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Art# A-08579
PLASMA CUTTING SYSTEM
100ULTRA-CUT™
Operating ManualRev. AQ Date: September 29, 2009 Manual # 0-4748Operating Features:
WE APPRECIATE YOUR BUSINESS!Congratulations on your new Thermal Dynamics product. We areproud to have you as our customer and will strive to provide youwith the best service and reliability in the industry. This product isbacked by our extensive warranty and world-wide 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 thecorrect use and operation of your Thermal Dynamics product.Your satisfaction with this product and its safe operation is ourultimate concern. Therefore please take the time to read the entiremanual, especially the Safety Precautions. They will help you toavoid potential hazards that may exist when working with thisproduct.
YOU ARE IN GOOD COMPANY!The Brand of Choice for Contractors and Fabricators Worldwide.
Thermal Dynamics is a Global Brand of manual and automationPlasma 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 technicalsupport, together with excellence in sales and marketing expertise.
Above all, we are committed to developing technologicallyadvanced products to achieve a safer working environment withinthe welding industry.
! WARNINGS
Read and understand this entire Manual and your employer’s safety practices beforeinstalling, operating, or servicing the equipment.
While the information contained in this Manual represents the Manufacturer's best judge-ment, the Manufacturer assumes no liability for its use.
Plasma Cutting Power Supply, Ultra-Cut® 100
Operting Manual No. 0-4748Published by:Thermadyne Corporation82 Benning StreetWest Lebanon, New Hampshire, USA 03784(603) 298-5711
www.thermal-dynamics.com
© Copyright 2005, 2006, 2007, 2008, 2009 byThermadyne Corporation
All rights reserved.
Reproduction of this work, in whole or in part, without written per-mission of the publisher is prohibited.
The publisher does not assume and hereby disclaims any liability toany party for any loss or damage caused by any error or omissionin this Manual, whether such error results from negligence, acci-dent, or any other cause.
Printed in the United States of America
Licensed under U. S. Patent No. 5,070,227
Publication Date: July 1, 2005Revision Date: September 29, 2009Record 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 ...................................................................... 1-11.02 Important Safety Precautions ....................................................................... 1-11.03 Publications .................................................................................................. 1-21.04 Note, Attention et Avertissement .................................................................. 1-31.05 Precautions De Securite Importantes ........................................................... 1-31.06 Documents De Reference ............................................................................. 1-51.07 Declaration of Conformity ............................................................................. 1-61.08 Statement of Warranty .................................................................................. 1-7
SECTION 2: SPECIFICATIONS ................................................................................................. 2-1
2.01 General Description Of The System.............................................................. 2-12.02 Plasma Power Supply ................................................................................... 2-12.03 Remote Arc Starter ...................................................................................... 2-12.04 Gas Control Module ...................................................................................... 2-12.05 Precision Plasma Cutting Torch .................................................................... 2-12.06 Specifications & Electrical Requirements ..................................................... 2-22.07 System Component Layout .......................................................................... 2-22.08 Power Supply Dimensions ............................................................................ 2-32.09 Power Supply Rear Panel Features ............................................................... 2-42.10 Gas Requirements ........................................................................................ 2-52.11 Gas Applications .......................................................................................... 2-52.12 XTTM-300 Torch Specifications .................................................................... 2-6
SECTION 3: INSTALLATION ...................................................................................................... 3-1
3.01 Installation Requirements ............................................................................. 3-13.02 System Layout ............................................................................................. 3-23.03 Cables & Leads Identification ....................................................................... 3-33.04 Lift the Power Supply .................................................................................... 3-43.05 Remove the Connections Cover ................................................................... 3-53.06 Ground Connections .................................................................................... 3-103.07 Connect Work Cable and Pilot and Negative Leads......................................3-123.08 Connect Coolant Leads ................................................................................3-133.09 Connect Control Cables for CNC, Remote Arc Starter, and GCM ................. 3-143.10 Connect Fiber Optic Cable (Type 2 internal control module) ........................ 3-153.11 Set Switches on the Command - Control Module (Type 2 Module) ............... 3-163.12 Height Control Connections ......................................................................... 3-183.13 Gas Control Module Installation ................................................................... 3-193.14 Fiber Optic Cable Installation .......................................................................3-213.15 Gas Control Module: Control, Input, and Output Connections.......................3-233.16 Install Remote Arc Starter ........................................................................... 3-243.17 Original & XTL Torch Valve Installation......................................................... 3-333.18 Connecting Torch .........................................................................................3-353.19 Install Consumable Torch Parts ....................................................................3-373.20 Complete the Installation .............................................................................3-41
TABLE OF CONTENTS (continued)
SECTION 4: OPERATION .......................................................................................................... 4-1
4.01 Power Supply Control Panel .......................................................................... 4-14.02 Start-Up Sequence ....................................................................................... 4-24.03 Gas Control Module Operation ...................................................................... 4-34.04 First Time Operation Matching Gas Control to Lead Length .......................... 4-74.05 Sequence Of Operation ................................................................................ 4-74.06 Gas Selection .............................................................................................. 4-104.07 Power Supply Status Codes ........................................................................ 4-114.08 Remote Arc Starter: Service Chart ............................................................. 4-144.09 Remote Arc Starter: Spark Gap Adjustment ...............................................4-15
SECTION 5: MAINTENANCE .................................................................................................... 5-1
5.01 General Maintenance .................................................................................... 5-15.02 External Coolant Filter Cleaning Procedure ................................................... 5-15.03 Internal Coolant Filter Cleaning Procedure .................................................... 5-25.04 Coolant Replacement Procedure ................................................................... 5-2
SECTION 6: REPLACEMENT ASSEMBLIES & PARTS ........................................................... 6-1
6.01 Main Component / System Replacement ...................................................... 6-16.02 System Layout ............................................................................................. 6-26.03 Recommended Gas Supply Hose ................................................................. 6-26.04 Leads and Cables ......................................................................................... 6-36.05 Power Supply External Replacement Parts ................................................... 6-86.06 Power Supply Replacement Parts - Right Side ............................................. 6-96.07 Power Supply Replacement Parts - Right Side ............................................6-106.08 Power Supply Replacement Parts - Right Side ............................................6-116.09 Power Supply Replacement Parts - Front Panel ........................................... 6-126.10 Power Supply Replacement Parts - Front Panel ........................................... 6-136.11 Power Supply Replacement Parts - Right Side ............................................6-146.12 Power Supply Replacement Parts - Rear Panel ............................................6-156.13 Power Supply Replacement Parts - Right Side ............................................6-166.14 Power Supply Replacement Parts ................................................................ 6-176.15 Power Supply Replacement Parts - Right Side ............................................6-186.16 Power Supply Replacement Parts ................................................................ 6-196.17 Power Supply Replacement Parts - Right Side ............................................6-206.18 Gas Control Module (GCM-2010) Replacement Parts .................................. 6-216.19 Gas Control Module (GCM-2010) Replacement Parts .................................. 6-226.20 Remote Arc Starter (RAS-1000) Replacement Parts .................................... 6-236.21 Remote Arc Starter (RAS-1000) Replacement Parts .................................... 6-246.22 Command & Control Module Type 2 - Replacement Parts ......................... 6-256.23 XTL Torch Valve Assembly External Replacement Parts ............................ 6-266.24 XTL Torch Valve Assembly Internal Replacement Parts ............................... 6-27
SECTION 7. TORCH MAINTENANCE.................................................................................... 7-1
7.01 Consumable Removal ................................................................................... 7-17.02 O-Ring Lubrication ........................................................................................ 7-27.03 Parts Wear ................................................................................................... 7-37.04 Torch Consumables Installation .................................................................... 7-47.05 Coolant Leak Trouble-Shooting ...................................................................... 7-6
TABLE OF CONTENTS (continued)
APPENDIX 1: Remote Arc Starter Schematic .......................................................................... A-1
APPENDIX 2: Gas Control and Torch Valve Schematic ............................................................. A-2
APPENDIX 3: Gas Control Module Plumbing Diagram .............................................................. A-4
APPENDIX 4: Gas Control Module PCB Layout ....................................................................... A-5
APPENDIX 5: Gas Control Display Interface PCB Layout ........................................................ A-6
APPENDIX 6: CCM CPU PCB Layout ..................................................................................... A-7
APPENDIX 7: CCM Input / Output PCB Layout ........................................................................ A-8
CNC functions .................................................................................................... A-10CNC Input / Output Descriptions ......................................................................... A-11Simplified CNC Circuit. ....................................................................................... A-13CNC Connections. .............................................................................................. A-14
APPENDIX 8: Schematic, 230-460V, Chopper Pilot ................................................................. A-16
APPENDIX 8: Schematic, 230-460V, Chopper Pilot Cont. ........................................................ A-18
APPENDIX 9: Schematic, 230-460V, Resistor Pilot ................................................................. A-20
APPENDIX 9: Schematic, 230-460V, Resistor Pilot Cont. ........................................................ A-22
APPENDIX 10: Schematic, CCC 400V, w/ Chopper Pilot ......................................................... A-24
APPENDIX 10: Schematic, CCC 400V, w/ Chopper Pilot Cont. ................................................ A-26
APPENDIX 11: Schematic, CE 400V, Chopper Pilot ................................................................ A-28
APPENDIX 11: Schematic, CE 400V, Chopper Pilot Cont. ....................................................... A-30
APPENDIX 12: Schematic, CE 400V, Resistor Pilot ................................................................ A-32
APPENDIX 12: Schematic, CE 400V, Resistor Pilot Cont. ....................................................... A-34
APPENDIX 13: Schematic, CSA 600V, Chopper Pilot .............................................................. A-36
APPENDIX 13: Schematic, CSA 600V, Chopper Pilot Cont. ..................................................... A-38
APPENDIX 14: PUBLICATION HISTORY................................................................................ A-40
Global Customer Service Contact Information ..................................................... Inside Rear Cover
TABLE OF CONTENTS (continued)
NOTESECTION 8. TORCH OPERATION, is provided separately.
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SECTION 1:GENERAL INFORMATION
1.01 Notes, Cautions and Warnings
Throughout this manual, notes, cautions, and warnings are used tohighlight important information. These highlights are categorized asfollows:
NOTE
An operation, procedure, or background informationwhich requires additional emphasis or is helpful in effi-cient operation of the system.
CAUTION
A procedure which, if not properly followed, may causedamage to the equipment.
! WARNING
A procedure which, if not properly followed, may causeinjury to the operator or others in the operating area.
1.02 Important Safety Precautions
WARNINGS
OPERATION AND MAINTENANCE OF PLASMA ARCEQUIPMENT CAN BE DANGEROUS AND HAZARDOUSTO YOUR HEALTH.
Plasma arc cutting produces intense electric and mag-netic emissions that may interfere with the proper func-tion of cardiac pacemakers, hearing aids, or other elec-tronic health equipment. Persons who work near plasmaarc cutting applications should consult their medical healthprofessional and the manufacturer of the health equip-ment to determine whether a hazard exists.
To prevent possible injury, read, understand and followall warnings, safety precautions and instructions beforeusing the equipment. Call 1-603-298-5711 or your localdistributor if you have any questions.
GASES AND FUMES
Gases and fumes produced during the plasma cutting process can bedangerous and hazardous to your health.
• Keep all fumes and gases from the breathing area. Keep yourhead out of the welding fume plume.
• Use an air-supplied respirator if ventilation is not adequate toremove all fumes and gases.
• The kinds of fumes and gases from the plasma arc depend on thekind of metal being used, coatings on the metal, and the differentprocesses. You must be very careful when cutting or weldingany metals which may contain one or more of the following:
Antimony Chromium MercuryArsenic Cobalt NickelBarium Copper SeleniumBeryllium Lead SilverCadmium Manganese Vanadium
• Always read the Material Safety Data Sheets (MSDS) that shouldbe supplied with the material you are using. These MSDSs willgive you the information regarding the kind and amount of fumesand gases that may be dangerous to your health.
• For information on how to test for fumes and gases in yourworkplace, refer to item 1 in Subsection 1.03, Publications inthis manual.
• Use special equipment, such as water or down draft cuttingtables, to capture fumes and gases.
• Do not use the plasma torch in an area where combustible orexplosive gases or materials are located.
• Phosgene, a toxic gas, is generated from the vapors of chlori-nated solvents and cleansers. Remove all sources of these va-pors.
• This product, when used for welding or cutting, produces fumesor gases which contain chemicals known to the State of Califor-nia to cause birth defects and, in some cases, cancer. (CaliforniaHealth & Safety Code Sec. 25249.5 et seq.)
ELECTRIC SHOCK
Electric Shock can injure or kill. The plasma arc process uses andproduces high voltage electrical energy. This electric energy can causesevere 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 workpiece 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 toitem 9 in Subsection 1.03, Publications.
• Disconnect power source before performing any service or re-pairs.
• 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 theworkplace. Any material that cannot be removed must be pro-tected.
• Ventilate all flammable or explosive vapors from the workplace.
• Do not cut or weld on containers that may have held combus-tibles.
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• Provide a fire watch when working in an area where fire hazardsmay exist.
• Hydrogen gas may be formed and trapped under aluminumworkpieces when they are cut underwater or while using a watertable. DO NOT cut aluminum alloys underwater or on a watertable unless the hydrogen gas can be eliminated or dissipated.Trapped hydrogen gas that is ignited will cause an explosion.
NOISE
Noise can cause permanent hearing loss. Plasma arc processes cancause noise levels to exceed safe limits. You must protect your earsfrom loud noise to prevent permanent loss of hearing.
• To protect your hearing from loud noise, wear protective earplugs 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 Subsec-tion 1.03, Publications, in this manual.
PLASMA ARC RAYS
Plasma Arc Rays can injure your eyes and burn your skin. The plasmaarc process produces very bright ultra violet and infra red light. Thesearc rays will damage your eyes and burn your skin if you are notproperly protected.
• To protect your eyes, always wear a welding helmet or shield.Also always wear safety glasses with side shields, goggles orother protective eye wear.
• Wear welding gloves and suitable clothing to protect your skinfrom the arc rays and sparks.
• Keep helmet and safety glasses in good condition. Replacelenses when cracked, chipped or dirty.
• Protect others in the work area from the arc rays. Use protectivebooths, screens or shields.
• Use the shade of lens as suggested in the following per ANSI/ASC Z49.1:
Minimum Protective SuggestedArc 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 usedwhen the arc is hidden by the workpiece.
LEAD WARNING
This product contains chemicals, including lead, or otherwise pro-duces chemicals known to the State of California to cause cancer, birthdefects and other reproductive harm. Wash hands after handling.(California Health & Safety Code § 25249.5 et seq.)
1.03 Publications
Refer to the following standards or their latest revisions for more infor-mation:
1. OSHA, SAFETY AND HEALTH STANDARDS, 29CFR 1910,obtainable from the Superintendent of Documents, U.S.Government Printing Office, Washington, D.C. 20402
2. ANSI Standard Z49.1, SAFETY IN WELDING AND CUTTING,obtainable from the American Welding Society, 550 N.W.LeJeune Rd, Miami, FL 33126
3. NIOSH, SAFETY AND HEALTH IN ARC WELDING AND GASWELDING AND CUTTING, obtainable from the Superinten-dent of Documents, U.S. Government Printing Office, Wash-ington, D.C. 20402
4. ANSI Standard Z87.1, SAFE PRACTICES FOR OCCUPATIONAND EDUCATIONAL EYE AND FACE PROTECTION, obtain-able from American National Standards Institute, 1430Broadway, New York, NY 10018
5. ANSI Standard Z41.1, STANDARD FOR MEN’S SAFETY-TOEFOOTWEAR, obtainable from the American National Stan-dards Institute, 1430 Broadway, New York, NY 10018
6. ANSI Standard Z49.2, FIRE PREVENTION IN THE USE OFCUTTING AND WELDING PROCESSES, obtainable fromAmerican National Standards Institute, 1430 Broadway,New York, NY 10018
7. AWS Standard A6.0, WELDING AND CUTTING CONTAIN-ERS WHICH HAVE HELD COMBUSTIBLES, obtainable fromAmerican Welding Society, 550 N.W. LeJeune Rd, Miami,FL 33126
8. NFPA Standard 51, OXYGEN-FUEL GAS SYSTEMS FORWELDING, CUTTING AND ALLIED PROCESSES, obtainablefrom the National Fire Protection Association, BatterymarchPark, Quincy, MA 02269
9. NFPA Standard 70, NATIONAL ELECTRICAL CODE, obtain-able 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 COMPRESSEDGASES IN CYLINDERS, obtainable from the CompressedGas Association, 1235 Jefferson Davis Highway, Suite 501,Arlington, VA 22202
12. CSA Standard W117.2, CODE FOR SAFETY IN WELDINGAND CUTTING, obtainable from the Canadian StandardsAssociation, Standards Sales, 178 Rexdale Boulevard,Rexdale, Ontario, Canada M9W 1R3
13. NWSA booklet, WELDING SAFETY BIBLIOGRAPHY obtain-able from the National Welding Supply Association, 1900Arch Street, Philadelphia, PA 19103
14. American Welding Society Standard AWSF4.1, RECOM-MENDED SAFE PRACTICES FOR THE PREPARATION FORWELDING AND CUTTING OF CONTAINERS AND PIPING
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THAT HAVE HELD HAZARDOUS SUBSTANCES, obtainablefrom the American Welding Society, 550 N.W. LeJeune Rd,Miami, FL 33126
15. ANSI Standard Z88.2, PRACTICE FOR RESPIRATORY PRO-TECTION, obtainable from American National StandardsInstitute, 1430 Broadway, New York, NY 10018
1.04 Note, Attention et Avertissement
Dans ce manuel, les mots “note,” “attention,” et “avertissement” sontutilisés pour mettre en relief des informations à caractère important.Ces mises en relief sont classifiées comme suit :
NOTE
Toute opération, procédure ou renseignement général surlequel il importe d’insister davantage ou qui contribue àl’efficacité de fonctionnement du système.
ATTENTION
Toute procédure pouvant résulter l’endommagement dumatériel en cas de non-respect de la procédure enquestion.
! AVERTISSEMENT
Toute procédure pouvant provoquer des blessures del’opérateur ou des autres personnes se trouvant dans lazone de travail en cas de non-respect de la procédure enquestion.
1.05 Precautions De Securite Importantes
AVERTISSEMENTS
L’OPÉRATION ET LA MAINTENANCE DU MATÉRIEL DESOUDAGE À L’ARC AU JET DE PLASMA PEUVENTPRÉSENTER DES RISQUES ET DES DANGERS DESANTÉ.
Coupant à l’arc au jet de plasma produit de l’énergieélectrique haute tension et des émissions magnétique quipeuvent interférer la fonction propre d’un “pacemaker”cardiaque, les appareils auditif, ou autre matériel de santéelectronique. Ceux qui travail près d’une application àl’arc au jet de plasma devrait consulter leur membreprofessionel de médication et le manufacturier de matérielde santé pour déterminer s’il existe des risques de santé.
Il faut communiquer aux opérateurs et au personnel TOUSles dangers possibles. Afin d’éviter les blessurespossibles, lisez, comprenez et suivez tous lesavertissements, toutes les précautions de sécurité et toutesles consignes avant d’utiliser le matériel. Composez le +603-298-5711 ou votre distributeur local si vous avezdes questions.
FUMÉE et GAZ
La fumée et les gaz produits par le procédé de jet de plasma peuventprésenter des risques et des dangers de santé.
• Eloignez toute fumée et gaz de votre zone de respiration. Gardezvotre tête hors de la plume de fumée provenant du chalumeau.
• Utilisez un appareil respiratoire à alimentation en air si l’aérationfournie ne permet pas d’éliminer la fumée et les gaz.
• Les sortes de gaz et de fumée provenant de l’arc de plasma dépendentdu genre de métal utilisé, des revêtements se trouvant sur le métal etdes différents procédés. Vous devez prendre soin lorsque vouscoupez ou soudez tout métal pouvant contenir un ou plusieurs deséléments suivants:
antimoine cadmium mercureargent chrome nickelarsenic cobalt plombbaryum cuivre séléniumbéryllium manganèse vanadium
• Lisez toujours les fiches de données sur la sécurité des matières(sigle américain “MSDS”); celles-ci devraient être fournies avec lematériel que vous utilisez. Les MSDS contiennent desrenseignements quant à la quantité et la nature de la fumée et des gazpouvant poser des dangers de santé.
• Pour des informations sur la manière de tester la fumée et les gaz devotre lieu de travail, consultez l’article 1 et les documents cités à lapage 5.
• Utilisez un équipement spécial tel que des tables de coupe à débitd’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 setrouvent des matières ou des gaz combustibles ou explosifs.
• Le phosgène, un gaz toxique, est généré par la fumée provenant dessolvants et des produits de nettoyage chlorés. Eliminez toute sourcede telle fumée.
• Ce produit, dans le procéder de soudage et de coupe, produit de lafumée ou des gaz pouvant contenir des éléments reconnu dansL’état de la Californie, qui peuvent causer des défauts de naissance etle cancer. (La sécurité de santé en Californie et la code sécurité Sec.25249.5 et seq.)
CHOC ELECTRIQUE
Les chocs électriques peuvent blesser ou même tuer. Le procédé au jet deplasma requiert et produit de l’énergie électrique haute tension. Cetteénergie électrique peut produire des chocs graves, voire mortels, pourl’opérateur et les autres personnes sur le lieu de travail.
• Ne touchez jamais une pièce “sous tension” ou “vive”; portez desgants et des vêtements secs. Isolez-vous de la pièce de travail ou desautres parties du circuit de soudage.
• Réparez ou remplacez toute pièce usée ou endommagée.
• Prenez des soins particuliers lorsque la zone de travail est humideou moite.
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• Montez et maintenez le matériel conformément au Code électriquenational des Etats-Unis. (Voir la page 5, article 9.)
• Débranchez l’alimentation électrique avant tout travail d’entretienou 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 plasmaproduit du métal, des étincelles, des scories chaudes pouvant mettre lefeu aux matières combustibles ou provoquer l’explosion de fuméesinflammables.
• Soyez certain qu’aucune matière combustible ou inflammable ne setrouve sur le lieu de travail. Protégez toute telle matière qu’il estimpossible de retirer de la zone de travail.
• Procurez une bonne aération de toutes les fumées inflammables ouexplosives.
• Ne coupez pas et ne soudez pas les conteneurs ayant pu renfermerdes matières combustibles.
• Prévoyez une veille d’incendie lors de tout travail dans une zoneprésentant des dangers d’incendie.
• Le gas hydrogène peut se former ou s’accumuler sous les pièces detravail en aluminium lorsqu’elles sont coupées sous l’eau ou surune table d’eau. NE PAS couper les alliages en aluminium sousl’eau ou sur une table d’eau à moins que le gas hydrogène peuts’échapper ou se dissiper. Le gas hydrogène accumulé explosera sienflammé.
RAYONS D’ARC DE PLASMA
Les rayons provenant de l’arc de plasma peuvent blesser vos yeux etbrûler votre peau. Le procédé à l’arc de plasma produit une lumièreinfra-rouge et des rayons ultra-violets très forts. Ces rayons d’arc nuirontà vos yeux et brûleront votre peau si vous ne vous protégez pascorrectement.
• Pour protéger vos yeux, portez toujours un casque ou un écran desoudeur. Portez toujours des lunettes de sécurité munies de paroislatérales ou des lunettes de protection ou une autre sorte de protec-tion oculaire.
• Portez des gants de soudeur et un vêtement protecteur appropriépour 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 travailcontre les rayons de l’arc en fournissant des cabines ou des écransde protection.
• Utilisez la nuance de lentille qui est suggèrée dans le recommenda-tion qui suivent ANSI/ASC Z49.1:
Nuance Minimum Nuance SuggeréeCourant 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 observéclairement. L’experience a démontrer que les filtres moinsfoncés peuvent être utilisés quand l’arc est caché parmoiceau de travail.
BRUIT
Le bruit peut provoquer une perte permanente de l’ouïe. Les procédésde soudage à l’arc de plasma peuvent provoquer des niveaux sonoressupérieurs aux limites normalement acceptables. Vous dú4ez vousprotéger les oreilles contre les bruits forts afin d’éviter une pertepermanente de l’ouïe.
• Pour protéger votre ouïe contre les bruits forts, portez des tamponsprotecteurs et/ou des protections auriculaires. Protégez égalementles 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, consultezl’article 1, page 5.
PLOMB AVERTISSEMENT
Ce produit contient des produits chimiques, comme le plomb, ouengendre des produits chimiques, reconnus par l’état de Californiecomme pouvant être à l’origine de cancer, de malformations fœtales oud’autres problèmes de reproduction. Il faut se laver les mains aprèstoute manipulation. (Code de Californie de la sécurité et santé,paragraphe 25249.5 et suivants)
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1.06 Documents De Reference
Consultez les normes suivantes ou les révisions les plus récentes ayantété faites à celles-ci pour de plus amples renseignements :
1. OSHA, NORMES DE SÉCURITÉ DU TRAVAIL ET DE PROTECTIONDE LA SANTÉ, 29CFR 1910, disponible auprès du Superintendentof Documents, U.S. Government Printing Office, Washington, D.C.20402
2. Norme ANSI Z49.1, LA SÉCURITÉ DES OPÉRATIONS DE COUPE ETDE SOUDAGE, disponible auprès de la Société Américaine deSoudage (American Welding Society), 550 N.W. LeJeune Rd., Mi-ami, FL 33126
3. NIOSH, LA SÉCURITÉ ET LA SANTÉ LORS DES OPÉRATIONS DECOUPE ET DE SOUDAGE À L’ARC ET AU GAZ, disponible auprès duSuperintendent of Documents, U.S. Government Printing Office,Washington, D.C. 20402
4. Norme ANSI Z87.1, PRATIQUES SURES POUR LA PROTECTIONDES YEUX ET DU VISAGE AU TRAVAIL ET DANS LES ECOLES,disponible de l’Institut Américain des Normes Nationales (AmericanNational Standards Institute), 1430 Broadway, New York, NY 10018
5. Norme ANSI Z41.1, NORMES POUR LES CHAUSSURESPROTECTRICES, disponible auprès de l’American National Stan-dards Institute, 1430 Broadway, New York, NY 10018
6. Norme ANSI Z49.2, PRÉVENTION DES INCENDIES LORS DEL’EMPLOI DE PROCÉDÉS DE COUPE ET DE SOUDAGE, disponibleauprès de l’American National Standards Institute, 1430 Broadway,New York, NY 10018
7. Norme A6.0 de l’Association Américaine du Soudage (AWS), LESOUDAGE ET LA COUPE DE CONTENEURS AYANT RENFERMÉ DESPRODUITS COMBUSTIBLES, disponible auprès de la AmericanWelding Society, 550 N.W. LeJeune Rd., Miami, FL 33126
8. Norme 51 de l’Association Américaine pour la Protection contre lesIncendies (NFPA), LES SYSTEMES À GAZ AVEC ALIMENTATIONEN OXYGENE POUR LE SOUDAGE, LA COUPE ET LES PROCÉDÉSASSOCIÉS, disponible auprès de la National Fire Protection Asso-ciation, Batterymarch Park, Quincy, MA 02269
9. Norme 70 de la NFPA, CODE ELECTRIQUE NATIONAL, disponibleauprès de la National Fire Protection Association, Batterymarch Park,Quincy, MA 02269
10. Norme 51B de la NFPA, LES PROCÉDÉS DE COUPE ET DESOUDAGE, disponible auprès de la National Fire Protection Asso-ciation, Batterymarch Park, Quincy, MA 02269
11. Brochure GCA P-1, LA MANIPULATION SANS RISQUE DES GAZCOMPRIMÉS EN CYLINDRES, disponible auprès de l’Associationdes Gaz Comprimés (Compressed Gas Association), 1235 JeffersonDavis Highway, Suite 501, Arlington, VA 22202
12. Norme CSA W117.2, CODE DE SÉCURITÉ POUR LE SOUDAGE ETLA COUPE, disponible auprès de l’Association des NormesCanadiennes, 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 deSoudage (National Welding Supply Association), 1900 Arch Street,Philadelphia, PA 19103
14. Norme AWSF4.1 de l’Association Américaine de Soudage,RECOMMANDATIONS DE PRATIQUES SURES POUR LAPRÉPARATION À LA COUPE ET AU SOUDAGE DE CONTENEURSET TUYAUX AYANT RENFERMÉ DES PRODUITS DANGEREUX ,disponible auprès de la American Welding Society, 550 N.W. LeJeuneRd., Miami, FL 33126
15. Norme ANSI Z88.2, PRATIQUES DE PROTECTION RESPIRATOIRE,disponible auprès de l’American National Standards Institute, 1430Broadway, New York, NY 10018
ULTRA-CUT 100
1-6 Manual 0-4748
1.07 Declaration of ConformityManufacturer: Thermal Dynamics CorporationAddress: 82 Benning Street
West Lebanon, New Hampshire 03784USA
The equipment described in this manual conforms to all applicable aspects and regulations of the ‘Low Voltage Directive’(European Council Directive 73/23/EEC as amended by Council Directive 93/68/EEC) and to the National legislation for theenforcement of this Directive.
The equipment described in this manual conforms to all applicable aspects and regulations of the "EMC Directive" (EuropeanCouncil 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 anddate 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 associatedaccessories.
* For environments with increased hazard of electrical shock, Power Supplies bearing the 'S' mark conform to EN50192 whenused 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 manufactur-ing process. This is to ensure the product is safe, when used according to instructions in this manual and related industrystandards, and performs as specified. Rigorous testing is incorporated into the manufacturing process to ensure the manufac-tured 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 areaof manufacture.
Manufacturers responsible representative: Steve WardOperations DirectorThermadyne EuropeEuropa BuildingChorley N Industrial ParkChorley, Lancashire,England PR6 7BX
ULTRA-CUT 100
1-7Manual 0-4748
1.08 Statement of Warranty
LIMITED WARRANTY: Thermal Dynamics® Corporation (hereinafter “Thermal”) warrants that its products will be free of defects in workmanshipor 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 accordancewith 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 partsof the product determined by Thermal to be defective.
THIS WARRANTY IS EXCLUSIVE AND IS IN LIEU OF ANY WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULARPURPOSE.
LIMITATION OF LIABILITY: Thermal shall not under any circumstances be liable for special or consequential damages, such as, but notlimited to, damage or loss of purchased or replacement goods, or claims of customers of distributor (hereinafter “Purchaser”) for serviceinterruption. The remedies of the Purchaser set forth herein are exclusive and the liability of Thermal with respect to any contract, or anythingdone in connection therewith such as the performance or breach thereof, or from the manufacture, sale, delivery, resale, or use of any goodscovered 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 PARTS OR ACCESSORIES ARE USED WHICH MAY IMPAIR THE SAFETY ORPERFORMANCE OF ANY THERMAL PRODUCT.
THIS WARRANTY IS INVALID 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 amaximum of two (2) years from date of sale by such distributor to the Purchaser, and with further limitations on such two (2) year period (seechart below).
Parts Labor
AutoCut© and UltraCut© Power Supplies and Components 2 Years 1 Year
Torch And Leads
XTTM-300 / XTTM-301 Torch (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 facilitywithin thirty (30) days of the repair. No transportation costs of any kind will be paid under this warranty. Transportation charges to sendproducts to an authorized warranty repair facility shall be the responsibility of the customer. All returned goods shall be at the customer’s riskand expense. This warranty supersedes all previous Thermal warranties.
Effective August 19, 2005
ULTRA-CUT 100
1-8 Manual 0-4748
Manual No. 0-4748 2-1 SPECIFICATIONS
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 systemperformance, 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 totransfer 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.
SPECIFICATIONS 2-2 Manual No. 0-4748
ULTRA-CUT 100
2.06 Specifications & Electrical Requirements
Input Power & Current 208/230V - 460V, 1/3 ph, 50 / 60 HzMax OCV (U0) 380 vdcMinimum Output Current 10 AmpsMax Output Current 100 AmpsOutput Voltage 60 - 230 vdcDuty Cycle Rating 100% @ 100A, 180VAmbient Temperaturefor Duty Cycle Rating
104F° (40°C)
Operating range 14°F to 122°F (-10°C to + 50°C)Power Factor 0.70 @ 100 A DC OutputCooling Forced Air (Class F)
Ultra-Cut 100 Specifications & Design Features
Input Power Input Current Suggested Sizes (See Note)Voltage Freq. 3-Ph 3-Ph Fuse (Amps) Wire (AWG)(Volts) (Hz) (kVA) (Amps) 3-Ph 3-Ph
208 50/60 23 64 80 #41
230 50/60 24 60 80 #41
400 50 28 40 50 #61
400 (CE) 50 28 40 50 #61
460 50/60 26 33 40 #81
Ultra-Cut 100 Power Supply
Line Voltages with Suggested Circuit Protection and Wire SizesBased on National Electric Code and Canadian Electrical Code
1 Extra Hard Usage Type SO, SOW, SOO, SOOW, ST, STW, STO, STOW, STOO, STOOW
2.07 System Component Layout
Primary power
Work
CNC
RemoteArc
Starter
Art # A-07328_AB
Torch
Coolant Supply
Coolant Return
Control Cable
Pilot Return
Coolant Supply
Coolant Return
Plasma Gas
Shield Gas
Work Cable
FiberOpticCable
Control Cable
Gas ControlModule
Power Supply
Torch Valve
Assembly Positioning Tube
Plasma Gas
Preflow Gas
Water Shield
Shield
Shield Gas
Negative
Pilot Return
Control Cable
100’ / 30.5 m Maximum Length125’ / 38.1 m Maximum Length
175’ / 53.3 m Maximum Length
Shield
I
JG
K
LP
O
A,
B,
C,
D,
E
H,
Q,
R,
S,
T
Manual No. 0-4748 2-3 SPECIFICATIONS
ULTRA-CUT 100
2.08 Power Supply Dimensions
Art # A-04793
37.75 inch 960 nm
27.5 inch 700 mm
33 inch 840 mm
27 inch 680 mm
41.25 inch1050 mm
343 lb / 156 kg
SPECIFICATIONS 2-4 Manual No. 0-4748
ULTRA-CUT 100
2.09 Power Supply Rear Panel Features
Terminal Cover Support Panel
Coolant Tank
Coolant Filter
Coolant Connections
Input PowerTerminals
Pilot (Pos) Terminal
Circuit Breaker Panel
Terminal Cover
AC Power Lamp
Ground TerminalsGas Control Console Connector
RETURN SUPPLY
Art # A-04794
CNC Connector
Remote Arc StarterConnector
Work Cable Terminal
Torch (Neg) Terminal
Leads Bracket
Manual No. 0-4748 2-5 SPECIFICATIONS
ULTRA-CUT 100
2.10 Gas Requirements
The customer will provide all gases and pressure regulators. Gases must be of high quality. Pressure regulatorsshall be double stage. The chart includes gases which may not be used in all applications.
Gas Quality Minimum Pressure Flow
O2 (Oxygen) 99.5% Purity(Liquid recommended)
120 psi8.3 bar / 827 kPa
70 scfh (1982 l/h)
N2 (Nitrogen)
99.5% Purity(Liquid recommended) <1000 ppm O2, <32
ppm H2O)
120 psi8.3 bar / 827 kPa 200 scfh (5700 l/h)
Compressed or Bottled Air
Clean, Dry, Free of Oil (see Note 1)
120 psi8.3 bar / 827 kPa
244 scfh (6910 l/h)
H35 (Argon-Hydrogen)H35 = 35% Hydrogen,
65% Argon
99.995% Purity(gas recommended)
120 psi8.3 bar / 827 kPa 90 scfh (2550 l/h)
H2O (Water) See Note 2 50 psi (3.5 bar) 10 gph (38 lph)
Note 3: Water Pressure Regulator No. 8-6118 is recommended to ensure proper water pressure.
Ultra-Cut 100 Power Supply: Gas Pressures, Flows, and Quality Requirements
Note 2: The tap water source does not need to be deionized, but in water systems with extremely high mineral content a water softener is recommended. Tap water with high levels of particulate matter must be filtered.
Note 1: The air source must be adequately filtered to remove all oil or grease. Oil or grease contamination from compressed or bottled air can cause fires in conjunction with oxygen.
For filtering, a coalescing filter able to filter to 0.01 microns should be placed as close aspossible to the gas inlets on the Gas Control Module.
2.11 Gas Applications
MATERIAL
PREFLOW PLASMA SHIELD PREFLOW PLASMA SHIELD PREFLOW PLASMA SHIELDAir Air Air Air Air AirN2 N2 H20 N2 N2 H20Air Air Air Air Air AirN2 N2 H20 N2 N2 H20Air Air Air Air Air AirN2 N2 H20 N2 N2 H20
85A CUT Air Air AirN2 H35 N2 N2 H35 N2
N2 N2 H20 N2 N2 H20
OPERATION
30A CUT
70 A CUT
100 A CUT
50 A CUT O2
Air
O2
O2
Air
Air
Air
GAS TYPEGAS TYPE GAS TYPE
AirO2
Air
O2
Air
Ultra-Cut-100 Gas ApplicationsMILD STEEL STAINLESS STEEL ALUMINUM
SPECIFICATIONS 2-6 Manual No. 0-4748
ULTRA-CUT 100
2.12 XTTM-300 Torch Specifications
A. Torch Dimensions
2.25"57.15 mm
2.0"50.8 mm
2.39"60.81 mm
1.49"37.8 mm
19.00"482.68 mm
15.50"393.78 mm
2.74"69.55 mm
1.57"39.96 mm
3.54"89.87 mm
6.30"160.10 mm
Art # A-04897
Mounting Tube
End Cap
Manual No. 0-4748 2-7 SPECIFICATIONS
ULTRA-CUT 100
B. Torch Specifications
AmbientTemperature
104° F40° C
Duty Cycle 100% @ 100 AmpsMaximum Current 100 AmpsVoltage (Vpeak) 500VArc Striking Voltage 10kV
Current Up to 100 Amps, DC,Straight Polarity
Plasma Gases:Compressed Air, Oxygen, Nitrogen, H35
Shield Gases:Compressed Air, Oxygen, Nitrogen, Water
Operating Pressure 125 psi ± 10 psi8.6 bar ± 0.7 bar
Maximum Input Pressure 135 psi / 9.3 barGas flow 10 - 300 scfh
XTTM-300 Torch Ratingsfor use with Ultra-Cut 100 Power Supply
XTTM-300 Torch Gas Specifications
C. Leads Lengths
Feet Meters10 3.0515 4.625 7.635 10.650 15.275 22.8100 30.4125 38.2150 45.7175 53.3
LengthGas Lead Assemblies
D. Torch Parts (Generic Parts Shown)
CartridgeShield Cup
Art # A-04741
ElectrodeTip
Plasma Gas Distributor
Shield Gas Distributor
Shield Cap
SPECIFICATIONS 2-8 Manual No. 0-4748
ULTRA-CUT 100
Intentionally blank
Manual No. 0-4748 3-1 INSTALLATION
ULTRA-CUT 100
SECTION 3: INSTALLATION
3.01 Installation Requirements
Electric Supply
The electrical supply network, the gas and water supply system must meet local safety standards. Thisconformity shall be checked by qualified personnel.
