100i, 200i, 300i, and 400i Plasma System

100i, 200i, 300i, and 400i
Plasma System
Service Manual
Article Number: 0560956456
Revision Date: June 14, 2016
Revision Number: AA
Language: ENG
WE APPRECIATE YOUR BUSINESS!
Congratulations on your new ESAB product. We are proud to have you as our customer and will
strive to provide you with the best service and reliability in the industry. This product is backed by
our extensive warranty and world-wide service network. To locate your nearest distributor or service
agency call 1-800-ESAB-123, or visit us on the web at www.ESAB.com.
This instruction manual has been designed to instruct you on the correct use and operation of your
ESAB product. Your satisfaction with this product and its safe operation is our ultimate concern.
Therefore please take the time to read the entire manual, especially the Safety Precautions. They will
help you to avoid potential hazards that may exist when working with this product.
YOU ARE IN GOOD COMPANY!
The Brand of Choice for Contractors and Fabricators Worldwide.
ESAB is a Global Brand of manual and mechanized Plasma Cutting Products.
We distinguish ourselves from our competition through market-leading, dependable products that
have stood the test of time. We pride ourselves on technical innovation, competitive prices, excellent delivery, superior customer service and technical support, together with excellence in sales and
marketing expertise.
Above all, we are committed to developing technologically advanced products to achieve a safer
working environment within the welding industry.
!
WARNING
Read and understand this entire Manual and your employer’s safety practices
before installing, operating, or servicing the equipment.
While the information contained in this Manual represents the Manufacturer’s
best judgement, the Manufacturer assumes no liability for its use.
Plasma Cutting Power Supply with Automated Gas Control 100i / 200i / 300i / 400i
Published by:
ESAB Welding and Cutting Products.
2800 Airport Rd.
Denton, Texas 76207
www.ESAB.com
© Copyright 2016 by ESAB Welding and Cutting Products.
All rights reserved.
Reproduction of this work, in whole or in part, without written permission of the publisher
is prohibited.
The publisher does not assume and hereby disclaims any liability to any party for any loss
or damage caused by any error or omission in this manual, whether such error results from
negligence, accident, or any other cause.
Original Publication Date: June 14, 2016
Revision Date:
Record the following information for Warranty purposes:
Where Purchased: ___________________________________
Purchase Date:______________________________________
Power Supply Serial #:_______________________________
Torch Serial #:_______________________________________
Be sure this information reaches the operator.
You can get extra copies through your supplier.
CAUTION
These INSTRUCTIONS are for experienced operators. If you are not fully familiar with
the principles of operation and safe practices for arc welding and cutting equipment,
we urge you to read our booklet, “Precautions and Safe Practices for Arc Welding,
Cutting, and Gouging,” Booklet F52-529. Do NOT permit untrained persons to install,
operate, or maintain this equipment. Do NOT attempt to install or operate this equipment until you have read and fully understand these instructions. If you do not fully
understand these instructions, contact your supplier for further information. Be sure
to read the Safety Precautions before installing or operating this equipment.
USER RESPONSIBILITY
This equipment will perform in conformity with the description thereof contained in this manual and accompanying
labels and/or inserts when installed, operated, maintained and repaired in accordance with the instructions provided. This
equipment must be checked periodically. Malfunctioning or poorly maintained equipment should not be used. Parts that
are broken, missing, worn, distorted or contaminated should be replaced immediately. Should such repair or replacement
become necessary, the manufacturer recommends that a telephone or written request for service advice be made to the
Authorized Distributor from whom it was purchased.
This equipment or any of its parts should not be altered without the prior written approval of the manufacturer. The
user of this equipment shall have the sole responsibility for any malfunction which results from improper use, faulty maintenance, damage, improper repair or alteration by anyone other than the manufacturer or a service facility designated by
the manufacturer.
!
READ AND UNDERSTAND THE INSTRUCTION MANUAL BEFORE INSTALLING OR
OPERATING.
PROTECT YOURSELF AN D OTHERS!
ASSUREZ-VOUS QUE CETTE INFORMATION EST DISTRIBUÉE À L’OPÉRATEUR.
VOUS POUVEZ OBTENIR DES COPIES SUPPLÉMENTAIRES CHEZ VOTRE FOURNISSEUR.
ATTENTION
Les INSTRUCTIONS suivantes sont destinées aux opérateurs qualifiés seulement.
Si vous n’avez pas une connaissance approfondie des principes de fonctionnement
et des règles de sécurité pour le soudage à l’arc et l’équipement de coupage, nous
vous suggérons de lire notre brochure « Precautions and Safe Practices for Arc Welding, Cutting and Gouging, » Brochure F52-529. Ne permettez PAS aux personnes
non qualifiées d’installer, d’opérer ou de faire l’entretien de cet équipement. Ne tentez
PAS d’installer ou d’opérer cet équipement avant de lire et de bien comprendre ces
instructions. Si vous ne comprenez pas bien les instructions, communiquez avec
votre fournisseur pour plus de renseignements. Assurez-vous de lire les Règles de
Sécurité avant d’installer ou d’opérer cet équipement.
RESPONSABILITÉS DE L’UTILISATEUR
Cet équipement opérera conformément à la description contenue dans ce manuel, les étiquettes d’accompagnement
et/ou les feuillets d’information si l’équipement est installé, opéré, entretenu et réparé selon les instructions fournies. Vous
devez faire une vérification périodique de l’équipement. Ne jamais utiliser un équipement qui ne fonctionne pas bien ou n’est
pas bien entretenu. Les pièces qui sont brisées, usées, déformées ou contaminées doivent être remplacées immédiatement.
Dans le cas où une réparation ou un remplacement est nécessaire, il est recommandé par le fabricant de faire une demande
de conseil de service écrite ou par téléphone chez le Distributeur Autorisé de votre équipement.
Cet équipement ou ses pièces ne doivent pas être modifiés sans permission préalable écrite par le fabricant. L’utilisateur de l’équipement sera le seul responsable de toute défaillance résultant d’une utilisation incorrecte, un entretien fautif, des
dommages, une réparation incorrecte ou une modification par une personne autre que le fabricant ou un centre de service
désigné par le fabricant.
!
ASSUREZ-VOUS DE LIRE ET DE COMPRENDRE LE MANUEL D’UTILISATION AVANT
D’INSTALLER OU D’OPÉRER L’UNITÉ.
PROTÉGEZ-VOUS ET LES AUTRES!
This Page Intentionally Blank
TABLE OF CONTENTS
SECTION 1: SAFETY......................................................................................... 1-1
1.01
Safety Precautions - ENGLISH......................................................................... 1-1
1.02
Précautions de sécurité - FRENCH CANADIAN................................................ 1-6
SECTION 2: TORCH MAINTENANCE.................................................................... 2-1
2.01
Coolant Leak Trouble-Shooting ....................................................................... 2-1
APPENDIX 1: CNC - CONTROL MODULE PCB CONNECTIONS........................................ A-1
APPENDIX 2: CNC .......................................................................................... A-2
CNC functions................................................................................................................ A-2
CNC Input / Output Descriptions.................................................................................... A-4
Simplified CNC Circuit.................................................................................................... A-6
CNC Connections........................................................................................................... A-8
APPENDIX 3: GSC CONTROL PCB LAYOUT............................................................. A-9
APPENDIX 4: DPC CONTROL PCB LAYOUT............................................................A-10
APPENDIX 5: GSC / DPC POWER SUPPLY PCB LAYOUT............................................A-11
APPENDIX 6: CCM CPU PCB LAYOUT...................................................................A-12
APPENDIX 7: CCM I/O PCB LAYOUT....................................................................A-14
APPENDIX 8: PILOT PCB LAYOUT.......................................................................A-16
APPENDIX 9: RELAY AND INTERFACE PCB LAYOUT..................................................A-18
APPENDIX 10: DISPLAY PCB LAYOUT..................................................................A-20
APPENDIX 11: SYSTEM BIAS PCB LAYOUT............................................................A-22
APPENDIX 12: MAIN INVERTER BOTTOM PCB LAYOUT.............................................A-24
APPENDIX 13: MAIN INVERTER TOP PCB LAYOUT...................................................A-26
APPENDIX 14: CONTROL AND FAULT PCB LAYOUT..................................................A-28
APPENDIX 15: CAP BIAS BOTTOM PCB LAYOUT......................................................A-30
APPENDIX 16: CAP BIAS TOP PCB LAYOUT...........................................................A-31
APPENDIX 17: SUPPRESSOR PCB LAYOUT............................................................A-32
APPENDIX 18: COOLING DIAGRAM.....................................................................A-33
APPENDIX 19: REMOTE ARC STARTER SCHEMATIC.................................................A-34
APPENDIX 20: SCHEMATIC, DFC AUTO GAS BOX SYSTEM..........................................A-36
APPENDIX 21: SYSTEM SCHEMATIC 100A, 380-415V PG 1.........................................A-38
APPENDIX 22: SYSTEM SCHEMATIC 100A, 380-415V PG 2.........................................A-40
APPENDIX 23: SYSTEM SCHEMATIC 200A, 380-415V PG 1.........................................A-42
TABLE OF CONTENTS
APPENDIX 24: SYSTEM SCHEMATIC 200A, 380-415V PG 2.........................................A-44
APPENDIX 25: SYSTEM SCHEMATIC 300A, 380-415V PG 1.........................................A-46
APPENDIX 26: SYSTEM SCHEMATIC 300A, 380-415V PG 2.........................................A-48
APPENDIX 27: SYSTEM SCHEMATIC 400A, 380-415V PG 1.........................................A-50
APPENDIX 28: SYSTEM SCHEMATIC 400A, 380-415V PG 2.........................................A-52
APPENDIX 29: ADVANCED TROUBLESHOOTING......................................................A-54
APPENDIX 30: HE 400 CONNECTION...................................................................A-88
APPENDIX 31: PUBLICATION HISTORY.................................................................A-92
iSERIES 100 /200 /300 /400
SECTION 1: SAFETY
1.01 Safety Precautions - ENGLISH
WARNING: These Safety Precautions are for your protection. They summarize precautionary information
from the references listed in Additional Safety Information section. Before performing any installation or
operating procedures, be sure to read and follow the safety precautions listed below as well as all other
manuals, material safety data sheets, labels, etc. Failure to observe Safety Precautions can result in injury or death.
!
PROTECT YOURSELF AND OTHERS -- Some welding, cutting, and gouging processes are noisy
and require ear protection. The arc, like the sun, emits ultraviolet (UV) and other radiation and can
injure skin and eyes. Hot metal can cause burns. Training in the proper use of the processes and
equipment is essential to prevent accidents. Therefore:
1. Always wear safety glasses with side shields in any work area, even if welding helmets, face shields, and
goggles are also required.
2. Use a face shield fitted with the correct filter and cover plates to protect your eyes, face, neck, and ears
from sparks and rays of the arc when operating or observing operations. Warn bystanders not to watch
the arc and not to expose themselves to the rays of the electric-arc or hot metal.
3. Wear flameproof gauntlet type gloves, heavy long-sleeve shirt, cuffless trousers, high-topped shoes, and
a welding helmet or cap for hair protection, to protect against arc rays and hot sparks or hot metal. A
flameproof apron may also be desirable as protection against radiated heat and sparks.
4. Hot sparks or metal can lodge in rolled up sleeves, trouser cuffs, or pockets. Sleeves and collars should
be kept buttoned, and open pockets eliminated from the front of clothing.
5. Protect other personnel from arc rays and hot sparks with a suitable non-flammable partition or curtains.
6. Use goggles over safety glasses when chipping slag or grinding. Chipped slag may be hot and can fly far.
Bystanders should also wear goggles over safety glasses.
FIRES AND EXPLOSIONS -- Heat from flames and arcs can start fires. Hot slag or sparks can also cause
fires and explosions. Therefore:
1. Remove all combustible materials well away from the work area or cover the materials with a protective
non-flammable covering. Combustible materials include wood, cloth, sawdust, liquid and gas fuels, solvents, paints and coatings, paper, etc.
2. Hot sparks or hot metal can fall through cracks or crevices in floors or wall openings and cause a hidden smoldering fire or fires on the floor below. Make certain that such openings are protected from hot
sparks and metal.“
3. Do not weld, cut or perform other hot work until the work piece has been completely cleaned so that there
are no substances on the work piece which might produce flammable or toxic vapors. Do not do hot work
on closed containers. They may explode.
4. Have fire extinguishing equipment handy for instant use, such as a garden hose, water pail, sand bucket,
or portable fire extinguisher. Be sure you are trained in its use.
5. Do not use equipment beyond its ratings. For example, overloaded welding cable can overheat and create
a fire hazard.
6. After completing operations, inspect the work area to make certain there are no hot sparks or hot metal
which could cause a later fire. Use fire watchers when necessary.
7. For additional information, refer to NFPA Standard 51B, “Fire Prevention in Use of Cutting and Welding
Processes”, available from the National Fire Protection Association, Battery march Park, Quincy, MA 02269.
Manual 0560956456
SAFETY INSTRUCTIONS 1-1
iSERIES 100 /200 /300 /400 ELECTRICAL SHOCK -- Contact with live electrical parts and ground can cause severe injury or death.
DO NOT use AC welding current in damp areas, if movement is confined, or if there is danger of falling.
1. Be sure the power source frame (chassis) is connected to the ground system of the input power.
2. Connect the work piece to a good electrical ground.
3. Connect the work cable to the work piece. A poor or missing connection can expose you or others to a
fatal shock.
4. Use well-maintained equipment. Replace worn or damaged cables.
5. Keep everything dry, including clothing, work area, cables, torch/electrode holder, and power source.
6. Make sure that all parts of your body are insulated from work and from ground.
7. Do not stand directly on metal or the earth while working in tight quarters or a damp area; stand on dry
boards or an insulating platform and wear rubber-soled shoes.
8. Put on dry, hole-free gloves before turning on the power.
9. Turn off the power before removing your gloves.
10. Refer to ANSI/ASC Standard Z49.1 (listed on next page) for specific grounding recommendations. Do not
mistake the work lead for a ground cable.
ELECTRIC AND MAGNETIC FIELDS — May be dangerous. Electric current flowing through any conductor causes localized Electric and Magnetic Fields (EMF ). Welding and cutting current creates EMF
around welding cables and welding machines. Therefore:
1. Welders having pacemakers should consult their physician before welding. EMF may interfere with some
pacemakers.
2. Exposure to EMF may have other health effects which are unknown.
3. Welders should use the following procedures to minimize exposure to EMF:
A. Route the electrode and work cables together. Secure them with tape when possible.
B. Never coil the torch or work cable around your body.
C. Do not place your body between the torch and work cables. Route cables on the same side of your
body.
D. Connect the work cable to the work piece as close as possible to the area being welded.
E. Keep welding power source and cables as far away from your body as possible.
FUMES AND GASES -- Fumes and gases, can cause discomfort or harm, particularly in confined
spaces. Do not breathe fumes and gases. Shielding gases can cause asphyxiation.
Therefore:
1. Always provide adequate ventilation in the work area by natural or mechanical means. Do not weld, cut,
or gouge on materials such as galvanized steel, stainless steel, copper, zinc, lead, beryllium, or cadmium
unless positive mechanical ventilation is provided. Do not breathe fumes from these materials.
2. Do not operate near degreasing and spraying operations. The heat or arc rays can react with chlorinated
hydrocarbon vapors to form phosgene, a highly toxic gas, and other irritant gases.
