 3-9116-1

Manual No. 0-5132 6-1 Power Supply Parts List

ULTRA-CUT 100

6.02 System Layout

Refer to section 3.05 for ground connections and ground cables.

175’ / 53.3 m Maximum Length

Primary power

Controller

Art # A-09124_AC

CNC

To uch

Screen

Pilot Return

Ultra-Cut

Power Supply

Fiber Optic

Control Cable

Ground Cable

Only When DMC Mounted On Top Of PS

125’ / 38.1 m Maximum Length

Negative

Coolant Supply

Coolant Return

Control Cable

DMC-3000

175’ / 53.3 m Maximum Length

Gas

Console

Plasma Gas

Fiber Optic

Shield Gas

Preflow

Control Cable

Water Shield

Marking

Work Cable

100’ / 30.5 m Maximum Length

Pilot Return

Remote

Arc

Starter

DPC-3000

Gas

Control

Shield

Coolant Supply

Coolant Return

Shield

Plasma Gas

Shield Gas

Positioning Tube

To r ch

Work

6.03 Recommended Gas Supply Hose

Item # Qty Description Catalog #

1 1/4”Gray Synflex Hose. No fittings included. Catalog number per foot 9-3743

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

1 1/2”Gray Synflex Hose. No fittings included. Catalog number per foot 9-2551

Power Supply Parts List 6-2 Manual No. 0-5132

6.04 Leads and Cables

ULTRA-CUT 100

#8 AWG Cable

#1 AWG Cable

Green

Red

Green / Yellow #4 AWG (16 mm2)

Green / Yellow 1/0 (50 mm2)

Green

Red

Pilot Return, Power Supply to Arc Starter

Negative Lead, Power Supply to Arc Starter

Coolant Supply Lead, Power Supply to Arc Starter

Coolant Return Lead, Power Supply to Arc Starter

Control Cable, Power Supply to Arc Starter

Ground Cable

Ground Cable, Remote Arc Starter To Earth Ground

Shielded Torch Lead Assembly, Remote Arc Starter to Torch

Art # A-09125_AC

H, Q, R, T, U

S,V

16 pin

P, W

14/11

1/0 Cable (50 mm2 )

Plasma Gas Lead, Torch Valve to Torch

Shield Gas Lead, Torch Valve to Torch

Control Cable, From Power Supply

Fiber Optic Cable, Power Supply to DMC-3000

For use with DFC-3000

S - Control Cable,

DMC-3000

V - TSC-3000 to PS

Work Cable

P - CNC Cable (14 Wire)

W - CNC Communitcation Cable (11 Wire)

DPC-3000

Manual No. 0-5132 6-3 Power Supply Parts List

ULTRA-CUT 100

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.

Power Supply Parts List 6-4 Manual No. 0-5132

Victor 100 ULTRA-CUT Operating Manual

Specifications and Main Features

Frequently Asked Questions

User Manual