Input Power Input Current Suggested Sizes (See Note)Voltage Freq. 3-Ph 3-Ph Fuse (Amps) Wire (AWG)(Volts) (Hz) (kVA) (Amps) 3-Ph 3-Ph
208 50/60 23 64 80 #41
230 50/60 24 60 80 #41
400 50 28 40 50 #61
400 (CE) 50 28 40 50 #61
460 50/60 26 33 40 #81
Ultra-Cut 100 Power Supply
Line Voltages with Suggested Circuit Protection and Wire SizesBased on National Electric Code and Canadian Electrical Code
1 Extra Hard Usage Type SO, SOW, SOO, SOOW, ST, STW, STO, STOW, STOO, STOOW
CAUTION
Fuse and wire sizes are for reference only. The installation must conform to national and local codes for the typeand method of wire being used.
Gas Supply
The customer must supply all gases and pressure regulators. Gases must be of high quality. Pressureregulators must be double-stage and installed as close as possible to the gas console. Contaminated gascan 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).
Cat. Number and Mixture Mixture Protects To7-3580 'Extra-CoolTM' 25 / 75 10° F / -12° C7-3581 'Ultra-CoolTM' 50 / 50 -27° F / -3° C
7-3582 'Extreme CoolTM' Concentrate* -65° F / -51° C
Coolant Capabilities
* For mixing with D-I CoolTM 7-3583
INSTALLATION 3-2 Manual No. 0-4748
ULTRA-CUT 100
3.02 System Layout
Refer to section 3.05 for ground connections and ground cables.
Primary power
Work
CNC
RemoteArc
Starter
Art # A-07233_AB
Torch
Coolant Supply
Coolant Return
Control Cable
Pilot Return
Coolant Supply
Coolant Return
Plasma Gas
Shield Gas
Work Cable
FiberOpticCable
Control Cable
Gas ControlModule
Power Supply
TorchValve
Assembly Positioning Tube
Plasma Gas
Preflow Gas
Water Shield
Shield
Shield Gas
Negative
Pilot Return
Control Cable
100’ / 30.5 m Maximum Length125’ / 38.1 m Maximum Length
175’ / 53.3 m Maximum Length
Shield
H
Q
R
T
S
A
B
C
D
E
P
K
L
O
I
JG
175’ / 53.3 m Maximum Length
Manual No. 0-4748 3-3 INSTALLATION
ULTRA-CUT 100
3.03 Cables & Leads Identification
Green / Yellow # 4 AWG
Green / Yellow 1/0 (50 mm )
A
Green
Red
Art # A
-07473
#8 AWG Cable
#1 AWG Cable
B
C
D
E
F
F1
K
L
H, Q, R, S,T
Work Cable
CNC Cable (14 Wire)
37
14
Coolant Supply Lead, Power Supply to Arc Starter
1/0 Cable (1/0 (50 mm )
Pilot Return, Power Supplyto Arc Starter
Negative Lead, Power Supplyto Arc Starter
Control Cable, Power Supplyto Arc Starter
Ground Cable
Ground Cable,Remote Arc Starter To Earth Ground
O
P
Fiber Optic Cable, Power Supply to Gas Control Module
Control Cable, Power Supply to Gas Control Module
Green
RedCoolant Return Lead, Power Supply to Arc Starter
2
2
14
GShielded Torch Lead Assembly, Remote Arc Starter to Torch
Plasma Gas Lead,Torch Valve to Torch
Shield Gas Lead,Torch Valve to Torch
I
J
INSTALLATION 3-4 Manual No. 0-4748
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 andvertical. Do not lift it any further than necessary to clear the shipping pallet.
Art # A-04796
Set the power supply on a solid, level surface. The installer may fasten the power supply to the floor or asupporting fixture with hardware passing through the horizontal parts of the power supply feet.
Manual No. 0-4748 3-5 INSTALLATION
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 aground wire connected to the inside of the panel. Do not disconnect this wire.
Connections Cover(Removed)
Connection Panel
Art # A-04797
INSTALLATION 3-6 Manual No. 0-4748
ULTRA-CUT 100
Check / Adjust Input Voltage Configuration
1. The power supply includes a voltage configuration board which must be positioned to match the primaryinput voltage. Remove the power supply left side panel and locate the voltage configuration board. The inputvoltage 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 withthe correct input voltage shown at the top of the board.
3. Re-connect the jumper. Re-install the power supply side panel.
Art # A-04856_AB
1. Unplug connector
2. Remove bolts.3. Invert board.4. Re-install board.5. Plug in connector.
208/230V / 460V Input Voltage Board
(Shown in 460V Position)
Inverter Module
Manual No. 0-4748 3-7 INSTALLATION
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 cords. Cut backthe insulation on the individual cords. Route the cable upward through leads bracket at the bottom of the rearpanel, then through the connections cover support panel on the rear panel of the power supply.
2. Install ring tongue terminals on the individual cords. Fasten the terminals to the individual cords securely.
3. Connect the individual cords as shown. Connect the power cable ground cord to the ground terminal block.
CAUTION
The clear connections cover must remain in place.
4. If required pass a system ground cable (F1) through the last opening in the connections cover support panelnext 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.
PILOT
WORK
TORCH
Input power cable
Ground Terminal Block
Connections Cover Support Panel
System Ground Cable
Art # A-07659_AB
to Remote Arc Starter
Connections CoverConnection Panel
Leads Bracket
to Remote Arc Starter
AC INPUT
System Ground Cable
Input power cable ground
L1
L2
L3
L1L2
L3
5. Re-install the connections cover on the power supply. Snug the hardware securely by hand. Do not over-tighten.
INSTALLATION 3-8 Manual No. 0-4748
ULTRA-CUT 100
0 - 10 ft (0 - 3 m) Ideal20 ft (6 m) Maximum
1/0Ground Cable
Power Supply
‘Star’Ground
Earth Ground Rod
1/0 Ground Cable
CNC Device
Torch
Cutting Table
Cutting Machine / Gantry
1/0 Work Cable
Remote ArcStarter (RAS-1000)
0 - 10 ft (0 - 3 m) Ideal20 ft (6 m) Maximum
Gas Control Module
Power Supply
‘Star’Ground
Earth Ground Rod
CNC Device
Torch
Cutting Table
Cutting Machine / Gantry
1/0 Work Cable
Remote ArcStarter (RAS-1000)
1/0Ground Cable
(F1)
Star Ground on Cutting Table
Star Ground on Cutting Table
1/0Ground Cable
Ultra-Cut or
Auto-Cut O2
Note: The gas control module can be mounted on top of the power supply. If it is, it should be grounded directly to the power supply with #4 AWG ground, (F). This alternate location requires grounding the power supply to the ‘Star’ ground with the 1/0 Ground Cable (F1).
Gas Control ModulePrimary location
#4 AWGGround
(F)
#4 AWG Ground (F)(Factory Installed)
Art # A-08253_AC
Customer supplied
Customer supplied
1/0Ground Cable
(F1)
Auto-Cut W/RAS
Manual No. 0-4748 3-9 INSTALLATION
ULTRA-CUT 100
0 - 10 ft (0 - 3 m) Ideal20 ft (6 m) Maximum
1/0Ground Cable
Customer Supplied
#4 AWG Ground (F)(Factory Installed)
GCM-1000Gas Control Module
Auto-Cut Power Supply
‘Star’Ground
Earth Ground Rod
1/0 Ground Cable(F1)
CNC Device
Torch
Cutting Table
Cutting Machine / Gantry
1/0 Work Cable
Auto-Cut Basic SystemWithout RAS
Art # A-08254_AC
INSTALLATION 3-10 Manual No. 0-4748
ULTRA-CUT 100
3.06 Ground Connections
A. Electromagnetic Interference (EMI)
Pilot arc starting generates a certain amount of electromagnetic interference (EMI), commonly called RF noise.This RF noise may interfere with other electronic equipment such as CNC controllers, remote controls, heightcontrollers, etc. To minimize RF interference, follow these grounding procedures when installing mechanizedsystems:
B. Grounding
1. The preferred grounding arrangement is a single point or “Star” ground. The single point, usually on the cuttingtable, is connected with 1/0 AWG (European 50 mm2) or larger wire to a good earth ground (measuring leassthan 3 ohms; an ideal ground measures 1 ohm or less. Refer to paragraph ‘C’, Creating An Earth Ground. Theground rod must be placed as close as possible to the cutting table, ideally less than 10 ft (3.0 m), but no morethan 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 RFfrequencies. Smaller diameter wire has increased resistance to RF frequencies, so using a largerdiameter wire is better.
2. Grounding for components mounted on the cutting table (CNC controllers, height controllers, plasma remotecontrols, etc.) should follow the manufacturer’s recommendations for wire size, type, and connection pointlocations.
For Thermal Dynamics components (except Remote Arc Starter and Gas Control Module) it is recommendedto use a minimum of 10 AWG (European 6 mm2) wire or flat copper braid with cross section equal to or greaterthan 10 AWG connected to the cutting table frame. The Remote Arc Starter uses 1/0 earth ground wire and theGas Control Module should use minimum # 4 AWG wire. The connection point must be to clean bare metal; rustand paint make poor connections. For all components, wires larger than the recommended minimum can beused and may improve noise protection.
3. The cutting machine frame is then connected to the “Star” point using 1/0 AWG (European 50 mm2) or largerwire.
4. The plasma power supply work cable (see NOTE) is connected to the cutting table at the single point “Star” ground.
NOTE
Do Not connect the work cable directly to the ground rod.
5. Make sure work cable and ground cables are properly connected. The work cable must have a solid connectionto the cutting table. The work and ground connections must be free from rust, dirt, grease, oil and paint. Ifnecessary grind or sand down to bare metal. Use lock washers to keep the connections tight. Using electricaljoint compound to prevent corrosion is also recommended.
6. The plasma power supply chassis is connected to the power distribution system ground as required by electri-cal codes. If the plasma supply is close to the cutting table (see NOTE) a second ground rod is not usuallyneeded, 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 toinstall a second earth ground rod next to the plasma power supply. The plasma power supply chassis wouldthen 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 withno shield at all.
Manual No. 0-4748 3-11 INSTALLATION
ULTRA-CUT 100
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 groundrod 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). Groundrods, typically 10 ft (3.0 m) long, may be welded end to end for greater lengths. Locate the rod as close aspossible to the work table. Install a ground wire, 1/0 AWG (European 50 mm2) or greater, between the groundrod 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 asshown.
CAUTION
No other connections should be made at the ground rod being tested.
This test assumes the 115 or 230 VAC source neutral is connected to the utility earth ground.
Art # A-07252
WARNING
Use extreme caution. Thistest uses live voltage.
NEUTRALEarth Grounded
HOTOn 115V AC Line: 3VAC = 3 ohms 1VAC = 1 ohm
On 230V AC Line: 1.5VAC = 3 ohms 0.5VAC = 1 ohm
Ground Rod with other connections removed
100W Incandescentlight bulb*
* Can replace light bulb with a 100w resistor.Use 100 ohm for 115VAC.Use 500 ohm for 230VAC
NEUTRALPROBE
VAC
HOTPROBE
Ground Testing
2. Increasing the ground rod length beyond 20 - 30 ft (6.1 – 9.1 m) does not generally increase the effectivenessof the ground rod. A larger diameter rod which has more surface area may help. Sometimes keeping the soilaround the ground rod moist by continuously running a small amount of water into it will work. Adding salt to thesoil by soaking it in salt water may also reduce its resistance. When these methods are used, periodicchecking 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 theplasma 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 increasedchance of RF interference.
INSTALLATION 3-12 Manual No. 0-4748
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3.07 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 thebottom 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.
PILOTWORK
TORCH
Connection Panel
AC INPUT
L1
L2
L3
Work Lead
Torch Lead - To Remote Arc Starter
WorkTorch
Lead Connection Detail
Connections CoverSupport Panel
Art # A-07660_AB
Connections Cover
Pilot
To Cutting TableLeads Bracket
Pilot Lead - To Remote Arc Starter
Manual No. 0-4748 3-13 INSTALLATION
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3.08 Connect Coolant Leads
1. Connect the color-coded coolant hoses to the coolant connections on the power supply rear panel. Thesupply line (out) is flagged green, the return line (in) is flagged red.
Coolant Connections
RETURN SUPPLYRETURN SUPPLY
Art # A-04800
To Remote Arc Starter
COOLANT
RED
GREEN
INSTALLATION 3-14 Manual No. 0-4748
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3.09 Connect Control Cables for CNC, Remote Arc Starter, and GCM
1. Connect one end of each cable to the power supply.
2. Connect the other end of the CNC cable to the CNC device.
3. The CNC cable shield must be attached to ground.
RETURN SUPPLY
Art # A-04802
To CNC
To Remote Arc Starter
To Gas Control Module
Customer WiringAccess Hole
Manual No. 0-4748 3-15 INSTALLATION
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3.10 Connect Fiber Optic Cable (Type 2 internal control module)
CAUTION
Check the type of internal control module. Use this section for connections to an internal control module withoutan external connections cover. Use the preceding section for connections to an internal module with an externalconnections cover.
1. Connect one end of each cable to the power supply as shown.
a. Remove the strain relief securing nut from the strain relief on the fiber optic cable(s). Loosen the strainrelief dome nut from the strain relief.
b. Pass the cable connector through the appropriate opening. Slide the strain relief securing nut onto thecable. Make a loop of the cable; carefully press the cable connector into the appropriate receptacle on theinternal control module.
c. Tighten the strain relief onto the cable(s). Do not overtighen.
To Gas Control Module
To Remote HMI (if installed)
Profile Detail, Fiber Optic Cable Installation
Cable Receptacles
To Slave Power Supply(if installed)
Art # A-06793
INSTALLATION 3-16 Manual No. 0-4748
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3.11 Set Switches on the Command - Control Module (Type 2 Module)
Compare the command - control module to the illustration. Follow instructions in this section for a modulewithout 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 staticcharges in your body or surroundings before touching the printed circuit boards.
SW1 SW3 SW4 SW5 SW8
3 41 2 3 41 21 2 1 2 1 2 1 2
SW-1-1: Auto Pilot Restart. 1 = ON = Auto Pilot Function enabled. 1 = OFF = Auto Pilot Function disabled (Factory default setting).SW-1-2: Pilot Delay 2 = OFF, 3 = OFF, 4 = OFF: 0 Seconds (Factory default setting).SW-1-3: Pilot Delay 2 = ON, 3 = OFF, 4 = OFF: 0.1 SecondsSW-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-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 1 = OFF = Short (85 ms.) (Factory default setting).
1 = ON = Long (3 s.)
ON
ON
Active only when SW-1-1 is set to ON.
Art # A-06791_AB
Future Use
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 8-2: Remote Current 1 = OFF = Disabled (Factory default setting). 1 = ON = (Remote Analog Current Control)*SW 8-3: Auto Transfer Retry1 = OFF = Enabled Up to 3 tries (Factory default setting). 1 = ON = Disabled
SW 8-4: Reserved for Factory use.
* SW 8-3 is reserved for Factory use prior to
Firmware V3.5
Manual No. 0-4748 3-17 INSTALLATION
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CAUTION
Printed circuit boards in the Command - Control Module are static - sensitive. Discharge any built-up staticcharges in your body or surroundings before touching the printed circuit boards.
SW-6: OK-to-Move: Contact closure, 120VAC @ 1A (Factory default setting) or DC Volts (16-18vdc@ up to 100 ma.)
SW-11: Analog Current Control. B = from Gas Control (Factory default setting) or A = from CNC. Position A requires that SW-8-2 be ON.
SW-12-1/2/3/4: Divided Arc signal All = OFF = 50:1 (Factory default setting)
1 = ON = 16.6:1 2 = ON = 30:1 3 = ON = 40:1 4 = Not used.
Art # A-06792
Only 1 on at a time.
SW11
SW13
SW6
SW12
No external connection cover
SW13: TVA and XTL Switch positions
SW13
1 2 1 2 TVA XTL TVA
INSTALLATION 3-18 Manual No. 0-4748
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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 requiresconnection to the full non-divided arc voltage. Also available on the terminal strip are 120VAC (120,0) and 24VAC (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
4
There is also a hole added in the rear panel above the J55-GCM receptacle for customer wiring. This, ratherthan the one in the CCM will be the preferred place for customer added wiring (and strain relief) for connec-tions to height controls, etc..
Manual No. 0-4748 3-19 INSTALLATION
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3.13 Gas Control Module Installation
The Gas Control Module must be installed in a suitable location where it is easily accessible to the systemoperator. The unit must be mounted to a flat horizontal surface. If the Module is mounted to a gantry or to any othersupport subject to vibration or motion, the installer must fasten the module to the support securely.
The Module should be located aas far away as possible from the Arc Starter due to electromagnetic interference.It is acceptable to locate the control cable in the same track as the cables from the Arc Starter.
The Module includes feet which lift the bottom panel off the mounting surface. There are ventilation holes on thebottom panel; the space between the bottom panel and the mounting surface must remain open for ventilating airto enter the module. Louvers on the back panel of the module must also remain unblocked, for the free passageof ventilating air.
Mounting Dimensions
NOTE
Height not shown is 14.125” (359 mm)
Art # A-07962
8.50”
215.90mm
0.28”7.14mm
11.00”
279.40mm
16.18”
410.97mm
13.68”
347.47mm
Gas Box
NOTE
The unit must be mounted so that the Flowmeters are plumb. If the Flowmeters are not plumb, incorrectflow indications may occur.
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Preparation
1. Remove the screws securing the Cover Panel to the Module.
2. Carefully remove the cover from the module noting the attached ground wire. Remove the ground wire ifneeded.
Art # A-06882
Gas Control Module Cover
Do not remove
Remove GroundWire
Cover Removal
Manual No. 0-4748 3-21 INSTALLATION
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3.14 Fiber Optic Cable Installation
1. Install the through-hole protector for the fiber-optic cable in the hole in connection panel on the back of theModule.
2. Pass the fiber-optic cable connector through the hole in connection panel on the back of the Module. Passenough of the cable into the Module to allow the cable to loop upward as shown.
CAUTION
Avoid kinking, twisting, or bunching the fiber optic cable. The cable can be damaged by being forcedinto tight-radius turns.
2
3
Circuit Board
Art # A-04772
Fiber Optic Cable
COMM
PLASMA
OUT
PREFLOW
OUT
J57
J56
SHIELD
OUT
H2O
INPUTS
TVAPOWER
SUPPLY
H35
F5
AIR N
2 O
2
1
COMM
J57
J56
INPUTS
TVAPOWER
SUPPLY
H35
F5
AIR N
2 O
2
SHIELDPLASMA
PREFLOW
H2O
SHIELD
H2O
INSTALLATION 3-22 Manual No. 0-4748
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3. Insert the fiber-optic cable connector into the receptacle on the vertically-mounted circuit board asshown.Cable must snap into place.
Circuit Board
Fiber Optic Cable
Art # A-04773
4. Tighten the through-hole protector for the fiber-optic cable.
5. Reinstall the Cover Panel making sure the ground wire is attached.
Manual No. 0-4748 3-23 INSTALLATION
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3.15 Gas Control Module: Control, Input, and Output Connections
1. Make all other connections to the rear of the Module. The connections are labeled. The Module must begrounded; the grounding terminal is marked Use #10 AWG (European 6 mm2) (or thicker) wire forgrounding. Keep the ground wire as short as possible.
2. Position the Module on a flat, horizontal, mounting surface.
3. Ensure that the Flowmeters are plumb.
4. Secure the Module to the mounting surface.
5. Connect all gas / water inputs to the rear panel of the module.
6. Connect the appropriate control cables to terminals marked ‘TVA’ (torch valve assembly) and ‘power sup-ply’.
Gas & Water Inputs (Check Valves)
Connection Panel
To Torch Valve Assembly
To Torch Valve Assembly
To Power Supply
SHIELD PLASMA PREFLOW
H OSHIELD
2 H O2
AIR N2 O2
H35 F5
TVAPOWERSUPPLY
COMMJ57 J56
INPUTS
When Cutting With O2 PlasmaAir MUST BE Connected
Ground Stud
SHIELD PLASMA PREFLOW
H OSHIELD
2 H O2
AIR N2 O2
H35 F5
TVAPOWERSUPPLY
COMMJ57 J56
INPUTS
When Cutting With O2 PlasmaAir MUST BE Connected
Gas Control BoxRear Panel
Art # A-06881
INSTALLATION 3-24 Manual No. 0-4748
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3.16 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 Starterfor these connections without crimping.
Mounting Dimensions
NOTE
Height not shown is 7.375” ( 187mm )
D.250”3 PLACES
6.35mm
8.00”203.20mm
12.00”304.80mm
2.00”50.80mm
1.49”
37.77mm
10.50”
266.70mm
7.51”190.83mm
.50”12.70mm
Arc Starter Box
Art # A-07961
Manual No. 0-4748 3-25 INSTALLATION
ULTRA-CUT 100
Installation
The Remote Arc Starter must be installed in a suitable location near the torch head. If the Arc Starter is mountedto 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 upperscrews 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.
Art # A-07029
Lower screws
Upper screws (4 per side)
Cover
Ground Wire
Cover Removal
3. Position the Arc Starter on a flat, horizontal mounting surface.
INSTALLATION 3-26 Manual No. 0-4748
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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 themounting surface.
Art # A-04749
Minimum 2
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; Redfor Return, Green for Supply.
Coolant Supply and Return Hoses(from power supply)
Art # A-04750
Manual No. 0-4748 3-27 INSTALLATION
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Coolant Return (Red)
Coolant Supply (Green)
Art # A-04751
Coolant Return(Red)
Red
Green
Art # A-04752_AB
Negative Cablefrom power supply
Negative cable must be attached so that it is in contact with the copper plate.
Copper plate
Negative Cable (from Power Supply rear panel)
INSTALLATION 3-28 Manual No. 0-4748
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Art # A-04753
Pilot Return Cablefrom Power supply
PILOT Return Cable (from Power Supply rear panel)
Art # A-04755
Control Cable from Power Supply rear panel
Manual No. 0-4748 3-29 INSTALLATION
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Output Connections
1. Refer to the illustrations. Make the following output connections to the Arc Starter.
NOTE
For newer leads with only one black wire, it must be connected to the pilot return.There are no innershield wires.
Pilot Lead Connection Detail
Inner Shield Connection Detail
Inner Shield LeadPilot Lead
Art # A-04933
Pilot Return Cable and Inner Shield Lead (from Torch Leads)
INSTALLATION 3-30 Manual No. 0-4748
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Art # A-04757
Coolant Return (Red) from Torch
Coolant Supply (Green) to Torch
Some items are removed for clarity.
Coolant Supply Fitting(Tagged with Green)
Coolant Return Fitting(Tagged with Red)
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.
Art # A-07029
Lower screws
Upper screws (4 per side)
Cover
Ground Wire
The Arc Starter must be grounded; the grounding terminal is marked . Refer to the previous section forgrounding details.
Manual No. 0-4748 3-31 INSTALLATION
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Ground Cable
Art # A-04758
1 Nut and 1 Washer Remain in Place
Torch Leads
• Use a clamp to secure the Torch Lead Shield braid to the port on the Remote Arc Starter as shown.
Art # A-04759
Coolant and Pilot Leads to Torch Valve Assembly
Torch Leads Shield
Shield Clamp
INSTALLATION 3-32 Manual No. 0-4748
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Connect Control Cable
1. Connect the Remote Arc Starter cable to the Remote Arc Starter receptacle.
Art # A-04801
RETURN SUPPLY
RETURN SUPPLY
Power Supply Rear Panel
COOLANT
Remote Arc Starter - Input Connection Panel
Remote Arc Starter
Manual No. 0-4748 3-33 INSTALLATION
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3.17 Original & XTL Torch Valve Installation
General Information
This assembly mounts as close as possible to the torch head. It accepts preflow, plasma, and shield gases fromthe Gas Control Module and supplies these gases to the Torch.
Mounting
1.450”36.83 mm
4.450”113.03 mm
.261” Dia.6.63 mm
Art # A-07648
1. Mount the Valve Kit as close as possible to the Torch. The valve kit can be mounted in any convenientposition, provided the outlet side (with two fittings) is closer to the torch than the inlet side (with three fittingsand a control cable connector).
2. Connect the Valve Kit outlets to the torch leads as shown. (XTL shown)
Art # A-07645
Do not remove brass plugsFront and side
Right-hand Thread:To Torch Shield Gas fitting
Left-hand Thread: To Torch Plasma Gas fitting
Outlet Side
INSTALLATION 3-34 Manual No. 0-4748
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3. Connect the gas supply lines and the control cable connector from the Gas Control Module to the Valve Kit asshown. Hold the check valves stationary while attaching the gas lines. (XTL shown)
Control Cable
Plasma Gas Inlet
Shield Gas Inlet
Preflow Gas Inlet
WMS™ Inlet
Art # A-07646
Exhaust Muffler
CAUTION
Hold all fittings stationary while attaching hoses or leaks can be created. Side pressure can break the check valvesor weaken their connection to the torch valve assembly. All fittings must be checked for leaks after assembly.
Manual No. 0-4748 3-35 INSTALLATION
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3.18 Connecting Torch
Connect the Torch as follows:
Art # A-04746
Pilot Lead Connector
Torch Head Assembly
Mounting Tube
O-Ring
Torch Leads End Cap
Plasma Gas(Left Hand Thread)
Shield Gas(Right Hand Thread)
Coolant Supply&
Power Lead (-)
Pilot Lead
Coolant Supply,Coolant Return,and Pilot Leads
Leads Cover
Groove for O-Ring
To Torch Valve
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 thatthe 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 3-36 Manual No. 0-4748
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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 gasconnection 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 theleads to the Torch Head. Do not overtighten.
CAUTION
The gas and coolant leads include compression fittings. Do not use sealant on these connections.
Slowly apply pressure to the gas lines. Check for leaks at all connections before continuing. If thereare no leaks, shut off the gas supplies and continue with installation.
7. Connect the pilot lead to the Torch Head. Press the two ends of the connector firmly together. Thread theplastic 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 neededto ensure a proper fit through the Mounting Tube and Torch Leads End Cap. Hold the Torch Head Assemblystationary; rotate the Mounting Tube to thread it onto the Torch Head.
CAUTION
Ensure that the leads do not twist within the mounting tube. Leads must lie as shown in the installation sketch.
9. The lower end of the Mounting Tube includes four threaded holes. Install an Allen set screw in any of thethreaded holes to secure the Torch Head Assembly to the Mounting Tube.
10. Install the appropriate consumable parts as shown on the following pages. The torch manual includesdiagrams showing the correct parts to install, depending on the metal to be cut and the gases in use.
Manual No. 0-4748 3-37 INSTALLATION
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3.19 Install Consumable Torch Parts
Install the consumable parts as follows to ensure proper operation. These steps will help ensure that parts areseated correctly.
Art # A-03887
WARNINGS
Do not install consumables into the Cartridge while the Cartridge is attached to the Torch Head.Keep foreign materials out of the consumables and Cartridge. Handle all parts carefully to avoid damage, which may affect torch performance.
1. Check the appropriate cut chart for the right combination of parts for the cutting application.
2. For 200 Amp parts only, thread the Shield Retainer onto the Shield Cup.
3. Stack the consumable parts together.
ShieldRetainer
Shield CupShie
ld Cap
Shield
Gas
Distrib
utor
Tip Plasma G
as
Distrib
utor
Electr
ode
Cartrid
geArt # A-08303
A B C1 - Assemble “A” 200 A only. 2 - Assemble “B”. 3 - Assemble “B” to “C”. 4 - Assemble “A” to “B-C” assembly.
4. Insert the stack of consumable parts into the cartridge. Ensure that the large O-ring on the torch tip fitscompletely into the cartridge. If any part of the O-ring protrudes from the cartridge, the parts are notseated properly.
5. Use the cartridge tool to hold the cartridge assembly, while turning the shield cup (and shield retainerfor 200 Amp parts) onto the cartridge assembly. For 300 Amp parts turn the shield retainer onto theshield cup now. When this group is fully assembled, the shield should protrude from the front of theshield cup or shield retainer. Without this protrusion the shield cup is not properly tightened onto thecartridge assembly.
6. Take the cartridge tool off the cartridge. Fit the cartridge assembly onto the torch head. The Speed Lokring should clidk into place and the cartridge assembly should touch the large O-ring on the torch body.
INSTALLATION 3-38 Manual No. 0-4748
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Torch Head O-Ring Torch Head
Art # A-08300_AB
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.
Manual No. 0-4748 3-39 INSTALLATION
ULTRA-CUT 100
55 - 100 Amp Parts Assembly
Cartridge Covers O-Ring on Torch Tip
Shield Cap Protrudes 0.063-0.083" (1.6 - 2.1 mm)
Electrode
Plasma Gas Distributor
Tip
Shield Gas Distributor
Shield Cap
O-Ring on Tip
1: Stack Parts 2: Press Cartridge onto Stacked Parts
4: Check Shield Cap Protrusion
Art # A-04873
No Gaps Between Parts
3: Thread Shield Cup onto Cartridge
Shield Cap
Shield Cup
Installing Assembled Cartridge Onto Torch Head
INSTALLATION 3-40 Manual No. 0-4748
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7. Connect the wire lead from the height finder to the ohmic clip if using ohmic torch height
sensing. A-03393
Ohmic Clip
NOTE
Ohmic height sensing is not recommended with water shield. Water on the plate interferes electricallywith the ohmic sensing circuit.
Manual No. 0-4748 3-41 INSTALLATION
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3.20 Complete the Installation
1. Remove the cap from the coolant tank. Fill the coolant tank to the level shown, with Thermal Dynamicscoolant. The coolant level is visible through the translucent coolant tank. The amount of coolant requiredvaries with torch leads length.
Cat. Number and Mixture Mixture Protects To7-3580 'Extra-CoolTM' 25 / 75 10° F / -12° C7-3581 'Ultra-CoolTM' 50 / 50 27° F / -33° C
7-3582 'Extreme CoolTM' Concentrate* -65° F / -51° C
Coolant Capabilities
* For mixing with D-I CoolTM 7-3583
RETURN SUPPLY
RETURN SUPPLY
Art # A-04803
COOLANT
Fill Range
Coolant Tank
2. After the complete system has been installed, check that the coolant has been pumped through thesystem as follows (see NOTE):
INSTALLATION 3-42 Manual No. 0-4748
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NOTE
Depending on the length of the torch leads, the system may require more coolant after turning thesystem 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 torchleads this sequence may need to be done three to five times.
f. After the system stays operational allow the pump to operate for ten minutes to properly purge any airfrom 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 areevident, consult the coolant leak trouble-shooting guide in the maintenance section of this manual.
Manual No. 0-4748 4-1 OPERATION
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SECTION 4: OPERATION
4.01 Power Supply Control Panel
Art # A-04862
AC Indicator
Temp Indicator
Gas Indicator
DC Indicator
Status Indicator
AC Power Indicator
Indicates AC power is being supplied to the inverters when the ON/OFF switch is in ON position. Whenswitch is first set to ON, the indicator stays off until the inrush cycle is complete and the correct voltage isconfirmed.
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: Normally ON. Indicates gas control is ready for operation. The indicator blinks during the
purge cycle or when the gas control is not in the RUN mode or when there is a communication error. Indicatoris 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 theoperating software installed in the system.
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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
ON
OFFO
IOFF
O
Art # A-04812
3. Check the AC indicator. If indicator is ON, system is ready to operate (pending fault checks by internal cir-cuitry). If indicator does not light after a few seconds check that each inverter is correctly configured for theinput voltage and all 3 phases are present. Check Status Indicator for any codes that can help determineproblem.
Manual No. 0-4748 4-3 OPERATION
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4.03 Gas Control Module Operation
Functional Overview
The Gas Control Module provides all Plasma and Secondary gas selection and control instrumentation. There arevarious controls and indicators used to set gas pressures and flows.
ENABLE
DISABLE
PLASMAPOWERSUPPLY
SHIELD
FLOW
GAS
PRESSURE
MODE GAS
GCM
2010
PLASMAPREFLOW
O2 - AIR
O2 - O2
H35 - N2
F5 - N2
AIR - AIR
N2 - H20
N2 - N2
Art # A-04771
MODE GAS
O2 - AIR
O2 - O2
H35 - N2
F5 - N2
AIR - AIR
N2 - H20
N2 - N2
ENABLE
DISABLE
PLASMAPOWER SUPPLY
FLOW
GAS
PRESSURE
99H20 MIST
RUN
SET PREFLOW
SET PLASMA& SHIELD
TEST
RUN
SET PREFLOW
SET PLASMA& SHIELD
TEST
OPERATION 4-4 Manual No. 0-4748
ULTRA-CUT 100Gas Control Module: Controls & Indicators
1. MODE Selection Switch
MODE
RUN
SET PREFLOW
SET PLASMA& SHIELD
TEST
PREFLOW
H2OMIST
PLASMA SHIELD
PRESSURE
PLASMAPOWER SUPPLY
GAS
FLOW
High PrecisionPlasma Cutting System
ENABLE
DISABLE
GASMODE
RUN
SET PREFLOW
SET PLASMA& SHIELD
TEST
O2 - AIRO2 - O2
H35 -N2
F5 - N2
AIR - AIRN2 - H2O
N2 - N2
Art # A-04765
99
GCM
2010
• Normally in the RUN position during torch operation.
• In the SET PREFLOW position, Preflow or Piloting gas (Air or N2) flows to the torch allowing the operator toadjust pressure. Gas automatically shuts off after 2 minutes if left in the SET PREFLOW position.
• In the SET PLASMA & SHIELD position, selected cutting gases, Plasma & Shield, flow to the torch to allowoperator to set the pressure (regulator & gauge) and flow (knob at top of flowmeter). Gases automatically shutoff after 2 minutes if left in the SET PLASMA & SHIELD position. GCM 2010 gas control revision AG or laterincludes inlet pressure sensors. In SET PLASMA & SHIELD position the LCD display shows alternately theplasma an shield inlet pressure. If either gas pressure is outside the acceptable range, the display shows “PSIlow (or high), the actual pressure and the limit it is below (or above).
• In the TEST position , selected cutting gasses, Plasma & Shield, also flow to the torch. The Plasma outletpressure (pressure going to the torch), is displayed.
• For GCM 2010 gas control revision AG or later the Mode Selection Switch includes a hidden function used atinitial setup to configure the gas control for the gas lead length. See Sequence of Operation, initial setup.
Manual No. 0-4748 4-5 OPERATION
ULTRA-CUT 1002. GAS Selection Switch
Selects combinations of plasma and shield gases.
GAS
O2 - AIRO2 - O2
H35 -N2
F5 - N2
AIR - AIRN2 - H2O
N2 - N2
PREFLOW
H2OMIST
PLASMA SHIELD
PRESSURE
PLASMAPOWER SUPPLY
GAS
FLOW
High PrecisionPlasma Cutting System
ENABLE
DISABLE
GASMODE
RUN
SET PREFLOW
SET PLASMA& SHIELD
TEST
O2 - AIRO2 - O2
H35 -N2
F5 - N2
AIR - AIRN2 - H2O
N2 - N2
99
Art # A-04766
GCM
2010
3. LCD Display
LED display shows Gas Control Status, such as Waiting for Communication, Plasma Power Supply Disabled,Initializing, Purging and Output Current setting. It also shows operational states like Preflow, Piloting,Cutting, and Postflow. In addition there are some low level CANBus errors that are indicated by message ̂ E#.
^E4 = CANBus error unacknowledged message.
^E5 = CNABus error Bus off
^E6 = CANBus error communication timed out.
OPERATION 4-6 Manual No. 0-4748
ULTRA-CUT 1004. Current Control
Adjusts the output current of the power supply.
High PrecisionPlasma Cutting System
PREFLOW
H2OMIST
PLASMA SHIELD
PRESSURE
PLASMAPOWER SUPPLY
GAS
FLOW
High PrecisionPlasma Cutting System
ENABLE
DISABLE
GASMODE
RUN
SET PREFLOW
SET PLASMA& SHIELD
TEST
O2 - AIRO2 - O2
H35 -N2
F5 - N2
AIR - AIRN2 - H2O
N2 - N2
99
Art # A-04767
GCM
2010
5. Plasma Power Supply Enable / Disable Switch
The DISABLE position removes input power from the Power Supply inverters, disables the coolant pump andfan, the pilot contactor & HF and removes AC power from the gsa control solenoids shutting off all gas flow.When the switch is returned to the ENABLE position an automatic gas purge is started and then the system isreturned to normal operation under control of the CNC device.
6. PREFLOW Control Knob and Pressure Gauge
Used to set preflow gas pressure and flow. MODE switch must be in SET PREFLOW position.
7. PLASMA and SHIELD Control Knobs, Pressure Gauges and Flow Meter
Used to set plasma and shield gas pressures and flows. Mode switch must be in SET PLASMA & SHIELDposition.
8. Gas Pressure Flow Switch
At lower flow rates shield gas pressure is first set per the cut charts then the flow is set using the flow meterwith the GAS switch set in the FLOW position. Some torch parts require higher flow rates that execeed thecapacity of the flow meter. In that case, Gas switch is set in the PRESSURE position and the regulator andgauge is used to set pressure per the cut charts when no “Ball” setting is shown.
9. H2O Mist Control Knob and Flow Meter
Used to set water flow rate. MODE switch must be in SET PLASMA & SHIELD position. GAS selection switchmust be in N2-H2O position.
NOTE
Water mist is not used in all applications.
Manual No. 0-4748 4-7 OPERATION
ULTRA-CUT 100
4.04 First Time Operation Matching Gas Control to Lead Length
For initial operation of GCM2010 with software version 2.1 or later.
1. Before applying AC power set the Power Supply ENABLE/DISABLE switch on the gas control module toDISABLE.
2. Set Gas Selection switch to the correct position for cutting process being used.
3. Turn on AC power and set Power Supply ENABLE/DIABLE switch to ENABLE. After a short delay toestablish communications, the gas control will start the Purge and priming sequence. (If torch and coolantleads were not already full of coolant you may be required to repeat this power on cycle and add coolantuntil the priming is complete).
4. Once the purge sequence is finished set the Mofe Switch between Run and Set Precharge. Display says“SET HOSE LENGTH” on the first line and LENGTH xxx FEET on the second. The xxx is most likely thefactory default of 175’ which is the system maximum.
5. Press in and hold the Current Control knob. Display changes to SELECT HOSE LENGTH and second linesteps downwards from 175’ to 50’ in 25’ increments. As soon as the correct length is displayed, release theknob.
6. Set the Mode Switch back to Run.
7. The initial/first time set up is complete and does not have to be done again unless the Gas Control or it’smain PC Board is replaced.
4.05 Sequence Of Operation
For first time operation see previous steps, “First Time Operation...”
1. Set the Plasma Power Supply Enable / Disable switch to Disable.
DANGER
Always shut off input power to the system before changing or inspecting torch parts.
a. Change the torch parts if necessary.
b. Set the Plasma Power Supply Enable / Disable switch (on the Gas Control Module) to Enable. TheModule performs purges of 15 seconds, 11 seconds, and another 11 seconds. This removes water fromthe torch parts.