3. If you develop momentary eye, nose, or throat irritation while operating, this is an indication that ventilation is not adequate. Stop work and take necessary steps to improve ventilation in the work area. Do not
continue to operate if physical discomfort persists.
4. Refer to ANSI/ASC Standard Z49.1 (see listing below) for specific ventilation recommendations.
5. WARNING: This product contains chemicals, including lead, known to the State of California to cause birth
defects and other reproductive harm. Wash hands after handling.
1-2 SAFETY INSTRUCTIONS
Manual 0560956456
iSERIES 100 /200 /300 /400
CYLINDER HANDLING -- Cylinders, if mishandled, can rupture and violently release gas. Sudden rupture
of cylinder, valve, or relief device can injure or kill. Therefore:
1. Use the proper gas for the process and use the proper pressure reducing regulator designed to operate
from the compressed gas cylinder. Do not use adaptors. Maintain hoses and fittings in good condition.
Follow manufacturer’s operating instructions for mounting regulator to a compressed gas cylinder.
2. Always secure cylinders in an upright position by chain or strap to suitable hand trucks, undercarriages,
benches, walls, post, or racks. Never secure cylinders to work tables or fixtures where they may become
part of an electrical circuit.
3. When not in use, keep cylinder valves closed. Have valve protection cap in place if regulator is not connected. Secure and move cylinders by using suitable hand trucks. Avoid rough handling of cylinders.
4. Locate cylinders away from heat, sparks, and flames. Never strike an arc on a cylinder.
5. For additional information, refer to CGA Standard P-1, “Precautions for Safe Handling of Compressed
Gases in Cylinders”, which is available from Compressed Gas Association, 1235 Jefferson Davis Highway,
Arlington, VA 22202.
EQUIPMENT MAINTENANCE -- Faulty or improperly maintained equipment can cause injury or death.
Therefore:
!
1. Always have qualified personnel perform the installation, troubleshooting, and maintenance work. Do not
perform any electrical work unless you are qualified to perform such work.
2. Before performing any maintenance work inside a power source, disconnect the power source from the
incoming electrical power.
3. Maintain cables, grounding wire, connections, power cord, and power supply in safe working order. Do
not operate any equipment in faulty condition.
4. Do not abuse any equipment or accessories. Keep equipment away from heat sources such as furnaces,
wet conditions such as water puddles, oil or grease, corrosive atmospheres and inclement weather.
5. Keep all safety devices and cabinet covers in position and in good repair.
6. Use equipment only for its intended purpose. Do not modify it in any manner.
ADDITIONAL SAFETY INFORMATION -- For more information on safe practices for electric arc welding
and cutting equipment, ask your supplier for a copy of “Precautions and Safe Practices for Arc Welding,
Cutting and Gouging”, Form 52-529.
!
The following publications, which are available from the American Welding Society, 550 N.W. LeJuene Road,
Miami, FL 33126, are recommended to you:
1.
2.
3.
4.
5.
6.
7.
8.
ANSI/ASC Z49.1 - “Safety in Welding and Cutting”.
AWS C5.1 - “Recommended Practices for Plasma Arc Welding”.
AWS C5.2 - “Recommended Practices for Plasma Arc Cutting”.
AWS C5.3 - “Recommended Practices for Air Carbon Arc Gouging and Cutting”.
AWS C5.5 - “Recommended Practices for Gas Tungsten Arc Welding“.
AWS C5.6 - “Recommended Practices for Gas Metal Arc Welding”.
AWS SP - “Safe Practices” - Reprint, Welding Handbook.
ANSI/AWS F4.1, “Recommended Safe Practices for Welding and Cutting of Containers That Have Held
Hazardous Substances.”
9. CSA Standard - W117.2 = Safety in Welding, Cutting and Allied Processes.
Manual 0560956456
SAFETY INSTRUCTIONS 1-3
iSERIES 100 /200 /300 /400 !
Meaning of symbols - As used throughout this manual: Means Attention! Be Alert! Your safety is involved.
DANGER
Means immediate hazards which, if not avoided, will result in immediate, serious personal injury or loss of life.
CAUTION
Means potential hazards which could result in personal injury or loss of life.
WARNING
Means hazards which could result in minor personal injury.
Enclosure Class
The IP code indicates the enclosure class, i.e. the degree of protection against penetration by solid objects or water.
Protection is provided against touch with a finger, penetration of solid objects greater than 12mm and against
spraying water up to 60 degrees from vertical. Equipment marked IP21S may be stored, but is not intended to be
used outside during precipitation unless sheltered.
CAUTION
This product is solely intended for plasma cutting. Any other use may result in personal
injury and / or equipment damage.
CAUTION
If equipment is placed on a surface that slopes more
than 15°, toppling over may occur. Personal injury and
/ or significant damage to equipment is possible.
15°
Art# A-12726
CAUTION
To avoid personal injury and/or equipment damage,
lift using method and attachment points shown here.
Art# A-12736
1-4 SAFETY INSTRUCTIONS
Manual 0560956456
iSERIES 100 /200 /300 /400
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Manual 0560956456
SAFETY INSTRUCTIONS 1-5
iSERIES 100 /200 /300 /400 1.02 Précautions de sécurité - FRENCH CANADIAN
AVERTISSEMENT : Ces règles de sécurité ont pour but d’assurer votre protection. Ils récapitulent les
informations de précaution provenant des références dans la section des Informations de sécurité supplémentaires. Avant de procéder à l’installation ou d’utiliser l’unité, assurez-vous de lire et de suivre les
précautions de sécurité ci-dessous, dans les manuels, les fiches d’information sur la sécurité du matériel et sur
les étiquettes, etc. Tout défaut d’observer ces précautions de sécurité peut entraîner des blessures graves ou
mortelles.
!
PROTÉGEZ-VOUS -- Les processus de soudage, de coupage et de gougeage produisent un niveau
de bruit élevé et exige l’emploi d’une protection auditive. L’arc, tout comme le soleil, émet des rayons
ultraviolets en plus d’autre rayons qui peuvent causer des blessures à la peau et les yeux. Le métal
incandescent peut causer des brûlures. Une formation reliée à l’usage des processus et de l’équipement est essentielle pour prévenir les accidents. Par conséquent:
1. Portez des lunettes protectrices munies d’écrans latéraux lorsque vous êtes dans l’aire de travail, même
si vous devez porter un casque de soudeur, un écran facial ou des lunettes étanches.
2. Portez un écran facial muni de verres filtrants et de plaques protectrices appropriées afin de protéger vos
yeux, votre visage, votre cou et vos oreilles des étincelles et des rayons de l’arc lors d’une opération ou
lorsque vous observez une opération. Avertissez les personnes se trouvant à proximité de ne pas regarder
l’arc et de ne pas s’exposer aux rayons de l’arc électrique ou le métal incandescent.
3. Portez des gants ignifugiés à crispin, une chemise épaisse à manches longues, des pantalons sans
rebord et des chaussures montantes afin de vous protéger des rayons de l’arc, des étincelles et du métal
incandescent, en plus d’un casque de soudeur ou casquette pour protéger vos cheveux. Il est également
recommandé de porter un tablier ininflammable afin de vous protéger des étincelles et de la chaleur par
rayonnement.
4. Les étincelles et les projections de métal incandescent risquent de se loger dans les manches retroussées,
les rebords de pantalons ou les poches. Il est recommandé de garder boutonnés le col et les manches et
de porter des vêtements sans poches en avant.
5. Protégez toute personne se trouvant à proximité des étincelles et des rayons de l’arc à l’aide d’un rideau
ou d’une cloison ininflammable.
6. Portez des lunettes étanches par dessus vos lunettes de sécurité lors des opérations d’écaillage ou de
meulage du laitier. Les écailles de laitier incandescent peuvent être projetées à des distances considérables. Les personnes se trouvant à proximité doivent également porter des lunettes étanches par dessus
leur lunettes de sécurité.
INCENDIES ET EXPLOSIONS -- La chaleur provenant des flammes ou de l’arc peut provoquer un incendie. Le laitier incandescent ou les étincelles peuvent également provoquer un incendie ou une explosion.
Par conséquent :
1. Éloignez suffisamment tous les matériaux combustibles de l’aire de travail et recouvrez les matériaux avec
un revêtement protecteur ininflammable. Les matériaux combustibles incluent le bois, les vêtements, la
sciure, le gaz et les liquides combustibles, les solvants, les peintures et les revêtements, le papier, etc.
2. Les étincelles et les projections de métal incandescent peuvent tomber dans les fissures dans les planchers
ou dans les ouvertures des murs et déclencher un incendie couvant à l’étage inférieur Assurez-vous que
ces ouvertures sont bien protégées des étincelles et du métal incandescent.
3. N’exécutez pas de soudure, de coupe ou autre travail à chaud avant d’avoir complètement nettoyé la
surface de la pièce à traiter de façon à ce qu’il n’ait aucune substance présente qui pourrait produire des
vapeurs inflammables ou toxiques. N’exécutez pas de travail à chaud sur des contenants fermés car ces
derniers pourraient exploser.
4. Assurez-vous qu’un équipement d’extinction d’incendie est disponible et prêt à servir, tel qu’un tuyau
d’arrosage, un seau d’eau, un seau de sable ou un extincteur portatif. Assurez-vous d’être bien instruit
par rapport à l’usage de cet équipement.
1-6 SAFETY INSTRUCTIONS
Manual 0560956456
iSERIES 100 /200 /300 /400
5. Assurez-vous de ne pas excéder la capacité de l’équipement. Par exemple, un câble de soudage surchargé
peut surchauffer et provoquer un incendie.
6. Une fois les opérations terminées, inspectez l’aire de travail pour assurer qu’aucune étincelle ou projection de métal incandescent ne risque de provoquer un incendie ultérieurement. Employez des guetteurs
d’incendie au besoin.
7. Pour obtenir des informations supplémentaires, consultez le NFPA Standard 51B, “Fire Prevention in Use
of Cutting and Welding Processes”, disponible au National Fire Protection Association, Batterymarch
Park, Quincy, MA 02269.
CHOC ÉLECTRI QUE -- Le contact avec des pièces électriques ou les pièces de mise à la terre sous
tension peut causer des blessures graves ou mortelles. NE PAS utiliser un courant de soudage c.a. dans
un endroit humide, en espace restreint ou si un danger de chute se pose.
1. Assurez-vous que le châssis de la source d’alimentation est branché au système de mise à la terre de
l’alimentation d’entrée.
2. Branchez la pièce à traiter à une bonne mise de terre électrique.
3. Branchez le câble de masse à la pièce à traiter et assurez une bonne connexion afin d’éviter le risque de
choc électrique mortel.
4. Utilisez toujours un équipement correctement entretenu. Remplacez les câbles usés ou endommagés.
5. Veillez à garder votre environnement sec, incluant les vêtements, l’aire de travail, les câbles, le porteélectrode/torche et la source d’alimentation.
6. Assurez-vous que tout votre corps est bien isolé de la pièce à traiter et des pièces de la mise à la terre.
7. Si vous devez effectuer votre travail dans un espace restreint ou humide, ne tenez vous pas directement
sur le métal ou sur la terre; tenez-vous sur des planches sèches ou une plate-forme isolée et portez des
chaussures à semelles de caoutchouc.
8. Avant de mettre l’équipement sous tension, isolez vos mains avec des gants secs et sans trous.
9. Mettez l’équipement hors tension avant d’enlever vos gants.
10. Consultez ANSI/ASC Standard Z49.1 (listé à la page suivante) pour des recommandations spécifiques
concernant les procédures de mise à la terre. Ne pas confondre le câble de masse avec le câble de mise
à la terre.
CHAMPS ÉLECTRIQUES ET MAGNÉTIQUES — comportent un risque de danger. Le courant électrique
qui passe dans n’importe quel conducteur produit des champs électriques et magnétiques localisés.
Le soudage et le courant de coupage créent des champs électriques et magnétiques autour des câbles
de soudage et l’équipement. Par conséquent :
1. Un soudeur ayant un stimulateur cardiaque doit consulter son médecin avant d’entreprendre une opération
de soudage. Les champs électriques et magnétiques peuvent causer des ennuis pour certains stimulateurs
cardiaques.
2. L’exposition à des champs électriques et magnétiques peut avoir des effets néfastes inconnus pour la santé.
3. Les soudeurs doivent suivre les procédures suivantes pour minimiser l’exposition aux champs électriques
et magnétiques :
A. Acheminez l’électrode et les câbles de masse ensemble. Fixez-les à l’aide d’une bande adhésive lorsque
possible.
B. Ne jamais enrouler la torche ou le câble de masse autour de votre corps.
C. Ne jamais vous placer entre la torche et les câbles de masse. Acheminez tous les câbles sur le même
côté de votre corps.
D. Branchez le câble de masse à la pièce à traiter le plus près possible de la section à souder.
E. Veillez à garder la source d’alimentation pour le soudage et les câbles à une distance appropriée de
votre corps.
Manual 0560956456
SAFETY INSTRUCTIONS 1-7
iSERIES 100 /200 /300 /400 LES VAPEURS ET LES GAZ -- peuvent causer un malaise ou des dommages corporels, plus particulièrement dans les espaces restreints. Ne respirez pas les vapeurs et les gaz. Le gaz de protection
risque de causer l’asphyxie.
Par conséquent :
1. Assurez en permanence une ventilation adéquate dans l’aire de travail en maintenant une ventilation
naturelle ou à l’aide de moyens mécanique. N’effectuez jamais de travaux de soudage, de coupage ou de
gougeage sur des matériaux tels que l’acier galvanisé, l’acier inoxydable, le cuivre, le zinc, le plomb, le
berylliym ou le cadmium en l’absence de moyens mécaniques de ventilation efficaces. Ne respirez pas
les vapeurs de ces matériaux.
2. N’effectuez jamais de travaux à proximité d’une opération de dégraissage ou de pulvérisation. Lorsque
la chaleur ou le rayonnement de l’arc entre en contact avec les vapeurs d’hydrocarbure chloré, ceci peut
déclencher la formation de phosgène ou d’autres gaz irritants, tous extrêmement toxiques.
3. Une irritation momentanée des yeux, du nez ou de la gorge au cours d’une opération indique que la ventilation n’est pas adéquate. Cessez votre travail afin de prendre les mesures nécessaires pour améliorer
la ventilation dans l’aire de travail. Ne poursuivez pas l’opération si le malaise persiste.
4. Consultez ANSI/ASC Standard Z49.1 (à la page suivante) pour des recommandations spécifiques concernant la ventilation.
5. AVERTISSEMENT : Ce produitcontient des produits chimiques, notamment du plomb, reconnu par l’Étatde la Californie pour causerdes malformations congénitaleset d’autresdommages touchant le système
reproductif. Se laver les mainsaprès manipulation.
MANIPULATION DES CYLINDRES -- La manipulation d’un cylindre, sans observer les précautions nécessaires, peut produire des fissures et un échappement dangereux des gaz. Une brisure soudaine du
cylindre, de la soupape ou du dispositif de surpression peut causer des blessures graves ou mortelles.
Par conséquent :
1. Utilisez toujours le gaz prévu pour une opération et le détendeur approprié conçu pour utilisation sur
les cylindres de gaz comprimé. N’utilisez jamais d’adaptateur. Maintenez en bon état les tuyaux et les
raccords. Observez les instructions d’opération du fabricant pour assembler le détendeur sur un cylindre
de gaz comprimé.