2. Select the desired plasma and shield gas by setting the Gas Selection switch to the desired position. 2seconds after gas selection, the module purges the new gas(es) through the leads.
3. Set the preflow gas pressure.
a. Set the MODE switch to SET PREFLOW.
b. Use the PREFLOW control knob to set preflow gas pressure. Refer to the torch manual for pressuresettings.
c . Use the AMPERAGE SET-UP control knob to set the desired pre-charge pressure set point. Press the control knob for 2 seconds without rotating. Then rotate the knob to adjust pressure.
OPERATION 4-8 Manual No. 0-4748
ULTRA-CUT 1004. Set the plasma and shield gas pressures and flows.
a. Set the MODE switch to SET PLASMA & SHIELD.
b. Use the PLASMA and SHIELD control knobs, pressure gauges, and flow meters to set plasma andshield gas pressures and flows. Refer to the torch manual for pressure settings.
c. In installations using water shield, use the H2O MIST control knob and flow meter to set water flow rate.Refer to the torch manual for flow rates.
5. Use the AMPERAGE SET-UP control knob to set the desired amperage output. The module will update theamperage every 2 seconds after the last adjustment to the knob. The module keeps the set point in memory.
6. Place the MODE switch to the RUN position.
7. Set the Plasma Power Supply Enable / Disable switch (on the Gas Control Module) to Enable. The Moduleperforms purges of 15 seconds, 11 seconds, and another 11 seconds. This removes water from the torchparts.
NOTE
When switching gases between operations, allow enough purge time to clear the prior gas from the torch leads.
CAUTION
While nothing prevents the operator from switching gases during piloting or cutting it is not recommended to doso. If the operator switches gases during piloting or cutting, the power supply will finish the cut with the first gaschosen. Then the gas control will switch to the new gas. Switching gases during piloting or cutting may damagetorch parts, torch leads, the control module, or the piece being cut.
Cut Quality
Cut quality requirements differ depending on application. For instance, nitride build-up and bevel angle may bemajor factors when the surface will be welded after cutting. Dross-free cutting is important when finish cut qualityis desired to avoid a secondary cleaning operation. Cut quality will vary on different materials and thicknesses.
Right SideCut Angle
Left SideCut Angle
A-00512
Kerf WidthCut SurfaceBevel Angle
Top EdgeRounding
Cut SurfaceDrag Lines
DrossBuild-Up
TopSpatter
A-00007
Cut Surface
The condition (smooth or rough) of the face of the cut.
Manual No. 0-4748 4-9 OPERATION
ULTRA-CUT 100Bevel Angle
The angle between the surface of the cut edge and a plane perpendicular to the surface of the plate. A perfectlyperpendicular cut would result in a 0° bevel angle.
Top-Edge Rounding
Rounding on the top edge of a cut due to wearing from the initial contact of the plasma arc on the workpiece.
Dross Build-up and Top Spatter
Dross is molten material which is not blown out of the cut area and re-solidifies on the plate. Top spatter isdross which accumulates on the top surface of the workpiece. Excessive dross may require secondary clean-up operations after cutting.
Kerf Width
The width of material removed during the cut.
Nitride Build-up
Nitride deposits which may remain on the cut edge of the carbon steel when nitrogen is present in the plasmagas stream. Nitride buildups may create difficulties if the steel is welded after the cutting process.
Direction of Cut
The plasma gas stream swirls as it leaves the torch to maintain a smooth column of gas. This swirl effect resultsin one side of a cut being more square than the other. Viewed along the direction of travel, the right side of thecut is more square than the left.
Right SideCut Angle
Left SideCut Angle
A-00512
Scrap
Clockwise
Counter-Clockwise
Art # A-04182
Workpiece
Scrap
Swirl Effect on Side Characteristics Of Cut
To make a square - edged cut along an inside diameter of a circle, the torch should move counterclockwisearound the circle. To keep the square edge along an outside diameter cut, the torch should travel in a clockwisedirection.
Underwater Cutting
Cutting on a water table either underwater or with the water touching the plate or with a water muffler systemis not recommended. If a water table is used the water level must be a minimum of 4 inches from the bottom ofthe plate. Failure to follow this recommendation could result in poor cut quality and short consumable partslife.
Ohmic Height Sensing
Ohmic height sensing is not recommended with water shield. Water on the plate interferes electrically with theohmic sensing circuit.
Marking
Marking requires adjusting the pre-charge pressures. Refer to the torch data section for details.
OPERATION 4-10 Manual No. 0-4748
ULTRA-CUT 100
4.06 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 substan-tially reduce torch parts life.
• Provides satisfactory results on nonferrous materials.2. Argon/Hydrogen (H35) Plasma
• Recommended for use on 3/4 in (19 mm) and thicker stainless steel. Recommended for 1/2 inch (12 mm) andthicker nonferrous materials. Ar/H2 is not normally used for thinner nonferrous materials because lessexpensive 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 causedifficulties in producing high quality welds if not removed).
4. Nitrogen (N2) Plasma
• Provides better cut quality on nonferrous materials such as stainless steel and aluminum.
• Can be used in place of air plasma with air shield or carbon dioxide (CO2).
• Provides much better parts life than air.
• A good clean welding grade nitrogen should be used.
B. Shield Gases
1. Compressed Air Shield
• Air shield is normally used when operating with air plasma.
• Improves cut quality on some ferrous materials.
• Inexpensive - reduces operating costs.2. Nitrogen (N2) Shield
• Nitrogen shield is used with Ar/H2 (H35) plasma.
• Provides smooth finishes on nonferrous materials.
• May reduce smoke when used with Ar/H2 plasma.3. Water Shield
• Water shield should be used only in mechanized applications - never in hand cutting!
• Normally used with nitrogen, Ar/H2, or air plasma.
• Provides very smooth cut surface.
• Reduces smoke and heat input to the workpiece.
• Effective up to 1/2 inch (12.7 mm) maximum material thickness.
• Tap water provides low operating expense.
Manual No. 0-4748 4-11 OPERATION
ULTRA-CUT 100
4.07 Power Supply Status Codes
On start-up and during operation, the power supply control circuitry performs various tests. If the circuitrydetects a condition requiring operator attention, the status indicator on the control panel flashes a 2-part codeto indicate a code group and then a particular condition within the group. After 4 seconds, the sequencerepeats.
Example: Indicator flashes 4 times; the condition is in group 4. After a 1.2 second delay, the indicator blinks3 times; the condition code is 4-3, indicating that the coolant is overheating. After a 4-second delay, theindicator repeats the sequence until the condition is corrected.
Some conditions can be active indefinitely, while others are momentary. The power supply latches momentaryconditions; some momentary conditions can shut down the system. The indicator may show multiple condi-tions 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.
Error Code Error Remedy / Comments
1-1System not Enabled or Missing AC Input Phase
Plasma Enable Off ; External E-Stop Activated or CCM TB1-1&2 jumper missing; Missing AC Phase; No power to GCM 2000 or 2010 Gas Control, check GCM control cable connected, reset CP4 or CP5 circuit breaker in power supply, blown fuse F19 in GCM.
1-2 Pilot Ignition FailurePilot did not start within 15 seconds. Preflow pressure too high; Defective Arc Starter
1-3 Lost PilotPilot went out without shutoff signal; Preflow pressure too high; cut current set too low for consumables.
1-4 Loss of Transfer Arc transfer (>50 ms.) then arc lost with START still on. Standoff too high; Current set too low.
1-5 Off the Plate Function not currently enabled
1-6 Pilot Timed out w/o Transfer
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; cut current too low for consumables; Preflow pressure too low.
1-7 Tip Saver Function not currently enabled.
1-8 Possible Shorted Torch
Detected tip voltage too close to electrode voltage. Plasma flow/pressure too low; Plasma leak; cut current too high; shorted torch body; consumable parts worn out.
Fault Code Key
OPERATION 4-12 Manual No. 0-4748
ULTRA-CUT 100
Error Code Error Remedy / Comments
2-1 Missing Phase Blown fuse, Broken or loose connection on power cable
2-2 Wrong input voltage
Inverter(s) not configured correctly for input voltage; Poor power quality (brownouts, dropouts); Input power capacity / wiring too small causing voltage drop; broken or loose power cable connections.
2-3Inverter or Pilot Regulator Over Temperature
Failed fan; Ambient above 40 deg C. (104 F); Blocked airflow
2-4 Power Supply not Ready Defective inverter
2-5 DC Output LowOutput less than 60 VDC; Defective inverter, shorted output; Shorted pilot regulator (chopper); CCM voltage sense (J6) wire open or disconnected.
2-6 Primary over current faultOver current detected in inverter primary circuit, remove power to reset; defective inverter; voltage surge;
2-7 Unexpected currentCurrent >20A in work or pilot leads before pilot ignition; Possible shorted torch; Defective current sensor.
2-8Unexpected current in pilot circuit
Current > 5A in pilot circuit; wrong or mismatched consumables; Pilot lead shorted to negative in torch tube; Possible shorted torch
2-9Unexpected current in work lead
Current > 5A in work lead; Short to chassis in RAS; Negative lead short to ground.
3-1
Gas Control Communication fault, Cannot establish Communication with gas control.
If GCM 1000: Control cable not connected or Basic ID signal open. GCM 2010 & 2000: Dirt on fiber ends or in connectors, blow out with clean dry air; fiber not locked into connector; sharp bends in fiber; fiber defective; Gas Control PCB defective, replace. CCM defective, replace.
3-2
Gas Control Communication reply fault, connection was established but CCM did receive a reply to a process request.
Gas Control did not reply to signal from CCM in allowed time. 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 problem persists Gas Control PCB likely defective, replace board.
3-3 Gas Pressure Low
If GCM 1000, Plasma < 15 PSI; faulty or disconnected pressure SW. If GCM2010_AG, GCM2000_AC or later or Gas Control has been updated with 19X2219_AG or later PCB: Plasma or Shield input out of range 105-135. If GCM2010_AG, GCM2000_AC or later or Gas Control has been updated with 19X2219_AG or later PCB: Plasma or Shield input out of range 105-135 PSI; Unplugged or Faulty pressure sensor.
3-4 Gas Control not ready Purging; not in RUN mode; Gas Control faulty, replace PCB.3-5 Gas Control Protocol Fault Application error or firmware compatibility fault
3-6Invalid Current Control level from GCM
GCM sent output current level outside the range of the power supply, Check firmware compatibility
3-7Gas Control returns wrong command sequence
Check firmware compatibility
3-8CCM and Gas Control type (Autocut-Ultracut) mismatch
Install correct CCM or Gas Control for system
3-9Gas Control Communication reply fault
Reply not compatible with request; Check firmware compatibility
3-10Warning. -- Gas Control firmware needs update
System will function but control may not be optimized for best performance / consumable life
Fault Code Key
Manual No. 0-4748 4-13 OPERATION
ULTRA-CUT 100
Error Code Error Remedy / Comments
4-1 Coolant Level low fault Check coolant level, add as needed.
4-2
Low coolant flow after power on purge. Not cutting: < 0.7 gal/min for 15 sec; Cutting: flow between 0.35 to 0.7 gal/min for 3 sec. or immediately if < 0.35gal/min;
Suction leak introducing air into coolant, suspect rear panel filter seal; clogged filter; defective pump.
4-3Coolant overheated (>70 deg. C, 158 deg F)
Coolant fan failed; radiator fins clogged with dirt; Ambient temperature > 40 deg C.
4-4
Coolant System not ready. During power on purge / priming, flow did not reach 0.35 gal/min for at least 5 seconds
If new installation recycle power to restart pump, may take a few times to fill hoses; Damaged torch coolant tube; Suction leak introducing air into coolant, suspect rear panel filter seal; clogged filter; defective pump.
4-5 Low Coolant Level - WarningWhile cutting detected low coolant level, does not stop cut. Add coolant as required.
5-1CANBUS Failure to Acknowledge fault.
If GCM 1000, Basic ID signal missing; Other gas controls, Fiber disconnected or broken, Transceiver (what fiber plugs into) fault, replace Gas control PCB or CCM
5-2CANBUS Off due to excessive data 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;
5-3CANBUS data error warning. Errors increasing, will soon fault.
Dirt on fiber ends or in connectors, blow out with clean dry air; fiber not locked into connector; sharp bends in fiber; fiber defective;
5-4 CCM Message not sentDirt on fiber ends or in connectors, blow out with clean dry air; fiber not locked into connector; sharp bends in fiber; fiber defective; CANBUS hardware error (CCM or Gas Control PCB)
6-1 CCM Analog Voltage Error Replace CCM6-2 CCM ADC or DAC error Replace CCM
6-3Coolant Flow too High error, flow > 2.7 gal/min
Torch coolant tube broken or missing; CCM fault, replace CCM
6-4 CCM Data Memory error Replace CCM
Fault Code Key
OPERATION 4-14 Manual No. 0-4748
ULTRA-CUT 100
4.08 Remote Arc Starter: Service Chart
Symptom Cause Check Remedy
Coolant has become conductiveUse conductivity meterFlush system, replace coolant.
Pilot return wire not connected Visual inspection Connect Wire.Spark gap set too close Check with feeler gauge Set to 0.063" ±0.002"High Frequency cap (C4) possibly open
Use capacitance meter Reconnect or replace.
Broken or missing ferrites Visual inspection Replace.
Short across in inductor (L1) Visual inspectionRemove short; increase coil gaps.
Spark gap bus caps (C1, C2, C3) broken or defective
Capacitance meter Replace.
Negative supply not connected correctly
Visual inspection Reconnect.
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 Make connections; replace harness.
No/ loose connection to spark gap
Visual inspection Reconnect.
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).
Visual inspection Replace coolant line(s).
Supply & return hose reversedVisual Inspection of color-coded connections
Match coolant connection colorsto arc starter fitting colors.
Blockage in coil orsupply/return hoses
Loosen fitting slightly and check for coolant flow
Flush system.
Shield Drain / Torch lead inner shield connector missing or loose.
Visual inspection of lead attachment to Arc Starter
Reconnect / tighten lead connectors.
Missing or loose ground connection
Visual inspection of ground wire to Arc Starter
Make or tighten connections to good ground.
Cap C5 not connected, open or loose
Visual inspection / capacitor measurement
Replace PCB.
Arc Starter Service Chart
Erratic System Behavior
(EMI Interference)
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
Manual No. 0-4748 4-15 OPERATION
ULTRA-CUT 100
4.09 Remote Arc Starter: SparkGap Adjustment
Art # A-04857
0.063" ± 0.002"1.6 ± 0.05 mm
OPERATION 4-16 Manual No. 0-4748
ULTRA-CUT 100
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Manual No. 0-4748 5-1 MAINTENANCE
ULTRA-CUT 100
SECTION 5: MAINTENANCE
5.01 General Maintenance
Perform the following checks periodically to ensure proper system performance.
Power Supply Maintenance ScheduleDailyCheck coolant level; add coolant as needed.Check gas hose connections and pressures.
MonthlyCheck cooling fan and radiator; clean as needed.Check gas hoses for cracks, leaks, or abrasion. Replace as needed.Check all electrical connectionsfor cracks or abrasion. Replace as needed.
Six MonthsClean or replace external coolant filter.Clean coolant tank.Vacuum out any dust buildup inside power supply.Check internal coolant filter
5.02 External Coolant Filter Cleaning Procedure
Periodic cleaning of the coolant filter ensures maximum coolant flow efficiency. Poor coolant flow causes ineffi-cient 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.
MAINTENANCE 5-2 Manual No. 0-4748
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 theright side panel (viewed from the front of unit) of the Power Supply. Remove the filter screen by unscrewing thefilter holder from the In-Line Filter Assembly. Clean the filter screen by rinsing with hot soapy water. Remove soapresidue by rinsing with clean hot water. Be sure that all the soap has been removed and the screen is dry of waterbefore re-installing in the In-Line Filter Assembly.
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 coolantline 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 willrun approximately for 20 seconds before the flow switch causes an interlock. This procedure may berepeated 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.
Manual No. 0-4748 5-3 MAINTENANCE
ULTRA-CUT 100
RETURN SUPPLY
RETURN SUPPLY
Art # A-04803
COOLANT
Fill Range
Coolant Tank
4. Turn system on, let it run for a few minutes and check coolant level, refill if necessary.
MAINTENANCE 5-4 Manual No. 0-4748
ULTRA-CUT 100
This page is blank intentionally.
Manual No. 0-4748 6-1 Power Supply Parts List
ULTRA-CUT 100
SECTION 6: REPLACEMENT ASSEMBLIES & PARTS
6.01 Main Component / System Replacement
Complete Unit / Component Catalog Number
Ultra-Cut® 100 Power Supply, 208/230V 3-9116-1
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
Gas Control Module (GCM-2010) with XTL Torch Valve Assembly 3-9131
(Requires Firmware version 3.2 or higher for C.C.M.)
Gas Control Module (GCM-2010) Only 7-4000
Original Torch Valve Assembly Repair Part Only 4-3049
XTL Torch Valve Assembly Only 4-3054
(Requires C.C.M. Firmware version 3.2 or higher and
GCM 2010 Firmware version 3.1 or higher)
Remote Arc Starter (RAS-1000) 3-9130
OPTIONAL EQUIPMENT:
Wheel Kit 9-9379
Power Supply Parts List 6-2 Manual No. 0-4748
ULTRA-CUT 100
6.02 System Layout
Primary power
Work
CNC
RemoteArc
Starter
Art # A-07233_AB
Torch
Coolant Supply
Coolant Return
Control Cable
Pilot Return
Coolant Supply
Coolant Return
Plasma Gas
Shield Gas
Work Cable
FiberOpticCable
Control Cable
Gas ControlModule
Power Supply
TorchValve
Assembly Positioning Tube
Plasma Gas
Preflow Gas
Water Shield
Shield
Shield Gas
Negative
Pilot Return
Control Cable
100’ / 30.5 m Maximum Length125’ / 38.1 m Maximum Length
175’ / 53.3 m Maximum Length
Shield
H
Q
R
T
S
A
B
C
D
E
P
K
L
O
I
JG
175’ / 53.3 m Maximum Length
Refer to section 3.05 for ground connections and ground cables.
6.03 Recommended Gas Supply Hose
Item # Qty Description Catalog #
1 3/8”Gray Synflex Hose. No fittings included. Catalog number per foot 9-3616
Manual No. 0-4748 6-3 Power Supply Parts List
ULTRA-CUT 100
6.04 Leads and Cables
Green / Yellow # 4 AWG
Green / Yellow 1/0 (50 mm )
A
Green
Red
Art # A
-07473
#8 AWG Cable
#1 AWG Cable
B
C
D
E
F
F1
K
L
H, Q, R, S,T
Work Cable
CNC Cable (14 Wire)
37
14
Coolant Supply Lead, Power Supply to Arc Starter
1/0 Cable (1/0 (50 mm )
Pilot Return, Power Supplyto Arc Starter
Negative Lead, Power Supplyto Arc Starter
Control Cable, Power Supplyto Arc Starter
Ground Cable
Ground Cable,Remote Arc Starter To Earth Ground
O
P
Fiber Optic Cable, Power Supply to Gas Control Module
Control Cable, Power Supply to Gas Control Module
Green
RedCoolant Return Lead, Power Supply to Arc Starter
2
2
14
GShielded Torch Lead Assembly, Remote Arc Starter to Torch
Plasma Gas Lead,Torch Valve to Torch
Shield Gas Lead,Torch Valve to Torch
I
J
Power Supply Parts List 6-4 Manual No. 0-4748
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 9-4780C Hose, Coolant Supply, (only), 20’ / 6 m 9-4781C Hose, Coolant Supply, (only), 25’ / 7.6 m 9-4782C Hose, Coolant Supply, (only), 30’ / 9.1 m 9-4783C Hose, Coolant Supply, (only), 35’ / 10.6 m 9-4784C Hose, Coolant Supply, (only), 40’ / 12 m 9-4785
NOTE 1:
Supply lead sets include Pilot Return Cable, Nega-tive Cable, Coolant Supply & Return Hoses, andControl Cable.
Manual No. 0-4748 6-5 Power Supply Parts List
ULTRA-CUT 100
Key Description Catalog #
C Hose, Coolant Supply, (only), 50’ / 15.2 m 9-4786C Hose, Coolant Supply, (only), 75’ / 23 m 9-4787C Hose, Coolant Supply, (only), 100’ / 30.5 m 9-4788
D Hose, Coolant Return, (only), 3’ / 1 m 9-4888
D Hose, Coolant Return, (only), 10’ / 3.05 m 9-4889
D Hose, Coolant Return, (only), 15’ / 4.6 m 9-4762D Hose, Coolant Return, (only), 20’ / 6 m 9-4763D Hose, Coolant Return, (only), 25’ / 7.6 m 9-4764D Hose, Coolant Return, (only), 30’ / 9.1 m 9-4765D Hose, Coolant Return, (only), 35’ / 10.6 m 9-4766D Hose, Coolant Return, (only), 40’ / 12 m 9-4767D Hose, Coolant Return, (only), 50’ / 15.2 m 9-4768D Hose, Coolant Return, (only), 75’ / 23 m 9-4769D Hose, Coolant Return, (only), 100’ / 30.5 m 9-4770
E Control Cable (only), Power Supply to Arc Starter 3’ / 1 m 9-4941
E Control Cable (only), Power Supply to Arc Starter 10’ / 3.05 m 9-4916
E Control Cable (only), Power Supply to Arc Starter 15’ / 4.5 m 9-4917
E Control Cable (only), Power Supply to Arc Starter 25’ / 7.6 m 9-4918
E Control Cable (only), Power Supply to Arc Starter 50’ / 15.2 m 9-4942
E Control Cable (only), Power Supply to Arc Starter 75’ / 22.9 m 9-4943
E Control Cable (only), Power Supply to Arc Starter 100’ / 30.5 m 9-4944
E Control Cable (only), Power Supply to Arc Starter 125' / 38.1 m 9-4922
F Ground Wire, Power Supply to Gas Control Module, 3' / 1 m 9-4923
F Ground Wire, Power Supply to Gas Control Module, 15’ / 4.5 m 9-4924
F Ground Wire, Power Supply to Gas Control Module, 25’ / 7.6 m 9-4925
F Ground Wire, Power Supply to Gas Control Module, 50’ / 15.2 m 9-4926
F Ground Wire, Power Supply to Gas Control Module, 75’ / 22.9 m 9-4927
F Ground Wire, Power Supply to Gas Control Module, 100’ / 30.5 m 9-4928
F Ground Wire, Power Supply to Gas Control Module, 125' / 38.1 m 9-4929
F Ground Wire, Power Supply to Gas Control Module, 150’ / 45.7 m 9-4930
F1 Ground Wire, Remote Arc Starter to Earth, 3' / 1 m 9-4931
F1 Ground Wire, Remote Arc Starter to Earth, 15’ / 4.5 m 9-4932
F1 Ground Wire, Remote Arc Starter to Earth, 25’ / 7.6 m 9-4933
F1 Ground Wire, Remote Arc Starter to Earth, 50’ / 15.2 m 9-4934
F1 Ground Wire, Remote Arc Starter to Earth, 75’ / 22.9 m 9-4935
F1 Ground Wire, Remote Arc Starter to Earth, 100’ / 30.5 m 9-4936
F1 Ground Wire, Remote Arc Starter to Earth, 125' / 38.1 m 9-4937
F1 Ground Wire, Remote Arc Starter to Earth, 150’ / 45.7 m 9-4938
Power Supply Parts List 6-6 Manual No. 0-4748
ULTRA-CUT 100
NOTE 2:
Gas lead sets include Plasma Gas Hose, Shield GasHose, Preflow Gas Hose, and Control Cable.
Key Description Catalog #
G Assembly, Torch Lead, 10’ / 3.05 m 4-3053G Assembly, Torch Lead, 15’ / 4.6 m 4-3009G Assembly, Torch Lead, 20’ / 6 m 4-3010G Assembly, Torch Lead, 25’ / 7.6 m 4-3011G Assembly, Torch Lead, 30’ / 9.1 m 4-3012G Assembly, Torch Lead, 35’ / 10.6 m 4-3013G Assembly, Torch Lead, 40’ / 12 m 4-3014G Assembly, Torch Lead, 50’ / 15.2 m 4-3015G Assembly, Torch Lead, 75’ / 23 m 4-3016G Assembly, Torch Lead, 100’ / 30.5 m 4-3017
H,Q,R,S,T Gas Lead Set, 10’ / 3.05 m (See Note 2) 4-3035
H,Q,R,S,T Gas Lead Set, 15’ / 4.5 m (See Note 2) 4-3036
H,Q,R,S,T Gas Lead Set, 25’ / 7.6 m (See Note 2) 4-3037
H,Q,R,S,T Gas Lead Set, 35’ / 10.6 m (See Note 2) 4-3051
H,Q,R,S,T Gas Lead Set, 50’ / 15.2 m (See Note 2) 4-3038
H,Q,R,S,T Gas Lead Set, 75’ / 22.9 m (See Note 2) 4-3039
H,Q,R,S,T Gas Lead Set, 100’ / 30.5 m (See Note 2) 4-3040
H,Q,R,S,T Gas Lead Set, 125' / 38.1 m (See Note 2) 4-3041
H,Q,R,S,T Gas Lead Set, 150’ / 45.7 m (See Note 2) 4-3042
H,Q,R,S,T Gas Lead Set, 175’ / 53.3 m (See Note 2) 4-3043
I Plasma Lead 4’ / 1.22 m (Torch Valve Assembly to Torch) 9-3333
J Shield Lead 4’/ 1.22 m (Torch Valve Assembly to Torch) 9-3334
L Control Cable, Fiber Optic, 3’ / 1 m 9-4898
L Control Cable, Fiber Optic, 15’ / 4.5 m 9-4899
L Control Cable, Fiber Optic, 25’ / 7.6 m 9-4900
L Control Cable, Fiber Optic, 35’ / 10.6 m 9-9335
L Control Cable, Fiber Optic, 50’ / 15.2 m 9-4901
L Control Cable, Fiber Optic, 75’ / 22.9 m 9-4902
L Control Cable, Fiber Optic, 100’ / 30.5 m 9-4903
L Control Cable, Fiber Optic, 125' / 38.1 m 9-4904
L Control Cable, Fiber Optic, 150’ / 45.7 m 9-4905
L Control Cable, Fiber Optic, 175’ / 53.3 m 9-4906
Manual No. 0-4748 6-7 Power Supply Parts List
ULTRA-CUT 100
Key Description Catalog #
K Control Cable, Power Supply to Gas Control Module, 3’ / 1 m 9-4907
K Control Cable, Power Supply to Gas Control Module, 15’ / 4.5 m 9-4908
K Control Cable, Power Supply to Gas Control Module, 25’ / 7.6 m 9-4909
K Control Cable, Power Supply to Gas Control Module, 35’ / 10.6 m 9-9332
K Control Cable, Power Supply to Gas Control Module, 50’ / 15.2 m 9-4910
K Control Cable, Power Supply to Gas Control Module, 75’ / 22.9 m 9-4911
K Control Cable, Power Supply to Gas Control Module, 100’ / 30.5 m 9-4912
K Control Cable, Power Supply to Gas Control Module, 125' / 38.1 m 9-4913
K Control Cable, Power Supply to Gas Control Module, 150’ / 45.7 m 9-4914
O Work Cable, 10’ / 3.05 m 9-9300
O Work Cable, 15’ / 4.5 m 9-9301
O Work Cable, 25’ / 7.6 m 9-9302
O Work Cable, 35' / 10.6 m 9-9303
O Work Cable, 50’ / 15.2 m 9-9304
O Work Cable, 75’ / 22.9 m 9-9305
O Work Cable, 100’ /30.5 m 9-9306
O Work Cable, 125' / 38.1 m 9-9307
P Control Cable, CNC to Power Supply, 25’ / 7.6 m 9-8312
P Control Cable, CNC to Power Supply, 50’ / 15.2 m 9-8313
P Control Cable, CNC to Power Supply, 75’ / 22.9 m 9-8315
P Control Cable, CNC to Power Supply, 100’ / 30.5 m 9-8316
P Control Cable, CNC to Power Supply, 125' / 38.1 m 9-8317
Power Supply Parts List 6-8 Manual No. 0-4748
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6.05 Power Supply External Replacement Parts
Item # Qty Description Catalog #
1 1 Power Supply Front Panel 9-0440
2 1 Power Supply Rear Panel 9-0441
3 1 Power Supply Top Panel 9-0445
4 1 Power Supply Right Side Panel 9-0442
5 1 Power Supply Left Side Panel 9-0443
6 1 Louver Panel 9-0444
7 1 Power Supply Connections Cover 9-0446
8 1 Lifting Eye 9-9373
Art # A-06888_AB
2
6
1
3
8
7
5
4
Manual No. 0-4748 6-9 Power Supply Parts List
ULTRA-CUT 100
6.06 Power Supply Replacement Parts - Right Side
Item # Qty Description Ref. Des. Catalog #
1 1 Heat Exchanger Fan FAN1 9-9338
2 1 Radiator 9-9339
NOTE: Heat Exchanger Fan is the same fan used with the Inverter
12
Art # A-08308
Power Supply Parts List 6-10 Manual No. 0-4748
ULTRA-CUT 100
6.07 Power Supply Replacement Parts - Right Side
Item # Qty Description Ref. Des. Catalog #
1 1 Output Filter PC PCB8 9-9341
2 1 Sensor HCT2 9-9368
3 1 Magnetic Contactor, pilot MC2 9-9343
4 1 Resistor R6 9-9340
5 1 Resistor R9
6 1 Capacitor C2
1
2
Art # A-08309
4
5
6
3
Manual No. 0-4748 6-11 Power Supply Parts List
ULTRA-CUT 100
6.08 Power Supply Replacement Parts - Right Side
Item # Qty Description Ref. Des. Catalog #
1 Chopper Module 9-9389
1 Sensor HCT1 9-9342
Chopper Module
Art # A-08311
HCT1
Power Supply Parts List 6-12 Manual No. 0-4748
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6.09 Power Supply Replacement Parts - Front Panel
Item # Qty Description Ref. Des. Catalog #
7 1 Main Power Switch (‘Circuit Protector’) CP1 9-9344 for 230-400-460 VAC units
7
Art # A-08312
Manual No. 0-4748 6-13 Power Supply Parts List
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6.10 Power Supply Replacement Parts - Front Panel
Item # Qty Description Ref. Des. Catalog #
1 PC Board PCB3 9-9365
1 PC Board 230/460VAC PCB4 9-9370
1 PC Board 600VAC PCB4 9-9492
1 Display PC Board PCB6 9-9347
PCB3
PCB4
PCB6
Art # A-08313
Power Supply Parts List 6-14 Manual No. 0-4748
ULTRA-CUT 100
6.11 Power Supply Replacement Parts - Right Side
Item # Qty Description Ref. Des. Catalog #
1 1 PCBoard 230-400-460VAC PCB1 9-9362
1 1 PCBoard 600VAC PCB1 9-9491
2 1 Magnetic Contactor MC1 9-9364
ONLY 1 for this unit
Art # A-08314
1 2 2
Manual No. 0-4748 6-15 Power Supply Parts List
ULTRA-CUT 100
6.12 Power Supply Replacement Parts - Rear Panel
Item # Qty Description Breaker Rating Cicuit Rating Ref. Des. Catalog #
12 1 Circuit Breaker (RAS) 125V, 2.5 A 120VAC @ 1A CP2 9-9348
13 1 Circuit Breaker (’TDC’) 125V, 3.15A 24VAC @ 2A CP3 9-9349
14 1 Circuit Breaker (AGC) 125V, 10A 24VAC @ 5A CP4 9-9350
15 1 Circuit Breaker (AGC) 125V, 2.5A 120VAC @ 1A CP5 9-9348
16 1 Circuit Breaker (AGC) 125V, 2.5A 15VDC @ 1A CP6 9-9348
17 1 Circuit Breaker (Pump) 250V, 10A 200VAC @ 3A CP7 9-9351
18 1 Circuit Breaker (Fan) 125V, 3.15A 24VDC @ 1A CP8 9-9349
1 Coolant Tank 9-5948
1 Tank Cap 8-5142
1 Filter, Coolant 8-4276
RETURN SUPPLY
Art # A-04932_AB
COOLANT
Coolant Tank
Tank Cap
Filter
RAS125V 2.5A
CCM125V3.15A
GCM125V 10A
GCM125V2.5A
GCM125V2.5A
PUMP250V 10A
FAN125V 3.15A
CIRCUITBREAKERS
J55
J59
J15
GCM
CNC
RAS
CP2
CP3
CP4
CP5
CP6
CP7
CP8
12
13
14
15
16
17
18
Art # A-06017_AC
Power Supply Parts List 6-16 Manual No. 0-4748
ULTRA-CUT 100
6.13 Power Supply Replacement Parts - Right Side
Item # Qty Description Ref. Des. Catalog #
1 1 Resistor R7 9-93632 1 Rectifier (Diode) D1 9-93453 1 Transformer T1 9-9355
for 230/460 VAC units4 1 Diode D2 9-94865 1 Terminal Strip TB3 N/A
Art # A-08310
1
2
3
4
5
Manual No. 0-4748 6-17 Power Supply Parts List
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6.14 Power Supply Replacement Parts
Item # Qty Description Catalog #
29 2 Inverter Module 208/230V 9-9360D2 Inverter Module 400V CE and 400V Non CE 9-9482D2 Inverter Module 600V 9-9485D
Not Shown:2 Inverter Cooling Fan 9-9338
NOTE: The Inverter Cooling Fan is the same fan used for Heat Exchanger cooling.
Art # A-04786_AB
Power Supply Parts List 6-18 Manual No. 0-4748
ULTRA-CUT 100
6.15 Power Supply Replacement Parts - Right Side
Item # Qty Description Ref. Des. Catalog #
30 1 Sensor (Thermistor) TH1 9-9361
30
Art # A-04787
Manual No. 0-4748 6-19 Power Supply Parts List
ULTRA-CUT 100
6.16 Power Supply Replacement Parts
Item # Qty Description Ref. Des. Catalog #
1 1 Relay PC Board PCB7 9-9366
2 1 24 VDC Power Supply N/A N/A
3 1 Internal Control PC Board PCB5 9-9346
Art # A-08315
1
2
3
Power Supply Parts List 6-20 Manual No. 0-4748
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6.17 Power Supply Replacement Parts - Right Side
Item # Qty Description Ref. Des. Catalog #
22 1 Sensor (Level Switch) LSW1 9-9354
24 1 Motor MOT1 9-9381
25 1 Pump/Check Valve/Bypass Valve Assembly 9-9380
26 1 Bypass Valve (part of assembly)
27 1 Pump (part of assembly)
28 1 Sensor (Flow Indicator) F1 9-9359Illustration is for Reference ONLY
27
22
25
2426
28
Art # A-08236
Manual No. 0-4748 6-21 Power Supply Parts List
ULTRA-CUT 100
6.18 Gas Control Module (GCM-2010) Replacement Parts
Item # Qty Description Catalog #
1 6 7W Solenoid for O2 use 9-93932 1 Gas Selection Manifold Assembly 9-93913 1 Check Valve, 1/4 NPT .5 PSI 9-93904 1 Mode Switch Assembly 9-94065 1 Gas Selection Switch Assembly 9-94036 1 LCD Display 9-94087 1 Rotary Encoder (Switch) 9-93988 1 Toggle Switch 9-34269 1 Solenoid / Logic PC Board 9-9409
10 1 Cover 9-941011 3 Gauge, 0-160 psi 8-680012 1 Regulator 8-322313 1 Pressure Transducer and wire harness 100 PSI 9-940714 2 Pressure Transducer and wire harness 250 PSI 9-9508
NOT SHOWN:1 Power Supply Connection Wire Harness (J3 & J5 to J56) 9-94001 LCD Interface PC Board Wire Harness 9-94011 Rotary Encoder (Switch) Wire Harness 9-94021 Solenoid Drive A Wire Harness (J12 to Solenoids 1-6) 9-94041 Solenoid Drive B Wire Harness (J1 to Solenoids 7-12) 9-9405
Art # A-07030_AB2
1
1
1
1
3
7
8
45
6
33
1
1
8
910
12
12
14
11
11
13
12
14
11
Power Supply Parts List 6-22 Manual No. 0-4748
ULTRA-CUT 100
6.19 Gas Control Module (GCM-2010) Replacement Parts
Item # Qty Description Catalog #
1 1 1” Black Instrument Knob 9-4233
2 1 Water Flow Meter with Valve 9-7005
3 1 Toggle Switch, 2 position SPDT 9-3426
4 1 Pressure gauge, 2” diameter 8-6800
6 1 Flow Meter 8-6801
Not shown -
Valve Assembly 9-9382
Tube 9-9383
Knob 9-9384
7 1 Protective Display Lens (only) 9-9395
PREFLOW
H2OMIST
PLASMA SHIELD
PRESSURE
PLASMAPOWER SUPPLY
GAS
FLOW
AMPERAGESET-UP
High PrecisionPlasma Cutting System
ENABLE
DISABLE
GASMODE
RUN
SET PREFLOW
SET PLASMA& SHIELD
TEST
O2 - AIRO2 - O2
H35 -N2
F5 - N2
AIR - AIRN2 - H2O
N2 - N2
99
GCM
2010
Art # A-04814
3
4
1
2
6
7
3
6
1 1
4
Manual No. 0-4748 6-23 Power Supply Parts List
ULTRA-CUT 100
6.20 Remote Arc Starter (RAS-1000) Replacement Parts
Item # Qty Description Catalog #
1 1 Harness, Internal (Not Shown) 9-4956
2 1 Pilot Cap Assembly 9-4960
3 1 EMI Filter 9-1023
4 1 HF Water Cooled Coil Assembly 9-4958
5 1 HF Transformer Assembly, Arc Starter 9-4959
6 1 Enclosure, Arc Starter Base 9-4961
7 1 Spark Gap/Cap Assembly HF 9-4957
8 1 Ferrite Bead 2" Long 9-4965
Art # A-04898_AB
3
5
4
6
7
8
8
2To TorchValve
Power Supply Parts List 6-24 Manual No. 0-4748
ULTRA-CUT 100
6.21 Remote Arc Starter (RAS-1000) Replacement Parts
Item # Qty Description Catalog #
1 1 Retainer, ABS Wall 9-4964
2 1 (Outer) Torch Lead Ground Assembly 9-4955
3 1 Bracket, Bulkhead Holder 9-4963
4 1 Cover, Arc Starter 9-4962
Art # A-048993
4
1
2
1
Coolant Leads,from Power Supply
Manual No. 0-4748 6-25 Power Supply Parts List
ULTRA-CUT 100
6.22 Command & Control Module Type 2 - Replacement Parts
Item # Qty Description Catalog #
1 1 Assembly, CCM (Ultra-Cut) 9-9417
2 1 Plate, CCM Face 9-9419
3 1 Panel, CCM Mount Not Available
4 1 Harness, CCM I/O Board 9-9421
3
4
2
1
Art # A-06867_AB
NOTE
This page covers parts for Command & Control module without an external connections cover. See previouspage for Command & Control module with an external connections cover.
Power Supply Parts List 6-26 Manual No. 0-4748
ULTRA-CUT 100
6.23 XTL Torch Valve Assembly External Replacement Parts
NOTE
The XTL Torch Valve Assembly requires Firmware versions 3.2 or higher for the C.C.M. and 3.1 or higher forthe GCM 2010. It also requires the resetting of DIP switches in the C.C.M..
Item # Qty Description Catalog #
1 1 Torch Valve Assembly 4-3054
2 1 Torch Valve Assembly Harness 9-9413
3 1 Plug, 14 Circuit 9-3294
4 1 Check Valve 8-4512
5 3 Check Valve 9-7006
6 1 1/8 NPT STR.TEE Fitting 8-0352
7 1 Street Elbow (Bushing) 8-3369
8 1 Top Cover 9-3324
9 1 Front Cover 9-3323
1
Art # A-07650
3
7
5
42
6
8
9
Manual No. 0-4748 6-27 Power Supply Parts List
ULTRA-CUT 100
6.24 XTL Torch Valve Assembly Internal Replacement Parts
NOTE
The XTL Torch Valve Assembly requires Firmware versions 3.2 or higher for the C.C.M. and 3.1 or higher forthe GCM 2010. It also requires the resetting of DIP switches in the C.C.M..
Item # Qty Description Catalog #
1 1 Exhaust Muffler 9-3321
2 2 Solenoid 9-3319
3 3 Solenoid 9-9392
Art # A-07651
SOL18SOL19
1
2
3
Power Supply Parts List 6-28 Manual No. 0-4748
ULTRA-CUT 100
Intentionally Blank
Manual 0-4748 7-1 TORCH MAINTENANCE
ULTRA-CUT 100
SECTION 7. TORCH MAINTENANCE
7.01 Consumable Removal
1. Use the Cartridge Tool to hold the Shield Cup & Cartridge Assembly stationary. Turn the Shield Cup toremove it from the Cartridge Assembly.
Assembled Cartridge
Cartridge Tool
Shield Cup
Art # A-04344_AB
2. Take the Cartridge Tool off the back of the Cartridge Assembly Use the Cartridge Tool to push the consum-able parts out of the Cartridge.
Cartridge Tool Cartridge Assembly
Art # A-04345_AB
TORCH MAINTENANCE 7-2 Manual 0-4748
ULTRA-CUT 100
7.02 O-Ring Lubrication
Lubricate all three O-Rings on the Cartridge Assembly and all three O-Rings on the Torch Head periodicallywith O-Ring Lubricant supplied. Remove the snap ring on the cartridge assembly and slide the locking ringdownward for access to the O-Ring under the locking ring.
O-Ring, Cat. No. 8-0544
Inner O-Ring (Cat. No. 8-0545) Location (Under Locking Ring)
O-Ring, Cat. No. 8-0540
Art # A-04071_AB
Snap Ring
Cartridge Assembly
O-Rings
Art # A-04066
Cat. No. 8-0539
Cat. No. 8-3487
Cat. No. 8-0530
Torch Head
Cat. No. 9-9041
CAUTION
Use only Thermal Dynamics No. 9-4893 O-Ring Lubricant (Christo Lube MCG-129) with this torch part. Use ofother lubricants may cause irreparable damage to the torch.
Manual 0-4748 7-3 TORCH MAINTENANCE
ULTRA-CUT 100
7.03 Parts Wear
Replace the Gas Distributor if it is charred or cracked.
Replace the Gas Distributor if the flange is damaged in any way.
Replace the tip and/or electrode if they are worn.
Good Electrode Worn ElectrodeGood Tip Worn Tip
Art # A-04745_AB
TORCH MAINTENANCE 7-4 Manual 0-4748
ULTRA-CUT 100
7.04 Torch Consumables Installation
Art # A-03887
WARNINGS
Do not install consumables into the Cartridge while the Cartridge is attached to the Torch Head.Keep foreign materials out of the consumables and Cartridge. Handle all parts carefully to avoid damage, which may affect torch performance.
1. Install the consumables as follows:
Cartridge Covers Upper O-Ring on Torch Tip
Shield Cap Protrudes 0.063-0.083" (1.6 - 2.1 mm)
Electrode
Plasma Gas Distributor
Tip
Shield Gas Distributor
Shield Cap
Upper O-Ring on Tip
1: Stack Parts 2: Press Cartridge onto Stacked Parts
4: Check Shield Cap Protrusion
Art # A-04716
No Gaps Between Parts
3: Thread Shield Cup onto Cartridge
Shield Cap
Shield Cup
Manual 0-4748 7-5 TORCH MAINTENANCE
ULTRA-CUT 100
2. Remove the Cartridge Tool from the Cartridge and install the assembled Cartridge onto the Torch Head.
CAUTION
The cartridge assembly must cover the O-Ring on the torch head.
Do not force the cartridge if it will not tighten fully. Remove the cartridge assembly and gently clean the threads onthe torch head with a wire brush. Apply oxygen-compatible lubricant (supplied with the torch) to the threads.
Torch Head O-Ring Torch Head
Art # A-07202
0.063 - 0.083"(1.6 - 2.1 mm)
Protrusion
Installing Assembled Cartridge Onto Torch Head
3. Slide the ohmic clip over the shield cup if using ohmic torch height control sensing.
A-03393
Ohmic Clip
4. Connect the wire lead from the height finder to the ohmic clip.
TORCH MAINTENANCE 7-6 Manual 0-4748
ULTRA-CUT 100
Amperage Plasma Gas Recommended Wear Depth for Replacement
Inch mm O2 0.04 1 Air 0.04 2 O2 0.04 1 Air 0.08 2 O2 0.04 1 Air 0.08 2 O2 0.04 1 H35 0.08 2
30
50
70
100
No
Yes
Yes
Are Parts New or Used?
Are Parts fullyassembled into
the Torch?
Unsure?
Disassembly fullyand re-assemble
the Torch Properly.See Installation Manual. Replace Torch Head
Is the Torch Damaged?
Replace ConsumableCartridge and Shield Cup.
Torch still leaks?
Remove and Lubricateall O-rings on Torch Head,Consumables Cartridge,
and Consumables.Re-assemble Torch.
Still leaks?
The parts probably are worn out. See chart for approximate life expectancy.
The torch may be damaged. See page to determine if head damage has occurred.
Order CoolantTube Replacement Kit
Leaking fromCoolant Supply or Coolant Return?
Yes
Yes
Yes
No Return
Supply
Used
Order Coolant Check ValveKit 9-4846
New
Torch leaks
Torch Electrodes
Are Torch Consumable Parts Installed?
Art # A-04704_AB
7.05 Coolant Leak Trouble-Shooting
Never operate the system if coolant leaks from the torch. A steady drip indicates that torch parts are damaged orinstalled improperly. Operating the system in this condition can damage the torch head. Refer to the followingchart for guidance on coolant leakage from the torch head.
Manual 0-4748 A-1 APPENDIX
ULTRA-CUT 100
APPENDIX 1: Remote Arc Starter Schematic
5 5
4 4
3 3
2 2
1 1
DD
CC
BB
AA
NE
G (
from
PS
)
120
VA
C
120
VA
C R
ET
CH
AS
SIS
GN
D
PIL
OT
RE
TUR
N (
from
torc
h)P
ILO
T R
ETU
RN
(fro
m to
rch)
NE
G
PLT
SH
LD
CG
ND
DW
G N
o:She
etof
Sup
erse
des
Sca
le
Dat
e:D
raw
n:
Ref
eren
ces
Dat
eB
yR
evis
ions
Rev
PC
B N
o:A
ssy
No:
Info
rmat
ion
Pro
prie
tary
to T
HE
RM
AL
DY
NA
MIC
S C
OR
PO
RAT
ION
.N
ot F
or R
elea
se, R
epro
duct
ion,
or
Dis
trib
utio
n w
ithou
t Writ
ten
Con
sent
.
NO
TE
: UN
LES
S O
TH
ER
WIS
E S
PE
CIF
IED
-1.
RE
SIS
TOR
VA
LUE
S A
RE
EX
PR
ES
SE
D IN
OH
MS
, 1/4
W 5
%.
2. C
APA
CIT
OR
VA
LUE
S A
RE
EX
PR
ES
SE
D IN
MIC
RO
FAR
AD
S (
uF).
Chk
:A
pp:
TIT
LE:
Last
Mod
ified
:S
ize
SC
HE
MAT
IC,TH
ER
MA
L D
YN
AM
ICS
IND
US
TRIA
L PA
RK
#2
WE
ST
LEB
AN
ON
, NH
037
84(6
03) 2
98-5
711
Tues
day,
Nov
embe
r 01
, 200
514
:47:
17
of
Info
rmat
ion
Pro
prie
tary
to T
HE
RM
AL
DY
NA
MIC
S C
OR
PO
RAT
ION
.
TIT
LE:
ofT
ITLE
:
8X29
0N
EG
& H
F (t
o To
rch)
8X291
DAT
9-21
-04
RA
S-1
000
AR
C S
TAR
TE
R
PO
WE
R S
UP
PLY
AR
C S
TAR
TE
R
TOR
CH
Jum
per i
n C
able
to ID
Arc
Sta
rter
Con
nect
ed
Wat
er C
oole
d In
duct
or
L1
T1 A
ssem
bly
TOR
CH
LE
AD
IN
NE
R S
HIE
LD
AB
E
CO
101
810
RS
11/0
1/05
14 P
IN
J59
--R
AS
14 P
IN
1 2 3 4 5 6 7 8 9 10 11 12 13 14
T111
X16
1 2
3 4
GA
P1
SPA
RK
GA
P 0
.060
"C2
1900
pf
C4
0.1
uf 1
000V
DC
R1
6.8
K 1
W
<P
art N
umb
er>
C6
0.1
uf 1
000V
DC
Line
1
Line
2
Load
1
Load
2
GN
DP
ILO
T
WO
RK
WO
RK
C3
1900
pf
R2
6.8
K 1
W
<P
art N
umb
er>
C5
0.04
7 uf
100
0VD
C
CH
AS
SIS
GN
D
C1
1900
pf
NE
G
C7
0.04
7 uf
100
0VD
C
16 P
IN
J58
16 P
IN
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
PIL
OT
NE
G (
from
PS
)
Art
# A
-068
96_A
B
WO
RK
42X
1191
1
1
Line
Filt
er 1
ph
AA
I
nitia
l Rel
ease
T
PM
8/26
/05
APPENDIX A-2 Manual 0-4748
ULTRA-CUT 100
APPENDIX 2: Gas Control and Torch Valve Schematic
Art # A-07200
5
5
4
4
3
D
C
B
A
(16) (17) (18) (19) (20) (21) (29) (30) (31) (32)(28) (33)
120 VAC(60)
(61)(61)(61)(61)
(1) (9)(7)(6)(5)(4)(3)
(10)
(14)(13)
(67)
(66)
(65)
(64)
(63)
(62)
(22)
(23)
(24)
(25)
(26)
(27)
(34)
(35)
(36)
(37)(37)(37)
(38)
(39)
(59)
(50)
(51)
(53)
(52)
120 VAC to SOLENOIDS
120 VAC to BOARD POWER
24 VAC
(56)
24 VAC RET
(57)
(54)(54)(54)(54)
)85(+ POTS-E (58))85(+ POTS-E )85(+ POTS-E (58))85(+ POTS-E )85(+ POTS-E (58))85(+ POTS-E )85(+ POTS-E (58))85(+ POTS-EE-STOP -
Shield
(8)(8)(8)(8)(8)(8)(15)
(55)
PLASMA ENABLE -PLASMA ENABLE -PLASMA ENABLE +
120 VAC120 VAC RET
+5VDC
120 VAC
120 VAC RET
24 VAC RET
24 VAC
15 VDC RET
+15 VDC
RUN
TEST
SET PREFLOWSET CUTFLOW
O2 - AIRO2 - O2H35 - N2F5 - N2AIR - AIRN2 - H2ON2 - N2
ENCODER
IN-CIRCUIT SERIALPROGRAMMING
ENCODER w/SW
AB
FLOWPRESSURE
DISABLE
F1 0.125A SOL1F2 0.125A SOL2F3 0.125A SOL3F4 0.125A SOL4F5 0.125A SOL5F6 0.125A SOL6F7 0.125A SOL7F8 0.125A SOL8F9 0.125A SOL9F10 0.125A SOL10F11 0.125A SOL11F12 0.125A SOL12F13 0.125A SOL13F14 0.250A SOL14 *F15 0.250A SOL15 *F16 0.125A SOL16 F17 0.125A SOL17F18 1A ( 120 VAC to Solenoids)F19 1A ( 120 VAC to Low Voltage Power Supply)F20 1A ( to E-Stop Relay)
* 19X2219_AG and earlier F14 & 15 are 0.125A
1AIR
2N2
3O2
4H35
5F5
6AIR
7N2
8AIR
9N2
10O2
SOLENOID MANIFOLD (from rear)
FRONT PANEL (rear)
1711
12
13
SOLENOID LOCATIONS
ULTRACUT GCM 2010 GAS CONTROL
POWER SUPPLY
PLASMA <
SHIELD <
PREFLOW <
FERRITECORE
Safety Gnd(low freq)
RF Gnd(Shield)
ENABLE
PS3
PS4
ShieldFlow
ShieldPress
PlasmaPrecharge/ Bypass
H2O Shield
FIBER-OPTIC
To CCM
U36 U35
SOL11SOL11
F20 1AF20 1A
J1110 PIN
J1110 PIN
1 2 3 4 5 6 7 8 9 10
SOL5SOL5
J5
16 PIN
J5
16 PIN
1
2
3
4
5
6
7
8
9
10
11
12
13
14
16
15
J55J55
12345678910111213141516171819202122232425262728293031323334353637
J12
18 PIN
J12
18 PIN
1 2 3 4 5 6 7 8 9 10 11 12 13 14 171615 19 2018
J75 PIN
J75 PIN
1 2 3 4 5
+
-
PLASMA ENABLE+
-
PLASMA ENABLE
1
2
5
4
SW6PLASMA ENABLE SW6PLASMA ENABLE2
1
3
SOL10SOL10
F18 1AF18 1A
SOL4SOL4
J3J31
2
3
SW7SHIELD FLOW / PRESSURE SW7SHIELD FLOW / PRESSURE21
3
D13GREEND13
GREEN
SOL9SOL9
SW2GASSW2GAS
A1234567
SOL1SOL1 SOL3SOL3
J9J9123456
J16J16
1 2 3 4 5 6
D25GREEND25GREEN
SOL8SOL8
+ -
E-STOP
+ -
E-STOP
1 2
54
E-STOPE-STOP
SOL2SOL2
J56J56
123456789
10111213141516171819202122232425262728293031323334353637
SW3MODESW3MODE
A1234
J10J10
1 2 3 4 5 6
SOL7SOL7
F19 1AF19 1A
J1J1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 18171615SOL12SOL12SOL6SOL6
Manual 0-4748 A-3 APPENDIX
ULTRA-CUT 100
Art # A-072003
2
2
1
1
D
C
B
A
(46)(47)
(43)
(45)(45)
(42)
(42) (44)
(44)
(40)
(49)
(48)
(40)(40)(40)(40)
(40)(40)
(41)
+5VDC
+5VDC
+5VDC
+5VDC
DWG No:
Sheetof
SupersedesScale
Date:
Drawn: References
DateByRevisionsRev PCB No:Assy No:
Information Proprietary to THERMAL DYNAMICS CORPORATION.Not For Release, Reproduction, or Distribution without Written Consent.
NOTE: UNLESS OTHERWISE SPECIFIED -1. RESISTOR VALUES ARE EXPRESSED IN OHMS, 1/4W 5%.2. CAPACITOR VALUES ARE EXPRESSED IN MICROFARADS (uF). Chk: App:
TITLE:Last Modified:
SizeSCHEMATIC,42X1202Monday, January 29, 2007
1 1
<OrgAddr1><OrgAddr2><OrgAddr3>
Ultracut GCM 2010 Gas Control & TVA
Wednesday, January 26, 2005
13:57:13
<OrgName>
DDWG No:
Sheetof
SupersedesScale
Date:
Drawn: References
DateByRevisionsRev PCB No:Assy No:
Information Proprietary to THERMAL DYNAMICS CORPORATION.Not For Release, Reproduction, or Distribution without Written Consent.
NOTE: UNLESS OTHERWISE SPECIFIED -1. RESISTOR VALUES ARE EXPRESSED IN OHMS, 1/4W 5%.2. CAPACITOR VALUES ARE EXPRESSED IN MICROFARADS (uF). Chk: App:
TITLE:Last Modified:
SizeSCHEMATIC,42X1202Monday, January 29, 2007
1 1
<OrgAddr1><OrgAddr2><OrgAddr3>
Ultracut GCM 2010 Gas Control & TVA
Wednesday, January 26, 2005
13:57:13
<OrgName>
DDWG No:
Sheetof
SupersedesScale
Date:
Drawn: References
DateByRevisionsRev PCB No:Assy No:
Information Proprietary to THERMAL DYNAMICS CORPORATION.Not For Release, Reproduction, or Distribution without Written Consent.
NOTE: UNLESS OTHERWISE SPECIFIED -1. RESISTOR VALUES ARE EXPRESSED IN OHMS, 1/4W 5%.2. CAPACITOR VALUES ARE EXPRESSED IN MICROFARADS (uF). Chk: App:
TITLE:Last Modified:
SizeSCHEMATIC,42X1202Monday, January 29, 2007
1 1
<OrgAddr1><OrgAddr2><OrgAddr3>
Ultracut GCM 2010 Gas Control & TVA
Wednesday, January 26, 2005
13:57:13
<OrgName>
D
LCD DISPLAY CONNECTOR
CURRENT CONTROL(Thumbwheel) optional
LCD DISPLAY
ULTRACUT TORCH VALVE ASSEMBLY (TVA or TVA-XTL)
DAT
RIBBONCABLE
15 16 1 2
{
INTERFACEBOARD
3 4 5 6 7 8 9 10 11 12 13 14
FERRITECORE
Safety Gnd(low freq)
RF Gnd(Shield)
AA ECO-B214 DAT 07/26/06
AB ECO-B367 RWH 01/29/0715
14
16
TVA-XTL
Preflow
Plasma
Gas Shield
Plasma
Shield
H2O Shield
Inlet sensors in 19X2219 PCB(rev AG or later)
LCD Display Assembly 19X2220
PLASMA EXAUST 1Normally Open
PLASMA EXAUST 2Normally Open
* Additional Solenoids used in TVA-XTL
18 19
Vent
15
14
16
TVA
Preflow
Plasma
Gas Shield
Plasma
Shield
H2O Shield
BOTH SECTIONS ON FOR OPERATIONOFF ONLY FOR PROGRAMMING
SOL15 TVA PLASMA PREFLOWSOL15 TVA PLASMA PREFLOW
JP1JP1 1 2 3 4
SOL18 *SOL18 *
JP3JP31
2
3
4
J6
18 PIN
J6
18 PIN
1
2
3
4
5
6
7
8
9
10
11
12
13
14
16
15
17
18
PS3 Plasma Inlet PressurePS3 Plasma Inlet Pressure
3
1
2 4
SOL17SOL17
J834 DUAL RIBBON HEADER
J834 DUAL RIBBON HEADER
12
34
56
78
910
1112
1314
1516 18 20 22 24 26
17 19 21 23 2528 30 32 34
27 29 31 33
J134 DUAL RIBBON HEADER
J134 DUAL RIBBON HEADER
12
34
56
78
910
1112
1314
1516 18 20 22 24 26
17 19 21 23 2528 30 32 34
27 29 31 33
J13
18 PIN
J13
18 PIN
1 2 3 4 5 6 7 8 9 10 11 12 13 14 1615
SOL19 *SOL19 *
J60J60
1
2
3
4
5
6
7
8
91011121314
SOL13SOL13
SW1SW11 4
2 3
PS1 Plasma Outlet PressurePS1 Plasma Outlet Pressure
3
1
2 4
JP4JP4
1
2
3
4
SOL16 TVA SHIELDSOL16 TVA SHIELDJ57J57
1
2
3
4
5
6
7
8
91011121314
PS4 Shield Inlet PressurePS4 Shield Inlet Pressure
3
1
2 4
SOL14 TVA PLASMA CUTFLOWSOL14 TVA PLASMA CUTFLOW
APPENDIX A-4 Manual 0-4748
ULTRA-CUT 100
APPENDIX 3: Gas Control Module Plumbing Diagram
Art # A-07577_AB
AIR
N2
O2
H35
F5
SOL1 SOL2 SOL3
SOL8 SOL9 SOL10
SOL6
SOL7
SOL11
SOL12
SOL13
GAS MANIFOLD
SOL5
SHIELD
PLASMA
PREFLOW
TVA & XTL-TVA
WATER H2O
Pressure Sensor
SOL4
SOL17
SOL14
SOL15
SOL16
New Plasma Inlet Pressure Sensor
New Shield Inlet Pressure Sensor
SOL18
SOL19
PLASMA
SHIELD
Atmosphere
SOL 18 & 19 normally open. Operate in parallel with normally closed SOL 14 & 15.
SOL 18 & 19 in XTL-TVA only.
Manual 0-4748 A-5 APPENDIX
ULTRA-CUT 100
APPENDIX 4: Gas Control Module PCB Layout
J13
Art # A-07621
J1 J13
F12 F11
F8 F15F17
F7 F16F9
F13
F14
F10
J12
TP10
TP9
TP8
F5
F3
F1
F2
F4
F6
TP1
J6 J7 J11
TP11 TP12 TP13 TP15
TP14 TP16
J8 J10TP18TP19
J3
F19
F18
TP4
TP2
TP3
F20
J5
JP1
TP6
TP5
TP7
APPENDIX A-6 Manual 0-4748
ULTRA-CUT 100
APPENDIX 5: Gas Control Display Interface PCB Layout
R21
D17
R8
R12
19X2220 REV
R7
R16R18
D11
R20
R9
R13
R5
D5
R15
C1
D4D1
8
R4
D1
R6
R19
D12
D2R3
D10
R22 R17
D6D3
D19
R2
R14
D13
R11
D7
D20
R10
68
69
D21
1 33
D15
R23
J1
D22
LCD INTERFACEC 2005TDC
D23
D14
70
D24
R24
D25
D9
D26
D16
R1
C2
16
342
172
+
D8
AB
Art # A-06904
J1
Manual 0-4748 A-7 APPENDIX
ULTRA-CUT 100
APPENDIX 6: CCM CPU PCB Layout
H1
J4
U6
1
TP11TP10TP9
TP1
TP3
TP6
TP4
TP7
TP5
TP2
TP8
4423
221
U4
1 2
1
SW3
C18
D10
R69
C19
C41
R30
R23
C15
C26
C12
C22
R65
R74
U26
R17
C3
J5
R1
R34D6
C16
C33
R47
R81
U25
R77
U24 1
R22
R9
R46
C13
C49
+
R73
1 21
SW9
R19
R24
R64
C56
C58
U12
R35
R28
L2
C21
C5
R5
C40
R80
U18
C57
C20
R43
R29
R52
C50
+
C27
R6
C38
C36
R82
C4
R15
R88
R45
6 9
51
J1
R56
U16
1
R71
C54
R67
C17
+
C32
L4
R68
R54
D1
R72
R50
L3
C43
C35
1 2
1
SW5
U9
D9
H3
R87
H4
R26
R86
PREFLOW
POST
R10
FLOW FUNCSYS
CONT
R42
AUTO PILOTOK TOMOVE/D
R11
19X2169 REVC 2004 TDC
Y1
C30
C55
R90
R25
R66
C6
C42
+
U30
1
D8
D15
R70
R2
U27
R79
C2
+
U5
R91
D11
R51
C25
R89
R18
R8
C51
D3
D13
U28 1
C8R31
R40
C34
+
R85
R38
C48
D7
R92
R57
R7
R4C1
R36
1 2
1
SW4
C9
R3
R62
R63
U17
R13
160
U14
140
120
80
R27
C31
R59
R55
R32
U13
1
C45
C39
L1
R44
R84
R61
R20
R58
R78
U29
C14
D2
R33
C7
U22
C52
R76
C46
R21
U11
1
R37
R16
C10
R41
D4
R83
R49
U15
R93
R39
C53
C59
+
C47
U23
1
U19
1
C24
C29
R94
D5
R48
R60
D14
C28
R75
R12
C11U10
C44
+
R53
C23
L6
1
U21C37
D12
R14
L5
+15VDAC DAC
-15V+3.3V
CLKO
GND
AGND
+5.0V
TEMPSENSE
+3.3VA
/WR
/RD
R C
GP1
U20GP2
U31
NC
U32
U71
321
1
SW1
4 321
1
TPAD1
SW8
4
U81
1
1
1
H6
H2
H5
1
CPU/COMMUNICATIONS
29
21
J3
30
3029
21
J2
Art # A-06906
ON
Note: Switch Settings May Vary.
AC
Switches
ON
TP9 TP10 TP11
TP2
TP1
TP3 TP4
TP5
TP6
TP7
TP8
J2
J3
J1
1 2
1
SW3
1 2
1
SW9
1 2
1
SW5
PREFLOW
POSTFLOW FUNC
SYSCONTAUTO PILOT
OK TOMOVE/D
1 2
1
SW4
321
1
SW1
4 321
1
SW8
4
APPENDIX A-8 Manual 0-4748
ULTRA-CUT 100
APPENDIX 7: CCM Input / Output PCB Layout
H1H1
C75C75
C79C79
C41C41
R149
R149
R144R144
R148R148
R103
R103
C11
C11
U1U111
D34D34
11
U10U10
R88R88
R128
R128
R39R39
R73R73
R118
R118
R120R120
C16C16
R81R81
2929
2211
J3J3
3030
R11R11
11U12U12
D8D8
D10D10
TP6TP6
SW6
SW6
U7U7
11
R75
R75
K5-E
-STO
PK5
-E-S
TOP
R20
R20
R1R1
R151R151
D37D37
J5J5
U14U14
11
U5U5
11
R139R139
U13U13
11
C56C56
C22C22
C50C50
U6U6
11
R10R10
R14R14
R2R2
D6D6
D29
D29
D12
D12
R104
R104
C6C6
R125
R125
D20
D20
R47R47
R5R5
R82R82
J36J36
J4J4
D18D18
R77R77R72R72
R9R9
TP7TP7
11 22
11
SW13SW13
J35J35
C3C3
R131R131
R13R13
C53
C53
C78
C78
R62
R62
C39C39
C77
C77
C87
C87
C33C33
R23
R23
R132
R132
U22U22
11
R145R145
C17C17K1-PSRK1-PSR
D22
D22
R69
R69
D21D21
TP9TP9
R76R76
C26
C26
C58C58
R64
R64
U3U311
R117
R117
R6R6
R79R79
R55R55
C40C40
C68
C68
C7C7
R41
R41
R44R44
R8R8
R66
R66
R121R121
D25
D25
D23D23
R31R31
R28
R28
R45R45
R123
R123
R102
R102
R135
R135
C2C2
D14D14C24C24
TP3TP3
U18
U18
11
R67
R67
R49R49
TP12TP12
U23U2311
C45C45
R57R57
R138R138
R127R127
C76
C76
C66
C66
R12R12
D26D26
C19C19
TP5TP5
R38R38
D7D7
R53
R53
C18C18
D30D30
R27
R27
C47C47
D17
D17
C30C30
BB
AA
SW11
SW11
H2H2
R71
R71
U20U20
H5H5
J1J1
H4H4
R97R97
H6H6
H8H8
R99R99
H9H9
C84C84
19X217419X2174
D2D2
11 11
R141R141
11
111111
11
11
R15R15
11
11
REVREV
C TDC 2005C TDC 2005
C8C8
ALL
SW O
FF F
OR
50:1
(DEF
AULT
)AL
L SW
OFF
FO
R 50
:1 (D
EFAU
LT)
SW12
-1 O
N FO
R 16
.7:1
(SC-
11)
SW12
-1 O
N FO
R 16
.7:1
(SC-
11)
U16U16
OK
TO M
OVE
SEL
ECT
OK
TO M
OVE
SEL
ECT
CONTACTSCONTACTS
11
DC VOLTSDC VOLTS
++
++
++C93C93
++
++U17U17
11
11
++
++
++
R43R43
H10H10
H11H11
OK CNCOK CNC
R46R46PSRPSR
CNC_E-STOPCNC_E-STOP
CNC_STARTCNC_START
HOLD_STARTHOLD_STARTR1
15R1
15
CNC PREFLOWCNC PREFLOW
GAS
ON
GAS
ON
E-ST
OP_
PSE-
STO
P_PS
C65
C65
C35
C35
U24U2411
++
GNDGND
+5V+5V
R80R80
+15V+15V
-15V-15V
+15V+15V -15V-15V
R87R87
+18V+18VGNDGND
ISOLATEDISOLATED
PILOTPILOT
R56R56
DEMANDDEMAND
CUTCUTDEMANDDEMAND
ARC V-ARC V-
R114R114
PILOT VPILOT VCC POTCC POT
D3D3
TP8TP8
R26
R26
K7-G
AS O
NK7
-GAS
ON
C34
C34
U19U19
L2L2
C27
C27
R29
R29
C83C83++
R90R90
C69
C69 ++
C52
C52
U2U2
11
C48C48
U9U9
11
R129
R129
R50R50
C15C15
TB1TB1
R59R59
C20
C20
R83
R83
C82C82
D9D9
C4C4
C23C23
C55
C55
R147R147
C88C88
C95C95
++
K2-STARTK2-START
C46C46
R61R61
R109R109
D4D4
D32D32
J9J9
Q1Q1
R143R143
C71C71
C49
C49
R91R91
R24
R24
R60R60
J6J6
R22
R22
R142
R142
R21
R21
R7R7
R108R108
R63R63
R40R40
R101R101
R37R37
C5C5
C64
C64
C92
C92 T1T1
R30R30
J8J8
R134
R134
R119
R119R1
16R1
16
R89R89
R48
R48
++
K3-E-STOP CNCK3-E-STOP CNC
R78R78
D36D36
D31D31
R140R140
R107R107
C37C37
R65R65
R100R100
C28
C28
R84R84U11U1111
K4-OKK4-OK
D1D1
C73
C73
R25
R25
R110R110
C54C54
D15D15
R133R133
R150R150
R122
R122
R19
R19
C31C31
TP11TP11
D39D39
2929
2211
J2J2
3030
D38
D38
R86R86
R68R68
R42
R42
D13D13
R126R126
R70
R70
R3R3
C80C80
R96R96
U4U4
TB2TB2
11
C21
C21
K6K6
C85C85
++R3
3R3
3
C70C70
D40D40
R17
R17
C51
C51
R136
R136
TP4TP4
D28D28
R93R93
R52
R52
C9C9
TP14TP14
D16D16
C61
C61
D35D35
C13
C13
R58R58
D5D5
R85R85
R98R98
R94
R94
C89C89
C62C62
C25C25
R74R74
R130R130TP1TP1
J7J7
TP13TP13
C91C91
R35
R35
TP10TP10
R18
R18
C29
C29
C72C72
C42C42
C74C74
D19D19
R4R4
++
R124
R124
R95R95
C81C81
D11
D11
R54
R54
C36
C36
D24D24
C12
C12
C86
C86
U21U2111
U15U15
R16
R16
11
L1L1
TP2TP2
C60C60
R32
R32
++
R51
R51
U8U8 C32C32
11
C14
C14
D27
D27
R113R113
D33
D33
C38C38
R105R105
R34
R34
R92R92
C59C59 R112R112
R106R106
H3H3
R146R146
R111R111
R36
R36
C10
C10
C57
C57
11
22
2525
2626
11 22
3333 3434
+29-41 VDC+29-41 VDC
C67C67
C63C63
C90C90
R223
R223
C94
C94
R155R155
C1C1
R158R158
D60
D60
R156R15633221111
SW12
SW12
44
R154
R154
R157R157
D61
D61
SW12
-2 O
N FO
R 30
:1SW
12-2
ON
FOR
30:1
SW12
-3 O
N FO
R 40
:1SW
12-3
ON
FOR
40:1
SW12
-4 S
PARE
SW12
-4 S
PARE
++
++
R152
R152
C44C44
H7H7
R224R224R225R225
C43C43
R227
R227
R228
R228
Q2Q2
R226
R226
Q3Q3
AD+AD+
Art # A-06901
TP14
TP7
TP6
J1
SW6
SW12
J36
TB1 TB2 J4 J9
TP11
J5 J6 J7
SW11 TP9
J8
TP12
J2
TP10 TP8
J35
TP4 TP3 TP2 SW13 TP5 TP1 TP13
J3
Manual 0-4748 A-9 APPENDIX
ULTRA-CUT 100
Art # A-04900_AC
TB1-1 E-Stop (Com)TB1-2 E-StopTB1-3 OK 2 Contacts 24V MaxTB1-4 Stop LatchedTB1-5 Start / Stop RetTB1-6 Start / Stop or Start Latched (NO)TB1-7 Divided Arc Voltage (-) TB1-8 Divided Arc Voltage (+) TB1-9 Remote Analog Current Control (0-10V) (-)TB1-10 Remote Analog Current Control (0-10V) (+)TB1-11 +10V @ 10ma For Remote CC POTTB1-12 OK 2 Contacts 24V Max
TB2-1 Hold Start (-)TB2-2 Hold Start (+)TB2-3 Preflow On (-)TB2-4 Preflow On (+)TB2-5TB2-6 Pilot On (Relay Contacts NO)TB2-7TB2-8 Pilot On (Relay Contacts NO)TB2-9TB2-10 OK to Move (Contacts or DC Volts) (-)TB2-11TB2-12 OK to Move (Contacts or DC Volts) (+)
TB
2T
B1
Sustained Start / StopTB1-5
TB1-6
Momentary Start / Stop
TB1-4
TB1-5
TB1-6
Stop
Start
Start / Stop Circuit Configurations
These points are jumpered together at the factory.Remove the jumper to use existing E-Stop circuits.
TB
31
TB3-1
TB3-2 }Marking Input
APPENDIX A-10 Manual 0-4748
ULTRA-CUT 100
CNC functions
CNC I/O circuits provide at least 1000V galvanic isolation from the plasma power supply.
While the CNC circuits are isolated from the power supply, many of the signal returns on J15 and TB1 & 2 are commonto each other. J15 pins 1, 4, 5 & 10 and TB1-1, 5, 7, 9, and TB2-1 & 3 are all common. J15 pin 12 and TB2-10 are alsoconnected to the others when SW6 (OK to Move select) is set for voltage.
Rear Panel CNC Connector J15:
14 Circuit (Amp CPC) Remote Standard:
Chassis gnd (for SC-11 cable shield) 11 Start/Stop 3 (+); 4 (-)1 Ok to Move (contacts or voltage 2) 12(-); 14 (+)1 Divided Arc volts (selectable
ratio 50:1; 40:1; 30:1; 16.6:1) 5 (-); 6 (+)
Arc Volts (w/100K series res) 7 (-); 9 (+)1 Analog Current Control (0-10V) 3 10 (-); 11 (+)
Isolated Circuit Comm (for SC-11) 8
Chassis Gnd 13
1 These are also duplicated on TB1 & TB2, use one or the other not both. Additional functions are only available on TB1 & 2.
2 SW6 on CCM I/O PCB selects OK to Move for isolated contact closure or DC Volts (15-18V) at <100ma. When set forcontacts, OK to Move circuit is rated for 120 VAC / 28 VDC @ 1A.
Internal CNC connections. TB1 & TB2 on CCM module.
Connections are provided on the CCM module TB1 & TB2 terminal blocks including most of the rear panel functionsplus some additional features. All these signals are isolated from the plasma power supply but signals marked(comm.) and (-) are common to each other.
Users are expected to install their own CNC cable to these connections. Knockout hole is provided in rear panel of CCMmodule. User shall provide strain relief / cord grip for user installed cable.
Function Connection
E-Stop TB1-1 (comm.) & TB1-2
OK To Move 2 (Contact)5 TB1-3: TB1-12
Stop Latched (NC) 4 TB1-4
Start/Stop Ret 4 TB1-5 (comm.)
Start /Stop or Start Latched (NO) 4 TB1-6
Divided Arc Voltage TB1-7(-); TB1- 8(+)
Remote Analog Current Control (0-10V) TB1-9(-); TB1-10(+)
+10V @ 10ma For Remote CC POT5 TB1-11
Hold Start TB2-1(-); TB2-2(+)
Preflow On TB2-3(-); TB2-4(+)
Pilot On (Relay Contacts NO) TB2-6; TB2-8
Manual 0-4748 A-11 APPENDIX
ULTRA-CUT 100
Function Connection
OK to Move (Contacts or DC Volts) TB2-10(-); TB2-12(+)
Plasma Marking Remote Select TB3-1: TB3-2
CNC Input / Output Descriptions
E-Stop input— Requires closed connection rated for 35ma. @ 20VDC for unit to operate. Factory installed jumper betweenTB1-1&2 must be removing when connecting user supplied E-Stop circuit.
4 Start/Stop input—Switch (momentary or sustained) rating 35ma. @ 20 VDC
Start / Stop circuit configurations. Momentary Start / Stop (Latched) is only available at TB1.
MOMENTARY START / STOP
START / STOP
TB1-6
TB1-5
TB1-4
SUSTAINED START / STOP
START
STOP
TB1-5
TB1-6
Divided Arc Voltage output — Arc Voltage signal is isolated from plasma supply, however (-) is common with otherisolated CNC signals. Max Divided Arc Voltage signal level depends on actual arc voltage times divide ratio howevercan not exceed approximately 12 V.
3 Analog Current Control input— Analog Current Control includes analog isolation module, separate isolationmodule not usually required however it’s low input is common with the other isolated CNC inputs. Scaling of AnalogCurrent Control input is 0V = 0A, 10V. = MAX output and is linear in between. However MIN output is 10A. User isresponsible for setting correct analog voltage to maintain at least 10A output. To use Analog Current Control on theI/O PCB set SW 11 to down position and on the CPU PCB set SW8-2 ON (up).
Hold Start input—Normally open, close to hold start. Circuit rating 10 ma. @ 20VDC. Delays pilot ignition, gaspreflow continues. Used for synchronizing starts when multiple plasma supplies are used on same cutting table. Usersupplies circuit to keep Hold Start inputs active until all torches have found height.
Preflow On input— Normally open, close to start preflow prior to normal START signal. Circuit rating 10 ma. @20VDC. Torch Height Controls (THC) normally issue START signal to plasma supply after torch height has beenfound. Then the plasma takes 1-2 seconds (or more) to perform preflow before igniting pilot. Some THCs have anoutput that can start preflow early during height finding saving 1-2 seconds on each cut.
Pilot On output – Relay contacts rated 1A @ 120 VAC / 28 VDC. Contacts close when pilot on. Can be wired parallelwith Ok to Move contacts to start machine motion when pilot established. Used when starting over holes. Starting overholes requires setting SW8-1 ON (up) on the CPU PCB for extended pilot time. Using extended pilot time to start overholes or for cutting over holes will reduce parts life.
OK to Move output — Active when cutting arc is established, arc is transferred. Used to signal cutting table to startX-Y motion. Relay contacts rated 1A @ 120 VAC or 28 VDC when SW6 set for contacts. When SW6 is set for DCV, outputsupplies 15-18 VDC @ 100 ma. May be wired parallel with Pilot On to start cutting machine motion as soon as pilotestablished.