2. Fixez les cylindres dans une position verticale, à l’aide d’une chaîne ou une sangle, sur un chariot manuel,
un châssis de roulement, un banc, un mur, une colonne ou un support convenable. Ne fixez jamais un
cylindre à un poste de travail ou toute autre dispositif faisant partie d’un circuit électrique.
3. Lorsque les cylindres ne servent pas, gardez les soupapes fermées. Si le détendeur n’est pas branché,
assurez-vous que le bouchon de protection de la soupape est bien en place. Fixez et déplacez les cylindres
à l’aide d’un chariot manuel approprié. Toujours manipuler les cylindres avec soin.
4. Placez les cylindres à une distance appropriée de toute source de chaleur, des étincelles et des flammes.
Ne jamais amorcer l’arc sur un cylindre.
5. Pour de l’information supplémentaire, consultez CGA Standard P-1, “Precautions for Safe Handling of
Compressed Gases in Cylinders”, mis à votre disposition par le Compressed Gas Association, 1235 Jefferson Davis Highway, Arlington, VA 22202.
ENTRETIEN DE L’ÉQUIPEMENT -- Un équipement entretenu de façon défectueuse ou inadéquate peut
causer des blessures graves ou mortelles. Par conséquent :
!
1. Efforcez-vous de toujours confier les tâches d’installation, de dépannage et d’entretien à un personnel
qualifié. N’effectuez aucune réparation électrique à moins d’être qualifié à cet effet.
2. Avant de procéder à une tâche d’entretien à l’intérieur de la source d’alimentation, débranchez l’alimentation électrique.
3. Maintenez les câbles, les fils de mise à la terre, les branchements, le cordon d’alimentation et la source
d’alimentation en bon état. N’utilisez jamais un équipement s’il présente une défectuosité quelconque.
1-8 SAFETY INSTRUCTIONS
Manual 0560956456
iSERIES 100 /200 /300 /400
4. N’utilisez pas l’équipement de façon abusive. Gardez l’équipement à l’écart de toute source de chaleur,
notamment des fours, de l’humidité, des flaques d’eau, de l’huile ou de la graisse, des atmosphères
corrosives et des intempéries.
5. Laissez en place tous les dispositifs de sécurité et tous les panneaux de la console et maintenez-les en
bon état.
6. Utilisez l’équipement conformément à son usage prévu et n’effectuez aucune modification.
INFORMATIONS SUPPLÉMENTAIRES RELATI VES À LA SÉCURITÉ -- Pour obtenir de l’information supplémentaire sur les règles de sécurité à observer pour l’équipement de soudage à l’arc électrique et le
coupage, demandez un exemplaire du livret “Precautions and Safe Practices for Arc Welding, Cutting and
Gouging”, Form 52-529.
!
Les publications suivantes sont également recommandées et mises à votre disposition par l’American Welding
Society, 550 N.W. LeJuene Road, Miami, FL 33126 :
1.
2.
3.
4.
5.
6.
7.
8.
ANSI/ASC Z49.1 - “Safety in Welding and Cutting”.
AWS C5.1 - “Recommended Practices for Plasma Arc Welding”.
AWS C5.2 - “Recommended Practices for Plasma Arc Cutting”.
AWS C5.3 - “Recommended Practices for Air Carbon Arc Gouging and Cutting”.
AWS C5.5 - “Recommended Practices for Gas Tungsten Arc Welding“.
AWS C5.6 - “Recommended Practices for Gas Metal Arc Welding”.
AWS SP - “Safe Practices” - Reprint, Welding Handbook.
ANSI/AWS F4.1, “Recommended Safe Practices for Welding and Cutting of Containers That Have Held
Hazardous Substances.”
9. CSA Standard - W117.2 = Safety in Welding, Cutting and Allied Processes.
!
SIGNIFICATION DES SYMBOLES - Ce symbole, utilisé partout dans ce manuel, signifie “Attention” ! Soyez
vigilant ! Votre sécurité est en jeu.
DANGER
Signifie un danger immédiat. La situation peut entraîner des blessures graves ou mortelles.
MISE EN GARDE
AVERTISSEMENT
Signifie un danger potentiel qui peut entraîner des blessures graves ou mortelles.
Signifie un danger qui peut entraîner des blessures corporelles mineures.
Classe de protection de l’enveloppe
L’indice de protection (codification IP) indique la classe de protection de l’enveloppe, c’est-à-dire, le degré de protection contre les corps solides étrangers ou l’eau. L’enveloppe protège contre le toucher, la pénétration d’objets
solides dont le diamètre dépasse 12 mm et contre l’eau pulvérisée à un angle de jusqu’à 60 degrés de la verticale.
Les équipements portant la marque IP21S peuvent être entreposés à l’extérieur, mais ne sont pas conçus pour
être utilisés à l’extérieur pendant une précipitation à moins d’être à l’abri.
MISE EN GARDE
Manual 0560956456
Ce produit a été conçu pour la découpe au plasma seulement. Toute autre utilisation pourrait causer des blessures et/ou endommager l’appareil.
SAFETY INSTRUCTIONS 1-9
iSERIES 100 /200 /300 /400 MISE EN GARDE
L’équipement pourrait basculer s’il est placé sur une
surface dont la pente dépasse 15°. Vous pourriez
vous blesser ou endommager l’équipement de façon
importante.
15°
Art# A-12726
MISE EN GARDE
Soulevez à l’aide de la méthode et des points d’attache
illustrés afin d’éviter de vous blesser ou d’endommager
l’équipement.
Art# A-12736
1-10 SAFETY INSTRUCTIONS
Manual 0560956456
iSERIES 100 /200 /300 /400
SECTION 2:
TORCH MAINTENANCE
2.01 Coolant Leak Trouble-Shooting
Never operate the system if coolant leaks from the torch. A steady drip indicates that torch parts are damaged or installed improperly. Operating the system in this condition can damage the torch head. Refer to the following chart for guidance on coolant
leakage from the torch head.
Torch leaks
Are Torch
Consumable Parts
Installed?
No
Leaking from
Coolant Supply or
Coolant Return?
Yes
Are Parts New
or Used?
Return
Order Coolant
Check Valve
Kit 9-4846
Supply
Order Coolant
Tube Replacement Kit
The parts probably are worn out.
See chart for approximate life expectancy.
Used
The torch may be damaged. See page
to determine if head damage has occurred.
New
Are Parts fully
assembled into
the Torch?
Yes
Is the Torch Damaged?
No
Unsure?
Remove and Lubricate
all O-rings on Torch Head,
Consumables Cartridge,
and Consumables.
Re-assemble Torch.
Still leaks?
Yes
Yes
Disassembly fully
and re-assemble
the Torch Properly.
See Installation Manual.
Replace Torch Head
Yes
Replace Consumable
Cartridge and Shield Cup.
Torch still leaks?
Art # A-09638
Manual 0560956456
TORCH INFORMATION 2-1
iSERIES 100 /200 /300 /400 Torch
Electrodes
Art # A-09653
Amperage
30
50
70
85
100
150
200
250
300
400
2-2 Plasma Gas
Recommended Wear
Depth for Electrode
Replacement
Inch
mm
O2
0.04
1
Air
0.04
1
N2
0.04
1
O2
0.04
1
Air
0.08
2
N2
0.04
1
O2
0.04
1
Air
0.08
2
N2
0.04
1
Air
0.08
2
O2
0.04
1
H35
0.08
2
N2
0.08
2
O2
0.06
1.5
H35
0.08
2
N2
0.08
2
O2
0.06
1.5
H35
0.08
2
N2
0.08
2
O2
0.06
1.5
O2
0.06
1.5
H35
0.08
2
N2
0.08
2
O2
0.08
2
H17
0.08
2
H35
0.08
2
N2
0.08
2
TORCH INFORMATION
Manual 0560956456
iSERIES 100 /200 /300 /400
APPENDIX 1: CNC - Control Module PCB Connections
TB1
(LV)
OK To Move 2
High +10V
10K
Analog Current Control
Wiper / Input
Low (-)
Divided Arc Volts
Output
Start/Stop Input
12
11
10
9
(+) 8
(-) 7
(+) 6
(-) 5
Stop (NC)
4
(LV) OK To Move 2
3
(+) 2
(-) 1
CNC Plasma Enable
TB2
OK To Move
(+)
SW6
DC
12
11
10
9
Pilot On Output
(Contacts)
Preflow On
Hold Start
8
7
6
5
(+) 4
(-) 3
(+) 2
Art # A-11512_AB
(-) 1
TB3
Spare #2 Output
Normally Open Contacts
12
Spare #2 Output
Normally Closed Contacts
10
Spare #1 Output
Normally Open Contacts
8
23X5560_AB
Expanded
Metal
Corner Current
Reduction
Remote
Plasma Marking
Manual 0560956456
11
9
7
(-) 6
(+) 5
(-) 4
+ 3
(-) 2
(+) 1
APPENDIX
A-1
iSERIES 100 /200 /300 /400
APPENDIX 2: CNC
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, TB2 & TB3
are common to each other. J15 pins 1, 4, 5, 10, 17, and TB1-1, 5, 7, 9, and TB2-1 & 3 are all common. J15 pin 12 and
TB2-10 are also connected to the others when SW6 (OK to Move select) is set for voltage.
Rear Panel CNC Connector J15:
37 Circuit (Amp CPC) Remote Standard:
These are also duplicated on TB1, TB2 & TB3 use one or the other not both.
Chassis gnd (for SC-11 cable shield) 1
Start/Stop
3 (+); 4 (-)
Ok to Move (contacts or voltage 1) 12(-); 14 (+)
Divided Arc volts (selectable ratio
50:1; 40:1; 30:1; 16.6:1, 25:1)
5 (-); 6 (+)
PreFlow ON 7 (+); 9 (-)
Corner Current Reduction 10 (+); 11 (-)
Isolated Circuit Comm (for SC-11)
8
Chassis Gnd 13
Keying plug15
Hold Start
16(+); 17 (-)
Plasma Mark
21 (+); 22 (-)
Cut Expanded Metal
23 (+); 24 (-)
CNC Plasma Enable2
25 (+); 26 (-)
Remote Analog Current Control 3
29 (+); 30 (signal); 31 (-)
Stop (Latched) SW4
32 (+); 33 (-)(comm.)
Pilot is ON (contacts)
34; 35
Spare (contact) 36; 37
A-2 APPENDIX
Manual 0560956456
iSERIES 100 /200 /300 /400
Internal CNC connections. TB1, TB2 & TB3 on CCM module.
Connections are provided on the CCM module TB1, TB2 & TB3 terminal blocks including most of the rear panel
functions plus 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
CCM module. User shall provide strain relief / cord grip for user installed cable.
TB1
FunctionConnection
CNC Enable/Disable
TB1-2 (+), TB1-1(-)(comm.)
OK to Move 2
TB1-3 &TB1-12 Contacts only, rated 1A @ 28 VAC/DC
Stop Latched (NC) 4
TB1-4 (+) & TB1-5 (-) (comm.) used with Start Latched
Start/Stop Ret 4
TB1-6 (+), TB1-5 (-) (comm.)
TB1-6 (+), TB1-5 (-) (comm.) used with Stop Latched
or Start Latched (NO) 4 Divided Arc Voltage
TB1-8 (+), TB1-7 (-) comm.
Remote Analog Current Control
TB1-9 Analog Comm. (-) or 10K CC Pot low
TB1-10 Analog in (+) or CC Pot Wiper
TB1-11 10K CC Pot Hi (+10V @ 1 ma. Supply)
TB2
FunctionConnection
Hold Start
TB2-2 (+),TB2-1 (-) (comm. )
Preflow ON
TB2-4 (+), TB2-3 (-) (comm.)
Pilot is ON (contacts)
TB2-6, TB2-8 rated 1A @ 120 VAC or 28 VDC
OK to Move (contacts or DC Volts)5
TB2-12 (+), TB2-10 (-)
TB3
FunctionConnection
Plasma Marking
TB3-2(+), TB3-1(-) (comm.)
Corner Current Reduction
TB-4(+), TB3-3(-)(comm.)
Cut Expanded Metal
TB3-6(+), TB3-5(-)(comm.)
Spare NO Contact
TB3-7, TB3-8
Spare NC Contact
TB3-9, TB3-10
Spare NO Contact
TB3-11, TB3-12
SW6 on CCM I/O PCB selects OK to Move for isolated contact closure or DC Volts (15-18V) at <100ma. When
set for contacts, OK to Move circuit is rated for 120 VAC / 28 VDC
1
Remove factory installed jumper from TB1-1 & 2 if using CNC Plasma Enable in J15.
2
See below.
3-5
Manual 0560956456
APPENDIX
A-3
iSERIES 100 /200 /300 /400
CNC Input / Output Descriptions
E-Stop input—Requires closed connection rated for 35ma. @ 20VDC for unit to operate. Factory installed jumper
between TB1-1&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.
SUSTAINED START / STOP
START / STOP
MOMENTARY
STOP
TB1-5
TB1-6
START
START / STOP
TB1-4
TB1-5
TB1-6
Divided Arc Voltage output — Arc Voltage signal is isolated from plasma supply, however (-) is common with
other isolated CNC signals. Max Divided Arc Voltage signal level depends on actual arc voltage times divide ratio
however can not exceed approximately 12 V.
Analog Current Control input— Analog Current Control includes analog isolation module, separate isolation
module not usually required however it’s low input is common with the other isolated CNC inputs. Scaling of Analog
Current Control input is 0V = 0A, 10V. = MAX output and is linear in between. However MIN output is 5A. User
is responsible for setting correct analog voltage to maintain at least 5A output. To use Analog Current Control on
the
I/O PCB set SW 11 to down position and on the CPU PCB set SW8-2 ON (up).
3
Hold Start input—Normally open, close to hold start. Circuit rating 10 ma. @ 20VDC. Delays pilot ignition, gas
preflow continues. Used by some height controls to flow gas while finding height. Also used for synchronizing starts
when multiple plasma supplies are used on same cutting table. User supplies circuit to keep Hold Start inputs active until all torches have found height. Used with CNC START. Apply START to begin gas flow. Same time apply
HOLD to delay ignition until height is found. Remove HOLD to ignite pilot, initiate arc transfer.
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 been
found. Then the plasma takes 1-2 seconds (or more) to perform preflow before igniting pilot. Some THCs have an
output that can start preflow early during height finding saving 1-2 seconds on each cut. PREFLOW ON should
remain active for at least 1 second after CNC START is applied. It is OK if it remains on until the end of the cut.
Need to recycle it to begin a new preflow prior to applying START for the next cut.
Pilot On output – Relay contacts rated 1A @ 120 VAC / 28 VDC. Contacts close when pilot on. Can be wired parallel
with Ok to Move contacts to start machine motion when pilot established. Used when starting over holes. Starting
over holes requires setting SW8-1 ON (up) on the CPU PCB for extended pilot time. Using extended pilot time to
start over holes 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
start
X-Y motion. Relay contacts rated 1A @ 120 VAC or 28 VDC when SW6 set for contacts. When SW6 is set for
DCV, output supplies 15-18 VDC @ 100 ma. May be wired parallel with Pilot On to start cutting machine motion
as soon as pilot established.