5 The following features are available in Ultracut CCM revision level BA and higher or S/N05517201 and higher.
5 OK to Move2 – Provides a second set of N.O. contacts that close when arc transfer is detected. Contacts are rated formaximum of 24 VAC/DC @ 1A.
APPENDIX A-12 Manual 0-4748
ULTRA-CUT 100
5 +10V @ 10ma. For Remote CC Pot – Previously CCM versions if one wanted to use a potentiometer for the RemoteAnalog Current Control (CC) input an external 10 V supply was required for Pot High.. Now an isolated (from mainplasma circuits) 10V supply is provided. Recommended value of the pot is 5K or 10K.
Ext. +10V
11 10 9
TB1
+10V WIPER
Art # A-09246
5 Plasma Marking Select (Remote) – Plasma Marking, available only with DFC 3000, may be activated with a contactclosure between TB3-1 & TB3-2 if SW8-4, DIP switch on the CPU board (smaller of the 2 CCM boards), is also on.Opening the connection between TB3-1 & TB3-2 switched back to normal cutting mode. For Ultracut power suppliesIt is OK to leave SW8-4 on whether you are marking or not.
Manual 0-4748 A-13 APPENDIX
ULTRA-CUT 100
Simplified CNC Circuit.
123456789
Remote Analog Current Control (+)
J15 CNC14 pin CPCrear panel
Remote Analog Current Control (-)
Divided Arc V (-)SC 11 Comm Ref
Divided Arc V (+) 1K
START / STOP (-)START / STOP (+)
ARC V_100K (+)
ARC V_100K (-)
1234567
J4
OK to MOVE (+)
OK to MOVE (-)
Active LOW Logic Input
Active LOW Logic Input
START / STOP
MOMENTARY START / STOP
TB1-5
TB1-4
TB1-6
SUSTAINED START / STOP
START
STOP
TB1-6
TB1-5
Active LOW Logic Input
ALL SW OFF for 50:1 (default)SW12-1 ON = 16.7:1 (SC-11)SW12-2 ON = 30:1SW12-3 ON = 40:1SW12-4 ON =
ARC V (+)
21
3
54
6
SW6
Active LOW Logic Input
+16 to 18 VDC(isolated)
PSR
OK to Move
ARC V (-)
Active LOW Logic Input
100K
36S
W12
-3
45
SW
12-4
18
SW
12-1
27
SW
12-2
21
3SW11
100K
1
87
6
2
+
-
U37ALT1013
Input Circuit Common(isolated)
OK to MOVE (+)
STOP (NC)
PREFLOW ON (+)
START/STOP OR START LATCH (+)START/STOP Ret (-)
PILOT ON output(Contacts)
OK TO MOVE output(contacts orDC Volts)
Remote Analog Current Control input (+)
E-STOP Ret (-)E-STOP input (+)
Remote Analog Current Control ret (-)
123456789
101112
TB1
HOLD START (+)
DIVIDED ARC V (+)
HOLD START (-)
DIVIDED ARC V (-)
123456789
101112
TB2
OK to MOVE (-)
PREFLOW ON (-)
123456789
1011121314
J15
To CPU PCB Analog Input
CCM Module
Art # A-07327_AB
J1
APPENDIX A-14 Manual 0-4748
ULTRA-CUT 100
CNC Connections.
A-07632
Start Motion(OK-To-Move)
Cutting Machine CNC Cable Power Supply
Shield
J15
1
3
4
9
6
7
8
13
14
12
5
OK-To-Move
2
(1)
3
4
9
6
7
14
12
5
2
START/STOP
*( )
( )
( )
( )
( )
( )
( )
( )
( ){ *
*
NC
.......... Source, 16 VDC, 10 ma.
... Divided Arc V (-)
..........
..........
..........
Arc V (-) through 100K ***
Arc V (+) through 100K ***
10
11
10
11
( )
( ) ..........
Divided Arc V (+)
Remote Analog Current Control (-)
Remote Analog Current Control (+)
...
Relay DCV (-)Contact or(1A @ DCV (+)120 VAC ( 15 - 18 VDC @or 28 VDC) up to 100 ma.)
* Power Supply Gnd not used for CNC cable Do not connect wire #1 to anything.
** Cable Shield drain wire must be connected to ground at cutting machine.
*** Used only for special Torch Height Control
**
Manual 0-4748 A-15 APPENDIX
ULTRA-CUT 100
This Page Intentionally Blank
APPENDIX A-16 Manual 0-4748
ULTRA-CUT 100
APPENDIX 8: Schematic, 230-460V, Chopper Pilot
Art # A-06992_AD
1
1
2
2
3
3
4
4
5
5
A
B
C
D
E
F
-15V
INP
UT_
NG
+5V
GN
D
+15V+1
5V
+15V
MIS
SIN
G_P
HA
SE
/ 230
PG
ND
1/ 4
60
/ 460
PG
ND
2460
230
CO
M
L1
L2
L3
E
+15V
+12VDC +12VDC
+12VDC
To PC
B7 C
N2-5
To PC
B7 C
N2-4
To PC
B7 C
N2-2
To PC
B7 C
N2-1
FAN
+ (24 VD
C)
FAN
- (24 VD
C)
To PC
B7 TB
3
To T1 PR
I - 0
V_C
HA
NG
E P
CB
100A INVERTER MODULEP_GND
VAC_IN
LINE to LINE, LINE TO GND CAPS & VARISTORS
PCB 1WK-5630
INPUT POWER INDICATORREAR PANEL
INPUT POWER INDICATORINTERNAL
16 CKT RIBBON CABLE
PCB 5 WK-5602 (partial)
MISSING PHASE
(pulses)<
LED1 DIM = LOW, BRIGHT = OKLED2 DIM = OK, BRIGHT = FAULTLED3 DIM = OK, BRIGHT = FAULTLED4 OFF = OK, ON = FAULTLED5 OFF = OK, ON + FAULT
CN6 16 CKT
BIAS SUPPLY FOR PCB5
(F2 -Sht2)
DC FAN POWER
CN1 CN5 CN6
CN4 CN5 CN6
(A1 Sht2)
(A1 Sht2)
(A1 Sht 2)
(A1 Sht 2)
(A2 Sht 2)
(A2 Sht 2)
CN6 16 CKTON / OFF
PCB3 WK-5694
PCB4 WK-5604
VAC_IN
P_GND
BIAS SUPPLY PCB
DETECTOR PCB
INTERFACE PCB
FILTER PCB
--460--
--230--
--230--
208-230/460 VAC 3 Phase
RIBBON CABLE SIGNALS
CN6 - 16 Ckt Ribbon Cable
2,4- I_REF (Scaled Cut Demand)5- PS_START (Start)6- REDUNDANT_START (Start2)8- INV_READY9- / PS_START disabled by Input_NG12- / OCR13- / PS_START disabled by OCR14- /TEMP_ERR15- / PS_START disabled by Temp _Err
MC1-CMC1-C
RY2RY2
ACAC
AC
+-
D1
ACAC
AC
+-
D1
CN1CN1
1
2
3
4
5
6
7
TB4TB4
+
RY2
RY2
+
RY2
RY2
230V230V
CN3CN31
4
TT
CN32CN32 1 2 3 4
CN1-230V
6
CN1-230V
6
1234
CN4 - PCB12CN4 - PCB12
2 3 41
C1C1
CN2CN2 12
LED3INPUT NGLED3INPUT NG
MC1-BMC1-B
N2N2
LED2MISSING PHASE
LED2MISSING PHASE
CN2-460VCN2-460V 1 2 3 4
+
-
+
-
1
2
3
45
6
1 2
34
TB3TB3 ++
CN2CN21
2
3
SS
CN1CN1 1 5 8
CN7CN7 1 2 3 4 5
MC1-AMC1-A
CN7CN7 1 2 3 4 5
CN4CN4 14
LED5ERRORLED5ERRORLED5ERRORLED5ERROR
1 2
34
INRUSHINRUSH
NE1NE1
CN2CN2 1 2 3
P (+)P (+)
CN4CN4 1 2 3 4
C.P1C.P1
NE2NE2
CN10CN10 1 2
N (-)N (-)
- +- +
3
1
2
4
CN32CN32 1 2 3 4
TB2TB2 ++
RR
P1P1
CN3CN3 1 2
CN18CN18 1 2 3
- +- +
3
1
2
4
TB1TB1
TB1TB1
Manual 0-4748 A-17 APPENDIX
ULTRA-CUT 100
Art # A-06992_AD
6
6
7
7
8
8
9
9
10
10
A
B
C
D
E
F
I_se
nseP
GN
DW
+15V
w-1
5Vw
Isen
se_W
GN
DP
CO
MM
ON
Iref_
G
P1
P_r
efP
_ena
GN
DW
GN
D_C
Isen
se_W
-15V
w
TEM
P_C
+15V
w
N2
GN
DP
+12V
-12V
I_se
nseP
SIG
NAL
P_r
efIre
f_G
P_e
na
GN
D_C
TEM
P_C
TORCH (-)
PILOT
WORK (+)
NEG ARC VOLTS
WORK
PILOT (TIP) VOLTS
DWG No:
Sheetof
SupersedesScale
Date:
Drawn: References
DateByRevisionsRev PCB No:Assy No:
Information Proprietary to THERMAL DYNAMICS CORPORATION.Not For Release, Reproduction, or Distribution without Written Consent.
NOTE: UNLESS OTHERWISE SPECIFIED -1. RESISTOR VALUES ARE EXPRESSED IN OHMS, 1/4W 5%.2. CAPACITOR VALUES ARE EXPRESSED IN MICROFARADS (uF). Chk: App:
TITLE:Last Modified:
SizeSCHEMATIC,
ThermalDynamics
AA
42X1209Friday, September 25, 2009
1 2
Industrial Park #2West Lebanon NH 03784603-298-5711
100-Amp Power Supply 208-230/460V (Chopper)
Tuesday, October 03, 2006
08:11:44
Thermal Dynamics
DDWG No:
Sheetof
SupersedesScale
Date:
Drawn: References
DateByRevisionsRev PCB No:Assy No:
Information Proprietary to THERMAL DYNAMICS CORPORATION.Not For Release, Reproduction, or Distribution without Written Consent.
NOTE: UNLESS OTHERWISE SPECIFIED -1. RESISTOR VALUES ARE EXPRESSED IN OHMS, 1/4W 5%.2. CAPACITOR VALUES ARE EXPRESSED IN MICROFARADS (uF). Chk: App:
TITLE:Last Modified:
SizeSCHEMATIC,
ThermalDynamics
AA
42X1209Friday, September 25, 2009
1 2
Industrial Park #2West Lebanon NH 03784603-298-5711
100-Amp Power Supply 208-230/460V (Chopper)
Tuesday, October 03, 2006
08:11:44
Thermal Dynamics
DDWG No:
Sheetof
SupersedesScale
Date:
Drawn: References
DateByRevisionsRev PCB No:Assy No:
Information Proprietary to THERMAL DYNAMICS CORPORATION.Not For Release, Reproduction, or Distribution without Written Consent.
NOTE: UNLESS OTHERWISE SPECIFIED -1. RESISTOR VALUES ARE EXPRESSED IN OHMS, 1/4W 5%.2. CAPACITOR VALUES ARE EXPRESSED IN MICROFARADS (uF). Chk: App:
TITLE:Last Modified:
SizeSCHEMATIC,
ThermalDynamics
AA
42X1209Friday, September 25, 2009
1 2
Industrial Park #2West Lebanon NH 03784603-298-5711
100-Amp Power Supply 208-230/460V (Chopper)
Tuesday, October 03, 2006
08:11:44
Thermal Dynamics
D
RAS
PILOT CURRENT SIGNAL <
WORK CURRENT SIGNAL <
HCT1 Hall Current Sensor, Pilot (B8, Sht 1)HCT2 Hall Current Sensor, Work (C9, Sht 1)
LSW1 Level SW, coolant, NC (B5, Sht 2)
MC1 Contactor, 3P ,Inv 1 input, Coil (B3, Sht 2) " Contacts (A2, B2, Sht 1) " Aux Contact (B3, Sht 2)MC2 Contactor, pilot, Coil (B3, Sht 2) " Contacts (C8, Sht 1)
MOT1 Motor, Pump 200VAC, 1P (E4, Sht 2)
NE1 Neon indicator, rear panel, 220VAC (C1, Sht 1)NE2 Neon indicator, internal, 220VAC (C1, Sht 1)
R6 Resistor, 20K ,30W (A8, Sht 1)R7 Resistor, 1K ,30W (E2, Sht 2)R9 Resistor, 50 ,40W (A9, Sht 1)
T1 Aux Transformer (D-F1, Sht 2)
TH1 Thermal Sensor, coolant return (B5, Sht 2)
COMPONENT LOCATOR
(C7 & A9, Sht 2)
Power SupplyRear Panel
DAT
< /O
VE
R_T
EM
P(C7, Sht 2)
> P
_DE
M (
P_I
ref)
> P
_Ena
ble
(P_e
na)PILOT REG.
(CHOPPER )PCB2WK-5754
HALL SENSOR
BIASPOWER
I_D
ET
<I_
SE
PILOT REG.(CHOPPER )PCB1WK-5750
<
(C7 & A9, Sht 2)
HALL SENSOR
PILOT REGULATOR (CHOPPER)
PCB 8WK-5687RC &RF CAPS
/PILOT ENABLE >
PILOT DEMAND >
/ OVERTEMP <
C1 Capacitor, 0.1 uf, 1250 VDC (D2, Sht 2)C2 Capacitor, 2 uf, 430VAC (A9, Sht 1)
C.P1 Circuit protector/ON-OFF SW (B2, Sht 1) 15A, 460V, 3PC.P2 Circuit protector 2.5A 125V (D2, Sht 1)C.P3 Circuit protector 3.15A 125V (D2, Sht 1)C.P4 Circuit protector 10A 125V (E2, Sht 1)C.P5 Circuit protector 2.5A 125V (E2, Sht 1)C.P6 Circuit protector 2.5A 125V (F2, Sht 1)C.P7 Circuit protector 5A 125V (E2, Sht 1)C.P8 Circuit protector 3.15A 125V (F3, Sht 1)
D1 Diode Bridge 20A, 1600V, 3P (D2, Sht 1)D2 Diode, Dual, 2x100A, 600V (B8, Sht 1)
FAN1 Fan, Coolant, 24 VDC (F4, Sht 2)FAN3 Fan, Chopper, 24 VDC (A8, Sht 1)
FL1 Flow sensor (B5, Sht 2)
ECO-B402 DAT 2/26/07
AB ECO-B448 DAT 4/13/07ECO-B646 GAC 10/31/07AC
ECO-B1391 TADDA 4-24-2009DATAE ECO-B1535 9-25-09
CN7CN7 12345
TB4TB4
CN4CN4 12345
THS1SW_TEMP_NC
THS1SW_TEMP_NC
MC2-CMC2-C
CN3CN3 1 2 3 4
CN3CN3 12
CN4CN4 1 2 3
LED4CHOPPER TEMP
LED4CHOPPER TEMP
CN6CN6 123
CN2CN2 1 2 3
C22 UFC22 UF
CN2CN2 1 2 3 4
CN33CN33 1 2 3 4TB2TB2
CN17CN17 1 2 3
CN5CN5 1234
TB1TB1
CN1CN1
12
HCT2HCT2
1 2 3 4
CN9CN9 1 2
R620K
30W
R620K
30W
CN8CN8 12
TB3TB3
MC2-AMC2-A
TB5TB5
CN4CN4 1 2 3 4 5
CN1CN11234
D2D2
1A1
2K1
3A2
4K2
CN5CN5 1 2 3 4
FAN3FAN3
+-
CN3CN3 1
R950R950
MC2-BMC2-B
TB2TB2
TB1TB1
WORKWORK
CN2CN2 123
HCT1HCT1
1 2 3 4
CN1CN11234
APPENDIX A-18 Manual 0-4748
ULTRA-CUT 100
APPENDIX 8: Schematic, 230-460V, Chopper Pilot Cont.
Art # A-06993_AD
1
1
2
2
3
3
4
4
5
5
A
B
C
D
E
FAC13V @ 2A
AC120V @ 1A
/PUMP
+15V
+15V
/FAN
/RAS
+15V
COM230460
COM230460
460
230
AC200V @ 3A
AC120V-RAS
FAN + (24 VDC)
FAN - (24 VDC)
0V-RAS
DC 15VDC 0V
AC24V-GCM
0V-A (24V ret)
AC120V-GCM
0V-B (120V ret)
To PC
B7 TB
3
To T1 PR
I - 0
To PC
B7 C
N2-1
To PC
B7 C
N2-2
To PC
B7 C
N2-4
To PC
B7 C
N2-5
CCM MODULE
(D9, A10)
COOLANT TEMP(ON COOLANT RETURN)
TO AC
INDICATOR
(on PCB6)
PILOTCONTACTOR
INPUTCONTACTOR
(C9)
FROM CN18 PCB3 sht 1
29-41 VDC +15VDC+5VDC-15VDC
ISOLATED COMM+16 to +18VDC
+15VDC_ISO-15VDC_ISO ISOLATED
VOLTAGES
PILOT DEM to PS
ANALOG DEM to CPU
CUT DEM to PSPILOT (TIP) VOLTAGENEG ARC VOLTS
CIRCUIT COMM (GND)
I/O PCB
CPU PCB
SW6 - OK to MOVE CONTACTS / VOLTS
SW11 - ANALOG CURRENT SELECT "B" DEFAULT, "A" REMOTESW12 - DIVIDED ARC V RATIO SELECT
SW13 - FACTORY ONLY
PCB 5 WK-5602 (partial) INTERFACE PCB
(F1 Sht 1)
(F1 Sht 1)
PCB7 WK-5628RELAY PCB
(F1 Sht 1)
(F1 Sht 1)
(F2 Sht 1)
(F2 Sht 1)
(D9, A10)
COOLANT FLOW (freq) *1 2 3
CN12CN121
2
CN2CN2
1
2
TP4TP4
CN4CN41
2
3
CN3CN31
2
3
D2 E-STOP_PSD2 E-STOP_PSC.P3C.P3
+V
GND
SIG
FL1FLOW_TURBINE_PULSE
+V
GND
SIG
FL1FLOW_TURBINE_PULSE
R BG
T1T1460
220
0,
13
0,,
100
0.
200
0..
110
0...
120.
0_
24.
0__
24_
0___
120.
0___
TP10TP10
1 2CN10CN10
1
2
3
TB1TB1
D15 PSRD15 PSR
R71K 30WR7
1K 30W
C.P5C.P5
D12 STATUS CODE D12 STATUS CODE
TP9TP9
1
2
3
CN7CN71
2
3
4
TP14TP14
CN6CN61
2
3
4
CN8CN81
2
3
4
MC2MC2
D1 GAS_OND1 GAS_ON
C.P6C.P6
TP7TP7
CN1CN1 1 2
CN9CN91
2
3
4
5
1 2
TP1TP1
CN14CN14 1 2
TB5TB5
RY3RY3
TP5TP5
CN9CN91
2
3
RY5RY5
D11 INITIALIZING / PROGRAMMINGD11 INITIALIZING / PROGRAMMING
MC1 AUXMC1 AUX
TP3TP3TP2TP2
TP15TP15
C.P7C.P7
D4 OK_CNCD4 OK_CNC
TB4TB4
LED1LEVELLED1LEVEL
CN5CN51
2
3
4
5
6
D23 CNC_STARTD23 CNC_START
FAN1FAN1
+ -
1
2
3
MC1MC1
LSW1-1
SW_LIQUID_LEVEL_NC
LSW1-1
SW_LIQUID_LEVEL_NC
C.P2C.P2
+RY1
+RY1
D21 CNC_E-STOPD21 CNC_E-STOP
RY5RY5
1 2 3
CN11CN11
1
2
CN8CN8 1 2 3 4
+
RY2
RELCOL_0+
RY2
RELCOL_0TP8TP8
C.P8C.P8
TB2TB2
D26 HOLD_STARTD26 HOLD_START
TP12TP12
CN2CN2 1 2 3 4 5
RY4RY4
PUMP
MOT1
PUMP
MOT1
' .
tTH1
tTH1
TP13TP13
TB3TB3
RY3RY3
TP6TP6
TP11TP11
CN13CN13 1 2 3
1
2
CN12CN12 1 2 3
1
2
D28 CNC_PREFLOWD28 CNC_PREFLOW
RY4RY4
D13 +5VD13 +5V
C.P4C.P4
Manual 0-4748 A-19 APPENDIX
ULTRA-CUT 100
Art # A-06993_AD
6
6
7
7
8
8
9
9
10
10
A
B
C
D
E
F
POT HI (GCM1000)
POT WIPER (GCM1000)
POT LOW (GCM 1000)
PLASMA ENABLE
PRESS OK (GCM 1000)
PLASMA ENABLE
24V
AC
24 V
AC
RE
T
+15V/ AC
/ TEMP
/ STATUS/ DC
/ GAS - COOLANT
- ARC V
- ARC V
AC24V-GCM
0V-A (24V ret)
AC120V-GCM
0V-B (120V ret)
AC120V-RAS
0V-RAS (120V ret)
DC 15V
DC 0V
NE
G A
RC
VO
LTS
PIL
OT
(TIP
) VO
LTS
WO
RK
0V-A (24V ret)
AC24V-GCM
0V-B (120V ret)
AC120V-GCM
WORK
NEG ARC VOLTS
DWG No:
Sheetof
SupersedesScale
Date:
Drawn: References
DateByRevisionsRev PCB No:Assy No:
Information Proprietary to THERMAL DYNAMICS CORPORATION.Not For Release, Reproduction, or Distribution without Written Consent.
NOTE: UNLESS OTHERWISE SPECIFIED -1. RESISTOR VALUES ARE EXPRESSED IN OHMS, 1/4W 5%.2. CAPACITOR VALUES ARE EXPRESSED IN MICROFARADS (uF). Chk: App:
TITLE:Last Modified:
SizeSCHEMATIC,
ThermalDynamics
AA
42X1209Friday, September 25, 2009
2 2
Industrial Park #2West Lebanon NH 03784603-298-5711
100-Amp Power Supply 208-230/460V (Chopper)
Tuesday, October 03, 2006
08:11:44
Thermal Dynamics
DDWG No:
Sheetof
SupersedesScale
Date:
Drawn: References
DateByRevisionsRev PCB No:Assy No:
Information Proprietary to THERMAL DYNAMICS CORPORATION.Not For Release, Reproduction, or Distribution without Written Consent.
NOTE: UNLESS OTHERWISE SPECIFIED -1. RESISTOR VALUES ARE EXPRESSED IN OHMS, 1/4W 5%.2. CAPACITOR VALUES ARE EXPRESSED IN MICROFARADS (uF). Chk: App:
TITLE:Last Modified:
SizeSCHEMATIC,
ThermalDynamics
AA
42X1209Friday, September 25, 2009
2 2
Industrial Park #2West Lebanon NH 03784603-298-5711
100-Amp Power Supply 208-230/460V (Chopper)
Tuesday, October 03, 2006
08:11:44
Thermal Dynamics
DDWG No:
Sheetof
SupersedesScale
Date:
Drawn: References
DateByRevisionsRev PCB No:Assy No:
Information Proprietary to THERMAL DYNAMICS CORPORATION.Not For Release, Reproduction, or Distribution without Written Consent.
NOTE: UNLESS OTHERWISE SPECIFIED -1. RESISTOR VALUES ARE EXPRESSED IN OHMS, 1/4W 5%.2. CAPACITOR VALUES ARE EXPRESSED IN MICROFARADS (uF). Chk: App:
TITLE:Last Modified:
SizeSCHEMATIC,
ThermalDynamics
AA
42X1209Friday, September 25, 2009
2 2
Industrial Park #2West Lebanon NH 03784603-298-5711
100-Amp Power Supply 208-230/460V (Chopper)
Tuesday, October 03, 2006
08:11:44
Thermal Dynamics
D
KEY PLUG
CN11 34 CKT CN10 26 CKT
J36 34 CKT J35 26 CKT
RIBBON CABLE
TEST SOCKET
RIBBON CABLE
TEST SOCKET
(E2)
(E2)
(E4)
(F4)
POWER SUPPLY REAR PANEL
TB1
TB2
DIVIDED ARC V +DIVIDED ARC V -
REMOTE ANALOG CURRENT CONTROL -REMOTE ANALOG CURRENT CONTROL +
E-STOP -E-STOP +
PILOT ON OUTPUT
HOLD START -HOLD START +PREFLOW ON -PREFLOW ON +
OK to MOVE -
OK to MOVE +
MOMENTARY START / STOP
START / STOP
STOP
START
+
-
JUMPER IN REMOTEHMI
PLASMA ENABLE
PCB6 DISPLAYWK-5603
START / STOP
DIVIDED ARC VOLTS
REMOTE ANALOG CURRENT CONTROL
OK TO MOVE
DAT
Signal - Basic IDUsed to identifyGCM 1000 present
RIBBON CABLE SIGNALS / = active low digital signal
CN10-J35 - 26 Ckt Ribbon Cable
2-Cut Demand4-Pilot Demand6-/ Start7-/ Start2 9-/ Pilot Enable10-/ HF Enable12-/ Pump Enable13-/ Fan Enable15-/ DC Indicator16-/ Over Temperature Indicator18-/ Gas-Coolant OK Indicator19-/ Status Lamp
CN11-J36 - 34 Ckt Ribbon Cable
1- Output Current Signal 3- / Arc Transferred (CSR)4- / Pilot On 6- Coolant Flow (freq)7- Coolant Temp (analog)9- / Temp OK (Inverter/Chopper)10- / Coolant Level OK12- Missing Phase13- / Ready to Operate15- / Input Volts OK16- / Inverter OCR18- / PS ID "00*"19- / PS ID "0*0"20- / PS ID "*00"21- E-Stop22- E-Stop29,31,33- 24 VAC Supply30,32,34- 24 VAC Return
ECO-B402 DAT 2/26/07
AB ECO-B448 DAT 4/13/07
INTERNAL TERMINAL STRIP TB3(Not in all units)
(E2)
(C9, sht 1)
(A9, sht 1)
UNDIVIDED ARC VOLTSFOR HEIGHT CONTROLS
24 VAC @ 1A
120 VAC @ 100ma.
(A9, sht1)
(B9, sht1)
(C9, sht1)
AC ECO-B646 GAC 10/31/07
* OK2
* OK2* +10VDC @ 10 ma.(for CC pot high)
TB3* REMOTE MARKING +
* REMOTE MARKING -
* Only in CCM w/ 19X2634 I/O PCB. Remote Marking only for DFC 3000 (not isolated)
AD ECO-B1391 DAT 4-24-2009
** RS 485 / 422 on CPU board19X2554 only. Iso
Rx-
Tx+
Rx+
Tx-
Rx-
Tx+
Rx+
Tx-
KEY PLUG
JUMPERfor 2 WIRE(RS485 only) wire to A & B
4W4W
2W
JUMPERfor 4 WIRE usesTX+, TX-RX+, RX-
J14
J14
2W
SW14SW14 - LINE TERMINATIONnormally on(refer to manual)
5
9876
123
4
SW10-ADDRESSnormally 0(refer tomanual)
0
Signal & GNDIsolated from Plasma Supply
RS 485 (2 wire) uses Tx+ & Tx- only(used for TSC 3000)
RS 422 (4 wire) connect TX+ to RX+ of CNC, Tx- to Rx- of CNC
Was 7 pin changed to 14 pin in 2009
GND
GND
& CNC COMM
DATAE ECO-B1535 9-25-09
100K100K
PSRPSR
77
GREEN DCGREEN DC
77
44
99
88
88
J6J6 1 5 8
99
GREEN ACGREEN AC
99
E-STOPE-STOP
J15-CNCJ15-CNC1
2
3
4
5
6
7
8
9
10
11
12
13
14
33
88
100K100K
K6-1K6-1
1010
1K1K
1010
22
11
1111
1111
K6K6
33
J54-REMOTE HMIJ54-REMOTE HMI
1
2
3
4
5
6
7
8
9
10
11
12
13
14
22
77
1212
J59-RASJ59-RAS1
2
3456
7
8
9
1011121314
1212
TP11TP11
22
1212
22
44
OK2 *OK2 *
CN23CN23
1
2
3
4
5
6 REDSTATUS
REDSTATUS
J4J4
1
3
5
7
YELLOW TEMPYELLOW TEMP
11
33
TP1TP1
11
66
1111
11
J55-GCMJ55-GCM12345678910111213141516171819202122232425262728293031323334353637
44
J8J8
1
2
3
4
J1J11
2
3
4
5
6
7
8
9
55CN24CN24
1
2
3
4
5
6
TP12TP12
55
55
GREEN GASGREEN GAS
J7J7
1
2
3
4
5
6
7
8
9
1010
66
J5J51
2
3
4
5
J9J9 1 2 3 4 5 6
J6 **J6 **1
2
3
4
5
6
66
GAS ONGAS ON
APPENDIX A-20 Manual 0-4748
ULTRA-CUT 100
APPENDIX 9: Schematic, 230-460V, Resistor Pilot
1
1
2
2
3
3
4
4
5
5
A
B
C
D
E
F
-15V
INP
UT_
NG
+5V
GN
D
+15V+1
5V
GN
D_C
TEM
P_C
+15V
MIS
SIN
G_P
HA
SE
/ 230
PG
ND
1/ 4
60
/ 460
PG
ND
2460
230
CO
M
L1
L2
L3
E
+15V
+12VDC +12VDC
+12VDC
To PC
B7 C
N2-5
To PC
B7 C
N2-4
To PC
B7 C
N2-2
To PC
B7 C
N2-1
FAN
+ (24 VD
C)
FAN
- (24 VD
C)
To PC
B7 TB
3
To T1 PR
I - 0
V_C
HA
NG
E P
CB
100A INVERTER MODULEP_GND
VAC_IN
LINE to LINE, LINE TO GND CAPS & VARISTORS
PCB 1WK-5630
INPUT POWER INDICATORREAR PANEL
INPUT POWER INDICATORINTERNAL
16 CKT RIBBON CABLE
/ OVERTEMP <
PCB 5 WK-5602 (partial)
MISSING PHASE
(pulses)<
LED1 DIM = LOW, BRIGHT = OKLED2 DIM = OK, BRIGHT = FAULTLED3 DIM = OK, BRIGHT = FAULTLED4 OFF = OK, ON = FAULTLED5 OFF = OK, ON + FAULT
CN6 16 CKT
BIAS SUPPLY FOR PCB5
(F2 -Sht2)
DC FAN POWER
CN1 CN5 CN6
CN4 CN5 CN6
(A1 Sht2)
(A1 Sht2)
(A1 Sht 2)
(A1 Sht 2)
(A2 Sht 2)
(A2 Sht 2)
CN6 16 CKTON / OFF
PCB3 WK-5694
PCB4 WK-5604
VAC_IN
P_GND
BIAS SUPPLY PCB
DETECTOR PCB
INTERFACE PCB
FILTER PCB
--460--
--230--
--230--
208-230/460 VAC 3 Phase
RIBBON CABLE SIGNALS
CN6 - 16 Ckt Ribbon Cable
2,4- I_REF (Scaled Cut Demand)5- PS_START (Start)6- REDUNDANT_START (Start2)8- INV_READY9- / PS_START disabled by Input_NG12- / OCR13- / PS_START disabled by OCR14- /TEMP_ERR15- / PS_START disabled by Temp _Err
TB1TB1
P1P1TB2TB2
N2N2
LED3INPUT NGLED3INPUT NG
CN32CN32 1 2 3 4 CN18CN18 1 2 3
P (+)P (+)
LED5ERRORLED5ERROR
CN7CN7 1 2 3 4 5
CN1CN1 1 5 8
1 2
34
CN3CN3 1 2
- +- +
3
1
2
4
C.P1C.P1
TB3TB3
RY2RY2
NE2NE2
CN4CN4 1 2 3 4
MC1-AMC1-A
CN32CN32 1 2 3 4
N (-)N (-)
TB4TB4MC1-CMC1-C
CN2CN2 12
RR
++
CN10CN10 1 2
CN4CN4 14
CN7CN7 1 2 3 4 5
LED2MISSING PHASE
LED2MISSING PHASE
CN2-460VCN2-460V 1 2 3 4
NE1NE1
SS
++
230V230V
CN3CN31
4
TT
CN17CN17 1 2 3
ACAC
AC
+-
D1
ACAC
AC
+-
D1
LED4CHOPPER TEMP
LED4CHOPPER TEMP
CN2CN21
2
3
- +- +
3
1
2
4
CN1CN1
1
2
3
4
5
6
7
1 2
34+
-
+
-
1
2
3
45
6
CN4 - PCB12CN4 - PCB12
1 2 3 4
+
RY2
RY2
+
RY2
RY2
TB1TB1
CN2CN2 1 2 3
INRUSHINRUSH
MC1-BMC1-B
CN1-460V
6
CN1-460V
6
1234
C1C1
Art # A-07128_AB
Manual 0-4748 A-21 APPENDIX
ULTRA-CUT 100
6
6
7
7
8
8
9
9
10
10
A
B
C
D
E
F
N2
P1
+12V
-12V
SIG
NA
LC
OM
MO
N
I_se
nseP
Iref_
G
GN
DW
P_e
na
GN
DW
Isen
se_W
-15V
w+1
5Vw
+15V
w-1
5Vw
Isen
se_W
GN
DP
I_se
nseP
GN
DP
Iref_
GP
_ref
P_e
na
P_r
ef
GN
D_C
TEM
P_C
TORCH (-)
PILOT
WORK (+)
WORK
PILOT (TIP) VOLTS
NEG ARC VOLTS
DWG No:
Sheetof
SupersedesScale
Date:
Drawn: References
DateByRevisionsRev PCB No:Assy No:
Information Proprietary to THERMAL DYNAMICS CORPORATION.Not For Release, Reproduction, or Distribution without Written Consent.
NOTE: UNLESS OTHERWISE SPECIFIED -1. RESISTOR VALUES ARE EXPRESSED IN OHMS, 1/4W 5%.2. CAPACITOR VALUES ARE EXPRESSED IN MICROFARADS (uF). Chk: App:
TITLE:Last Modified:
SizeSCHEMATIC,
ThermalDynamics
AA
42X1203Wednesday, October 31, 2007
1 2
Industrial Park #2West Lebanon NH 03784603-298-5711
100-Amp Power Supply 208-230/460V (Resistor)
Tuesday, October 03, 2006
08:11:44
Thermal Dynamics
DDWG No:
Sheetof
SupersedesScale
Date:
Drawn: References
DateByRevisionsRev PCB No:Assy No:
Information Proprietary to THERMAL DYNAMICS CORPORATION.Not For Release, Reproduction, or Distribution without Written Consent.
NOTE: UNLESS OTHERWISE SPECIFIED -1. RESISTOR VALUES ARE EXPRESSED IN OHMS, 1/4W 5%.2. CAPACITOR VALUES ARE EXPRESSED IN MICROFARADS (uF). Chk: App:
TITLE:Last Modified:
SizeSCHEMATIC,
ThermalDynamics
AA
42X1203Wednesday, October 31, 2007
1 2
Industrial Park #2West Lebanon NH 03784603-298-5711
100-Amp Power Supply 208-230/460V (Resistor)
Tuesday, October 03, 2006
08:11:44
Thermal Dynamics
DDWG No:
Sheetof
SupersedesScale
Date:
Drawn: References
DateByRevisionsRev PCB No:Assy No:
Information Proprietary to THERMAL DYNAMICS CORPORATION.Not For Release, Reproduction, or Distribution without Written Consent.
NOTE: UNLESS OTHERWISE SPECIFIED -1. RESISTOR VALUES ARE EXPRESSED IN OHMS, 1/4W 5%.2. CAPACITOR VALUES ARE EXPRESSED IN MICROFARADS (uF). Chk: App:
TITLE:Last Modified:
SizeSCHEMATIC,
ThermalDynamics
AA
42X1203Wednesday, October 31, 2007
1 2
Industrial Park #2West Lebanon NH 03784603-298-5711
100-Amp Power Supply 208-230/460V (Resistor)
Tuesday, October 03, 2006
08:11:44
Thermal Dynamics
D
RAS
PCB 8WK-5687RC &RF CAPS
HALL SENSOR
HALL SENSOR
PILOT REG.(CHOPPER )PCB1WK-5750
BIASPOWER
PILOT REGULATOR (CHOPPER)
< /O
VE
R_T
EM
P
> P
_DE
M (
P_I
ref)
> P
_Ena
ble
(P_e
na)PILOT REG.
(CHOPPER )PCB2WK-5754
I_D
ET
I_S
E<<
PILOT CURRENT SIGNAL <
WORK CURRENT SIGNAL <
/PILOT ENABLE >
PILOT DEMAND >
C1 Capacitor, 0.1 uf, 1250 VDC (D2, Sht 2)C2 Capacitor, 2 uf, 430VAC (A9, Sht 1)
C.P1 Circuit protector/ON-OFF SW (B2, Sht 1) 15A, 460V, 3PC.P2 Circuit protector 2.5A 125V (D2, Sht 1)C.P3 Circuit protector 3.15A 125V (D2, Sht 1)C.P4 Circuit protector 10A 125V (E2, Sht 1)C.P5 Circuit protector 2.5A 125V (E2, Sht 1)C.P6 Circuit protector 2.5A 125V (F2, Sht 1)C.P7 Circuit protector 5A 125V (E2, Sht 1)C.P8 Circuit protector 3.15A 125V (F3, Sht 1)
D1 Diode Bridge 20A, 1600V, 3P (D2, Sht 1)
FAN1 Fan, Coolant, 24 VDC (F4, Sht 2)FAN3 Fan, Chopper, 24 VDC (A8, Sht 1)
FL1 Flow sensor (B5, Sht 2)
HCT1 Hall Current Sensor, Pilot (B8, Sht 1)HCT2 Hall Current Sensor, Work (C9, Sht 1)
LSW1 Level SW, coolant, NC (B5, Sht 2)
MC1 Contactor, 3P ,Inv 1 input, Coil (B3, Sht 2) " Contacts (A2, B2, Sht 1) " Aux Contact (B3, Sht 2)MC2 Contactor, pilot, Coil (B3, Sht 2) " Contacts (B8, Sht 1)
MOT1 Motor, Pump 200VAC, 1P (E4, Sht 2)
NE1 Neon indicator, rear panel, 220VAC (C1, Sht 1)NE2 Neon indicator, internal, 220VAC (C1, Sht 1)
R1 Resistor, Pilot, 4 Ohm, 1 KW (C8, Sht 1)R6 Resistor, 20K ,30W (A8, Sht 1)R7 Resistor, 1K ,30W (E2, Sht 2)R9 Resistor, 50 ,40W (A9, Sht 1)
T1 Aux Transformer (D-F1, Sht 2)
TH1 Thermal Sensor, coolant return (B5, Sht 2)
COMPONENT LOCATOR
(C7, Sht 2)
(C7 & A9,Sht 2)
Power SupplyRear Panel
DAT
For this version of the power supply Pilot Regulator is not used except to provide power and pass signals from HCT1, the pilot current sensor.A Pilot Resistor, R1, is used instead.
ECO-B402 DAT 2/26/07
AB ECO-B448 DAT 4/13/07
(C7 & A9,Sht 2)
AC ECO-B646 GAC 10/31/07
CN2CN2 1 2 3 4
HCT2HCT2
1 2 3 4
CN4CN4 1 2 3
TB1TB1
TB2TB2
TB5TB5
TB1TB1
CN2CN2 123
HCT1HCT1
1 2 3 4
TB2TB2
WORKWORK
CN1CN1
12
CN5CN5 1 2 3 4
CN5CN5 1234FAN3FAN3
+-
CN2CN2 1 2 3 CN3CN3 1
CN33CN33 1 2 3 4
CN3CN3 12
MC2-AMC2-A
TB4TB4
CN4CN4 1 2 3 4 5
R14 Ohm 1KWR14 Ohm 1KW
MC2-BMC2-B
MC2-CMC2-CCN1CN1
1234
CN4CN4 12345
CN7CN7 12345
CN1CN11234
CN6CN6 123
THS1SW_TEMP_NC
THS1SW_TEMP_NC
R620K
30W
R620K
30W
TB3TB3
CN8CN8 12
C22 UFC22 UF
CN9CN9 1 2
R950R950
CN3CN3 1 2 3 4
Art # A-07128_AB
APPENDIX A-22 Manual 0-4748
ULTRA-CUT 100
APPENDIX 9: Schematic, 230-460V, Resistor Pilot Cont.
1
1
2
2
3
3
4
4
5
5
A
B
C
D
E
FAC13V @ 2A
AC120V @ 1A
/PUMP
+15V
+15V
/FAN
/RAS
+15V
COM230460
COM230460
460
230
AC200V @ 3A
AC120V-RAS
FAN + (24 VDC)
FAN - (24 VDC)
0V-RAS
DC 15VDC 0V
AC24V-GCM
0V-A (24V ret)
AC120V-GCM
0V-B (120V ret)
To PC
B7 TB
3
To T1 PR
I - 0
To PCB7 C
N2-1
To PCB7 C
N2-2
To PCB7 C
N2-4
To PCB7 C
N2-5
CCM MODULE
(D9, A10)
(D9, A10)
COOLANT TEMP(ON COOLANT RETURN)
TO AC
INDICATOR
(on PCB6)
PILOTCONTACTOR
INPUTCONTACTOR
(C9)
FROM CN18 PCB3sht 1
29-41 VDC +15VDC+5VDC-15VDC
ISOLATED COMM+16 to +18VDC
+15VDC_ISO-15VDC_ISO ISOLATED
VOLTAGES
PILOT DEM to PS
ANALOG DEM to CPU
CUT DEM to PSPILOT (TIP) VOLTAGENEG ARC VOLTS
CIRCUIT COMM (GND)
I/O PCB
CPU PCB
SW6 - OK to MOVE CONTACTS / VOLTS
SW11 - ANALOG CURRENT SELECT "B" DEFAULT, "A" REMOTESW12 - DIVIDED ARC V RATIO SELECT
SW13 - FACTORY ONLY
PCB 5 WK-5602 (partial) INTERFACE PCB
(F1 Sht 1)
(F1 Sht 1)
PCB7 WK-5628RELAY PCB
(F1 Sht 1)
(F1 Sht 1)
(F2 Sht 1)
(F2 Sht 1)
RY3RY3
FAN1FAN1
+ -
TP9TP9
D28 CNC_PREFLOWD28 CNC_PREFLOW
1
2
C.P7C.P7 RY3RY3
1 2
C.P4C.P4
D26 HOLD_STARTD26 HOLD_START
CN14CN14 1 2
D12 STATUS CODE D12 STATUS CODE
C.P3C.P3
CN20CN201
2
3
RY4RY4
D23 CNC_STARTD23 CNC_START
CN8CN81
2
3
4
T1T1460
220
0,
13
0,,
100
0.
200
0..
110
0...
120.
0_
24.
0__
24_
0___
120.
0___
+V
GND
SIG
FL1FLOW_TURBINE_PULSE
+V
GND
SIG
FL1FLOW_TURBINE_PULSE
R BG
TP4TP4
TP13TP13
TP7TP7
MC2MC2
CN6CN61
2
3
4
C.P5C.P5
CN8CN8 1 2 3 4
C.P2C.P2
1 2 3
MC1MC1
TB5TB5
C.P6C.P6D13 +5VD13 +5V
TB3TB3
LED1LEVELLED1LEVEL
RY5RY5
TP1TP1
1 2
CN2CN2
1
2
tTH1
tTH1
1
2
3
D11 INITIALIZING / PROGRAMMINGD11 INITIALIZING / PROGRAMMING
CN12CN12 1 2 3
PUMP
MOT1
PUMP
MOT1
' .
1 2 3
TP5TP5
1
2
TB2TB2
TP8TP8
CN9CN91
2
3
4
5
TP14TP14
1
2
3
CN3CN31
2
3
RY5RY5
TP2TP2
CN9CN91
2
3
D1 GAS_OND1 GAS_ON
CN7CN71
2
3
4
TB1TB1
CN13CN13 1 2 3
TP11TP11
+
RY2
RELCOL_0+
RY2
RELCOL_0
D21 CNC_E-STOPD21 CNC_E-STOP
MC1 AUXMC1 AUX
R71K 30WR7
1K 30W
CN2CN2 1 2 3 4 5
CN11CN11
1
2
CN10CN101
2
3
4
5
6
CN1CN1 1 2
D15 PSRD15 PSR
RY4RY4
C.P8C.P8
+RY1
+RY1
LSW1-1
SW_LIQUID_LEVEL_NC
LSW1-1
SW_LIQUID_LEVEL_NC
D4 OK_CNCD4 OK_CNC
TP3TP3
CN10CN101
2
3
TP10TP10
TP6TP6
TP12TP12
TB4TB4
D2 E-STOP_PSD2 E-STOP_PS
CN12CN121
2
Art # A-07129_AB
Manual 0-4748 A-23 APPENDIX
ULTRA-CUT 100
6
6
7
7
8
8
9
9
10
10
A
B
C
D
E
F
POT HI (GCM1000)
POT WIPER (GCM1000)
POT LOW (GCM 1000)
PLASMA ENABLE
PRESS OK (GCM 1000)
PLASMA ENABLE
24VA
C24
VA
C R
ET
+15V/ AC
/ TEMP
/ STATUS/ DC
/ GAS - COOLANT
- ARC V
- ARC V
AC24V-GCM
0V-A (24V ret)
AC120V-GCM
0V-B (120V ret)
AC120V-RAS
0V-RAS (120V ret)
DC 15V
DC 0V
NE
G A
RC
VO
LTS
PIL
OT
(TIP
) VO
LTS
WO
RK
WORK
0V-A (24V ret)
NEG ARC VOLTS
AC24V-GCM
0V-B (120V ret)
AC120V-GCM
DWG No:
Sheetof
SupersedesScale
Date:
Drawn: References
DateByRevisionsRev PCB No:Assy No:
Information Proprietary to THERMAL DYNAMICS CORPORATION.Not For Release, Reproduction, or Distribution without Written Consent.
NOTE: UNLESS OTHERWISE SPECIFIED -1. RESISTOR VALUES ARE EXPRESSED IN OHMS, 1/4W 5%.2. CAPACITOR VALUES ARE EXPRESSED IN MICROFARADS (uF). Chk: App:
TITLE:Last Modified:
SizeSCHEMATIC,
ThermalDynamics
AA
42X1203Wednesday, October 31, 2007
2 2
Industrial Park #2West Lebanon NH 03784603-298-5711
100-Amp Power Supply 208-230/460V (Resistor)
Tuesday, October 03, 2006
08:11:44
Thermal Dynamics
DDWG No:
Sheetof
SupersedesScale
Date:
Drawn: References
DateByRevisionsRev PCB No:Assy No:
Information Proprietary to THERMAL DYNAMICS CORPORATION.Not For Release, Reproduction, or Distribution without Written Consent.
NOTE: UNLESS OTHERWISE SPECIFIED -1. RESISTOR VALUES ARE EXPRESSED IN OHMS, 1/4W 5%.2. CAPACITOR VALUES ARE EXPRESSED IN MICROFARADS (uF). Chk: App:
TITLE:Last Modified:
SizeSCHEMATIC,
ThermalDynamics
AA
42X1203Wednesday, October 31, 2007
2 2
Industrial Park #2West Lebanon NH 03784603-298-5711
100-Amp Power Supply 208-230/460V (Resistor)
Tuesday, October 03, 2006
08:11:44
Thermal Dynamics
DDWG No:
Sheetof
SupersedesScale
Date:
Drawn: References
DateByRevisionsRev PCB No:Assy No:
Information Proprietary to THERMAL DYNAMICS CORPORATION.Not For Release, Reproduction, or Distribution without Written Consent.
NOTE: UNLESS OTHERWISE SPECIFIED -1. RESISTOR VALUES ARE EXPRESSED IN OHMS, 1/4W 5%.2. CAPACITOR VALUES ARE EXPRESSED IN MICROFARADS (uF). Chk: App:
TITLE:Last Modified:
SizeSCHEMATIC,
ThermalDynamics
AA
42X1203Wednesday, October 31, 2007
2 2
Industrial Park #2West Lebanon NH 03784603-298-5711
100-Amp Power Supply 208-230/460V (Resistor)
Tuesday, October 03, 2006
08:11:44
Thermal Dynamics
D
KEY PLUG
CN11 34 CKT CN10 26 CKT
J36 34 CKT J35 26 CKT
RIBBON CABLE
TEST SOCKET
RIBBON CABLE
TEST SOCKET
(E2)
(E2)
(E4)
(F4)
POWER SUPPLY REAR PANEL
TB1
TB2
DIVIDED ARC V +DIVIDED ARC V -
REMOTE ANALOG CURRENT CONTROL -REMOTE ANALOG CURRENT CONTROL +
E-STOP -E-STOP +
PILOT ON OUTPUT
HOLD START -HOLD START +PREFLOW ON -PREFLOW ON +
OK to MOVE -
OK to MOVE +
MOMENTARY START / STOP
START / STOP
STOP
START
+
-
JUMPER IN REMOTEHMI
PLASMA ENABLE
PCB6 DISPLAYWK-5603
START / STOP
DIVIDED ARC VOLTS
REMOTE ANALOG CURRENT CONTROL
OK TO MOVE
DAT
Signal - Master ID Used to identify resistor pilot unit
Signal - Basic IDUsed to identifyGCM 1000 present
RIBBON CABLE SIGNALS / = active low digital signal
CN10-J35 - 26 Ckt Ribbon Cable
2- Cut Demand4- Pilot Demand6- / Start7- / Start2 9- / Pilot Enable10- / HF Enable12- / Pump Enable13- / Fan Enable15- / DC Indicator16- / Over Temperature Indicator18- / Gas-Coolant OK Indicator19- / Status Lamp
CN11-J36 - 34 Ckt Ribbon Cable
1- Output Current Signal 3- / Arc Transferred (CSR)4- / Pilot On 6- Coolant Flow (freq)7- Coolant Temp (analog)9- / Temp OK (Inverter/Chopper)10- / Coolant Level OK12- Missing Phase13- / Ready to Operate15- / Input Volts OK16- / Inverter OCR18- / PS ID "00*"19- / PS ID "0*0"20- / PS ID "*00"21- E-Stop22- E-Stop29,31,33- 24 VAC Supply30,32,34- 24 VAC Return
ECO-B402 DAT 2/26/07ECO-B448 DAT 4/13/07AB
(A9 SHT1)
(B9 SHT1)
(C9 SHT1)
(E2)
INTERNAL TERMINAL STRIP TB3
(C9, sht 1)
(A9, sht 1)
UNDIVIDED ARC VOLTSFOR HEIGHT CONTROLS
24 VAC @ 1A
120 VAC @ 100ma.
(Not in all units)
ECO-B646 GAC 10/31/07AC
GREEN GASGREEN GAS88
11
1K1K
33
J4J4
1
3
5
7
44
GAS ONGAS ON
1010
REDSTATUS
REDSTATUS
GREEN ACGREEN AC
88
1212
55
33
J15-CNCJ15-CNC1
2
3
4
5
6
7
8
9
10
11
12
13
14
J55-GCMJ55-GCM12345678910111213141516171819202122232425262728293031323334353637
TP1TP1
CN23CN23
1
2
3
4
5
6
77
J8J8
1
2
3
4
TP11TP11
1212
1010
J9J9 1 2 3 4 5 6
J7J7
1
2
3
4
5
6
7
8
9
55
77
K6K6K6-1K6-1
11
99
22 J1J11
2
3
4
5
6
7
8
9
1212
E-STOPE-STOP
J6J6 1 5 8
33
100K100K
99
77
1010
YELLOW TEMPYELLOW TEMP
22
44
J5J51
2
3
4
5
55
PSRPSR
1111
J59-RASJ59-RAS1
2
3
4
5
6
7
8
91011121314
99
11
CN24CN24
1
2
3
4
5
6
44
66
J54-REMOTE HMIJ54-REMOTE HMI
1
2
3
4
5
6
7
1111
66
1111
22
66
TP12TP12
88
GREEN DCGREEN DC
100K100K
Art # A-07129_AB
APPENDIX A-24 Manual 0-4748
ULTRA-CUT 100
APPENDIX 10: Schematic, CCC 400V, w/ Chopper Pilot
1
1
2
2
3
3
4
4
5
5
A
B
C
D
E
F
-15V
INP
UT_
NG
+5V
GN
D
+15V+1
5V
+15V
MIS
SIN
G_P
HA
SE
/ 200
PG
ND
1/ 4
00
/ 400
PG
ND
2400
200
CO
M
L1
L2
L3
E
+15V
+12VDC +12VDC
+12VDC
To PC
B7 C
N2-5
To PC
B7 C
N2-4
To PC
B7 C
N2-2
To PC
B7 C
N2-1
FAN
+ (24 VD
C)
FAN
- (24 VD
C)
To PC
B7 TB
3
To T1 PR
I - 0
V_C
HA
NG
E P
CB
400
V o
nly
100A INVERTER MODULEP_GND
VAC_IN
LINE to LINE, LINE TO GND CAPS & VARISTORS
PCB 1WK-5630
INPUT POWER INDICATORREAR PANEL
INPUT POWER INDICATORINTERNAL
16 CKT RIBBON CABLE
PCB 5 WK-5602 (partial)
MISSING PHASE
(pulses)<
LED1 DIM = LOW, BRIGHT = OKLED2 DIM = OK, BRIGHT = FAULTLED3 DIM = OK, BRIGHT = FAULTLED4 OFF = OK, ON = FAULTLED5 OFF = OK, ON + FAULT
CN6 16 CKT
BIAS SUPPLY FOR PCB5
(F2 -Sht2)
DC FAN POWER
CN1 CN5 CN6
CN4 CN5 CN6
(A1 Sht2)
(A1 Sht2)
(A1 Sht 2)
(A1 Sht 2)
(A2 Sht 2)
(A2 Sht 2)
CN6 16 CKTON / OFF
PCB3 WK-5694
PCB4 WK-5604
VAC_IN
P_GND
BIAS SUPPLY PCB
DETECTOR PCB
INTERFACE PCB
FILTER PCB
--400--
400 VAC 3 Phase
RIBBON CABLE SIGNALS
CN6 - 16 Ckt Ribbon Cable
2,4- I_REF (Scaled Cut Demand)5- PS_START (Start)6- REDUNDANT_START (Start2)8- INV_READY9- / PS_START disabled by Input_NG12- / OCR13- / PS_START disabled by OCR14- /TEMP_ERR15- / PS_START disabled by Temp _Err
CN32CN32 1 2 3 4
LED3INPUT NGLED3INPUT NG
N2N2
TB2TB2P1P1
TB1TB1
1 2
34
CN1CN1 1 5 8
CN7CN7 1 2 3 4 5
LED5ERRORLED5ERROR
P (+)P (+)
CN18CN18 1 2 3
RY2RY2
TB3TB3
C.P1C.P1
- +- +
3
1
2
4
CN3CN3 1 2
MC1-AMC1-A
CN4CN4 1 2 3 4
NE2NE2
MC1-CMC1-CTB4TB4
N (-)N (-)
CN32CN32 1 2 3 4
CN2CN2 12
LED2MISSING PHASE
LED2MISSING PHASE
CN1-not usedCN1-not used
1 2 3 4
CN7CN7 1 2 3 4 5
CN4CN4 14
CN10CN10 1 2
++
RR ++
SS
NE1NE1
200V200V
CN3CN31
4
TT
ACAC
AC
+-
D1
ACAC
AC
+-
D1
CN2CN21
2
3
CN1CN1
1
2
3
4
5
6
7
- +- +
3
1
2
4
+
RY2
RY2
+
RY2
RY2
CN4 - PCB12CN4 - PCB12
1 2 3 4
+
-
+
-
1
2
3
45
6
1 2
34
CN2-400V
6
CN2-400V
6
1234
MC1-BMC1-B
INRUSHINRUSH
CN2CN2 1 2 3
TB1TB1
C1C1
Art # A-06998_AD
Manual 0-4748 A-25 APPENDIX
ULTRA-CUT 100
Art # A-06998_AD
6
6
7
7
8
8
9
9
10
10
A
B
C
D
E
F
N2
P1
+12V
-12V
SIG
NAL
CO
MM
ON
I_se
nseP
Iref_
G
GN
DW
P_e
na
GN
D_C
TEM
P_C
GN
DW
Isen
se_W
-15V
w+1
5Vw
+15V
w-1
5Vw
Isen
se_W
GN
DP
I_se
nseP
GN
DP
Iref_
GP
_ref
P_e
na
P_r
ef
GN
D_C
TEM
P_C
TORCH (-)
PILOT
WORK (+)
WORK
PILOT (TIP) VOLTS
NEG ARC VOLTS
DWG No:
Sheetof
SupersedesScale
Date:
Drawn: References
DateByRevisionsRev PCB No:Assy No:
Information Proprietary to THERMAL DYNAMICS CORPORATION.Not For Release, Reproduction, or Distribution without Written Consent.
NOTE: UNLESS OTHERWISE SPECIFIED -1. RESISTOR VALUES ARE EXPRESSED IN OHMS, 1/4W 5%.2. CAPACITOR VALUES ARE EXPRESSED IN MICROFARADS (uF). Chk: App:
TITLE:Last Modified:
SizeSCHEMATIC,
ThermalDynamics
AA
42X1212Friday, September 25, 2009
1 2
Industrial Park #2West Lebanon NH 03784603-298-5711
100A Power Supply 400V CCC (Chopper)
Tuesday, October 03, 2006
08:11:44
Thermal Dynamics
DDWG No:
Sheetof
SupersedesScale
Date:
Drawn: References
DateByRevisionsRev PCB No:Assy No:
Information Proprietary to THERMAL DYNAMICS CORPORATION.Not For Release, Reproduction, or Distribution without Written Consent.
NOTE: UNLESS OTHERWISE SPECIFIED -1. RESISTOR VALUES ARE EXPRESSED IN OHMS, 1/4W 5%.2. CAPACITOR VALUES ARE EXPRESSED IN MICROFARADS (uF). Chk: App:
TITLE:Last Modified:
SizeSCHEMATIC,
ThermalDynamics
AA
42X1212Friday, September 25, 2009
1 2
Industrial Park #2West Lebanon NH 03784603-298-5711
100A Power Supply 400V CCC (Chopper)
Tuesday, October 03, 2006
08:11:44
Thermal Dynamics
DDWG No:
Sheetof
SupersedesScale
Date:
Drawn: References
DateByRevisionsRev PCB No:Assy No:
Information Proprietary to THERMAL DYNAMICS CORPORATION.Not For Release, Reproduction, or Distribution without Written Consent.
NOTE: UNLESS OTHERWISE SPECIFIED -1. RESISTOR VALUES ARE EXPRESSED IN OHMS, 1/4W 5%.2. CAPACITOR VALUES ARE EXPRESSED IN MICROFARADS (uF). Chk: App:
TITLE:Last Modified:
SizeSCHEMATIC,
ThermalDynamics
AA
42X1212Friday, September 25, 2009
1 2
Industrial Park #2West Lebanon NH 03784603-298-5711
100A Power Supply 400V CCC (Chopper)
Tuesday, October 03, 2006
08:11:44
Thermal Dynamics
D
RAS
PCB 8WK-5687RC &RF CAPS
HALL SENSOR
HALL SENSOR
PILOT REG.(CHOPPER )PCB1WK-5750
BIASPOWER
PILOT REGULATOR (CHOPPER)
< /O
VE
R_T
EM
P
> P
_DE
M (
P_I
ref)
> P
_Ena
ble
(P_e
na)PILOT REG.
(CHOPPER )PCB2WK-5754
I_D
ET
I_S
E<<
PILOT CURRENT SIGNAL <
WORK CURRENT SIGNAL <
/ OVERTEMP <
/PILOT ENABLE >
PILOT DEMAND >
C1 Capacitor, 0.1 uf, 1250 VDC (D2, Sht 2)C2 Capacitor, 2 uf, 430VAC (A9, Sht 1)
C.P1 Circuit protector/ON-OFF SW (B2, Sht 1) 15A, 460V, 3PC.P2 Circuit protector 2.5A 125V (D2, Sht 1)C.P3 Circuit protector 3.15A 125V (D2, Sht 1)C.P4 Circuit protector 10A 125V (E2, Sht 1)C.P5 Circuit protector 2.5A 125V (E2, Sht 1)C.P6 Circuit protector 2.5A 125V (F2, Sht 1)C.P7 Circuit protector 5A 125V (E2, Sht 1)C.P8 Circuit protector 3.15A 125V (F3, Sht 1)
D1 Diode Bridge 20A, 1600V, 3P (D2, Sht 1)D2 Diode, Dual, 2x100A, 600V (B8, Sht 1)
FAN1 Fan, Coolant, 24 VDC (F4, Sht 2)FAN3 Fan, Chopper, 24 VDC (A8, Sht 1)
FL1 Flow sensor (B5, Sht 2)
HCT1 Hall Current Sensor, Pilot (B8, Sht 1)HCT2 Hall Current Sensor, Work (C9, Sht 1)
LSW1 Level SW, coolant, NC (B5, Sht 2)
MC1 Contactor, 3P ,Inv 1 input, Coil (B3, Sht 2) " Contacts (A2, B2, Sht 1) " Aux Contact (B3, Sht 2)MC2 Contactor, pilot, Coil (B3, Sht 2) " Contacts (C8, Sht 1)
MOT1 Motor, Pump 200VAC, 1P (E4, Sht 2)
NE1 Neon indicator, rear panel, 220VAC (C1, Sht 1)
NE2 Neon indicator, internal, 220VAC (C1, Sht 1)
R6 Resistor, 20K ,30W (A8, Sht 1)R7 Resistor, 1K ,30W (E2, Sht 2)R9 Resistor, 50 ,40W (A9, Sht 1)
T1 Aux Transformer (D-F1, Sht 2)
TH1 Thermal Sensor, coolant return (B5, Sht 2)
COMPONENT LOCATOR
(C7, Sht 2)
Power SupplyRear Panel
DAT
ECO-B402 DAT 2/26/07
AB ECO-B448 DAT 4/13/07
(C7 & A9,Sht 2)
(C7 & A9,Sht 2)
ECO-B646 GAC 10/31/07ACECO-B1391 DAT 4-24-09AD
AE DATECO-B1535 9-25-09
CN2CN2 1 2 3 4
TB1TB1
CN4CN4 1 2 3
HCT2HCT2
1 2 3 4
TB5TB5
TB2TB2
D2D2
1A1
2K1
3A2
4K2
TB1TB1
TB2TB2
HCT1HCT1
1 2 3 4
CN2CN2 123
CN5CN5 1234
CN5CN5 1 2 3 4
CN1CN1
12
WORKWORK
CN33CN33 1 2 3 4
CN3CN3 1CN2CN2 1 2 3
MC2-AMC2-A
CN3CN3 12
MC2-BMC2-B
CN4CN4 1 2 3 4 5
TB4TB4
MC2-CMC2-C
CN17CN17 1 2 3
CN1CN11234
LED4CHOPPER TEMP
LED4CHOPPER TEMP
CN4CN4 12345
CN1CN11234
CN7CN7 12345
FAN3FAN3
+-
R620K
30W
R620K
30W
THS1SW_TEMP_NC
THS1SW_TEMP_NC
CN6CN6 123
R950R950
CN9CN9 1 2
C22 UFC22 UF
CN8CN8 12
TB3TB3
CN3CN3 1 2 3 4
APPENDIX A-26 Manual 0-4748
ULTRA-CUT 100
APPENDIX 10: Schematic, CCC 400V, w/ Chopper PilotCont.
1
1
2
2
3
3
4
4
5
5
A
B
C
D
E
F
400
AC
120 @ 1A
AC13V @ 2A
/PUMP
+15V
+15V
400
/FAN
200-not used
/RAS
COM200400
COM
AC200V @ 3A
200
+15V
0V-A (24V ret)
To PC
B7 C
N2-1
AC120V-GCM
0V-B (120V ret)
To PC
B7 C
N2-2
To PC
B7 C
N2-4
To PC
B7 C
N2-5
To PC
B7 TB
3
0V-RAS
AC120V-RAS
FAN + (24 VDC)
DC 15VDC 0V
FAN - (24 VDC)
AC24V-GCM
To T1 PR
I - 0(F1 Sht 1)
(F1 Sht 1)
PILOTCONTACTOR
INPUTCONTACTOR
(D9, A10)
PILOT (TIP) VOLTAGE
COOLANT TEMP(ON COOLANT RETURN)
ISOLATED COMM+16 to +18VDC
CCM MODULE
FROM CN18 PCB3 sht 1
+15VDC_ISO-15VDC_ISO
(F1 Sht 1)
(F1 Sht 1)
(F2 Sht 1)
ISOLATEDVOLTAGES
(D9, A10)
(F2 Sht 1)
NEG ARC VOLTS
SW6 - OK to MOVE CONTACTS / VOLTS
SW11 - ANALOG CURRENT SELECT "B" DEFAULT, "A" REMOTESW12 - DIVIDED ARC V RATIO SELECT
SW13 - FACTORY ONLY
PCB7 WK-5628RELAY PCB
CIRCUIT COMM (GND)
(C9)
PCB 5 WK-5602 (partial) INTERFACE PCB
PILOT DEM to PS
ANALOG DEM to CPU
CUT DEM to PS
TO AC
INDICATOR
(on PCB6)
29-41 VDC +15VDC+5VDC-15VDC
COOLANT FLOW (freq) *
I/O PCB
CPU PCB
RY11RY11
CN2CN2 1 2 3 4 5
LED1LEVELLED1LEVEL
1
2
TP12TP12
D26 HOLD_STARTD26 HOLD_START
D12 STATUS CODE D12 STATUS CODE
FAN1FAN1
+ -
D9 GAS_OND9 GAS_ON
C.P7C.P7
TP18TP18
1
2
CN8CN8 1 2 3 4
C.P3C.P3
1 2 3
CN9CN91
2
3
D11 INITIALIZING / PROGRAMMINGD11 INITIALIZING / PROGRAMMING
D28 CNC_PREFLOWD28 CNC_PREFLOW
TP8TP8
D8 OK_CNCD8 OK_CNC
+
RY10
+
RY10
1 2
CN1CN1 1 2
TP2TP2
LSW1-1
SW_LIQUID_LEVEL_NC
LSW1-1
SW_LIQUID_LEVEL_NC
CN9CN91
2
3
4
5
MC2MC2
TP6TP6
CN10CN101
2
3
D13 +5VD13 +5VCN12CN12
1
2
CN5CN51
2
3
4
5
6
TP7TP7
D15 PSRD15 PSR
MC1 AUXMC1 AUX
1 2
CN6CN61
2
3
4R8
1K 30WR8
1K 30W
TB5TB5
RY3RY3
TP17TP17
RY4RY4
CN11CN11
1
2
CN7CN71
2
3
4
D21 CNC_E-STOPD21 CNC_E-STOP
CN3CN31
2
3
RY5RY5
1 2 3
TB1TB1
RY7RY7
1
2
3
TP16TP16
C.P5C.P5
+V
GND
SIG
FL1FLOW_TURBINE_PULSE
+V
GND
SIG
FL1FLOW_TURBINE_PULSE
R BG
C.P2C.P2
TP5TP5
tTH1
tTH1
CN14CN14 1 2
D23 CNC_STARTD23 CNC_START
C.P6C.P6
TP14TP14
+RY1
+RY1
CN12CN12 1 2 3
CN2CN2
1
2
TB2TB2
TB4TB4
MC1MC1
T1T1460
220
0,
13
0,,
100
0.
200
0..
110
0...
120.
0_
24.
0__
24_
0___
120.
0___
1
2
3
TP15TP15
PUMP
MOT1
PUMP
MOT1
' .
TP9TP9
RY9RY9
TP4TP4
CN13CN13 1 2 3
TB3TB3
C.P8C.P8
C.P4C.P4
TP3TP3
CN8CN81
2
3
4
CN4CN41
2
3
TP10TP10
D7 E-STOP_PSD7 E-STOP_PS
Art # A-06999_AD
Manual 0-4748 A-27 APPENDIX
ULTRA-CUT 100
Art # A-06999_AD
6
6
7
7
8
8
9
9
10
10
A
B
C
D
E
F
PLASMA ENABLE
PRESS OK (GCM 1000)
24V
AC
24 V
AC
RE
T
PLASMA ENABLE
+15V/ AC
/ TEMP
/ STATUS/ DC
/ GAS - COOLANT
POT HI (GCM1000)
POT WIPER (GCM1000)
POT LOW (GCM 1000)
- ARC V
- ARC V
WORK
DC 15V
DC 0V
AC120V-RAS
0V-RAS (120V ret)
0V-A (24V ret)
NEG ARC VOLTS
NE
G A
RC
VO
LTS
AC24V-GCM
AC24V-GCM
0V-A (24V ret)
AC120V-GCM
0V-B (120V ret)
PIL
OT
(TIP
) VO
LTS
0V-B (120V ret)
WO
RK
AC120V-GCM
DWG No:
Sheetof
SupersedesScale
Date:
Drawn: References
DateByRevisionsRev PCB No:Assy No:
Information Proprietary to THERMAL DYNAMICS CORPORATION.Not For Release, Reproduction, or Distribution without Written Consent.
NOTE: UNLESS OTHERWISE SPECIFIED -1. RESISTOR VALUES ARE EXPRESSED IN OHMS, 1/4W 5%.2. CAPACITOR VALUES ARE EXPRESSED IN MICROFARADS (uF). Chk: App:
TITLE:Last Modified:
SizeSCHEMATIC,
ThermalDynamics
AA
42X1212Friday, September 25, 2009
2 2
Industrial Park #2West Lebanon NH 03784603-298-5711
100A Power Supply 400V CCC (Chopper)
Tuesday, October 03, 2006
08:11:44
Thermal Dynamics
DDWG No:
Sheetof
SupersedesScale
Date:
Drawn: References
DateByRevisionsRev PCB No:Assy No:
Information Proprietary to THERMAL DYNAMICS CORPORATION.Not For Release, Reproduction, or Distribution without Written Consent.
NOTE: UNLESS OTHERWISE SPECIFIED -1. RESISTOR VALUES ARE EXPRESSED IN OHMS, 1/4W 5%.2. CAPACITOR VALUES ARE EXPRESSED IN MICROFARADS (uF). Chk: App:
TITLE:Last Modified:
SizeSCHEMATIC,
ThermalDynamics
AA
42X1212Friday, September 25, 2009
2 2
Industrial Park #2West Lebanon NH 03784603-298-5711
100A Power Supply 400V CCC (Chopper)
Tuesday, October 03, 2006
08:11:44
Thermal Dynamics
DDWG No:
Sheetof
SupersedesScale
Date:
Drawn: References
DateByRevisionsRev PCB No:Assy No:
Information Proprietary to THERMAL DYNAMICS CORPORATION.Not For Release, Reproduction, or Distribution without Written Consent.
NOTE: UNLESS OTHERWISE SPECIFIED -1. RESISTOR VALUES ARE EXPRESSED IN OHMS, 1/4W 5%.2. CAPACITOR VALUES ARE EXPRESSED IN MICROFARADS (uF). Chk: App:
TITLE:Last Modified:
SizeSCHEMATIC,
ThermalDynamics
AA
42X1212Friday, September 25, 2009
2 2
Industrial Park #2West Lebanon NH 03784603-298-5711
100A Power Supply 400V CCC (Chopper)
Tuesday, October 03, 2006
08:11:44
Thermal Dynamics
D
DAT
ECO-B402 DAT 2/26/07
AB ECO-B448 DAT 4/13/07AC ECO-B646 GAC 10/31/07
ECO-B1391 DAT 4-24-09ADAE DAT
(E2)
MOMENTARY START / STOP
START / STOP
* REMOTE MARKING -
STOP
START
* Only in CCM w/ 19X2634 I/O PCB. Remote Marking only for DFC 3000 (not isolated)
Rx-
Tx+
Rx+
Tx-
Signal & GNDIsolated from Plasma Supply
INTERNAL TERMINAL STRIP TB3
KEY PLUG
TB1
TB2
(C9, sht 1)
+
-
RS 485 (2 wire) uses Tx+ & Tx- only(used for TSC 3000)
Signal - Basic IDUsed to identifyGCM 1000 present
RIBBON CABLE
TEST SOCKET
RS 422 (4 wire) connect TX+ to RX+ of CNC, Tx- to Rx- of CNC
DIVIDED ARC V +
(E2)
(E2)
DIVIDED ARC V -
REMOTE ANALOG CURRENT CONTROL -REMOTE ANALOG CURRENT CONTROL +
JUMPER IN REMOTEHMI
** RS 485 / 422 on CPU board19X2554 only.
(A9, sht1)
(B9, sht1)
(C9, sht1)
TB3
KEY PLUG
Was 7 pin changed to 14 pin in 2009
(E4)
(F4)
CN11 34 CKT CN10 26 CKT
START / STOP
DIVIDED ARC VOLTS
PILOT ON OUTPUT
REMOTE ANALOG CURRENT CONTROL
* OK2
Iso
J36 34 CKT
PCB6 DISPLAYWK-5603
JUMPERfor 2 WIRE(RS485 only) wire to A & B
4W4W
2W
JUMPERfor 4 WIRE usesTX+, TX-RX+, RX-
J35 26 CKT
J14
J14
2W
SW14SW14 - LINE TERMINATIONnormally on(refer to manual)
* OK2
RIBBON CABLE
5
9876
123
4
SW10-ADDRESSnormally 0(refer tomanual)
0
TEST SOCKET
HOLD START -HOLD START +
(A9, sht 1)
UNDIVIDED ARC VOLTSFOR HEIGHT CONTROLS
* +10VDC @ 10 ma.(for CC pot high)
OK TO MOVE
GND
GND
& CNC COMM
PREFLOW ON -PREFLOW ON +
PLASMA ENABLE
24 VAC @ 1A
120 VAC @ 100ma.
(Not in all units)
OK to MOVE -
POWER SUPPLY REAR PANEL
E-STOP -E-STOP +
* REMOTE MARKING +
RIBBON CABLE SIGNALS / = active low digital signal
CN10-J35 - 26 Ckt Ribbon Cable
2-Cut Demand4-Pilot Demand6-/ Start7-/ Start2 9-/ Pilot Enable10-/ HF Enable12-/ Pump Enable13-/ Fan Enable15-/ DC Indicator16-/ Over Temperature Indicator18-/ Gas-Coolant OK Indicator19-/ Status Lamp
CN11-J36 - 34 Ckt Ribbon Cable
1- Output Current Signal 3- / Arc Transferred (CSR)4- / Pilot On 6- Coolant Flow (freq)7- Coolant Temp (analog)9- / Temp OK (Inverter/Chopper)10- / Coolant Level OK12- Missing Phase13- / Ready to Operate15- / Input Volts OK16- / Inverter OCR18- / PS ID "00*"19- / PS ID "0*0"20- / PS ID "*00"21- E-Stop22- E-Stop29,31,33- 24 VAC Supply30,32,34- 24 VAC Return
Rx-
Tx+
Rx+
Tx-
OK to MOVE +
ECO-B1535 9-25-09
88
66
33
GAS ONGAS ON
OK2 *OK2 *
GREEN2 DCGREEN2 DC
GREEN1 GASGREEN1 GAS
1111
99
J9J9 1 2 3 4 5 6
2211
YELLOW TEMPYELLOW TEMP
REDSTATUS
REDSTATUS
77
TP1TP1
33
44
J7J7
1
2
3
4
5
6
7
8
9
100K14100K14
1K1K
22
CN24CN24
1
2
3
4
5
6
55
11
88
99
K7-1K7-1
66
77
22
TP11TP11
J54-REMOTE HMIJ54-REMOTE HMI
1
2
3
4
5
6
7
8
9
10
11
12
13
14
J1J11
2
3
4
5
6
7
8
9
1111
J8J8
1
2
3
4
J4J4
1
3
5
7
J5J51
2
3
4
5
J6 **J6 **1
2
3
4
5
6
1010
E-STOPE-STOP
77
55
22
1111
PSRPSR
K6K6 J59-RASJ59-RAS1
2
3456
7
8
9
1011121314
1212
44
GREEN ACGREEN AC
1212
1212
J55-GCMJ55-GCM12345678910111213141516171819202122232425262728293031323334353637
TP13TP13
100K100K
1010
11
66
88
44
55
J6J6 1 5 8
J15-CNCJ15-CNC1
2
3
4
5
6
7
8
9
10
11
12
13
14
CN23CN23
1
2
3
4
5
6
33
11
99
1010
APPENDIX A-28 Manual 0-4748
ULTRA-CUT 100
APPENDIX 11: Schematic, CE 400V, Chopper Pilot
Art # A-06996_AD
1
1
2
2
3
3
4
4
5
5
A
B
C
D
E
F
-15V
INP
UT_
NG
+5V
GN
D
+15V+1
5V
+15V
MIS
SIN
G_P
HA
SE
/ 200
PG
ND
1/ 4
00
/ 400
PG
ND
2400
200
CO
M
L1
L2
L3
E
+15V
+12VDC +12VDC
+12VDC
To PC
B7 C
N2-5
To PC
B7 C
N2-4
To PC
B7 C
N2-2
To PC
B7 C
N2-1
FAN
+ (24 VD
C)
FAN
- (24 VD
C)
To PC
B7 TB
3
To T1 PR
I - 0
V_C
HA
NG
E P
CB
400
V o
nly
100A INVERTER MODULEP_GND
VAC_IN
LINE to LINE, LINE TO GND CAPS & VARISTORS
PCB 1WK-5630
INPUT POWER INDICATORREAR PANEL
INPUT POWER INDICATORINTERNAL
16 CKT RIBBON CABLE
PCB 5 WK-5602 (partial)
MISSING PHASE
(pulses)<
LED1 DIM = LOW, BRIGHT = OKLED2 DIM = OK, BRIGHT = FAULTLED3 DIM = OK, BRIGHT = FAULTLED4 OFF = OK, ON = FAULTLED5 OFF = OK, ON + FAULT
CN6 16 CKT
BIAS SUPPLY FOR PCB5
(F2 -Sht2)
DC FAN POWER
CN1 CN5 CN6
CN4 CN5 CN6
(A1 Sht2)
(A1 Sht2)
(A1 Sht 2)
(A1 Sht 2)
(A2 Sht 2)
(A2 Sht 2)
CN6 16 CKT
ON / OFF
PCB3 WK-5694
PCB4 WK-5604
VAC_IN
P_GND
BIAS SUPPLY PCB
DETECTOR PCB
INTERFACE PCB
FILTER PCB
--400--
400 VAC 3 Phase
RIBBON CABLE SIGNALS
CN6 - 16 Ckt Ribbon Cable
2,4- I_REF (Scaled Cut Demand)5- PS_START (Start)6- REDUNDANT_START (Start2)8- INV_READY9- / PS_START disabled by Input_NG12- / OCR13- / PS_START disabled by OCR14- /TEMP_ERR15- / PS_START disabled by Temp _Err
MC1-CMC1-C
RY2RY2
ACAC
AC
+-
D1
ACAC
AC
+-
D1
CN1CN1
1
2
3
4
5
6
7
TB4TB4
+
RY2
RY2
+
RY2
RY2
200V200V
L1L1
TT
CN3CN31
4
CN32CN32 1 2 3 4
CN2-400V
6
CN2-400V
6
1234
L7L7
CN4 - PCB12CN4 - PCB12
1 2 3 4
C1C1
CN2CN2 12
LED3INPUT NGLED3INPUT NG
MC1-BMC1-B
N2N2
CN1-not usedCN1-not used
1 2 3 4
LED2MISSING PHASE
LED2MISSING PHASE
+
-
+
-
1
2
3
45
6
1 2
34
EMIFILTER
NFC1
EMIFILTER
NFC1
L1
L2
L3
L4
L6
L5
TB3TB3 ++
CN2CN21
2
3
SS
CN1CN1 1 5 8
L3L3
CN7CN7 1 2 3 4 5
MC1-AMC1-A
CN7CN7 1 2 3 4 5
CN4CN4 14
LED5ERRORLED5ERROR
1 2
34
INRUSHINRUSH
NE1NE1
CN2CN2 1 2 3
P (+)P (+)
L2L2
CN4CN4 1 2 3 4
C.P1C.P1
L4L4
NE2NE2
CN10CN10 1 2
N (-)N (-)
- +- +
3
1
2
4
L5L5
CN32CN32 1 2 3 4
TB2TB2 ++
RR
P1P1
CN3CN3 1 2
CN18CN18 1 2 3
L6L6
- +- +
3
1
2
4
TB1TB1
TB1TB1
Manual 0-4748 A-29 APPENDIX
ULTRA-CUT 100
Art # A-06996_AD
6
6
7
7
8
8
9
9
10
10
A
B
C
D
E
F
N2
P1
+12V
-12V
SIG
NAL
CO
MM
ON
I_se
nseP
Iref_
G
GN
DW
P_e
na
GN
D_C
TEM
P_C
GN
DW
Isen
se_W
-15V
w+1
5Vw
+15V
w-1
5Vw
Isen
se_W
GN
DP
I_se
nseP
GN
DP
Iref_
GP
_ref
P_e
na
P_r
ef
GN
D_C
TEM
P_C
TORCH (-)
PILOT
WORK (+)
WORK
PILOT (TIP) VOLTS
NEG ARC VOLTS
DWG No:
Sheetof
SupersedesScale
Date:
Drawn: References
DateByRevisionsRev PCB No:Assy No:
Information Proprietary to THERMAL DYNAMICS CORPORATION.Not For Release, Reproduction, or Distribution without Written Consent.