A-4 APPENDIX
Manual 0560956456
iSERIES 100 /200 /300 /400
OK to Move2 – Provides a second set of N.O. contacts that close when arc transfer is detected. Contacts are rated
for maximum of 24 VAC/DC @ 1A. Simplified CNC Circuit.
5
+10V @ 10ma. For Remote CC Pot – Previously CCM versions if one wanted to use a potentiometer for the Remote
Analog Current Control (CC) input an external 10 V supply was required for Pot High.. Now an isolated (from main
plasma circuits) 10V supply is provided. Recommended value of the pot is 5K or 10K.
5
TB1
Ext. +10V
11 +10V
10
WIPER
9
Art # A-09246
Plasma Marking Select (Remote) – Plasma Marking, available only with Automatic Gas Control, may be activated with a contact closure 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
ISeries power supplies It is OK to leave SW8-4 on whether you are marking or not.
5
The following functions may not yet be available on your system. *
*Corner Current Reduction (input)--- When activated, normally from a table controller’s corner or height control
inhibit signal, signaling that the cutting speed is being reduced to navigate a corner or small radius, the cutting
current is reduced at a fixed rate to a predetermined level to provide an improved cut at the lower speed.
*Cut Expanded Metal (input)---Normally the plasma supply is optimized for pierce cutting, high pierce height
directly above the metal to be cut, short pilot time, etc. Activating this input adjusts the plasma supply to optimize
it’s parameters for cutting expanded metal, perforated metal, running edge starting, etc. Among other changes
the transfer height is reduced to same as cut height. In addition to activating the Cut Expanded Metal input CCM
switch SW1-1 should be turned on automatically restart the pilot and SW8-1 set on for longer pilot time.
*Spare contacts --- Not currently activated. Planned for future CCM code release.
Manual 0560956456
APPENDIX
A-5
iSERIES 100 /200 /300 /400
Simplified CNC Circuit
TB2
12
11
10
9
8
7
6
5
4
3
2
1
5
-
+10V
5
6
8
V OL TA GE D IV IDER
G ND
AL L SW
SW1 2 A (
SW1 2 B (
SW1 2 C (
TB2
Spare #2 NO 12
11
4
(+)
(-)
(+)
(-)
+
4
SW 12D
Prefl ow ON
Prefl ow ON
Hol d Start
Hol d Start
B
3
PILOT is ON
3
SW 12C
PILOT is ON
OK
SW6B
1
OK to M OV E (-)
C ONTA CT S
SW 12A
OK to M OV E (+)
SW6A
D C VO LT S
7
OK2 (cont act)
12
+10V (CC Pot Hi ) 11
CC Pot W iper
10
CC Pot L ow
9
Di v A rc V (+)
8
Di v A rc V (-)
7
/Start - Stop (+)
6
/Start - Stop (-)
5
Stop Mo m NC
4
OK2 (cont act)
3
/ CNC Enabl e (+)
2
/ CNC Enabl e (-)
1
+18VDC
2
TB1
OK TO MOV E SELECT
18 V D C or Con tacts
SW 12B
Ult racut X T Simplified CNC
OFF f o r
1 ) ON =
2 ) ON =
3 ) ON =
50:
16.
30:
40:
1 ( def aul t )
7 : 1 ( SC- 1 1 )
1
1
Spare #2 NC 10
Spare #1b NO
/ Cut Ex panded M etal (-)
/ Cut Ex panded M etal (+)
/ Corner Current Reducti on (-)
/ Corner Current Reducti on (+)
/ Plasma M arki ng (-)
/ Plasma M arki ng (+)
9
8
7
6
5
4
3
2
1
PSR
Art # A-11579
A-6 APPENDIX
Manual 0560956456
iSERIES 100 /200 /300 /400
J54 - Rem ote HM I & CN C CO M M
(100)
(101)
(102)
Harness to Relay PCB
(109)
(108)
(115)
Harness to CPU PCB
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
G ND
SPA RE #1a
(142)
(116)
(117)
(118)
(119)
(120)
(133)
(134)
(137)
(139)
(138)
(143)
J22
C hassi s
(140)
(141)
(136)
(135)
(132)
(153)
(133)
(134)
(135)
(136)
(137)
(138)
(139)
(140)
(141)
(142)
(143)
(144)
(145)
(144)
(145)
(146)
(147)
(148)
(149)
(150)
(151)
(146)
(147)
(148)
(149)
(150)
(151)
(152)
(154)
(155)
(132)
(152)
(153)
(154)
(155)
(156)
(157)
(158)
(159)
(156)
(157)
(158)
(159)
J15-1 to chassis used f or
SC-11 cable shield
1 - 24 V AC
2 - 24 V AC Re t
3- Jumper to 24 V AC
5-H M I Pl asma Enabl e SW
6-H M I Pl asma Enabl e SW
7 - K ey Pl ug
8 - Tx +
9 - GND
RS 485
10 - GN D
/ 422
12 - Tx 13 - Rx +
14 - Rx -
Comm
J15-CNC
J21
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
1
2
3
4
5
6
7
8
9
10
11
12
13
14
The COM M Ref at pin
8 is also f or the SC-11
J15-13 connects SC-11
chassis to PS chassis.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
3- / CNC Start (+)
4- / CNC Start (-)
5- D ivided A rc V (-)
6- D ivided A rc V (+)
7- / Preflow ON (+)
8- COM M Ref (1K Ohm)
9- / Preflow ON (-)
12- OK to M ove (-)
14- OK to M ove (+)
15 - K ey Plug
16- / H old Start (+)
17- / H old Start (-)
21- / Plasma M ark (+)
22- / Plasma M ark (-)
23- / Cut Expanded M etal (+)
24- / Cut Expanded M etal (-)
25- / CNC Plasma Enable (+)
26- / CNC Plasma Enable (-)
29- Remote CC Pot H igh
30- Remote CC (analog)
31- Remote CC Pot L ow
32- Stop SW (momentary) *
33- Stop SW Ret
34- Pilot is ON (a)
35- Pilot is ON (b)
36- Spare OU T #1 (a)
37- Spare OU T #1 (b)
* Used with Mom en tary C NC St art SW
Art # A-11579
Manual 0560956456
APPENDIX
A-7
iSERIES 100 /200 /300 /400
CNC Connections
Cutting Machine
CNC Cable
Power Supply
J15
START/STOP
1
2
3
4
5
6
7
8
9
10
11
(9)
(10)
(11)
Start Motion
(OK-To-Move)
{
(12)
*
NC
..........
Source, 16 VDC, 10 ma.
... Divided Arc V (-)
.......... Divided Arc V (+)
.......... Pre Flow ON (+)
..........
Pre Flow ON (-)
..........
...
Corner Current Reduction (+)
Corner Current Reduction (-)
12
13 *
(14)
14
(16)
15
16
DC
(+)
*
(1)
( 2)
(3)
(4)
( 5)
(6)
( 7)
SW6
OK-To-Move
Relay
DCV (-)
Contact or
(1A @
DCV (+)
120 VAC
( 15 - 18 VDC @
or 28 VDC)
up to 100 ma.)
.......... /Hold Start(+)
17 .......... /Hold Start(-)
18
19
20
21 .......... /Plasma Mark (+)
22 .......... /Plasma Mark (-)
23 .......... /Cut Expanded Metal (+)
24 .......... /Cut Expanded Metal (-)
25 .......... /CNC Plasma Enable (+)
26 .......... /CNC Plasma Enable (-)
(17)
(21)
(22)
(23)
(24)
(25)
(26)
27
28
29
30
31
32
33
34
35
(29)
(30)
(31)
(32)
(33)
(34)
(35)
10 K
(36)
(37)
36
37
..........
..........
..........
..........
..........
..........
..........
Remote CC Pot High (+10VDC)
Remote CC 0-10V Signal or Pot Wiper
Remote CC Pot Low (-)
Stop SW (momentary)
Stop SW Ret
Pilot is ON (a)
Relay contact 1A @
120 VAC or 28
Pilot is ON (b)
.......... Spare OUT #1 (a)
.......... Spare OUT #1 (b)
Shield
**
Represents switch,
relay, open
collector transistor, etc.
A-8 *
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.
APPENDIX
Art # A-11901
Manual 0560956456
iSERIES 100 /200 /300 /400
APPENDIX 3: GSC Control PCB Layout
J6
TP5
TP4
SW2 SW1
TP3
J5
TP6
TP2
J1
TP7
J2
J8
TP1
J3
LED
D1
D-17
D21
D22
LED
D_E1
D_E15
J4
Art # A-09188_AC
J9
Manual 0560956456
APPENDIX
A-9
iSERIES 100 /200 /300 /400
APPENDIX 4: DPC Control PCB Layout
D7
J9
J6
TP3
D11
TP7
D10
D12
J5
TP1
D6
TP6
D5
D4
D3
TP4
J4
SW2
J3
J8
D2
TP8
D1
TP11
D9
D8
J2
SW1
TP2
J1
TP10
TP9
J10
Art # A-09189_AB
TP5
A-10 APPENDIX
Manual 0560956456
iSERIES 100 /200 /300 /400
APPENDIX 5: GSC / DPC Power Supply PCB Layout
J2
D9
D7
D6
TP1
TP6
D5
F2
TP3
TP7
TP2
TP8
D16
TP5
TP4
Art # A-09597_AB
F1
J1
Manual 0560956456
APPENDIX
A-11
iSERIES 100 /200 /300 /400
APPENDIX 6: CCM CPU PCB Layout
= Test Point
= Test Point
Art # A-11675_AC
A-12 APPENDIX
Manual 0560956456
iSERIES 100 /200 /300 /400
CCM CPU PCB
Test Points
TP1GND
TP2ISO +5.0V
TP3+24V
TP4+3.3V
TP5ISO GND
TP6+5.0V
TP7TOTAL DEMAND 3.3V=400A
TP9/WR
TP10/RD
TP11
CPU TEMP SENSE
TP12+3.3VA
TP13-15VDAC
TP14PC2
TP15+15VDAC
TP16CLKO
TP18OSC_CLOCK
LED Reference
D2
Red
RXD
D3
Red
TXD
D4
Red
Fiber Out 2
D7
Red Fiber Out 1
D11
Green Future Use
D17Green Future Use
Manual 0560956456
APPENDIX
A-13
iSERIES 100 /200 /300 /400
APPENDIX 7: CCM I/O PCB Layout
A-14 = Test Point
Art # A-11676_AD
= Test Point
APPENDIX
Manual 0560956456
iSERIES 100 /200 /300 /400
CCM I/O PCB
J Connectors
Test Points
J21 BASIC CNC
TP1GND
J22 EXTENDED CNC
TP2/COOLANT FANS ON
J23RELAY - INTERFACE BOARD
TP3/TORCH PUMP ON
J24ARC / TIP VOLTS
TP4LOW COOLANT FLOW (SW)
J25 TEST
TP5COOLANT FLOW SIGNAL (PULSE)
J26 GAS BOX
TP6+15V ISOLATED
J28 TO CPU
TP7-15V ISOLATED
J29 TO CPU
TP8+18V ISOLATED
TP9ANALOG CURRENT CONTROL 0-3.3V
TP10
GND ISOLATED
TP11
/PILOT ENABLE
TP12+5VDC
TP13-15VDC
TP14+15VDC
TP1524VDC
TP18
+5V ISOLATED
TP19
WORK CURRENT
LED Reference
D2
Green PLASMA ENABLE
D3
Green E-STOP_PS
D4
Green GAS ON
D6
Green CNC START
D8
Green HOLD START
D12Green PREFLOW ON
D13Green CSD
D18Green MARK
D20Green SPARE1
D25Green EXP METAL
D33Green OK TO MOVE
D37Green PSR
D41Green SPARE FIELD OUT 2
D43Green SPARE FIELD OUT 1
Manual 0560956456
APPENDIX
A-15
iSERIES 100 /200 /300 /400
APPENDIX 8: Pilot PCB Layout
= Test Point
= Test Point
Art # A-11677_AB
A-16 APPENDIX
Manual 0560956456
iSERIES 100 /200 /300 /400
Pilot PCB Test Points
TP1GND
TP2PILOT GATE
TP3+5V
TP4TIP
LED Reference
D2
Green PILOT ENABLE
D11
Green +5V
Manual 0560956456
APPENDIX
A-17
iSERIES 100 /200 /300 /400
APPENDIX 9: Relay and Interface PCB Layout
= Test Point
= Test Point
A-18 APPENDIX
Art # A-11678_AB
Manual 0560956456
iSERIES 100 /200 /300 /400
Relay and Interface PCB Test Points
TP1GND
TP2-15V
TP3+5VDC
TP4+12V
TP5+24V
TP6+15V
TP7+5VDC
LED Reference
D2
Green 1 TORCH GAS ON
D7
Green PILOT ENABLE
D11
Green PILOT CURRENT DETECTED
D12Green WORK CURRENT DETECTED
D22Green CONTACTORS ON
D23Green RF ON
D24Green FANS ON
D25Green PLASMA ENABLED
D26Green 1 TORCH ON
D27Green TORCH COOLANT ON
Manual 0560956456
APPENDIX
A-19
iSERIES 100 /200 /300 /400
APPENDIX 10: Display PCB Layout
= Test Point
= Test Point
Art # A-11679
A-20 APPENDIX
Manual 0560956456
iSERIES 100 /200 /300 /400
Display PCB Test Points
TP1GND
TP2+5VDC
TP3+24VDC
Manual 0560956456
APPENDIX
A-21
iSERIES 100 /200 /300 /400
APPENDIX 11: System Bias PCB Layout
= Test Point
= Test Point
Art # A-11680_AB
A-22 APPENDIX
Manual 0560956456
iSERIES 100 /200 /300 /400
System Bias PCB Test Points
TP1GND
TP224VDC
TP3DC INPUT POSITIVE
TP4Vcc1
TP5Vcc2
TP6GATE
TP7PRIMARY GND
TP8+12V PRIMARY
TP9P_ISOL_GND
TP10
DC SENSE POSITIVE
LED Reference
D3
Red
MISSING PHASE
D4
Red
AC V HIGH
D14Red
AC V LOW
D15Green VAC_IDA
D26Green +12V PRIMARY
D27Green VAC_IDB
D30Green 24VDC
D44Green TRANSFORMER ON
Manual 0560956456
APPENDIX
A-23
iSERIES 100 /200 /300 /400
APPENDIX 12: Main Inverter Bottom PCB Layout
A-24 Art # A-11681_AC
= Test Point
= Test Point
APPENDIX
Manual 0560956456
iSERIES 100 /200 /300 /400
Main Inverter Bottom PCB Test Points
TP1GND
TP2GATE 2A
TP3GATE 1A
TP4GATE 3A
TP5GATE 4A
TP6GATE 2B
TP7GATE 1B
TP8GATE 4B
TP9GATE 3B
TP10+12VP
TP11+12VDC
TP12
THERMISTOR SIDE A
TP13
THERMISTOR SIDE B
TP14+5VDC
TP15PGND
LED Reference
D3
Red
D4
Green READY
Manual 0560956456
CAP IMBALANCE
APPENDIX
A-25
iSERIES 100 /200 /300 /400
APPENDIX 13: Main Inverter Top PCB Layout
A-26 Art # A-11682_AC
= Test Point
= Test Point
APPENDIX
Manual 0560956456
iSERIES 100 /200 /300 /400
Main Inverter Top PCB Test Points
TP1GND
TP2GATE 2A
TP3GATE 1A
TP4GATE 3A
TP5GATE 4A
TP6GATE 2B
TP7GATE 1B
TP8GATE 4B
TP9GATE 3B
TP10+12VP
TP11+12VDC
TP12
THERMISTOR SIDE A
TP13
THERMISTOR SIDE B
TP14+5VDC
TP15PGND
LED Reference
D3
Red
D4
Green READY
Manual 0560956456
CAP IMBALANCE
APPENDIX
A-27
iSERIES 100 /200 /300 /400
APPENDIX 14: Control and Fault PCB Layout
= Test Point
= Test Point
Art # A-11683_AC
A-28 APPENDIX
Manual 0560956456
iSERIES 100 /200 /300 /400
Control and Fault PCB Test Points
TP1GND
TP22+12VDC
TP23+5VDC
TP24
GATE 1+
TP25A_OUT1
TP26B_OUT1
TP27
GATE 1-
TP28I_SNS1
TP29
GATE 2+
TP30
I_DMD1 0.5V-6.7V
TP31
GATE 2-
TP32-12VDC
TP33
START 2
TP34SHDN
TP35ENABLE
TP36
READY IN
TP37
READY OUT
LED Reference
D1
Red
INV FLT
D14Red
OVER TEMP
D24Green PWM ON
D32Red
PRI OC
Manual 0560956456
APPENDIX
A-29
iSERIES 100 /200 /300 /400
APPENDIX 15: Cap Bias Bottom PCB Layout
Art # A-11685_AC
A-30 APPENDIX
Manual 0560956456
iSERIES 100 /200 /300 /400
APPENDIX 16: Cap Bias Top PCB Layout
Art # A-11686_AC
Manual 0560956456
APPENDIX
A-31
iSERIES 100 /200 /300 /400
APPENDIX 17: Suppressor PCB Layout
Art # A-11684_AC
A-32 APPENDIX
Manual 0560956456
Manual 0560956456
APPENDIX
Art # A-13072
Over Flow
Supply
Coolant tank
Cold Plate 1
Cold Plate 2
Cold Plate 3
Pump
Level Switch
Coolant
Return
Radiator
HS1 Temp
Sensor
Flow
Flow
Bubble
Sensor
Flow Switch
DESCRIPTION
ECO B2502
Torch Coolant
Supply
Torch Coolant
Return
Filter 1
REV
AA
APPROVED
AJR
XT-300
RAS 1000
**FOR 400 AMP
SYSTEMS
HE400
DATE
8-8-2013
iSERIES XT POWER SUPPLIES
100A-400A
iSERIES 100 /200 /300 /400
APPENDIX 18: COOLING DIAGRAM
A-33
iSERIES 100 /200 /300 /400
APPENDIX 19: Remote Arc Starter Schematic
2
Jumper in cable
to ID Arc Starter
is connected.