NOTE: UNLESS OTHERWISE SPECIFIED -1. RESISTOR VALUES ARE EXPRESSED IN OHMS, 1/4W 5%.2. CAPACITOR VALUES ARE EXPRESSED IN MICROFARADS (uF). Chk: App:
TITLE:Last Modified:
SizeSCHEMATIC,
ThermalDynamics
AA
42X1211Friday, September 25, 2009
1 2
Industrial Park #2West Lebanon NH 03784603-298-5711
100A Power Supply 400V CE (Chopper)
Tuesday, October 03, 2006
08:11:44
Thermal Dynamics
DDWG No:
Sheetof
SupersedesScale
Date:
Drawn: References
DateByRevisionsRev PCB No:Assy No:
Information Proprietary to THERMAL DYNAMICS CORPORATION.Not For Release, Reproduction, or Distribution without Written Consent.
NOTE: UNLESS OTHERWISE SPECIFIED -1. RESISTOR VALUES ARE EXPRESSED IN OHMS, 1/4W 5%.2. CAPACITOR VALUES ARE EXPRESSED IN MICROFARADS (uF). Chk: App:
TITLE:Last Modified:
SizeSCHEMATIC,
ThermalDynamics
AA
42X1211Friday, September 25, 2009
1 2
Industrial Park #2West Lebanon NH 03784603-298-5711
100A Power Supply 400V CE (Chopper)
Tuesday, October 03, 2006
08:11:44
Thermal Dynamics
DDWG No:
Sheetof
SupersedesScale
Date:
Drawn: References
DateByRevisionsRev PCB No:Assy No:
Information Proprietary to THERMAL DYNAMICS CORPORATION.Not For Release, Reproduction, or Distribution without Written Consent.
NOTE: UNLESS OTHERWISE SPECIFIED -1. RESISTOR VALUES ARE EXPRESSED IN OHMS, 1/4W 5%.2. CAPACITOR VALUES ARE EXPRESSED IN MICROFARADS (uF). Chk: App:
TITLE:Last Modified:
SizeSCHEMATIC,
ThermalDynamics
AA
42X1211Friday, September 25, 2009
1 2
Industrial Park #2West Lebanon NH 03784603-298-5711
100A Power Supply 400V CE (Chopper)
Tuesday, October 03, 2006
08:11:44
Thermal Dynamics
D
RAS
PCB 8WK-5687RC &RF CAPS
HALL SENSOR
HALL SENSOR
PILOT REG.(CHOPPER )PCB1WK-5750
BIASPOWER
PILOT REGULATOR (CHOPPER)
< /O
VE
R_T
EM
P
> P
_DE
M (
P_I
ref)
> P
_Ena
ble
(P_e
na)PILOT REG.
(CHOPPER )PCB2WK-5754
I_D
ET
I_S
E<<
PILOT CURRENT SIGNAL <
WORK CURRENT SIGNAL <
/ OVERTEMP <
/PILOT ENABLE >
PILOT DEMAND >
C1 Capacitor, 0.1 uf, 1250 VDC (D2, Sht 2)C2 Capacitor, 2 uf, 430VAC (A9, Sht 1)
C.P1 Circuit protector/ON-OFF SW (C2, Sht 1) 15A, 460V, 3PC.P2 Circuit protector 2.5A 125V (D2, Sht 1)C.P3 Circuit protector 3.15A 125V (D2, Sht 1)C.P4 Circuit protector 10A 125V (E2, Sht 1)C.P5 Circuit protector 2.5A 125V (E2, Sht 1)C.P6 Circuit protector 2.5A 125V (F2, Sht 1)C.P7 Circuit protector 5A 125V (E2, Sht 1)C.P8 Circuit protector 3.15A 125V (F3, Sht 1)
D1 Diode Bridge 20A, 1600V, 3P (D2, Sht 1)D2 Diode, Dual, 2x100A, 600V (B8, Sht 1)
FAN1 Fan, Coolant, 24 VDC (F4, Sht 2)FAN3 Fan, Chopper, 24 VDC (A8, Sht 1)
FL1 Flow sensor (B5, Sht 2)
HCT1 Hall Current Sensor, Pilot (B8, Sht 1)HCT2 Hall Current Sensor, Work (C9, Sht 1)
L1 Toroid Core input common mode filter (A2, Sht 1)L2-7 Toroid Core common mode filter (B1, C1, Sht 1)L8 Toroid Core output common mode filter (A6, Sht 1)
LSW1 Level SW, coolant, NC (B5, Sht 2)
MC1 Contactor, 3P ,Inv 1 input, Coil (B3, Sht 2) " Contacts (A2, B2, Sht 1) " Aux Contact (B3, Sht 2)MC2 Contactor, pilot, Coil (B3, Sht 2) " Contacts (C8, Sht 1)
MOT1 Motor, Pump 200VAC, 1P (E4, Sht 2)
NE1 Neon indicator, rear panel, 220VAC (C1, Sht 1)NE2 Neon indicator, internal, 220VAC (D1, Sht 1)
NFC1 Noise Filter, EMI, input (A2, Sht 1)
R6 Resistor, 20K ,30W (A8, Sht 1)R7 Resistor, 1K ,30W (E2, Sht 2)R9 Resistor, 50 ,40W (A9, Sht 1)
T1 Aux Transformer (D-F1, Sht 2)
TH1 Thermal Sensor, coolant return (B5, Sht 2)
COMPONENT LOCATOR
(C7, Sht 2)
Power SupplyRear Panel
DAT
ECO-B402 DAT 2/26/07
AB ECO-B448 DAT 4/13/07
(C7 & A9,Sht 2)
(C7 & A9,Sht 2)
ECO-B646 GAC 10/31/07AC4-24-09DATECO-B1391AD
DATAE ECO-B1535 9-25-09
R950R950
TB1TB1
CN33CN33 1 2 3 4CN17CN17 1 2 3
CN2CN2 1 2 3 4CN9CN9 1 2
TB2TB2
CN3CN3 1 2 3 4
HCT1HCT1
1 2 3 4
D2D2
1A1
2K1
3A2
4K2
CN5CN5 1234
TB5TB5
MC2-AMC2-A
TB2TB2
CN3CN3 1
C22 UFC22 UF
MC2-BMC2-B
MC2-CMC2-C
CN8CN8 12
FAN3FAN3
+-
CN5CN5 1 2 3 4
R620K
30W
R620K
30W
CN4CN4 1 2 3
CN1CN11234
CN1CN11234
CN2CN2 1 2 3
L8L8
CN1CN1
12
CN2CN2 123
TB1TB1
THS1SW_TEMP_NC
THS1SW_TEMP_NC
HCT2HCT2
1 2 3 4
CN6CN6 123
CN4CN4 1 2 3 4 5
LED4CHOPPER TEMP
LED4CHOPPER TEMP
CN4CN4 12345
TB4TB4
CN3CN3 12
WORKWORK
TB3TB3
CN7CN7 12345
APPENDIX A-30 Manual 0-4748
ULTRA-CUT 100
APPENDIX 11: Schematic, CE 400V, Chopper Pilot Cont.
Art # A-06997_AD
1
1
2
2
3
3
4
4
5
5
A
B
C
D
E
F
400
AC
120 @ 1A
AC13V @ 2A
/PUMP
+15V
+15V
400
/FAN
200-not used
/RAS
COM200400
COM
AC200V @ 3A
200
+15V
0V-A (24V ret)
To PC
B7 C
N2-1
AC120V-GCM
0V-B (120V ret)
To PC
B7 C
N2-2
To PC
B7 C
N2-4
To PC
B7 C
N2-5
To PC
B7 TB
3
0V-RAS
AC120V-RAS
FAN + (24 VDC)
DC 15VDC 0V
FAN - (24 VDC)
AC24V-GCM
To T1 PR
I - 0(F1 Sht 1)
(F1 Sht 1)
PILOTCONTACTOR
INPUTCONTACTOR
(D9, A10)
PILOT (TIP) VOLTAGE
COOLANT TEMP(ON COOLANT RETURN)
ISOLATED COMM+16 to +18VDC
CCM MODULE
FROM CN18 PCB3 sht 1
+15VDC_ISO-15VDC_ISO
(F1 Sht 1)
(F1 Sht 1)
(F2 Sht 1)
ISOLATEDVOLTAGES
(D9, A10)
(F2 Sht 1)
NEG ARC VOLTS
SW6 - OK to MOVE CONTACTS / VOLTS
SW11 - ANALOG CURRENT SELECT "B" DEFAULT, "A" REMOTESW12 - DIVIDED ARC V RATIO SELECT
SW13 - FACTORY ONLY
PCB7 WK-5628RELAY PCB
CIRCUIT COMM (GND)
(C9)
PCB 5 WK-5602 (partial) INTERFACE PCB
PILOT DEM to PS
ANALOG DEM to CPU
CUT DEM to PS
TO AC
INDICATOR
(on PCB6)
29-41 VDC +15VDC+5VDC-15VDC
COOLANT FLOW (freq) *
I/O PCB
CPU PCB
+V
GND
SIG
FL1FLOW_TURBINE_PULSE
+V
GND
SIG
FL1FLOW_TURBINE_PULSE
R BG
RY3RY3
TP17TP17
CN9CN91
2
3
4
5
CN2CN2
1
2
D8 OK_CNCD8 OK_CNC
LED1LEVELLED1LEVEL
PUMP
MOT1
PUMP
MOT1
' .
CN14CN14 1 2
C.P7C.P7
TP18TP18
CN6CN61
2
3
4
CN5CN51
2
3
4
5
6
MC2MC2
R81K 30WR8
1K 30W
TB2TB2
+
RY10
+
RY10
1
2
CN9CN91
2
3
D23 CNC_STARTD23 CNC_START
TP10TP10
1 2
C.P6C.P6
C.P2C.P2
CN3CN31
2
3
1
2
3
RY4RY41
2
D7 E-STOP_PSD7 E-STOP_PS
TB4TB4
TP14TP14
TP6TP6
TP3TP3
TP9TP9
TP5TP5
RY9RY9
RY5RY5
TP2TP2
TP12TP12
D26 HOLD_STARTD26 HOLD_START
D11 INITIALIZING / PROGRAMMINGD11 INITIALIZING / PROGRAMMING
TP16TP16
CN10CN101
2
3
CN8CN81
2
3
4
CN1CN1 1 2
tTH1
tTH1
CN11CN11
1
2
MC1MC1
1 2 3
D12 STATUS CODE D12 STATUS CODE
TP4TP4
D28 CNC_PREFLOWD28 CNC_PREFLOW
CN13CN13 1 2 3
+RY1
+RY1
C.P5C.P5
TB1TB1
T1T1460
220
0,
13
0,,
100
0.
200
0..
110
0...
120.
0_
24.
0__
24_
0___
120.
0___
D13 +5VD13 +5V
TB3TB3
CN7CN71
2
3
4
1
2
3
TP7TP7
RY11RY11
TP8TP8
C.P8C.P8
FAN1FAN1
+ -
TB5TB5
TP15TP15
D15 PSRD15 PSR
CN8CN8 1 2 3 4
CN12CN121
2
C.P3C.P3
D9 GAS_OND9 GAS_ON
D21 CNC_E-STOPD21 CNC_E-STOP
LSW1-1
SW_LIQUID_LEVEL_NC
LSW1-1
SW_LIQUID_LEVEL_NC
CN4CN41
2
3
CN12CN12 1 2 3
MC1 AUXMC1 AUX
RY7RY7
1 2
1 2 3
C.P4C.P4
CN2CN2 1 2 3 4 5
Manual 0-4748 A-31 APPENDIX
ULTRA-CUT 100
Art # A-06997_AD
6
6
7
7
8
8
9
9
10
10
A
B
C
D
E
F
PLASMA ENABLE
PRESS OK (GCM 1000)
24V
AC
24 V
AC
RE
T
PLASMA ENABLE
+15V/ AC
/ TEMP
/ STATUS/ DC
/ GAS - COOLANT
POT HI (GCM1000)
POT WIPER (GCM1000)
POT LOW (GCM 1000)
- ARC V
- ARC V
WORK
DC 15V
DC 0V
AC120V-RAS
0V-RAS (120V ret)
0V-A (24V ret)
NEG ARC VOLTS
NE
G A
RC
VO
LTS
AC24V-GCM
AC24V-GCM
0V-A (24V ret)
AC120V-GCM
0V-B (120V ret)
PIL
OT
(TIP
) VO
LTS
0V-B (120V ret)
WO
RK
AC120V-GCM
DWG No:
Sheetof
SupersedesScale
Date:
Drawn: References
DateByRevisionsRev PCB No:Assy No:
Information Proprietary to THERMAL DYNAMICS CORPORATION.Not For Release, Reproduction, or Distribution without Written Consent.
NOTE: UNLESS OTHERWISE SPECIFIED -1. RESISTOR VALUES ARE EXPRESSED IN OHMS, 1/4W 5%.2. CAPACITOR VALUES ARE EXPRESSED IN MICROFARADS (uF). Chk: App:
TITLE:Last Modified:
SizeSCHEMATIC,
ThermalDynamics
AA
42X1211Friday, September 25, 2009
2 2
Industrial Park #2West Lebanon NH 03784603-298-5711
100A Power Supply 400V CE (Chopper)
Tuesday, October 03, 2006
08:11:44
Thermal Dynamics
DDWG No:
Sheetof
SupersedesScale
Date:
Drawn: References
DateByRevisionsRev PCB No:Assy No:
Information Proprietary to THERMAL DYNAMICS CORPORATION.Not For Release, Reproduction, or Distribution without Written Consent.
NOTE: UNLESS OTHERWISE SPECIFIED -1. RESISTOR VALUES ARE EXPRESSED IN OHMS, 1/4W 5%.2. CAPACITOR VALUES ARE EXPRESSED IN MICROFARADS (uF). Chk: App:
TITLE:Last Modified:
SizeSCHEMATIC,
ThermalDynamics
AA
42X1211Friday, September 25, 2009
2 2
Industrial Park #2West Lebanon NH 03784603-298-5711
100A Power Supply 400V CE (Chopper)
Tuesday, October 03, 2006
08:11:44
Thermal Dynamics
DDWG No:
Sheetof
SupersedesScale
Date:
Drawn: References
DateByRevisionsRev PCB No:Assy No:
Information Proprietary to THERMAL DYNAMICS CORPORATION.Not For Release, Reproduction, or Distribution without Written Consent.
NOTE: UNLESS OTHERWISE SPECIFIED -1. RESISTOR VALUES ARE EXPRESSED IN OHMS, 1/4W 5%.2. CAPACITOR VALUES ARE EXPRESSED IN MICROFARADS (uF). Chk: App:
TITLE:Last Modified:
SizeSCHEMATIC,
ThermalDynamics
AA
42X1211Friday, September 25, 2009
2 2
Industrial Park #2West Lebanon NH 03784603-298-5711
100A Power Supply 400V CE (Chopper)
Tuesday, October 03, 2006
08:11:44
Thermal Dynamics
D
DAT
ECO-B402 DAT 2/26/07
AB ECO-B448 DAT 4/13/07AC ECO-B646 GAC 10/31/07AD ECO-B1391 DAT 4-24-09
DATAE
(E2)
MOMENTARY START / STOP
START / STOP
* REMOTE MARKING -
STOP
START
* Only in CCM w/ 19X2634 I/O PCB. Remote Marking only for DFC 3000 (not isolated)
Rx-
Tx+
Rx+
Tx-
Signal & GNDIsolated from Plasma Supply
INTERNAL TERMINAL STRIP TB3
KEY PLUG
TB1
TB2
(C9, sht 1)
+
-
RS 485 (2 wire) uses Tx+ & Tx- only(used for TSC 3000)
Signal - Basic IDUsed to identifyGCM 1000 present
RIBBON CABLE
TEST SOCKET
RS 422 (4 wire) connect TX+ to RX+ of CNC, Tx- to Rx- of CNC
DIVIDED ARC V +
(E2)
(E2)
DIVIDED ARC V -
REMOTE ANALOG CURRENT CONTROL -REMOTE ANALOG CURRENT CONTROL +
JUMPER IN REMOTEHMI
** RS 485 / 422 on CPU board19X2554 only.
(A9, sht1)
(B9, sht1)
(C9, sht1)
TB3
KEY PLUG
Was 7 pin changed to 14 pin in 2009
(E4)
(F4)
CN11 34 CKT CN10 26 CKT
START / STOP
DIVIDED ARC VOLTS
PILOT ON OUTPUT
REMOTE ANALOG CURRENT CONTROL
* OK2
Iso
J36 34 CKT
PCB6 DISPLAYWK-5603
JUMPERfor 2 WIRE(RS485 only) wire to A & B
4W4W
2WJUMPERfor 4 WIRE usesTX+, TX-RX+, RX-
J35 26 CKT
J14
J14
2W
SW14SW14 - LINE TERMINATIONnormally on(refer to manual)
* OK2
RIBBON CABLE
5
9876
123
4
SW10-ADDRESSnormally 0(refer tomanual)
0
TEST SOCKET
HOLD START -HOLD START +
(A9, sht 1)
UNDIVIDED ARC VOLTSFOR HEIGHT CONTROLS
* +10VDC @ 10 ma.(for CC pot high)
OK TO MOVE
GND
GND
& CNC COMM
PREFLOW ON -PREFLOW ON +
PLASMA ENABLE
24 VAC @ 1A
120 VAC @ 100ma.
(Not in all units)
OK to MOVE -
POWER SUPPLY REAR PANEL
E-STOP -E-STOP +
* REMOTE MARKING +
RIBBON CABLE SIGNALS / = active low digital signal
CN10-J35 - 26 Ckt Ribbon Cable
2-Cut Demand4-Pilot Demand6-/ Start7-/ Start2 9-/ Pilot Enable10-/ HF Enable12-/ Pump Enable13-/ Fan Enable15-/ DC Indicator16-/ Over Temperature Indicator18-/ Gas-Coolant OK Indicator19-/ Status Lamp
CN11-J36 - 34 Ckt Ribbon Cable
1- Output Current Signal 3- / Arc Transferred (CSR)4- / Pilot On 6- Coolant Flow (freq)7- Coolant Temp (analog)9- / Temp OK (Inverter/Chopper)10- / Coolant Level OK12- Missing Phase13- / Ready to Operate15- / Input Volts OK16- / Inverter OCR18- / PS ID "00*"19- / PS ID "0*0"20- / PS ID "*00"21- E-Stop22- E-Stop29,31,33- 24 VAC Supply30,32,34- 24 VAC Return
Rx-
Tx+
Rx+
Tx-
OK to MOVE +
ECO-B1535 9-25-09
88
22
55
1212
J6J6 1 5 8
J4J4
1
3
5
7
K6K6
J5J51
2
3
4
5
CN24CN24
1
2
3
4
5
6
YELLOW TEMPYELLOW TEMP
REDSTATUS
REDSTATUS
33
77
33
11
TP11TP11
44
66
TP1TP1
GAS ONGAS ON
J15-CNCJ15-CNC1
2
3
4
5
6
7
8
9
10
11
12
13
14
100K100K
22
2211
55
CN23CN23
1
2
3
4
5
6
88
J59-RASJ59-RAS1
2
3456
7
8
9
1011121314
GREEN1 GASGREEN1 GAS
J6 **J6 **1
2
3
4
5
6
J54-REMOTE HMIJ54-REMOTE HMI
1
2
3
4
5
6
7
8
9
10
11
12
13
14
66
1212
66
OK2 *OK2 *
1111
99
1K1K
1010
77
J1J11
2
3
4
5
6
7
8
9
PSRPSR
4455
1111
88
GREEN ACGREEN AC33
1010
J8J8
1
2
3
4
11
1212
99
44
K7-1K7-1
GREEN2 DCGREEN2 DC
77
E-STOPE-STOP
J7J7
1
2
3
4
5
6
7
8
9
1010
J9J9 1 2 3 4 5 6
22
J55-GCMJ55-GCM12345678910111213141516171819202122232425262728293031323334353637
11
1111
99
TP13TP13
100K6100K6
APPENDIX A-32 Manual 0-4748
ULTRA-CUT 100
APPENDIX 12: Schematic, CE 400V, Resistor Pilot
1
1
2
2
3
3
4
4
5
5
A
B
C
D
E
F
-15V
INP
UT_
NG
+5V
GN
D
+15V+1
5V
GN
D_C
TEM
P_C
+15V
MIS
SIN
G_P
HA
SE
/ 200
PG
ND
1/ 4
00
/ 400
PG
ND
2400
200
CO
M
L1
L2
L3
E
+15V
+12VDC +12VDC
+12VDC
To PC
B7 C
N2-5
To PC
B7 C
N2-4
To PC
B7 C
N2-2
To PC
B7 C
N2-1
FAN
+ (24 VD
C)
FAN
- (24 VD
C)
To PC
B7 TB
3
To T1 PR
I - 0
V_C
HAN
GE
PCB
400
V o
nly
100A INVERTER MODULEP_GND
VAC_IN
LINE to LINE, LINE TO GND CAPS & VARISTORS
PCB 1WK-5630
INPUT POWER INDICATORREAR PANEL
INPUT POWER INDICATORINTERNAL
16 CKT RIBBON CABLE
/ OVERTEMP <
PCB 5 WK-5602 (partial)
MISSING PHASE
(pulses)<
LED1 DIM = LOW, BRIGHT = OKLED2 DIM = OK, BRIGHT = FAULTLED3 DIM = OK, BRIGHT = FAULTLED4 OFF = OK, ON = FAULTLED5 OFF = OK, ON + FAULT
CN6 16 CKT
BIAS SUPPLY FOR PCB5
(F2 -Sht2)
DC FAN POWER
CN1 CN5 CN6
CN4 CN5 CN6
(A1 Sht2)
(A1 Sht2)
(A1 Sht 2)
(A1 Sht 2)
(A2 Sht 2)
(A2 Sht 2)
CN6 16 CKT
ON / OFF
PCB3 WK-5694
PCB4 WK-5604
VAC_IN
P_GND
BIAS SUPPLY PCB
DETECTOR PCB
INTERFACE PCB
FILTER PCB
--400--
400 VAC 3 Phase
RIBBON CABLE SIGNALS
CN6 - 16 Ckt Ribbon Cable
2,4- I_REF (Scaled Cut Demand)5- PS_START (Start)6- REDUNDANT_START (Start2)8- INV_READY9- / PS_START disabled by Input_NG12- / OCR13- / PS_START disabled by OCR14- /TEMP_ERR15- / PS_START disabled by Temp _Err
CN32CN32 1 2 3 4
LED3INPUT NGLED3INPUT NG
N2N2
TB2TB2P1P1
TB1TB1
1 2
34
CN1CN1 1 5 8
CN7CN7 1 2 3 4 5
LED5ERRORLED5ERROR
P (+)P (+)
CN18CN18 1 2 3
RY2RY2
TB3TB3
C.P1C.P1
L5L5
- +- +
3
1
2
4
CN3CN3 1 2
MC1-AMC1-A
CN4CN4 1 2 3 4
NE2NE2
MC1-CMC1-CTB4TB4
N (-)N (-)
CN32CN32 1 2 3 4
CN2CN2 12
L6L6
LED2MISSING PHASE
LED2MISSING PHASE
CN1-not usedCN1-not used
1 2 3 4
CN7CN7 1 2 3 4 5
CN4CN4 14
L4L4
CN10CN10 1 2
++
RR
EMIFILTER
NFC1
EMIFILTER
NFC1
L1
L2
L3
L4
L6
L5
++
SS
NE1NE1
200V200V
CN17CN17 1 2 3
CN3CN31
4
TT
ACAC
AC
+-
D1
ACAC
AC
+-
D1
L7L7
L8L8
CN2CN21
2
3
LED4CHOPPER TEMP
LED4CHOPPER TEMP
CN1CN1
1
2
3
4
5
6
7
L1L1
- +- +
3
1
2
4
+
RY2
RY2
+
RY2
RY2
CN4 - PCB12CN4 - PCB12
1 2 3 4
+
-
+
-
1
2
3
45
6
L3L3
1 2
34
CN2-400V
6
CN2-400V
6
1234
MC1-BMC1-B
INRUSHINRUSH
CN2CN2 1 2 3
L2L2
TB1TB1
C1C1
Art # A-06994_AB
Manual 0-4748 A-33 APPENDIX
ULTRA-CUT 100
6
6
7
7
8
8
9
9
10
10
A
B
C
D
E
F
N2
P1
+12V
-12V
SIG
NA
LC
OM
MO
N
I_se
nseP
Iref_
G
GN
DW
P_e
na
GN
DW
Isen
se_W
-15V
w+1
5Vw
+15V
w-1
5Vw
Isen
se_W
GN
DP
I_se
nseP
GN
DP
Iref_
GP
_ref
P_e
na
P_r
ef
GN
D_C
TEM
P_C
TORCH (-)
PILOT
WORK (+)
WORK
PILOT (TIP) VOLTS
NEG ARC VOLTS
DWG No:
Sheetof
SupersedesScale
Date:
Drawn: References
DateByRevisionsRev PCB No:Assy No:
Information Proprietary to THERMAL DYNAMICS CORPORATION.Not For Release, Reproduction, or Distribution without Written Consent.
NOTE: UNLESS OTHERWISE SPECIFIED -1. RESISTOR VALUES ARE EXPRESSED IN OHMS, 1/4W 5%.2. CAPACITOR VALUES ARE EXPRESSED IN MICROFARADS (uF). Chk: App:
TITLE:Last Modified:
SizeSCHEMATIC,
ThermalDynamics
AA
42X1210Wednesday, October 31, 2007
1 2
Industrial Park #2West Lebanon NH 03784603-298-5711
100A Power Supply 400V CE (Resistor)
Tuesday, October 03, 2006
08:11:44
Thermal Dynamics
DDWG No:
Sheetof
SupersedesScale
Date:
Drawn: References
DateByRevisionsRev PCB No:Assy No:
Information Proprietary to THERMAL DYNAMICS CORPORATION.Not For Release, Reproduction, or Distribution without Written Consent.
NOTE: UNLESS OTHERWISE SPECIFIED -1. RESISTOR VALUES ARE EXPRESSED IN OHMS, 1/4W 5%.2. CAPACITOR VALUES ARE EXPRESSED IN MICROFARADS (uF). Chk: App:
TITLE:Last Modified:
SizeSCHEMATIC,
ThermalDynamics
AA
42X1210Wednesday, October 31, 2007
1 2
Industrial Park #2West Lebanon NH 03784603-298-5711
100A Power Supply 400V CE (Resistor)
Tuesday, October 03, 2006
08:11:44
Thermal Dynamics
DDWG No:
Sheetof
SupersedesScale
Date:
Drawn: References
DateByRevisionsRev PCB No:Assy No:
Information Proprietary to THERMAL DYNAMICS CORPORATION.Not For Release, Reproduction, or Distribution without Written Consent.
NOTE: UNLESS OTHERWISE SPECIFIED -1. RESISTOR VALUES ARE EXPRESSED IN OHMS, 1/4W 5%.2. CAPACITOR VALUES ARE EXPRESSED IN MICROFARADS (uF). Chk: App:
TITLE:Last Modified:
SizeSCHEMATIC,
ThermalDynamics
AA
42X1210Wednesday, October 31, 2007
1 2
Industrial Park #2West Lebanon NH 03784603-298-5711
100A Power Supply 400V CE (Resistor)
Tuesday, October 03, 2006
08:11:44
Thermal Dynamics
D
RAS
PCB 8WK-5687RC &RF CAPS
HALL SENSOR
HALL SENSOR
PILOT REG.(CHOPPER )PCB1WK-5750
BIASPOWER
PILOT REGULATOR (CHOPPER)
< /O
VE
R_T
EM
P
> P
_DE
M (
P_I
ref)
> P
_Ena
ble
(P_e
na)PILOT REG.
(CHOPPER )PCB2WK-5754
I_D
ET
I_S
E<<
PILOT CURRENT SIGNAL <
WORK CURRENT SIGNAL <
/PILOT ENABLE >
PILOT DEMAND >
C1 Capacitor, 0.1 uf, 1250 VDC (D2, Sht 2)C2 Capacitor, 2 uf, 430VAC (A9, Sht 1)
C.P1 Circuit protector/ON-OFF SW (C2, Sht 1) 15A, 460V, 3PC.P2 Circuit protector 2.5A 125V (D2, Sht 1)C.P3 Circuit protector 3.15A 125V (D2, Sht 1)C.P4 Circuit protector 10A 125V (E2, Sht 1)C.P5 Circuit protector 2.5A 125V (E2, Sht 1)C.P6 Circuit protector 2.5A 125V (F2, Sht 1)C.P7 Circuit protector 5A 125V (E2, Sht 1)C.P8 Circuit protector 3.15A 125V (F3, Sht 1)
D1 Diode Bridge 20A, 1600V, 3P (D2, Sht 1)
FAN1 Fan, Coolant, 24 VDC (F4, Sht 2)FAN3 Fan, Chopper, 24 VDC (A8, Sht 1)
FL1 Flow sensor (B5, Sht 2)
HCT1 Hall Current Sensor, Pilot (B8, Sht 1)HCT2 Hall Current Sensor, Work (C9, Sht 1)
L1 Toroid Core input common mode filter (A2, Sht 1)L2-7 Toroid Core common mode filter (B1, C1, Sht 1)L8 Toroid Core output common mode filter (A6, Sht 1)
LSW1 Level SW, coolant, NC (B5, Sht 2)
MC1 Contactor, 3P ,Inv 1 input, Coil (B3, Sht 2) " Contacts (A2, B2, Sht 1) " Aux Contact (B3, Sht 2)MC2 Contactor, pilot, Coil (B3, Sht 2) " Contacts (B8, Sht 1)
MOT1 Motor, Pump 200VAC, 1P (E4, Sht 2)
NE1 Neon indicator, rear panel, 220VAC (C1, Sht 1)NE2 Neon indicator, internal, 220VAC (D1, Sht 1)
NFC1 Noise Filter, EMI, input (A2, Sht 1)
R1 Resistor, Pilot, 4 Ohm, 1 KW (C8, Sht 1)R6 Resistor, 20K ,30W (A8, Sht 1)R7 Resistor, 1K ,30W (E2, Sht 2)R9 Resistor, 50 ,40W (A9, Sht 1)
T1 Aux Transformer (D-F1, Sht 2)
TH1 Thermal Sensor, coolant return (B5, Sht 2)
COMPONENT LOCATOR
(C7, Sht 2)
Power SupplyRear Panel
DAT
For this version of the power supply Pilot Regulator is not used except to provide power and pass signals from HCT1, the pilot current sensor.A Pilot Resistor, R1, is used instead.
ECO-B402 DAT 2/26/07
AB ECO-B448 DAT 4/13/07
(C7 & A9,Sht 2)
(C7 & A9,Sht 2)
ECO-B646 GAC 10/31/07AC
CN2CN2 1 2 3 4
TB1TB1
CN4CN4 1 2 3
HCT2HCT2
1 2 3 4
TB5TB5
TB2TB2
TB1TB1
TB2TB2
HCT1HCT1
1 2 3 4
CN2CN2 123
CN5CN5 1234
CN5CN5 1 2 3 4
CN1CN1
12
WORKWORK
CN33CN33 1 2 3 4
CN3CN3 1CN2CN2 1 2 3
MC2-AMC2-ACN3CN3 12
MC2-BMC2-B
CN4CN4 1 2 3 4 5
TB4TB4
MC2-CMC2-C
CN1CN11234
R14 Ohm 1KWR14 Ohm 1KW
CN4CN4 12345
CN1CN11234
CN7CN7 12345
FAN3FAN3
+-
R620K
30W
R620K
30W
THS1SW_TEMP_NC
THS1SW_TEMP_NC
CN6CN6 123
R950R950
CN9CN9 1 2
C22 UFC22 UF
CN8CN8 12
TB3TB3
CN3CN3 1 2 3 4
Art # A-06994_AB
APPENDIX A-34 Manual 0-4748
ULTRA-CUT 100
APPENDIX 12: Schematic, CE 400V, Resistor Pilot Cont.1
1
2
2
3
3
4
4
5
5
A
B
C
D
E
FAC13V @ 2A
AC120V @ 1A
/PUMP
+15V
+15V
/FAN
/RAS
+15V
COM200400
COM200400
400
200 (not used)
AC200V @ 3A
AC120V-RAS
FAN + (24 VDC)
FAN - (24 VDC)
0V-RAS
DC 15VDC 0V
AC24V-GCM
0V-A (24V ret)
AC120V-GCM
0V-B (120V ret)
To PC
B7 TB
3
To T1 PR
I - 0
To PCB7 C
N2-1
To PC
B7 C
N2-2
To PC
B7 C
N2-4
To PC
B7 C
N2-5
CCM MODULE
(D9, A10)
(D9, A10)
COOLANT TEMP(ON COOLANT RETURN)
TO AC
INDICATOR
(on PCB6)
PILOTCONTACTOR
INPUTCONTACTOR
(C9)
FROM CN18 PCB3sht 1
29-41 VDC +15VDC+5VDC-15VDC
ISOLATED COMM+16 to +18VDC
+15VDC_ISO-15VDC_ISO ISOLATED
VOLTAGES
PILOT DEM to PS
ANALOG DEM to CPU
CUT DEM to PSPILOT (TIP) VOLTAGENEG ARC VOLTS
CIRCUIT COMM (GND)
I/O PCB
CPU PCB
SW6 - OK to MOVE CONTACTS / VOLTS
SW11 - ANALOG CURRENT SELECT "B" DEFAULT, "A" REMOTESW12 - DIVIDED ARC V RATIO SELECT
SW13 - FACTORY ONLY
PCB 5 WK-5602 (partial) INTERFACE PCB
(F1 Sht 1)
(F1 Sht 1)
PCB7 WK-5628RELAY PCB
(F1 Sht 1)
(F1 Sht 1)
(F2 Sht 1)
(F2 Sht 1)
1 2 3
CN12CN121
2
CN2CN2
1
2
TP4TP4
CN20CN201
2
3
+
RY2
RELCOL_0+
RY2
RELCOL_0
CN3CN31
2
3
D2 E-STOP_PSD2 E-STOP_PS
C.P8C.P8
+V
GND
SIG
FL1FLOW_TURBINE_PULSE
+V
GND
SIG
FL1FLOW_TURBINE_PULSE
R BG
T1
TX1P8S
T1
TX1P8S
400
200
0,
13
0,,
100
0.
200
0..
110
0...
120.
0_
24.
0__
24_
0___
120.