A
PLASMA
POWER
SUPPLY
J59-RAS
1
2
3
4
5
6
7
8
9
10
11
12
13
14
GND
3
4
RAS
1000 XT
5
6
A
IGNITION UNIT SIG 4.5
J58
Chassis gnd
120 VAC
120 VAC RET
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
115 Vac
GND
115 Vac RET
Ho
Hb
(99)
(98)
(49)
(52)
Torch Shield
NEG
NEG
0.047 uf
CGND
GND
PU
100K
0.047 uf
B
RAS Capacitor PCB
Brass Ring
NEG
B
0.1 uf
Neon
(-)
Electrode
1
PLT
PILOT
(+)
PILOT
TORCH
Tip
L1
Work
(+)
GND
WORK
C
C
Art # A-13073
Revision
Rev
AA
By
ECO B2487
Date
Victor Technologies Headquarters
RWH 07/30/2013
16052 Swingley Ridge Road, Suite 300
St Louis, Missouri 63017 USA
D
Date Printed
7/30/2013
Drawn
Date Revised
7/30/2013
Date
The information contained herein is proprietary to Victor Technologies.
Not for release, reproduction or distribution without written consent.
Size
Sheet
Title
Drawing Number
SCHEMATIC
A-34 2
3
4
APPENDIX
A
03/13/2013
1 of
1
042X1361
RAS 1000 XT Arc Starter
1
DAT
D
5
6
Manual 0560956456
iSERIES 100 /200 /300 /400
This Page Intentionally Blank
Manual 0560956456
APPENDIX
A-35
iSERIES 100 /200 /300 /400
APPENDIX 20: Schematic, DFC Auto Gas Box System
2
1
3
DMC3000 - MANIFOLD CONTROLLER ASSEMBLY
E_STOP NO
E_STOP COM
See list by DPC 3000 Power Supply
P1
(1)
(3)
1
2
3
4
5
6
7
8
(2b)
(5)
(6)
(8)
(9)
(5)
(6)
1
2
3
4
5
6
7
8
9
10
11
12
13
14
(Isolated)
HMI Serial/Control
J14
J62
4W
2W
1
2
3
4
5
6
7
8
9
10
11
12
13
14
J14
4W
2W
SW14 - LINE
SW14
TERMINATION
normally on
(refer to manual)
8
7
C
90 1
2
3
6 54
DMC3000 Control PCB LEDs
SOLENOID DRIVE ON INDICATOR (GREEN LEDs)
D1 - SOL_V1 (H35 PLASMA))
D2 - SOL_V2 (O2_PLASMA)
D3 - SOL_V3 (AIR_PLASMA)
D4 - SOL_V4 (N2 PLSMA)
D5 - SOL_V5 (AUX PLASMA)
D6 - SOL_V6 (O2 SHIELD)
D7 - SOL_V7 (AIR_SHIELD)
D8 - SOL_V8 (N2 SHIELD)
J21
D9 - SOL_V9 (H2O SHIELD)
1
D10 - SOL_V10 (O2 PREFLOW)
2
D11 - SOL_V11 (AIR PREFLOW)
3
D12 - SOL_V12 (N2 PREFLOW)
MANIFOLD ID
D13 - SOL_V13 (ARGON MARKING)
D14 - SOL_V14 (AIR MARKING)
D15 - SOL_V15 (N2 MARKING)
D16 - (SPARE)
D17 - +5VDC
1
2
3
4
5
6
SW2-2
SW1-3
SW2-3
SW1-4
SW2-4
J6
J2
1
2
3
4
5
6
7
8
9
10
11
12
13
14
P5
1
2
3
4
5
6
7
8
9
1
2
3
4
5
6
USB
CPU LEDS
3
4
4
5
5
6
6
(S1-T)
(8)
(9)
SHIELD
7
7
8
8
9
10
11
12
13
14
9
10
11
12
13
14
CHASSIS GND
TSC 3000
H35_PLASMA
SOL2 O2_PLASMA
(S2-T)
(S2-B)
SOL3 AIR_PLASMA
(S3-T)
(S3-B)
SOL5
(S5-T)
(S5-B)
SOL7
(S7-T)
(S7-B)
SOL4
N2_PLASMA
(S4-T)
(S4-B)
FUEL_PLASMA
SOL6
O2_SHIELD
(S6-T)
(S6-B)
AIR_SHIELD
SOL8
(S8-T)
N2_SHIELD
(S8-B)
(S9-T)
RS232 Prog
SOL9
(S9-B)
H20_SHIELD
SOL10
O2_PREFLOW
(S10T)
(S10B)
J3
HW ID
P4
1
2
TX/RX
+5 VDC
D21
D22
CCM CANBUS
ACTIVE
DPC CANBUS
ACTIVE
U4/U5
U7/U9
FiberOptic
AIR_PREFLOW
SOL12
N2_PREFLOW
(S12T)
(S12B)
SOL13 ARGON_MARKING
(S13T)
(S13B)
(S14T)
(S14B)
SOL15
(S15T)
(S14B)
SOL DRIVE B
FiberOptic
Tx Gray;
Rx Black
SOL11
(S11T)
(S11B)
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
SOL14 AIR_MARKING
N2_MARKING
TEST POINTS - CONTROL PCB
TP1 - GND
TP2 - Processor TEMP
TP3 - +VREF
TP4 - Processor CLKO
TP5 - +3.3V
TP6 - AGND
TP7 - +5V
D2 = SLAVE SUPPLY
CAN BUS ACTIVE
D3 = GCM CAN BUS ACTIVE
D11 = INITIALIZING /
PROGRAMMING
D12 = STATUS CODE
D13 = +5VDC
D17 = RS485 TXD
D18 = RS485 RXD
SOL1
(S1-B)
SOL DRIVE A
DMC FiberOptic Ports
J65
2
E_STOP NO
MANIFOLD
P8
JTAG
1
2
3
SOLENOID FAULT INDICATOR (RED LEDs)
D_E1 - SOL_V1 FLAG (H35_PLASMA)
D_E2 - SOL_V2 FLAG (O2_PLASMA)
D_E3 - SOL_V3 FLAG (AIR_PLASMA)
D_E4 - SOL_V4 FLAG (N2_PLASMA)
D_E5 - SOL_V5 FLAG (AUX_PLASMA)
D_E6 - SOL_V6 FLAG (O2_SHIELD)
D_E7 - SOL_V7 FLAG (AIR_SHIELD)
D_E8 - SOL_V8 FLAG (N2_SHIELD)
D_E9 - SOL_V9 FLAG (H2O_SHIELD)
D_E10 - SOL_V10 FLAG (O2_PREFLOW)
D_E11 - SOL_V11 FLAG (AIR_PREFLOW)
D_E12 - SOL_V12 FLAG (N2_PREFLOW)
D_E13 - SOL_V13 FLAG (ARGON_MARKING)
D_E14 - SOL_V14 FLAG (AIR_MARKING)
D_E15 - SOL_V15 FLAG (N2_MARKING)
THC (future)
SW10-ADDRESS
+5 VDC
normally 0
Data +
(refer to
Data manual)
COM
Shield
SW2-1
SW1-2
BLK
P54
1
2
E_STOP COM
GROUNDING SCREW
19X2200
P1
(5)
P61
24 VAC
24 VAC RET
HMI PRESENT
D
PLASMA ENABLE
COM
Tx+ (A) KEY
SIG COM
SIG COM
Tx- (B)
Rx+
RxSHIELD
SHIELD
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
J61
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
(0V)
(20V)
(1)
(2)
(3)
(3)
(2)
(1)
(5)
(6)
(8)
(9)
(10)
Tx+ (A)
(12)
Tx- (B)
(9)
(10)
(8)
(12)
P3
POWER
P5
1
2
3
4
5
6
7
8
9
LEDS - INTERFACE PCB:
D1 = RX (RS 485)
D14 = RX (RS 232)
D15 = TX (RS 232)
TEST POINTS - INTERFACE PCB
TP1 - GND
TP2 - UNREG VDC
TP3 - +5VDC
TP4 - +20 VDC
HMI INTERFACE PCB
19X2407
1
2
3
4
5
6
POWER SUPPLY
24 VAC to 20 VDC
P2
1
2
3
4
5
6
COM1
RS232
1
2
3
4
5
6
7
8
9
10
Configured
for RS485
+
-
(0V)
SW1
COM2
HMI POWER
(20V)
P10
PLASMA ENABLE
(6)
GND
TPC- 660E TOUCH SCREEN PANEL
1
2
3
4
5
6
7
8
9
Tx- (B)
SERIAL
Rx+
COMMUNICATION Rx-
SW1-1
4
3
2
1
STATUS LED (RED)
1
2
3
4
5
6
7
8
9
10
11
12
13
14
POWER
1
3
NOTE:
DMC solenoids are 18 VDC.
Coils are about 46 ohms.
24 VDC is applied for 1 second
then reduced by pulse width
modulation to an average of
approximately 7-8 VDC.
20
19
18
17
16
15
14
13
12
11
10
9
8
7
6
5
4
3
2
1
OPTION SWITCHES
J1
RED
J54
(2a)
1
2
3
4
5
6
7
8
9
10
I
(PW1)
KEY PLUG
Tx+ (A)
(PW2)
PLASMA ENABLE
(PW3)
VAC
24 VAC RET
(1)
KEY PLUG
DMC3000 CONTROL PCB
19X2385
WHT
POWER LED (GREEN)
GAS FiberOptic
JUMPER
for 2 WIRE
(RS485 only)
wire to A & B
F2 3A SB
GRN
PLASMA ENABLE
BYPASS RELAY 24
E-STOP
+24 VDC
E-STOP
(PW4)
(3)
(2c)
1
2
JUMPER
for 4 WIRE
uses
TX+, TXRX+, RX-
E-STOP
120 VAC RET
-12V
GND
+5V
+12V
+24V SW
+24V FUSED
GND
1
2
3
4
5
6
7
8
P7
1
2
I/O PCB
P2
F1 1.6A SB
120VAC DMC
120VAC DMC RET
PANEL INDICATORS
U10 / U13
CPU PCB
120 VAC
SMPS +24; +/-12; +5
FERRITE
CORE
SLAVE FiberOptic
B
19X2384
FERRITE
CORE
U4 / U7
CPU PCB
J57 P57
Power Supply PCB (19X2384) LEDS
(PW5)
CCM
(JMP)
(PW6)
120 VAC ULTRACUT
120 VAC ULTRACUT RET
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
(PW7)
SHIELD
J56
(PW8)
+15 VDC
15 VDC RET
24 VAC RET
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
7
CHASSIS GND
P56
8
24 VAC
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
1
2
UNIT E-STOP
P55
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
1
2
A
J55
120VAC DMC
PLASMA ENABLE -
(2a)
PLASMA ENABLE +
(2c)
ULTRACUT POWER SUPPLY
120VAC DMC RET
19X2367
755x000
CONTROL
CABLE
ISOLATED
P4
RS 485
J63 HARNESS NOT INSTALLED
(for future use with Height Control)
E1
RS 485
J63
1
2
3
4
5
6
7
8
9
1
2
3
4
5
6
HMI CONTROL &
COMMUNICATIONS
GROUNDING SCREW
Art # A-13074
1
A-36 2
APPENDIX
3
Manual 0560956456
iSERIES 100 /200 /300 /400
4
6
5
DPC3000 - PRESSURE CONTROL ASSEMBLY
19X2383
PANEL INDICATORS
Power Supply PCB (19X2384) LEDS
POWER LED (GRN)
STATUS LED (RED)
MANIFOLD (partial)
DPC3000 CONTROL PCB
(WHT)
D5 = +VDC Fused (24VDC )
D6 = +12VDC
D7 = +24VDC SW (24VDC to Valves
& Solenoids through E-Stop Relay
D9 = +5VDC
D16 = -12VDC
19X2382
(WHT)
(BLK)
(1)
19X2384
(1)
120 VAC
P1
1
120 VAC
KEY PLUG
J60
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
(2a)
120 VAC RET
(2a)
E_STOP NO
(8)
E_STOP COM
(9)
3
E-STOP
4
E-STOP
120 VAC RET
5
5
(PW4)
+12VDC
(PW5)
+24VDC SW
(PW8)
8
F4 3A SB
E-STOP
GND
+5VDC
(PW7)
7
6
(PW2)
(PW3)
GND
E-STOP
PURPLE
SW2-2
ORANGE
SW2-4
2
LEDs Listed Below
4
PLASMA_CUTTING
+12V
5
6
7
8
1
2
3
4
5
6
7
8
9
SOL2 PLASMA_VENT
(S3-T)
(S3-B)
(S2-B)
V1
(V1-1)
1
(V1-2)
2
3
V2
SHIELD
1
(V2-1)
(V2-2)
2
3
SHIELD_H2O
U1/U2
1
2
(S1-B)
2
3
PURPLE
B
1
2
3
Shield_Water_P-in
P2-WFS
BLACK/SHIELD
1
+5V
WHITE
2
RED
3
FS-1
1
2
3
H2O_Shield_FlowSensor
Tx Gray;
Rx Black
DPC3000 Control PCB LEDs
DPC CANBUS
ACTIVE
D1 D2 D3 D4 D5 D6 D7 D8 D9 D10 D11 D12 -
GROUNDING SCREW
(V4-B)
3
D12
FiberOptic
(V4-1)
1
2
PS2
ORANGE
V4
2
1
Plasma_Cut/Mark_P-in
DPC FiberOptic Port
PLASMA_MARK (S1-T)
1
3
PS4
BLK
TX/RX
3
SOL1
BLK
PURPLE
ORANGE
BLK
1
2
(V3-2)
2
1
2
PS5
PURPLE
Plasma_PILOT
TEST POINTS - CONTROL PCB
TP1 - GND
TP2 - FLOW (H2O Shield)
TP3 - +5V
TP4 - +VREF
TP5 - +24V Fused
TP6 - +3.3VA
TP7 - 3.3V
TP8 - +12V
TP9 - Processor CLKO
TP10 - Processor TEMP
TP11 - -12V
3
PS1
Shield_Gas_P-in
ORANGE
J8
(V3-1)
1
BLK
PURPLE
ORANGE
JTAG
Valves
V3
2
Plasma_P-out
1
2
3
4
5
6
7
8
9
10
11
12
13
14
16
15
14
13
12
11
10
9
8
7
6
5
4
3
2
1
(V5-2)
2
3
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
J10
(V5-1)
Plasma_Cut_Hi
ORANGE
Shield_Gas_P-out
P6
1
1
PURPLE
P1
Press_sensors
PROG via RS232
(S2-B)
V5
3
PS6
BLK
3
2
Plas_Pilot_P-in
J5
SOL3
1
SW2-1
SW2-3
1
MANIFOLD (partial)
Proportional valves V1-V5
powered by up to 24 VDC
Actual average voltage is
proportional to the amount
valve opening.
Coil resistance (cold):
V1 = 23 ohms;
V2= 59 ohms;
V3 & 4 = 42 ohms
V5 = 55 ohms.
A
PS3
BLK
SW1-4
8
NOTE:
DPC SOL solenoids are 18 VDC.
Coils are about 46 ohms.
24 VDC is applied for about 0.1
second then reduced by pulse
width modulation to an average
of approximately 9-10 VDC.
3
SW1-3
P9
-12VDC
(PW6) +24 VDC_FUSED
6
+24 VDC
7
(8)
(9)
2
3
4
(PW1)
1
F3 1.6A SB
2
P60
FERRITE
CORE
P2
SMPS +24; +/-12; +5
2
MANAFOLD ID
SW1-2
STATUS LEDS
FERRITE
CORE
1
1
SW1-1
4
3
2
1
(WHT)
J23
3
2
OPTION SWITCHES
P4
P3 - HWID
3
Plasma_Cut_Lo
PLASMA_PWM
PLASMA_VENT_PWM
SHIELD_H20_PWM
SHIELD_GAS_PWM
MARKING_PWM
PLASMA_PILOT_PWM
+5VDC
DPC STATUS
SHIELD_H20_FLOW
PLASMA_CUT_PWM
PLASMA_LOW_PWM
CANBUS COMMUNICATION
C
GROUNDING SCREW
DMC MANIFOLD
SOL#
H35 >
SOL# = ON/OFF CONTROL VALVE
V# = PROPORTIONAL VALVE
PS# = PRESSURE SENSOR
FS# = FLOW SENSOR (LIQUID)
INLET PASSAGES
OUTLET PASSAGES
HOSE
1
2
3
4
5
6
7
8
DPC MANIFOLD
MARKING >
O2 >
SOL1
PS4
AUX >
V4
> GAS SHIELD
PLASMA
H2O >
9
> H2O SHIELD
10
11
12
PRE-FLOW >
13
14
15
PS6
PLASMA OUT
SOL3
V3
PS3
SOL2
VENT
V2
> PREFLOW
AIR >
ARGON >
>
> MARKING
H2O SHIELD >
PS2
GAS SHIELD >
PS1
SHIELD OUT
V1
D
PS5
N2 >
> PLASMA
NOTE:
1: DO NOT DAISY CHAIN GROUNDS. USE A SEPARATE GROUND
CONDUCTOR FOR EACH ASSEMBLY TO STAR GND.
2: KEEP GROUNDS AS SHORT AS POSSIBLE.
3: USE #4 OR GREATER SIZE CABLE FOR GROUNDING
4: MAKE SURE ASSEMBLIES ARE SECURED PROPERLY BEFORE USE
5: ALL COVERS MUST BE FULLY INSTALLED BEFORE USE.
4
Manual 0560956456
5
APPENDIX
Art # A-13074
Rev
AA
Revisions
ECO-B1391
AB ECO-B1507 - added text
By
Date
DAT
DAT
4-24-2009
THERMAL DYNAMICS
INDUSTRIAL PARK #2
WEST LEBANON, NH 03784
(603) 298-5711
4-19-2010
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).
TITLE:
Last Modified: Monday, April 19, 2010
14:00:59
SCHEMATIC,
DFC 3000 SYSTEM SCHEMATIC
PCB No:
Assy No:
References
Scale
Supersedes
N/A
Friday, December 08, 2006
Drawn:
Date:
DAT
4/24/2009
Chk: App: Sheet
1 of 1
Size DWG No:
42X1292
6
A-37
iSERIES 100 /200 /300 /400
APPENDIX 21: System Schematic 100A, 380-415V PG 1
1
2
3
4
5
A
L1
1
L3
1
Earth
1
IN1
2
1
IN2
(21)
OUT2
AC INPUT
1
2
1
2
(8)
J103B
(9)
Toriod Core
1
2
019x502700
MAIN PCB LEDS
D3, RED, CAP
IMBALANCE
D4, GREEN, READY
CAP BIAS PCB LEDS
D6, GREEN, -12V
D11, GREEN, +12VP
D13, GREEN, +12V
IM #1 Section B (upper)
CONTROL PCB LEDS
D1, RED, INV FLT
D14, RED, OVER TEMP
D24, GREEN, PWM ON
D32, RED, PRI OC
OUT3
CHASSIS GND
(2)
J105B
J104B
W1C
(22)
2
1
GND2B
IN3
W1B
OUT1
L5
(7)
(20)
2
1
1
2
INVERTER MODULE (IM) #`1 (bottom)
W1A
1
2
(1)
1
L2
1
2
EMI
FILTER
PCB
(3-22)
(2-21)
(1-20)
B
380-415
VAC
INPUT
(Customer
supplied
power cord
must pass
through
ferrite core
assembly.)
(7)
L4
(8)
(3)
(9)
Toriod Core
J105A
1
2
IM #1 Section A (lower)
AC INPUT
J104A
1
2
J103A
1
2
WORK (+)
019x502000
C
CHASSIS GND
AC
SUPPRESSION
J50 PCB
019X504000
1
2
3
4
5
6
7
8
9
10
11
12
13
14
(1)
(2)
(3)
18 AWG wire
both in and out of
CB1
1
2
3
4
(1-20)
(2-21)
(3-22)
(26)
(27A&B)
(28)
CB1
F1
(12)
LT2
1
2
3
4
GND
019X501900
+24VDC
+V
E
(85A)
(86B)
(27B)
(85B)
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
GND
480V-ID
400V-ID
208-230V-ID
COM
(27A)
AC INPUT
J63
F
J63 = Mini-Fit Jr goes to
J12 on T1 primary
400 VAC -- Single 18 AWG
in pins 1 & 12
480 VAC -- Single 18 AWG
in pins 1 & 12
230 VAC -- 18 AWG
wires in pins
1, 6, 7, 12
1
2
3
4
5
6
7
8
9
10
11
12
J60
TO AUX TRANSFORMER
(44A)
(43A)
TO J12
T1 PRIMARY
(Sht 2, A1)
Art # A-13075
1
A-38 2
4
3
2
1
(86A)
C4
CB1
Capacitor, fan starting, 8uf 440VAC (Sht 2, E1)
Circuit Breaker /ON/OFF SW, 15A 480V
(Sht 1, E1)
CB2-4
Circuit Breaker, 5A, 250V (Sht 2, B3)
F1, 2
Fuse, 8A, 500V, S.B. (Sht 1,E1)
FAN1,2
Fan, Heat Exchanger , 230 VAC (Sht 2, D2)
FL1
Flow meter, pulse output (Sht 2, B2)
FS1
Flow SW, 0.5 GPM (3.8 lpm), N.O. (Sht 2, A2)
HCT1
Current Sensor, Hall Effect 200A, Work Lead
(Sht 1, C8)
To J27 on CCM I/O PCB
K1
Relay, 24VAC, Inrush Control, (Sht2, B9)
(Sht 2, E3)
L1
Inductor, (Sht 1, B7)
J62
L3-5
Toriod Core Common Mode Ind (Sht1 B8, B&C3)
24 VDC
(29)
1
LS1
Level Switch, Coolant Tank (Sht 2, A3)
(30)
24 VDC
2
LT1, LT2 Indicator, Neon, 250V, AC Volts Present
(31)
MISSING
PHASE
a
3
(Sht 1, B2 & C2)
MISSING PHASE b (32)
4
M1
Motor, Pump, ½ hp 230VAC, 50/60 Hz, 1Ph
(33)
AC V HIGH a
5
(Sht 2, C2)
(34)
AC
V
HIGH
b
6
MC1
Relay, 120VAC, Inrush, coil (Sht2, B9)
(35)
AC V LOW a
7
contact
(Sht2, A1)
(36)
24
VDC_RET
8
(37)
24 VDC_RET
MC2
Relay, 120 VAC, Fan Control, coil
9
(38)
AC V LOW b
(Coil at Sht 2, A7)(Contacts at Sht 2, D1)
10
(39)
VAC_IDA a
MC3
Relay, 120 VAC, Pump Motor Control, coil
11
(40)
/ VAC_IDA b
(Coil at Sht 2, A7)(Contacts at Sht 2, C1)
12
(41)
VAC_IDB
a
R2
Inrush, 4.7 Ohm, 30W (Sht2, A1)
13
(42)
/ VAC_IDB b
R3,4
Ext RC, 100 ohm 55W (Sht1, A7)
14
230V 400V 480V ERR
SA1-3
Snubber, Contactor & Relay coils
/VAC_IDAb 0
1
0
1
(Sht 2, A8 & A9)
/VAC_IDBb 0
0
1
1
T1
Aux Transformer (Sht 2, B2)
Measure relative to TP1 (24VDC_RET)
TB4
Terminal Block (Sht 1, C9)
"0" = 10-12V
"1" = 24V
J61
TS1
Temperature Sensor, NTC, Coolant Return
VOLTAGE SELECTION
(Sht 2, A5)
TS2
Temperature
Sensor, NTC, Ambient (Sht 2, A5)
Wire #48 from J61-1 to:
J61-2 for 208-230 VAC
W1
Contactor , Input (Coil Sht 2, A8), (Contacts C2)
LT1 & LT2
INPUT POWER
NEON INDICATORS
Rear Panel & Internal
SYSTEM BIAS SUPPLY PCB
F2
Component Locations (not
including PCB components)
(13)
INTERNAL AC INDICATOR
8A, 500V, SB
8A, 500V, SB
(11)
J52
CHASSIS GND
ON / OFF
16 A
LT1
PANEL AC INDICATOR
AC LINE
D
(10)
J51
(48)
J61-3 for 400 VAC
J61-4 for 480 VAC
System Bias LEDs & Test Points
LEDS
D3, RED, MISSING PHASE
D4, RED, AC V HIGH
D14, RED, AC V LOW
D26, GREEN, +12V PRI
D30, GREEN, 24VDC
D44, GREEN, T1 ON
TEST POINTS
TP1 SECONDARY GND
TP2 24VDC
TP3 DC INPUT POSITIVE
TP4 VCC1
TP5 VCC2
TP6 GATE
TP7 PRIMARY GND
TP8 +12V PRIMARY
TP9 P ISOL GND
3
APPENDIX
4
Manual 0560956456
iSERIES 100 /200 /300 /400
6
7
8
9
10
TORCH
To TB4-7
TEST POINTS
TP1 GND
TP2 PILOT GATE
TP3 +5V
J43
ELECTRODE
1
A
L3
(49)
1
PILOT BOARD
LED'S
D2 PILOT ENABLE
D11 +5V
TORCH
(49)
RAS
PILOT
To TB4-6 TIP
PILOT PCB J44
J58A
1
(52)
J41 (J87)
2
1
1
R3 & R4
CHASSIS GND
10 ckt Ribbon
TO J3 on RELAY PCB
(Sht 2, A5)
TO CCM
CPU PCB
J31
J102A
(49A)
B
Work
1
(+)
(55)
HCT1
Hall Effect Sensor
(51)
2
3
4
4
+15 VDC
J16
TO J1 on RELAY PCB
(Sht 2, B9)
(51)
(51)
OUTPUT
3
(51)
1
(50)
2
WORK (+)
5
4
3
2
1
1
ELECTRODE (-)
Tip
WORK
(51)
ARC VOLTS
J100 -- 30 CKT RIBBON
(+)
(53)
WORK
(Sht 2, D3)
To / From Optional
1 Torch Module
(Refer to 1 Torch
section for details.)
J45
SHIELD
TIP VOLTS
To J24 on I-O PCB
(Sht 2, C3)
1
2
3
4
5
6
7
8
2
1
(51B)
J42
C
TB4
COMMON
OUTPUT
INVERTER
L1
SIG (+)
WORK (+)
4
3
2
1
TIP
-15 VDC
ELECTRODE (-)
J102B
(49B)
5
(-)
CHASSIS GND
019X501600
1
2
3
4
5
6
7
8
9
10
J100 -- 30 CKT RIBBON
(52)
1
2
J40
2
1
J46-F J46-M
(Sht 2, C3)
J41
5
4
3
2
1
Electrode
J58C
(50)
TO CCM
CPU PCB
J32
TORCH
(Sht 1, A9)
TIP
(Sht 1, A9)
(56)
o
AC 120V- TB4-4
(57)
b
AC 120V- Ret- TB4-3
(58)
g
AC 24V-TB4-2
(59)
w
AC 24V- Ret -TB4-1
(49)
(52)
(51)
(60)
7
ARC VOLTS (TORCH)
6
TIP VOLTS (PILOT)
5
WORK
4
(61)
3
(62)
2
(63)
1
120 VAC @ 100 ma.
24 VAC @ 1A
(J10 Sht 2, B8)
RIBBON CABLE 30 ckt.