0___
TP10TP10
1 2
CN10CN101
2
3
TB1TB1
D15 PSRD15 PSR
C.P5C.P5
R71K 30WR7
1K 30W
D12 STATUS CODE D12 STATUS CODE
C.P2C.P2
TP9TP9
1
2
3
CN7CN71
2
3
4
TP14TP14
CN6CN61
2
3
4
CN8CN81
2
3
4
MC2MC2
D1 GAS_OND1 GAS_ON
TP7TP7
CN1CN1 1 2
CN9CN91
2
3
4
5
1 2
TP1TP1
CN14CN14 1 2
C.P6C.P6
TB5TB5
RY3RY3
TP5TP5
CN9CN91
2
3
RY5RY5
D11 INITIALIZING / PROGRAMMINGD11 INITIALIZING / PROGRAMMING
C.P3C.P3
MC1 AUXMC1 AUX
TP3TP3TP2TP2
D4 OK_CNCD4 OK_CNC
TB4TB4
LED1LEVELLED1LEVEL
CN10CN101
2
3
4
5
6
D23 CNC_STARTD23 CNC_START
FAN1FAN1
+ -
1
2
3
MC1MC1
LSW1-1LSW1-1
+RY1
+RY1
D21 CNC_E-STOPD21 CNC_E-STOP
RY5RY5
1 2 3
CN11CN11
1
2
CN8CN8 1 2 3 4
TP8TP8
TB2TB2
D26 HOLD_STARTD26 HOLD_START
TP12TP12
CN2CN2 1 2 3 4 5
C.P7C.P7
RY4RY4
PUMP
MOT1
PUMP
MOT1
' .
tTH1
tTH1
TP13TP13
TB3TB3
RY3RY3
TP6TP6
TP11TP11
CN13CN13 1 2 3
1
2
CN12CN12 1 2 3
C.P4C.P4
1
2
D28 CNC_PREFLOWD28 CNC_PREFLOW
RY4RY4
D13 +5VD13 +5V
Art # A-06995_AB
Manual 0-4748 A-35 APPENDIX
ULTRA-CUT 100
Art # A-06995_AB
6
6
7
7
8
8
9
9
10
10
A
B
C
D
E
F
POT HI (GCM1000)
POT WIPER (GCM1000)
POT LOW (GCM 1000)
PLASMA ENABLE
PRESS OK (GCM 1000)
PLASMA ENABLE
24VA
C24
VA
C R
ET
+15V/ AC
/ TEMP
/ STATUS/ DC
/ GAS - COOLANT
- ARC V
- ARC V
AC24V-GCM
0V-A (24V ret)
AC120V-GCM
0V-B (120V ret)
AC120V-RAS
0V-RAS (120V ret)
DC 15V
DC 0V
NE
G A
RC
VO
LTS
PIL
OT
(TIP
) VO
LTS
WO
RK
WORK
0V-A (24V ret)
NEG ARC VOLTS
AC24V-GCM
0V-B (120V ret)
AC120V-GCM
DWG No:
Sheetof
SupersedesScale
Date:
Drawn: References
DateByRevisionsRev PCB No:Assy No:
Information Proprietary to THERMAL DYNAMICS CORPORATION.Not For Release, Reproduction, or Distribution without Written Consent.
NOTE: UNLESS OTHERWISE SPECIFIED -1. RESISTOR VALUES ARE EXPRESSED IN OHMS, 1/4W 5%.2. CAPACITOR VALUES ARE EXPRESSED IN MICROFARADS (uF). Chk: App:
TITLE:Last Modified:
SizeSCHEMATIC,
ThermalDynamics
AA
42X1210Wednesday, October 31, 2007
2 2
Industrial Park #2West Lebanon NH 03784603-298-5711
100A Power Supply 400V CE (Resistor)
Tuesday, October 03, 2006
08:11:44
Thermal Dynamics
DDWG No:
Sheetof
SupersedesScale
Date:
Drawn: References
DateByRevisionsRev PCB No:Assy No:
Information Proprietary to THERMAL DYNAMICS CORPORATION.Not For Release, Reproduction, or Distribution without Written Consent.
NOTE: UNLESS OTHERWISE SPECIFIED -1. RESISTOR VALUES ARE EXPRESSED IN OHMS, 1/4W 5%.2. CAPACITOR VALUES ARE EXPRESSED IN MICROFARADS (uF). Chk: App:
TITLE:Last Modified:
SizeSCHEMATIC,
ThermalDynamics
AA
42X1210Wednesday, October 31, 2007
2 2
Industrial Park #2West Lebanon NH 03784603-298-5711
100A Power Supply 400V CE (Resistor)
Tuesday, October 03, 2006
08:11:44
Thermal Dynamics
DDWG No:
Sheetof
SupersedesScale
Date:
Drawn: References
DateByRevisionsRev PCB No:Assy No:
Information Proprietary to THERMAL DYNAMICS CORPORATION.Not For Release, Reproduction, or Distribution without Written Consent.
NOTE: UNLESS OTHERWISE SPECIFIED -1. RESISTOR VALUES ARE EXPRESSED IN OHMS, 1/4W 5%.2. CAPACITOR VALUES ARE EXPRESSED IN MICROFARADS (uF). Chk: App:
TITLE:Last Modified:
SizeSCHEMATIC,
ThermalDynamics
AA
42X1210Wednesday, October 31, 2007
2 2
Industrial Park #2West Lebanon NH 03784603-298-5711
100A Power Supply 400V CE (Resistor)
Tuesday, October 03, 2006
08:11:44
Thermal Dynamics
D
KEY PLUG
CN11 34 CKT CN10 26 CKT
J36 34 CKT J35 26 CKT
RIBBON CABLE
TEST SOCKET
RIBBON CABLE
TEST SOCKET
(E2)
(E2)
(E4)
(F4)
POWER SUPPLY REAR PANEL
TB1
TB2
DIVIDED ARC V +DIVIDED ARC V -
REMOTE ANALOG CURRENT CONTROL -REMOTE ANALOG CURRENT CONTROL +
E-STOP -E-STOP +
PILOT ON OUTPUT
HOLD START -HOLD START +PREFLOW ON -PREFLOW ON +
OK to MOVE -
OK to MOVE +
MOMENTARY START / STOP
START / STOP
STOP
START
+
-
JUMPER IN REMOTEHMI
PLASMA ENABLE
PCB6 DISPLAYWK-5603
START / STOP
DIVIDED ARC VOLTS
REMOTE ANALOG CURRENT CONTROL
OK TO MOVE
DAT
Signal - Basic IDUsed to identifyGCM 1000 present
Signal - Master ID Used to identify resistor pilot unit
RIBBON CABLE SIGNALS / = active low digital signal
CN10-J35 - 26 Ckt Ribbon Cable
2- Cut Demand4- Pilot Demand6- / Start7- / Start2 9- / Pilot Enable10- / HF Enable12- / Pump Enable13- / Fan Enable15- / DC Indicator16- / Over Temperature Indicator18- / Gas-Coolant OK Indicator19- / Status Lamp
CN11-J36 - 34 Ckt Ribbon Cable
1- Output Current Signal 3- / Arc Transferred (CSR)4- / Pilot On 6- Coolant Flow (freq)7- Coolant Temp (analog)9- / Temp OK (Inverter/Chopper)10- / Coolant Level OK12- Missing Phase13- / Ready to Operate15- / Input Volts OK16- / Inverter OCR18- / PS ID "00*"19- / PS ID "0*0"20- / PS ID "*00"21- E-Stop22- E-Stop29,31,33 - 24 VAC Supply30,32,34 - 24 VAC Return
ECO-B402 DAT 2/26/07
AB ECO-B448 DAT 4/13/07
(E2)
INTERNAL TERMINAL STRIP TB3
(C9, sht 1)
(A9, sht 1)
UNDIVIDED ARC VOLTSFOR HEIGHT CONTROLS
24 VAC @ 1A
120 VAC @ 100ma.
(Not in all units)
(A9 SHT1)
(B9 SHT1)
(C9 SHT1)
AC ECO-B646 GAC 10/31/07
100K100K
1212
PSRPSR
22
GREEN DCGREEN DC
77
44
99
33
88
11
J6J6 1 5 8
GREEN ACGREEN AC 44
99
E-STOPE-STOP
J15-CNCJ15-CNC1
2
3
4
5
6
7
8
9
10
11
12
13
14
33
88
100K100K
K6-1K6-1
55
1K1K
1010
77
1111
K6K6
J54-REMOTE HMIJ54-REMOTE HMI
1
2
3
4
5
6
7
22
77
1212
J59-RASJ59-RAS1
2
3
4
5
6
7
8
91011121314
66
TP11TP11
1212
22
CN23CN23
1
2
3
4
5
6 REDSTATUS
REDSTATUS
J4J4
1
3
5
7
88
YELLOW TEMPYELLOW TEMP
11
33
TP1TP1
SW_LIQUID_LEVEL_NCSW_LIQUID_LEVEL_NC
66
1111
11
99
J55-GCMJ55-GCM12345678910111213141516171819202122232425262728293031323334353637
44
J8J8
1
2
3
4
1010
J1J11
2
3
4
5
6
7
8
9
CN24CN24
1
2
3
4
5
6
TP12TP12
55
55
GREEN GASGREEN GAS
J7J7
1
2
3
4
5
6
7
8
9
1010
1111
J5J51
2
3
4
5
J9J9 1 2 3 4 5 6
66
GAS ONGAS ON
APPENDIX A-36 Manual 0-4748
ULTRA-CUT 100
APPENDIX 13: Schematic, CSA 600V, Chopper Pilot
1
1
2
2
3
3
4
4
5
5
A
B
C
D
E
F
-15V
INP
UT_
NG
+5V
GN
D
+15V+1
5V
+15V
MIS
SIN
G_P
HA
SE
/ 200
PG
ND
1/ 6
00
/ 600
PG
ND
2600
200
CO
M
L1
L2
L3
E
+15V
+12VDC +12VDC
+12VDC
To PC
B7 C
N2-5
To PC
B7 C
N2-4
To PC
B7 C
N2-2
To PC
B7 C
N2-1
FAN
+ (24 VD
C)
FAN
- (24 VD
C)
To PC
B7 TB
3
To T1 PR
I - 0
V_C
HA
NG
E P
CB
600
V o
nly
100A INVERTER MODULEP_GND
VAC_IN
LINE to LINE, LINE TO GND CAPS & VARISTORS
PCB 1WK-5857
INPUT POWER INDICATORREAR PANEL
INPUT POWER INDICATORINTERNAL
16 CKT RIBBON CABLE
PCB 5 WK-5602 (partial)
MISSING PHASE
(pulses)<
LED1 DIM = LOW, BRIGHT = OKLED2 DIM = OK, BRIGHT = FAULTLED3 DIM = OK, BRIGHT = FAULTLED4 OFF = OK, ON = FAULTLED5 OFF = OK, ON + FAULT
CN6 16 CKT
BIAS SUPPLY FOR PCB5
(F2 -Sht2)
DC FAN POWER
CN1 CN5 CN6
CN4 CN5 CN6
(A1 Sht2)
(A1 Sht2)
(A1 Sht 2)
(A1 Sht 2)
(A2 Sht 2)
(A2 Sht 2)
CN6 16 CKTON / OFF
PCB3 WK-5694
PCB4 WK-5604
VAC_IN
P_GND
BIAS SUPPLY PCB
DETECTOR PCB
INTERFACE PCB
FILTER PCB
--600--
600 VAC 3 Phase
RIBBON CABLE SIGNALS
CN6 - 16 Ckt Ribbon Cable
2,4- I_REF (Scaled Cut Demand)5- PS_START (Start)6- REDUNDANT_START (Start2)8- INV_READY9- / PS_START disabled by Input_NG12- / OCR13- / PS_START disabled by OCR14- /TEMP_ERR15- / PS_START disabled by Temp _Err
CN32CN32 1 2 3 4
LED3INPUT NGLED3INPUT NG
N2N2
TB2TB2P1P1
TB1TB1
1 2
34
CN1CN1 1 5 8
CN7CN7 1 2 3 4 5
LED5ERRORLED5ERROR
P (+)P (+)
CN18CN18 1 2 3
RY2RY2
TB3TB3
C.P1C.P1
- +- +
3
1
2
4
CN3CN3 1 2
MC1-AMC1-A
CN4CN4 1 2 3 4
NE2NE2
MC1-CMC1-CTB4TB4
N (-)N (-)
CN32CN32 1 2 3 4
CN2CN2 12
CN1-not usedCN1-not used
1 2 3 4
LED2MISSING PHASE
LED2MISSING PHASE
CN7CN7 1 2 3 4 5
CN4CN4 14
CN10CN10 1 2
++
RR ++
SS
NE1NE1
230V230V
TT
CN3CN31
4
ACAC
AC
+-
D1
ACAC
AC
+-
D1
CN2CN21
2
3
CN1CN1
1
2
3
4
5
6
7
- +- +
3
1
2
4
+
RY2
RY2
+
RY2
RY2
CN4 - PCB12CN4 - PCB12
1 2 3 4
+
-
+
-
1
2
3
45
6
1 2
34
CN2-600V
6
CN2-600V
6
1234
MC1-BMC1-B
INRUSHINRUSH
CN2CN2 1 2 3
TB1TB1
C1C1
Art # A-07000_AD
Manual 0-4748 A-37 APPENDIX
ULTRA-CUT 100
6
6
7
7
8
8
9
9
10
10
A
B
C
D
E
F
+12V
-12V
SIG
NAL
CO
MM
ON
I_se
nseP
Iref_
G
GN
DW
P_e
na
GN
D_C
TEM
P_C
GN
DW
Isen
se_W
-15V
w+1
5Vw
+15V
w-1
5Vw
Isen
se_W
GN
DP
I_se
nseP
GN
DP
Iref_
GP
_ref
P_e
na
P_r
ef
GN
D_C
TEM
P_C
TORCH (-)
PILOT
WORK (+)
WORK
PILOT (TIP) VOLTS
NEG ARC VOLTS
N2 P1
DWG No:
Sheetof
SupersedesScale
Date:
Drawn: References
DateByRevisionsRev PCB No:Assy No:
Information Proprietary to THERMAL DYNAMICS CORPORATION.Not For Release, Reproduction, or Distribution without Written Consent.
NOTE: UNLESS OTHERWISE SPECIFIED -1. RESISTOR VALUES ARE EXPRESSED IN OHMS, 1/4W 5%.2. CAPACITOR VALUES ARE EXPRESSED IN MICROFARADS (uF). Chk: App:
TITLE:Last Modified:
SizeSCHEMATIC,
ThermalDynamics
AA
42X1213Friday, September 25, 2009
1 2
Industrial Park #2West Lebanon NH 03784603-298-5711
100A Power Supply 600V CSA (Chopper)
Tuesday, October 03, 2006
08:11:44
Thermal Dynamics
DDWG No:
Sheetof
SupersedesScale
Date:
Drawn: References
DateByRevisionsRev PCB No:Assy No:
Information Proprietary to THERMAL DYNAMICS CORPORATION.Not For Release, Reproduction, or Distribution without Written Consent.
NOTE: UNLESS OTHERWISE SPECIFIED -1. RESISTOR VALUES ARE EXPRESSED IN OHMS, 1/4W 5%.2. CAPACITOR VALUES ARE EXPRESSED IN MICROFARADS (uF). Chk: App:
TITLE:Last Modified:
SizeSCHEMATIC,
ThermalDynamics
AA
42X1213Friday, September 25, 2009
1 2
Industrial Park #2West Lebanon NH 03784603-298-5711
100A Power Supply 600V CSA (Chopper)
Tuesday, October 03, 2006
08:11:44
Thermal Dynamics
DDWG No:
Sheetof
SupersedesScale
Date:
Drawn: References
DateByRevisionsRev PCB No:Assy No:
Information Proprietary to THERMAL DYNAMICS CORPORATION.Not For Release, Reproduction, or Distribution without Written Consent.
NOTE: UNLESS OTHERWISE SPECIFIED -1. RESISTOR VALUES ARE EXPRESSED IN OHMS, 1/4W 5%.2. CAPACITOR VALUES ARE EXPRESSED IN MICROFARADS (uF). Chk: App:
TITLE:Last Modified:
SizeSCHEMATIC,
ThermalDynamics
AA
42X1213Friday, September 25, 2009
1 2
Industrial Park #2West Lebanon NH 03784603-298-5711
100A Power Supply 600V CSA (Chopper)
Tuesday, October 03, 2006
08:11:44
Thermal Dynamics
D
RAS
PCB 8WK-5687RC &RF CAPS
HALL SENSOR
HALL SENSOR
PILOT REG.(CHOPPER )PCB1WK-5750
BIASPOWER
PILOT REGULATOR (CHOPPER)
< /O
VE
R_T
EM
P
> P
_DE
M (
P_I
ref)
> P
_Ena
ble
(P_e
na)PILOT REG.
(CHOPPER )PCB2WK-5754
I_D
ET
I_S
E<<
PILOT CURRENT SIGNAL <
WORK CURRENT SIGNAL <
/ OVERTEMP <
/PILOT ENABLE >
PILOT DEMAND >
C1 Capacitor, 0.1 uf, 1250 VDC (D2, Sht 2)C2 Capacitor, 2 uf, 430VAC (A9, Sht 1)C3 Capacitor 47 uf 400V (C1, Sht 2)
C.P1 Circuit protector/ON-OFF SW (B2, Sht 1) 10A, 690V, 3PhC.P2 Circuit protector 2.5A 125V (D2, Sht 1)C.P3 Circuit protector 3.15A 125V (D2, Sht 1)C.P4 Circuit protector 10A 125V (E2, Sht 1)C.P5 Circuit protector 2.5A 125V (E2, Sht 1)C.P6 Circuit protector 2.5A 125V (F2, Sht 1)C.P7 Circuit protector 5A 125V (E2, Sht 1)C.P8 Circuit protector 3.15A 125V (F3, Sht 1)
D1 Diode Bridge 20A, 1600V, 3Ph (D2, Sht 1)D2 Diode, Dual, 2x100A, 600V (B8, Sht 1)D3 Diode Bridge 25A, 800V, 1Ph (C1, Sht 2)
FAN1 Fan, Coolant, 24 VDC (F4, Sht 2)FAN3 Fan, Chopper, 24 VDC (A8, Sht 1)
FL1 Flow sensor (B5, Sht 2)
HCT1 Hall Current Sensor, Pilot (B8, Sht 1)HCT2 Hall Current Sensor, Work (C9, Sht 1)
LSW1 Level SW, coolant, NC (B5, Sht 2)
MC1 Contactor, 3P ,Inv 1 input, Coil (B3, Sht 2) " Contacts (A2, B2, Sht 1) " Aux Contact (B3, Sht 2)MC2 Contactor, pilot, Coil (B3, Sht 2) " Contacts (C8, Sht 1)
MOT1 Motor, Pump 200VAC, 1P (E4, Sht 2)
NE1 Neon indicator, rear panel, 220VAC (C1, Sht 1)
NE2 Neon indicator, internal, 220VAC (C1, Sht 1)
R6 Resistor, 20K ,30W (A8, Sht 1)R7 Resistor, 1K ,30W (E2, Sht 2)R9 Resistor, 50 ,40W (A9, Sht 1)
T1 Aux Transformer (D-F1, Sht 2)
TH1 Thermal Sensor, coolant return (B5, Sht 2)
COMPONENT LOCATOR
(C7, Sht 2)
Power SupplyRear Panel
DAT
(C2, Sht 2)
ECO-B402 DAT 2/26/07AB ECO-B448 DAT 4/13/07
(C7 & A9,Sht 2)
(C7 & A9,Sht 2)
ECO-B646 GAC 10/31/07ACAD ECO-B1391 DAT 4-24-09
DATAE ECO-B1535 9-25-09
CN2CN2 1 2 3 4
TB1TB1
CN4CN4 1 2 3
HCT2HCT2
1 2 3 4
TB5TB5
TB2TB2
D2D2
1A1
2K1
3A2
4K2
TB1TB1
TB2TB2
HCT1HCT1
1 2 3 4
CN2CN2 123
CN5CN5 1234
CN5CN5 1 2 3 4
CN1CN1
12
WORKWORK
CN33CN33 1 2 3 4
CN3CN3 1CN2CN2 1 2 3
MC2-AMC2-A
CN3CN3 12
MC2-BMC2-B
CN4CN4 1 2 3 4 5
TB4TB4
MC2-CMC2-C
CN17CN17 1 2 3
CN1CN11234
LED4CHOPPER TEMP
LED4CHOPPER TEMP
CN4CN4 12345
CN1CN11234
CN7CN7 12345
FAN3FAN3
+-
R620K
30W
R620K
30W
THS1SW_TEMP_NC
THS1SW_TEMP_NC
CN6CN6 123
R950R950
CN9CN9 1 2
C22 UFC22 UF
CN8CN8 12
TB3TB3
CN3CN3 1 2 3 4
Art # A-07000_AD
APPENDIX A-38 Manual 0-4748
ULTRA-CUT 100
APPENDIX 13: Schematic, CSA 600V, Chopper Pilot Cont.
1
1
2
2
3
3
4
4
5
5
A
B
C
D
E
F
600
AC120 @
1A
AC13V @ 2A
/PUMP
+15V
+15V
600
/FAN
200-not used
/RAS
COM200600
COM
AC200V @ 3A
200
+15V
0V-A (24V ret)To P
CB
7 CN
2-1
AC120V-GCM
0V-B (120V ret)
To PC
B7 C
N2-2
To PC
B7 C
N2-4
To PC
B7 C
N2-5
To PC
B7 TB
3
0V-RAS
AC120V-RAS
FAN + (24 VDC)
DC 15VDC 0V
FAN - (24 VDC)
AC24V-GCM
To T1 PR
I - 0(F1 Sht 1)
(F1 Sht 1)
PILOTCONTACTOR
INPUTCONTACTOR
(D9, A10)
PILOT (TIP) VOLTAGE
COOLANT TEMP(ON COOLANT RETURN)
ISOLATED COMM+16 to +18VDC
CCM MODULE
FROM CN18 PCB3 sht 1
+15VDC_ISO-15VDC_ISO
(F1 Sht 1)
(F1 Sht 1)
(F2 Sht 1)
ISOLATEDVOLTAGES
(D9, A10)
(F2 Sht 1)
NEG ARC VOLTS
SW6 - OK to MOVE CONTACTS / VOLTS
SW11 - ANALOG CURRENT SELECT "B" DEFAULT, "A" REMOTESW12 - DIVIDED ARC V RATIO SELECT
SW13 - FACTORY ONLY
PCB7 WK-5628RELAY PCB
CIRCUIT COMM (GND)
(C9)
PCB 5 WK-5602 (partial) INTERFACE PCB
PILOT DEM to PS
ANALOG DEM to CPU
CUT DEM to PS
TO AC
INDICATOR
(on PCB6)
29-41 VDC +15VDC+5VDC-15VDC
COOLANT FLOW (freq) *
I/O PCB
CPU PCB
D7 E-STOP_PSD7 E-STOP_PS
TP10TP10
CN4CN41
2
3
D26 HOLD_STARTD26 HOLD_START
TP12TP12
1
2
LED1LEVELLED1LEVEL
CN2CN2 1 2 3 4 5
RY11RY11
D12 STATUS CODE D12 STATUS CODE
1
2
TP18TP18
C.P7C.P7
D9 GAS_OND9 GAS_ON
FAN1FAN1
+ -
D11 INITIALIZING / PROGRAMMINGD11 INITIALIZING / PROGRAMMING
CN9CN91
2
3
1 2 3
C.P3C.P3
CN12CN12 1 2 3 4 CN1CN1 1 2
1 2
+
RY10
+
RY10
D8 OK_CNCD8 OK_CNC
TP8TP8
D28 CNC_PREFLOWD28 CNC_PREFLOW
TP2TP2
CN10CN101
2
3
TP6TP6
MC2MC2
CN9CN91
2
3
4
5
LSW1-1
SW_LIQUID_LEVEL_NC
LSW1-1
SW_LIQUID_LEVEL_NC
CN5CN51
2
3
4
5
6
CN12CN121
2
D13 +5VD13 +5V
R81K 30WR8
1K 30W
CN6CN61
2
3
4
1 2
MC1 AUXMC1 AUX
D15 PSRD15 PSR
TP7TP7
RY4RY4
TP17TP17
RY3RY3
TB5TB5
CN11CN11
1
2
RY5RY5
CN3CN31
2
3
D21 CNC_E-STOPD21 CNC_E-STOP
CN7CN71
2
3
4
1 2 3
TP16TP16
1
2
3
RY7RY7
TB10TB10
TP5TP5
C.P2C.P2
+V
GND
SIG
FL1FLOW_TURBINE_PULSE
+V
GND
SIG
FL1FLOW_TURBINE_PULSE
R BG
C.P5C.P5
tTH1
tTH1
TP14TP14
C.P6C.P6
D23 CNC_STARTD23 CNC_START
CN14CN14 1 2
TB4TB4
TB9TB9
CN2CN2
1
2
CN12CN12 1 2 3
+RY1
+RY1
MC1MC1
RY9RY9
TP9TP9
PUMP
MOT1
PUMP
MOT1
' .
TP15TP15
1
2
3
T1T1460
220
0,
13
0,,
100
0.
200
0..
110
0...
120.
0_
24.
0__
24_
0___
120.
0___
TP4TP4
CN8CN81
2
3
4
TP3TP3
C.P4C.P4
C.P8C.P8
TB3TB3
CN13CN13 1 2 3
Art # A-07001_AD
Manual 0-4748 A-39 APPENDIX
ULTRA-CUT 100
6
6
7
7
8
8
9
9
10
10
A
B
C
D
E
F
PLASMA ENABLE
PRESS OK (GCM 1000)
24V
AC
24 V
AC
RE
T
PLASMA ENABLE
+15V/ AC
/ TEMP
/ STATUS/ DC
/ GAS - COOLANT
POT HI (GCM1000)
POT WIPER (GCM1000)
POT LOW (GCM 1000)
- ARC V
- ARC V
WORK
DC 15V
DC 0V
AC120V-RAS
0V-RAS (120V ret)
0V-A (24V ret)
NEG ARC VOLTS
NE
G A
RC
VO
LTS
AC24V-GCM
AC24V-GCM
0V-A (24V ret)
AC120V-GCM
0V-B (120V ret)
PIL
OT
(TIP
) VO
LTS
0V-B (120V ret)
WO
RK
AC120V-GCM
DWG No:
Sheetof
SupersedesScale
Date:
Drawn: References
DateByRevisionsRev PCB No:Assy No:
Information Proprietary to THERMAL DYNAMICS CORPORATION.Not For Release, Reproduction, or Distribution without Written Consent.
NOTE: UNLESS OTHERWISE SPECIFIED -1. RESISTOR VALUES ARE EXPRESSED IN OHMS, 1/4W 5%.2. CAPACITOR VALUES ARE EXPRESSED IN MICROFARADS (uF). Chk: App:
TITLE:Last Modified:
SizeSCHEMATIC,
ThermalDynamics
AA
42X1213Friday, September 25, 2009
2 2
Industrial Park #2West Lebanon NH 03784603-298-5711
100A Power Supply 600V CSA (Chopper)
Tuesday, October 03, 2006
08:11:44
Thermal Dynamics
DDWG No:
Sheetof
SupersedesScale
Date:
Drawn: References
DateByRevisionsRev PCB No:Assy No:
Information Proprietary to THERMAL DYNAMICS CORPORATION.Not For Release, Reproduction, or Distribution without Written Consent.
NOTE: UNLESS OTHERWISE SPECIFIED -1. RESISTOR VALUES ARE EXPRESSED IN OHMS, 1/4W 5%.2. CAPACITOR VALUES ARE EXPRESSED IN MICROFARADS (uF). Chk: App:
TITLE:Last Modified:
SizeSCHEMATIC,
ThermalDynamics
AA
42X1213Friday, September 25, 2009
2 2
Industrial Park #2West Lebanon NH 03784603-298-5711
100A Power Supply 600V CSA (Chopper)
Tuesday, October 03, 2006
08:11:44
Thermal Dynamics
DDWG No:
Sheetof
SupersedesScale
Date:
Drawn: References
DateByRevisionsRev PCB No:Assy No:
Information Proprietary to THERMAL DYNAMICS CORPORATION.Not For Release, Reproduction, or Distribution without Written Consent.
NOTE: UNLESS OTHERWISE SPECIFIED -1. RESISTOR VALUES ARE EXPRESSED IN OHMS, 1/4W 5%.2. CAPACITOR VALUES ARE EXPRESSED IN MICROFARADS (uF). Chk: App:
TITLE:Last Modified:
SizeSCHEMATIC,
ThermalDynamics
AA
42X1213Friday, September 25, 2009
2 2
Industrial Park #2West Lebanon NH 03784603-298-5711
100A Power Supply 600V CSA (Chopper)
Tuesday, October 03, 2006
08:11:44
Thermal Dynamics
D
DAT
ECO-B402 DAT 2/26/07
AB ECO-B448 DAT 4/13/07AC ECO-B646 GAC 10/31/07
ECO-B1391 TADDA 4-24-09DATAE
(E2)
MOMENTARY START / STOP
START / STOP
* REMOTE MARKING -
STOP
START
* Only in CCM w/ 19X2634 I/O PCB. Remote Marking only for DFC 3000 (not isolated)
Rx-
Tx+
Rx+
Tx-
Signal & GNDIsolated from Plasma Supply
INTERNAL TERMINAL STRIP TB3
KEY PLUG
TB1
TB2
(C9, sht 1)
+
-
RS 485 (2 wire) uses Tx+ & Tx- only(used for TSC 3000)
Signal - Basic IDUsed to identifyGCM 1000 present
RIBBON CABLE
TEST SOCKET
RS 422 (4 wire) connect TX+ to RX+ of CNC, Tx- to Rx- of CNC
DIVIDED ARC V +
(E2)
(E2)
DIVIDED ARC V -
REMOTE ANALOG CURRENT CONTROL -REMOTE ANALOG CURRENT CONTROL +
JUMPER IN REMOTEHMI
** RS 485 / 422 on CPU board19X2554 only.
(A9, sht1)
(B9, sht1)
(C9, sht1)
TB3
KEY PLUG
Was 7 pin changed to 14 pin in 2009
(E4)
(F4)
CN11 34 CKT CN10 26 CKT
START / STOP
DIVIDED ARC VOLTS
PILOT ON OUTPUT
REMOTE ANALOG CURRENT CONTROL
* OK2
Iso
J36 34 CKT
PCB6 DISPLAYWK-5603
JUMPERfor 2 WIRE(RS485 only) wire to A & B
4W4W
2W
JUMPERfor 4 WIRE usesTX+, TX-RX+, RX-
J35 26 CKT
J14
J14
2W
SW14SW14 - LINE TERMINATIONnormally on(refer to manual)
* OK2
RIBBON CABLE
5
9876
123
4
SW10-ADDRESSnormally 0(refer tomanual)
0
TEST SOCKET
HOLD START -HOLD START +
(A9, sht 1)
UNDIVIDED ARC VOLTSFOR HEIGHT CONTROLS
* +10VDC @ 10 ma.(for CC pot high)
OK TO MOVE
GND
GND
& CNC COMM
PREFLOW ON -PREFLOW ON +
PLASMA ENABLE
24 VAC @ 1A
120 VAC @ 100ma.
(Not in all units)
OK to MOVE -
POWER SUPPLY REAR PANEL
E-STOP -E-STOP +
* REMOTE MARKING +
RIBBON CABLE SIGNALS / = active low digital signal
CN10-J35 - 26 Ckt Ribbon Cable
2-Cut Demand4-Pilot Demand6-/ Start7-/ Start2 9-/ Pilot Enable10-/ HF Enable12-/ Pump Enable13-/ Fan Enable15-/ DC Indicator16-/ Over Temperature Indicator18-/ Gas-Coolant OK Indicator19-/ Status Lamp
CN11-J36 - 34 Ckt Ribbon Cable
1- Output Current Signal 3- / Arc Transferred (CSR)4- / Pilot On 6- Coolant Flow (freq)7- Coolant Temp (analog)9- / Temp OK (Inverter/Chopper)10- / Coolant Level OK12- Missing Phase13- / Ready to Operate15- / Input Volts OK16- / Inverter OCR18- / PS ID "00*"19- / PS ID "0*0"20- / PS ID "*00"21- E-Stop22- E-Stop29,31,33- 24 VAC Supply30,32,34- 24 VAC Return
Rx-
Tx+
Rx+
Tx-
OK to MOVE +
ECO-B1535 9-25-09
99
11
1010
OK2 *OK2 *
GAS ONGAS ON
33
66
88
GREEN1 GASGREEN1 GASGREEN2 DCGREEN2 DC
1122
J9J9 1 2 3 4 5 6
99
1111
TP1TP1
77
REDSTATUS
REDSTATUS
YELLOW TEMPYELLOW TEMP
22
1K1K
100K5100K5
J7J7
1
2
3
4
5
6
7
8
9
44
33
55
CN24CN24
1
2
3
4
5
6
99
88
11
77
66
K7-1K7-1
J54-REMOTE HMIJ54-REMOTE HMI
1
2
3
4
5
6
7
8
9
10
11
12
13
14TP11TP11
22 J1J11
2
3
4
5
6
7
8
9
J6 **J6 **1
2
3
4
5
6
J5J51
2
3
4
5
J4J4
1
3
5
7
J8J8
1
2
3
4
1111
1010
1111
22
55
77
E-STOPE-STOP
PSRPSR
J59-RASJ59-RAS1
2
3456
7
8
9
1011121314
K6K6
1212
1010
100K100K
TP13TP13
J55-GCMJ55-GCM12345678910111213141516171819202122232425262728293031323334353637
1212
1212
GREEN ACGREEN AC
44
88
66
11
CN23CN23
1
2
3
4
5
6
J15-CNCJ15-CNC1
2
3
4
5
6
7
8
9
10
11
12
13
14
J6J6 1 5 8
55
44
33
Art # A-07001_AD
APPENDIX A-40 Manual 0-4748
ULTRA-CUT 100
APPENDIX 14: PUBLICATION HISTORY
Cover Date Rev Change(s)
July 1, 2005 - - First issue
Aug. 1, 2005 - - Updated: CCM switch settings and coolant specs, added: static discharge warn-ing, torch O-ring lubrication data, catalog numbers for RAS, torch valve, gascontrol module, external power supply replacement parts, gas control box catalognumbers.
Aug. 19, 2005 - - Added: internal coolant filter cleaning, torch valve parts catalog numbers, metriccut charts.
Sep. 2, 2005 - - Modified warranty statement, corrected torch parts identification, added revisionhistory.
Sep. 30, 2005 - - Added optional hose selection chart, corrected input power ratings, correctedtorch consumables selection charts.
Oct. 21, 2005 - - Updated speed charts, updated fault chart, added voltages, added CCM info,added 30A SS N2/H20 towater shield in torch sections.
Jan. 4, 2006 - - Updated layout sketches to show new water lead between GCM-2010 and TorchValve. Updated GCM-2010 and Torch Valve to show new water lead. Added infoon routing input cables through bracket on lower back edge of power supply.Updated grounding method for Remote Arc Starter Cover. Added marking data totorch section. Updated Remote Arc Starter Schematic.
Jan. 28, 2006 - - Updated gas specs chart, section 2.
Feb. 20, 2006 - - Updated torch sections for 30A MS O2/O2 (new chart); 70A SS & AL, new partnumbers and charts; 100A SS & AL, new part numbers. Updated grounding data.Updated shield cup installation art; added info on setting pre-charge pressure formarking; updated schematic for GCM. Added system schematics.
Apr. 25, 2006 AA In Section 8, updated 30A Aluminum N2/H20 speeds. Corrected minimum outputcurrent to 10A. Added maximum input gas pressure. Added preflow gases togas applications chart. Added torch specifications. Changed ‘F1’ ground wiresize from 1/0 to #4. Added note, ‘side pressure can break check valves/connec-tions to torch valve’. Added error code group 6, Non-recoverable fault, ContactTDC for resolution’ (CCM software V2.3.1). Started using new cover styles.Ref: ECO B-122.
Aug 25, 2006 AA.01 Added leads lengths C and D as part of ECO B122 missed earlier. Corrected artpages 2-2, 3-2, 3-3, 6-2 and 6-3. inserted Gas Control Module diagram in Apdx 3.Updated rev. to new version to include numbers.
Oct 10, 2006 AB.01 Added 400V, 400V CE and 600V inerter module part numbers.
Jan. 10, 2007 AC.01 Updated Error codes in section 4 and added notice to update to Firmware revision2.4 or later. Updated Gas Control PCB layout in the Appendix. Added CNC cableshiel grounding.
Mar. 5, 2007 AD.01 Updated with new XTL TVA art and part numbers per ECOB356. Correctedplasma and shield hose lengths to 4’ with new part numbers. Corrected art insection 3 showing hookup of work leads, input power etc..
Mar. 8, 2007 AE.01 Corrected Switch setting errors pgs. 3-5, 3-6 and 3-7 for SW8-2.
Mar. 28, 2007 AF.01 Updated the Gas Requirement table in section 2.
July 10, 2007 AG.01 Added mounting dimensions for the GCM, RAS and the XTL TVA section 6.
Oct 15, 2007 AH Removed ref. to deionizer parts per ECOB524 and updated new pump and motorassemblies per ECOB444.
Oct. 29, 2007 AI Added star grounding information ECOB653, updated o-ring number ECOB467
Manual 0-4748 A-41 APPENDIX
ULTRA-CUT 100
Cover Date Rev Change(s)
Jan. 14, 2008 AJ Added flow meter replacement parts per ECOB704. Updated Schematics perECOB402.
Jan. 28, 2008 AK Per ECOB738 added GCM plumbing diagram.
Feb. 5, 2008 AL Per ECOB646 added input terminal strip information to sections 3 and 6.
Mar. 25, 2008 AM Per ECOB846 updated sw13 information for CCM switch settings section 3.
Apr. 11, 2008 AN Per ECOB475 updated art for GCM PCB on pg.A-5 and multiple additions andcorrections to sections 3, 4 and 6. Also added pilot transfer retry info switchsetting per ECOB799 pg. 3-16
Nov. 11, 2008 AO Updated section 3 per ECOB1163 to show single shielded leads. Also updatedsome sheet metal repair parts Catalog numbers from section 6.
July 16, 2009 AP Corrected part number for item 13 on page 6-21 to show 9-9407 per ECOB1477.
Sept. 29, 2009 AQ Updated Appendix with new CNC Functions information and system schematics with serial communication connector per ECOB1535.
NOTE
Before April 25, 2006, Thermal Dynamics used the date on the manual cover to indicate the most recentrevision.
APPENDIX A-42 Manual 0-4748
ULTRA-CUT 100
Intentionally Blank
Thermadyne USA2800 Airport RoadDenton, Tx 76207 USATelephone: (940) 566-2000800-426-1888Fax: 800-535-0557Email: sales@thermalarc.com
Thermadyne Victor BrasilAvenida Brasil13629-CordovilRio de Janeiro, Brazil 21012-351Telephone: 55-21-2485-8998Fax: 55-21-2-485-8735
Thermadyne Canada2070 Wyecroft RoadOakville, OntarioCanada, L6L5V6Telephone: (905)-827-1111Fax: 905-827-3648
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Thermadyne, ChinaRM 102A685 Ding Xi RdChang Ning DistrictShanghai, PR, 200052Telephone: 86-21-69171135Fax: 86-21-69171139
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Thermadyne ItalyOCIM, S.r.L.Via Benaco, 320098 S. GiulianoMilan, ItalyTel: (39) 02-98 80320Fax: (39) 02-98 281773
Thermadyne South Africa209 Risi Ave.LinmeyerJohannesberg, 2197South AfricaTel: (27) 11-917 3600Fax: (27) 11-917 8580
Thermadyne International2070 Wyecroft RoadOakville, OntarioCanada, L6L5V6Telephone: (905)-827-9777Fax: 905-827-9797
Global Customer Service Contact Information
Corporate Headquarters16052 Swingley Ridge RoadSuite 300St. Louis, MO 63017Telephone: 636-728-3000Email: TDCSales@Thermadyne.comwww.thermadyne.com
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