CCM (J31& 32) - INVERTER (J100)
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
READY +
READY INVERTER_FLT +
INVERTER_FLT OVERTEMP_FLT +
OVERTEMP_FLT PWR_PRESENT +
PWR_PRESENT OUT_COM (+3 to 5VDC)
VAC_SELA
VAC_SELB
IS_IDA
IS_IDB
IS_IDC
ENABLE +
ENABLE START2 +
START2 SPARE
SYNC_IN +
SYNC_IN NC
NC
47 OHM to COMM
DEMAND +
DEMAND 47 OHM to COMM
CURRENT +
CURRENT 47 OHM to COMM
RIBBON CABLE 40 ckt CCM (J23) - RELAY PCB (J4)
32 COMMON
1 COMMON
33 -15 VDC
2 /1TORCH START *
34 COMMON
3 NA
35 24 VDC
4 /1TORCH GAS SOL ON *
36 COMMON
5 /MAIN TORCH IDLE *
37 24 VDC
6 /1TORCH PRESS OK *
38 COMMON
7 FLOW SENSOR (pulses)
39 24 VDC
8 LOW COOLANT FLOW
40 COMMON
9 COOLANT LEVEL OK
10 COMMON
11 NA
RIBBON CABLE 16 ckt
12 /PLASMA ENABLE-HMI
CCM ( J37) - DISPLAY
13 /COOLANT PUMP ON
PCB (J17)
14 COMMON
1,3,5,7
24 VDC
15 /PILOT ENABLE
2,4,6,8
COMMON
16 /RAS ON
9,10
NC
17 /CONTACTORS ON
11-16
SERIAL DATA
18 COMMON
19 /COOLANT FANS ON
20 /1TORCH CONTACTOR ON * RIBBON CABLE 10 ckt
21 /PLASMA ENABLE RELAY
RELAY PCB (J3) – PILOT PCB (J42)
22 COMMON
23 PILOT CURRENT SIG1,2
24 VDC
24 NC
3,4,7,10 COMMON
25 PILOT CURRENT SIG+
5
PILOT ENABLE +
26 COMMON
6
PILOT ENABLE –
27 WORK CURRENT SIG8
PILOT CURRENT SIG –
28 WORK CURRENT SIG+
9
PILOT CURRENT SIG +
29 NC
30 AMBIENT TEMP
31 COOLANT TEMP
* Used with 1 Torch Option
D
E
Art # A-13075
Rev
00
Revision
Initial Design
AA
AB
ECO-B2687
By
Date
DAT
10/03/2012
DAT
9/16/2014
DAT
Revision
Rev
By
Date
2800 Airport Rd.
Denton, Texas 76207 USA
10/17/2014
Size
Drawing Number
SCHEMATIC
6
Manual 0560956456
7
8
10
APPENDIX
10/03/2012
DAT
The information contained herein is proprietary to Thermal Dynamics.
Not for release, reproduction or distribution without written consent.
Title
Ultra-Cut XT 100A CE 380-415 VAC
5
F
Date Printed
Date Revised
11/20/2014
12/16/2014
Drawn
Date
C
Sheet
1 of
2
042X1354
9
A-39
iSERIES 100 /200 /300 /400
APPENDIX 22: System Schematic 100A, 380-415V PG 2
3
(90)
2
(89)
3
COOLANT LEVEL
COOLANT
MC1A
J74
(84)
(59)
(58)
(57)
(56)
FS1
(44A)
4
J71
AMBIENT
1
2
(83)
COMMON
SIG (+)
-15 VDC
+15 VDC
A
(43A)
1
LS1
From Sys Bias J63
(Sht 1, F2)
5
4
0.7 GPM
TS2
(Sht 1, C8)
2
TO HCT1 (Work)
1
J12 = Mini-Fit Jr
400 VAC -- Single 18 AWG in pins 1 & 4
480 VAC -- Single 18 AWG in pins 1 & 8
230 VAC -- 18 AWG wires in pins 1,5,2,6
(92)
COOLANT
TS1
(93)
(94)
(95)
2
3
T1
J49
460V
24V RET
BLUE
RED
24V
B
YELLOW
BLUE
120V_2 RET
400V
RED
220V
(74)
(75)
CB3 5 A(73)
3
2
YELLOW
120V_2
4
120V-1 RET
(71)
(72)
CB4 5 A
1
TORCH FLOW SENSOR
12
11
10
9
8
7
6
5
4
3
2
1
(77)
(78)
CB2 5 A(76)
5
SIGNAL (pulse)
J6
(79)
6
120VAC_2
24VAC
BIAS TRANSFORMER
1
2
3
(64A)
(64B)
(65A)
(65B)
4
N/C
MC2B
(64A)
230 VAC _ SW _ RET
(A9)
1
2
3
(70)
FAN2
1
2
3
(55)
1
2
3
4
5
6
7
8
230 VAC _ SW
(A9)
230 VAC_SW
goes to J70
for HE 400
R
J72
1
2
3
E
C4
BK
FAN1
BN
BL
R
6
5
4
3
2
1
1
2
J36 - 30 CKT RIBBON
Harness from System Bias PCB J62
(Sht 1, E3)
24 VDC
24 VDC
MISSING PHASE a
MISSING PHASE b
AC V HIGH a
AC V HIGH b
AC V LOW a
24 VDC_RET
24 VDC_RET
AC V LOW b
VAC_IDA a
/ VAC_IDA b
VAC_IDB a
/ VAC_IDB b
(29)
(30)
(31)
(32)
(33)
(34)
(35)
(36)
(37)
(38)
(39)
(40)
(41)
(42)
1
2
3
4
5
6
7
8
9
10
11
12
13
14
J27
.
J62-12 (/VAC_IDAb)
J62-14 (/VAC_IDBb)
230V
0
0
400V
1
0
J28 30 CKT PIN HEADER
I / O PCB TEST POINTS
------------------------------------TP1 PCB COMMON
TP2 COOLANT FANS ON
TP3 PUMP ON
TP4 LOW FLOW (SW)
TP5 FLOW SIGNAL (pulse, Ultracut only)
TP6 +15VDC_ISO (ref to TP10)
TP7 -15VDC_ISO (ref to TP10)
TP8 +16-18 VDC_ISO (ref to TP10)
TP9 ANALOG CURRENT SIGNAL
(remote & Autocut only)
TP10 ISOLATED VOLTAGE COMMON
TP11 1 TORCH CONTACTOR ON
TP12 +5 VDC
TP13 -15 VDC
TP14 +15 VDC
TP15 +24 VDC
TP18 +5 VDC_ISO (ref to TP10)
CHASSIS GND
Alternate fan.
100 & 200A units may use either this
single larger fan (same as 300 & 400A
units) or the 2 smaller fans shown above.
J34 - 30 CKT RIBBON
I / O PCB LEDS
---------------------------------------------D2 CNC PLASMA ENABLE
D3 E-STOP_PS
D4 GAS ON (Auto-cut, PAK)
D6 CNC START
D8 HOLD START
D12 PREFLOW ON
D13 CSD (corner current reduction)
D18 MARK
D20 SPARE
D25 EXP METAL
D33 OK_CNC
D37 PSR
D41 SPARE OUT 2
D43 SPARE OUT 1
J24
(70)
CPU PCB (CCM )
J28 30 CKT RECEPTACLE - BOTTOM ENTRY
I-O PCB (CCM)
(53)
(51)
J73
(69)
(70)
FAN1
TIP VOLTS
(69)
(65A)
D
J72
(Sht 1, B8)
WORK
(69)
MC2A
Harness from Pilot PCB J45
ARC VOLTS
230 VAC
Torch Coolant Pump
(67)
(64B)
J85
M1
1
2
3
19X501100
J13 to CB5
and to MC2
& MC3, also
J14, J16
all 18 AWG
J84
N/C
J35 - 30 CKT RIBBON
J16
J32 - 30 CKT RIBBON
N/C
J33 - 30 CKT RIBBON
Mini-Fit
MC3BCHASSIS GND
019X501700
J11
N/C
(66)
Test Points
TP1, GND
TP2, -15V
TP3, +5VDC
TP4, +12V
TP5, +24V
TP6, +15V
TP7, +5VDC
1 TORCH INTERFACE
J31 - 30 CKT RIBBON
MC3A
TEMP SENSOR
Refer to 1 Torch Module Schematic for Details
To J100 of IM #1B
To J100 of IM #1A
(Sht 1, B&C- 5&6)
120V_1
J13
3
D2, GREEN, 1TORCH GAS ON
D7, GREEN, PILOT ENABLED
D11, GREEN, PILOT CURRENT
D12, GREEN, WORK CURRENT
D22, GREEN, CONTACTORS ON
D23, GREEN, RF ON
D24, GREEN, FANS ON
D25, GREEN, PLASMA ENABLED
D26, GREEN, 1TORCH ON
D27, GREEN, COOLANT ON
120VAC_1
J9
J14
0V
C
J2
14
13
12
11
10
9
8
7
6
5
4
3
2
1
1 2 3 4
5 6 7 8
J1
RELAY & INTERFACE PCB
+5VDC
1
2
3
4
(81)
(82)
3
2
1
1
5
2
6
3
7
4
8
J12
J7
COOLANT FLOW SW LEVEL SENSORS WORK CURRENT SENSOR
(80)
1
2
3
4
5
4
3
2
1
r
b
g
1
4
J5
FL1
Mini-Fit Jr
8
7
6
5
4
3
2
1
4.7 30W (87)
2
1
R2
480V ERR
0
1
1
1
19X501200
I / O PCB DIP SW
--------------------------------------------SW6 OK TO MOVE
(CONTACTS, VOLTS)
SW11 ANALOG CC SOURCE
SW12 DIVIDED ARC VOLTAGE
(50:1, 16.7:1, 30:1, 40:1, 25:1)
Measure relative to TP1 (24VDC_RET)
"0" = 10-12V
"1" = 24V
F
Art # A-13076
1
A-40 2
3
APPENDIX
4
Manual 0560956456
iSERIES 100 /200 /300 /400
6
7
TO PILOT PCB
(Sht 1, B8)
(162)
(161)
MC3
SA4
SA1
(97)
(96)
(98)
(99)
(97)
ARC_SUPPRESSOR
MC1
(60)
CONTROL OUTPUTS
24 VAC
J59 - RAS
CHASSIS GND
24 VDC
GND
120 VAC_1
J4 -- 40 CKT RIBBON CABLE
HMI/GCM
(101)
(102)
(103)
(104)
(106)
AC 24V GCM2
(62)
AC 120V - GCM
(60)
(108)
(109)
(110)
(111)
(113)
(61)
AC 24V - RET - GCM2
AC 120V- Ret- GCM
AC 120V- Ret- TB4-3
(63)
(62) 1
1
2
3
4
J18
GND
GND
J19
4 WIRE
(98)
J30
J37
(101)
(102)
AC 24V-TB4-2
(109)
AC 120V- TB4-4
(108)
(115)
AC 24V Ret- GCM1
J23- 40 ckt ribbon cable
ENABLE
PLAS_ENABLE SW
PLAS_ EN_SW_RET
/ GAS PRESS OK
/ BASIC ID
TB1
CPU PCB TEST POINTS
-------------------------------------------TP1 GND (PCB common)
TP2 +5V_ISO (REF TP5)
TP3 +24 VDC
TP4 +3.3V
TP5 GND_ISO
TP6 +5.0 V
TP7 TOTAL DEMAND
(3.3V = 400A)
TP9 /WR
TP10 /RD
TP11 CPU TEMP SENSE
TP12 +3.3VA
TP13 -15VDAC
TP14 PC2
TP15 +15VDAC
TP16 CLKO
TP18 OSC_CLOCK
OK2 (contact)
+10V (CC Pot Hi)
CC Pot Wiper
CC Pot Low
Div Arc V (+)
Div Arc V (-)
/Start - Stop (+)
/Start - Stop (-)
Stop Mom NC
OK2 (contact)
/ CNC Enable (+)
/ CNC Enable (-)
12
11
10
9
8
7
6
5
4
3
2
1
Harness
AC 24V- Ret -TB4-1
(118)
(119)
(120)
2
(107)
GND
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
OK
TB2
OK to MOVE (+) 12
11
10
9
8
7
6
5
4
3
2
1
OK to MOVE (-)
PILOT is ON
PILOT is ON
Preflow ON (+)
Preflow ON (-)
Hold Start (+)
Hold Start (-)
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
+10V
GND
GND
PSR
SPARE #1a
00
Initial Design
AA
AB
By
DAT
DAT
ECO-B2687
DAT
Date
Revision
Rev
6
Manual 0560956456
12 - Tx13 - Rx+
14 - Rx-
019X501800
16 CKT RIBBON
(121)
(122)
(123)
(124)
(125)
(126)
(127)
(128)
(129)
(130)
(131)
(130)
(131)
(112)
(114)
(121)
(122)
(124)
(129)
(128)
(123)
(112)
(114)
(103)
(110)
AC 24V-GCM1
AC 24V Ret - GCM1
(104)
AC 24V-GCM2
(111)
AC 24V Ret-GCM2
(166)
(125)
(126)
(127)
J69
2
1
(142)
(133)
(134)
(137)
(139)
(138)
(143)
(167)
AC 120V - GCM
AC 120V- Ret- GCM
(106)
(113)
CHASSIS GND
(153)
(143)
(144)
(145)
(144)
(145)
(146)
(147)
(148)
(149)
(150)
(151)
(146)
(147)
(148)
(149)
(150)
(151)
(152)
(154)
(155)
(132)
(152)
(153)
(154)
(155)
(156)
(157)
(158)
(159)
(156)
(157)
(158)
(159)
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
(133)
(134)
(135)
(136)
(137)
(138)
(139)
(140)
(141)
(142)
(140)
(141)
(136)
(135)
(132)
J55 - GCM
1- PLAS_ENABLE SW *
2- PLAS_ EN_SW_RET
3- GAS PRESS OK RET
4- / GAS PRESS OK
5- POT HIGH (GCM 1000)
6- POT WIPER (GCM 1000)
7- POT LOW (GCM 1000)
8- BASIC ID RET
9- / BASIC ID **
1011GCM 1000 XT
Jumper
1415- 24 VAC - RET
C
* Plasma Enable SW
in GCM 2010.
Jumpered in
GCM 1000 XT
and DMC 3000.
** Jumper in
GCM 1000 XT
27- GAS SEL SW RET
28- GAS SEL SW
D
J15-1 to chassis used for
SC-11 cable shield
J15-13 connects SC-11
chassis to PS chassis.
J15-CNC
The COMM Ref at pin 8
is also for the SC-11
3- / CNC Start (+)
4- / CNC Start (-)
5- Divided Arc V (-)
6- Divided Arc V (+)
7- / Preflow ON (+)
8- COMM Ref (1K Ohm)
9- / Preflow ON (-)
10- / Spare Digital Input (+)
11- / Spare Digital Input (-)
12- OK to Move (-)
14- OK to Move (+)
15 - Key Plug
16- / Hold Start (+)
17- / Hold Start (-)
E
21- / Plasma Mark (+)
22- / Plasma Mark (-)
23- / Spare Digital Input(+)
24- / Spare Digital Input (-)
25- / CNC Plasma Enable (+)
26- / CNC Plasma Enable (-)
29- Remote CC Pot High
30- Remote CC (analog)
31- Remote CC Pot Low
32- Stop SW (momentary) *
33- Stop SW Ret
34- Pilot is ON (a)
35- Pilot is ON (b)
36- Spare OUT #1 (a)
37- Spare OUT #1 (b)
* Used with Momentary CNC Start SW
Date
Thermal Dynamics Corporation
10/03/2012
2800 Airport Rd.
Denton, Texas 76207 USA
9/16/2014
F
Date Printed
Date Revised
12/16/2014
11/20/2014
Drawn
Date
10/17/2014
Size
Drawing Number
SCHEMATIC
7
8
APPENDIX
9
10/3/2012
DAT
The information contained herein is proprietary to Thermal Dynamics.
Not for release, reproduction or distribution without written consent.
Title
Ultra-Cut XT 100A CE 380-415 VAC
5
B
Comm
Harness
J22
By
5-HMI Plasma Enable SW
6-HMI Plasma Enable SW
7 - Key Plug
8 - Tx+
9 - GND RS 485
10 - GND / 422
Display PCB
Art # A-13076
Revision
1 - 24 VAC
2 - 24 VAC Ret
3- Jumper to 24 VAC
2
3
4
5
6
7
8
9
10
11
12
13
14
J17
J21
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
3 - Key Plug
(61)
3
J26
CPU PCB DIP SW
TB3
--------------------------------------------12
Spare
SW1 AUTO PILOT RESTART
11
Digital
SW3 PREFLOW TIME
10
Inputs
SW4 POSTFLOW TIME
9
SW5 FUNCTION
Spare #1b NO 8
7
SW8 SYSTEM CONTROL
6
Spare
5
(pilot time, etc.)
Digital
4
Inputs
SW9
RESERVED (future)
3
SW10 ADDRESS (default = 0)
/ Plasma Marking (-) 2
/ Plasma Marking (+) 1
SW13 UNIT TYPE (AC / UC)
SW14 LINE TERMINATION
(serial comm.)
Rev
(116)
(117)
GAS ON
30 CKT PIN HEADER
CPU PCB LEDs
---------------------------D2 RXD (red)
D3 TXD (red)
D4 CAN BUS (slave)
D7 CAN BUS (MAIN)
D11 5 VDC POWER
D17 STATUS CODE
D18 INITIALIZING /
PROGRAMMING (red)
A
(61)
INRUSH CONTROL
(116)
(117)
(120)
(115)
(119)
(118)
1
2
3
4
5
6
5
1
2
3
4
5
6
7
8
9
10
11
12
13
14
J54 - Remote HMI & CNC COMM
(100)
1
AC 24V GCM1
J20
J29 30 CKT RECEPTACLE - BOTTOM ENTRY
J29
RxTx+
Rx+
Tx-
2 WIRE
1
2
3
4
5
6
7
8
9
10
11
12
NORMAL PROGRAM
PROG
USB IC
(63)
J47
1
2
3
4
1
2
3
4
5
6
7
8
9
1
2
3
4
5
6
1
2
3
4
5
6
7
8
9
10
11
12
120 VAC Ret
(107)
4
USB Cable to Front Panel
RS 232 D-SUB
SERIAL PROG
PORT
(99)
K1
J10
J39
USB
PORT
120 VAC to RAS
120VAC
(100)
18
17
16
15
14
13
12
11
10
9
8
7
6
5
4
3
2
1
120 VAC_2
J38
1
2
3
4
5
6
7
( 69)
W1
16
15
14
13
12
11
10
9
8
7
6
5
4
3
2
1
2
1
J8
230 VAC Ret
( 69)
(D2)
(96)
Pump Motor Control
(163)
(160)
10 CKT RIBBON
4
3
PILOT A SIG Vin+
PILOT A SIG Vin-
/ PILOT ENABLE
/ PILOT ENABLE RET
5
6
7
8
9
10
(D2)
230 VAC _ SW _ RET
10
J70 - HE
230 VAC to HE 400 (70)
(70)
230 VAC _ SW
ARC_SUPPRESSOR
PILOT PCB
9
MC2 Fan Control
SA3
ARC_SUPPRESSOR
J3
8
C
Sheet
2 of
2
042X1354
10
A-41
iSERIES 100 /200 /300 /400
APPENDIX 23: System Schematic 200A, 380-415V PG 1
1
2
3
4
5
A
INVERTER 1/2 MODULE (IM) #2 (top)
(1)
(2)
(3)
1
2
IN1
EMI
FILTER
PCB
2
1
1
2
(21)
2
1
IN2
1
2
(20)
OUT1
OUT2
GND2B
IM #2 Section A (lower)
AC INPUT
1
2
(8)
OUT3
IN3
1
2
J104A
(22)
2
1
J105A
L6
(7)
J103A
(9)
1
2
Toriod Core
CHASSIS GND
019x502000
B
L2
1
L3
1
Earth
IN3
(1)
1
CHASSIS GND
(2)
(2-21)
(3-22)
(28)
F1
8A, 500V, SB
E
(7)
019X504000
019x502700
J105A
L4
MAIN PCB LEDS
D3, RED, CAP
IMBALANCE
D4, GREEN, READY
CAP BIAS PCB LEDS
D6, GREEN, -12V
D11, GREEN, +12VP
D13, GREEN, +12V
IM #1 Section B (upper)
CONTROL PCB LEDS
D1, RED, INV FLT
D14, RED, OVER TEMP
D24, GREEN, PWM ON
D32, RED, PRI OC
J104A
1
2
J103A
1
2
Toriod Core
(10)
1
2
3
4
(11)
PANEL AC INDICATOR
(12)
J52
IM #1 Section A (lower)
AC INPUT
1
2
(9)
J51
WORK (+)
019x502000
LT1
LT1 & LT2
INPUT POWER
NEON INDICATORS
LT2Rear Panel & Internal
Component Locations (not including PCB components)
Capacitor, fan starting, 8uf 440VAC (Sht 2, E1)
Circuit Breaker /ON/OFF SW, 15A 480V
(Sht 1, E1)
CB2-4
Circuit Breaker, 5A, 250V (Sht 2, B3)
(13)
(3)
F1,
2
Fuse,
8A, 500V, S.B. (Sht 1,E1)
INTERNAL AC INDICATOR
AC LINE
FAN1,2
Fan, Heat Exchanger , 230 VAC (Sht 2, D2)
FL1
Flow meter, pulse output (Sht 2, B2)
CHASSIS GND
FS1
Flow SW, 0.5 GPM (3.8 lpm), N.O. (Sht 2, A2)
HCT1
Current Sensor, Hall Effect 200A, Work Lead
(Sht 1, C8)
18 AWG wire
K1
Relay, 24VAC, Inrush Control, (Sht2, B9)
both in and out of
L1
Inductor, (Sht 1, B7)
CB1
L3-5
Toriod Core Common Mode Ind (Sht1 B8, B&C3)
LS1
Level Switch, Coolant Tank (Sht 2, A3)
(FRONT PANEL)
LT1,
LT2
Indicator, Neon, 250V, AC Volts Present
To J27 on CCM I/O PCB
(Sht 1, B2 & C2)
(Sht 2, E3)
M1
Motor, Pump, ½ hp 230VAC, 50/60 Hz, 1Ph
SYSTEM BIAS SUPPLY PCB
J62
(Sht 2, C2)
019X501900
F2
24
VDC
(29)
MC1
Relay, 120VAC, Inrush, coil (Sht2, B9)
8A, 500V, SB
+24VDC
1
24 VDC
(30)
contact (Sht2, A1)
2
MISSING PHASE a (31)
+V
MC2
Relay, 120 VAC, Fan Control, coil
3
MISSING PHASE b (32)
AC INPUT
4
(Coil at Sht 2, A7)(Contacts at Sht 2, D1)
(33)
AC V HIGH a
(86A)
1
5
MC3
Relay, 120 VAC, Pump Motor Control, coil
(34)
AC V HIGH b
2
6
(Coil at Sht 2, A7)(Contacts at Sht 2, C1)
3
(35)
AC
V
LOW
a
4
7
R2
Inrush, 4.7 Ohm, 30W (Sht2, A1)
(27A)
(36)
24 VDC_RET
5
8
R3,4
Ext RC, 100 ohm 55W (Sht1, A7)
6
(37)
24 VDC_RET
7
9
SA1-3
Snubber, Contactor & Relay coils
(38)
AC V LOW b
8
(85A)
10
GND
9
(Sht 2, A8 & A9)
(39)
VAC_IDA a
(86B)
11
10
T1
Aux Transformer (Sht 2, B2)
(40)
/ VAC_IDA b
11
12
12
TB4
Terminal
Block (Sht 1, C9)
(41)
VAC_IDB
a
13
13
(27B)
(42)
/ VAC_IDB b
TS1
Temperature Sensor, NTC, Coolant Return
14
14
K1A
K1B
15
(Sht 2, A5)
16
17
TS2
Temperature Sensor, NTC, Ambient (Sht 2, A5)
(85B)
18
230V 400V 480V ERR
W1
Contactor , Input (Coil Sht 2, A8), (Contacts C2)
1
2
3
4
GND
J63
J63 = Mini-Fit Jr goes to
J12 on T1 primary
400 VAC -- Single 18 AWG
in pins 1 & 12
480 VAC -- Single 18 AWG
in pins 1 & 12
230 VAC -- 18 AWG
wires in pins
1, 6, 7, 12
1
2
3
4
5
6
7
8
9
10
11
12
J60
TO AUX TRANSFORMER
(48)
J61
VOLTAGE SELECTION
(44A)
(43A)
TO J12
T1 PRIMARY
(Sht 2, A1)
Art # A-13077
1
1
2
Toriod Core
480V-ID
400V-ID
208-230V-ID
COM
(1-20)
(26)
(27A&B)
CB1
ON / OFF
16 A
1
2
3
4
5
6
7
8
9
10
11
12
13
14
(1)
D
A-42 J103B
(9)
AC
SUPPRESSION
PCB
J50
F
1
2
(8)
(8)
(3)
380-415
VAC
INPUT
(Customer
supplied
power cord
must pass
through
ferrite core
assembly.)
AC INPUT
1
2
OUT3
CHASSIS GND
(2)
J105B
L5
J104B
W1C
(22)
2
1
4
3
2
1
C
1
OUT2
GND2B
(3-22)
L1
(21)
2
1
IN2
(7)
W1B
OUT1
1
2
1
2
INVERTER MODULE (IM) #`1 (bottom)
W1A
(20)
2
1
(1-20)
IN1
EMI
FILTER
PCB
(2-21)
1
2
2
/VAC_IDAb
/VAC_IDBb
0
0
1
0
C4
CB1
0
1
1
1
Measure relative to TP1 (24VDC_RET)
"0" = 10-12V
"1" = 24V
Wire #48 from J61-1 to:
J61-2 for 208-230 VAC
J61-3 for 400 VAC
J61-4 for 480 VAC
System Bias LEDs & Test Points
LEDS
D3, RED, MISSING PHASE
D4, RED, AC V HIGH
D14, RED, AC V LOW
D26, GREEN, +12V PRI
D30, GREEN, 24VDC
D44, GREEN, T1 ON
TEST POINTS
TP1 SECONDARY GND
TP2 24VDC
TP3 DC INPUT POSITIVE
TP4 VCC1
TP5 VCC2
TP6 GATE
TP7 PRIMARY GND
TP8 +12V PRIMARY
TP9 P ISOL GND
3
APPENDIX
4
Manual 0560956456
iSERIES 100 /200 /300 /400
6
7
8
9
10
TORCH
To TB4-7
TEST POINTS
TP1 GND
TP2 PILOT GATE
TP3 +5V
J43
ELECTRODE
J58A
TO CCM
CPU PCB
J32
WORK (+)
OUTPUT
1
2
3
4
5
6
7
8
2
1
J42
To / From Optional
1 Torch Module
(Refer to 1 Torch
section for details.)
J45
10 ckt Ribbon
(51B)
Tip
WORK
B
SHIELD
Work
1
(+)
TIP VOLTS
To J24 on I-O PCB
WORK (51)
(Sht 2, D3)
4
3
2
1
(+)
(53)
TO J3 on RELAY PCB
(Sht 2, A5)
J102B
(49B)
5
ELECTRODE (-)
019X501600
INVERTER
(Sht 2, C3)
J100 -- 30 CKT RIBBON
TIP
J40
1
2
3
4
5
6
7
8
9
10
OUTPUT
(51F)
SHIELD
(-)
CHASSIS GND
1
2
2
1
J46-F J46-M
(51C)
J41
5
4
3
2
1
Electrode
J58C
(50)
4
3
2
1
WORK (+)
1
J41 (J87)
J102A
(49C)
5
ELECTRODE (-)
1
(52)
CHASSIS GND
(Sht 2, C3)
J100 -- 30 CKT RIBBON
PILOT RAS
To TB4-6TIP
J44
PILOT PCB
R3 & R4
TO CCM
CPU PCB
J33
A
2
1
D2 PILOT ENABLE
D11 +5V
1
L3
(49)
1
PILOT BOARD LED'S
TORCH
(49)
(49)
ARC VOLTS
(55)
L1
TO CCM
CPU PCB
J31
HCT1
(Sht 2, C3)
(51)
(51)
Hall Effect Sensor
TO J1 on RELAY PCB
(Sht 2, B9)
2
3
4
2
3
4
SIG (+)
OUTPUT
C
TB4
COMMON
1
J16
(50)
+15 VDC
WORK (+)
5
4
3
2
1
-15 VDC
J102A
(49A)
ELECTRODE (-)
1
J100 -- 30 CKT RIBBON
TORCH
(Sht 1, A9)
TIP
(Sht 1, A9)
(56)
o
AC 120V- TB4-4
(57)
b
AC 120V- Ret- TB4-3
(58)
g
AC 24V-TB4-2
(59)
w
AC 24V- Ret -TB4-1
(49)
(52)
(51)
(60)
7
ARC VOLTS (TORCH)
6
TIP VOLTS (PILOT)
5
WORK
4
(61)
3
(62)
2
(63)
1
120 VAC @ 100 ma.
24 VAC @ 1A
(J10 Sht 2, B8)
RIBBON CABLE 30 ckt.
CCM (J31-36) - INVERTER (J100)
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
READY +
READY INVERTER_FLT +
INVERTER_FLT OVERTEMP_FLT +
OVERTEMP_FLT PWR_PRESENT +
PWR_PRESENT OUT_COM (+3 to 5VDC)
VAC_SELA
VAC_SELB
IS_IDA
IS_IDB
IS_IDC
ENABLE +
ENABLE START2 +
START2 SPARE
SYNC_IN +
SYNC_IN NC
NC
47 OHM to COMM
DEMAND +
DEMAND 47 OHM to COMM
CURRENT +
CURRENT 47 OHM to COMM
RIBBON CABLE 40 ckt CCM (J23) - RELAY PCB (J4)
32 COMMON
1 COMMON
33 -15 VDC
2 /1TORCH START *
34 COMMON
3 NA
4 /1TORCH GAS SOL ON * 35 24 VDC
36 COMMON
5 /MAIN TORCH IDLE *
37 24 VDC
6 /1TORCH PRESS OK *
7 FLOW SENSOR (pulses) 38 COMMON
8 LOW COOLANT FLOW 39 24 VDC
40 COMMON
9 COOLANT LEVEL OK
10 COMMON
11 NA
RIBBON CABLE 16 ckt
12 /PLASMA ENABLE-HMI
CCM ( J37) - DISPLAY PCB (J17)
13 /COOLANT PUMP ON
14 COMMON
1,3,5,7
24 VDC
15 /PILOT ENABLE
2,4,6,8
COMMON
16 /RAS ON
9,10
NC
17 /CONTACTORS ON
11-16
SERIAL DATA
18 COMMON
19 /COOLANT FANS ON
RIBBON CABLE 10 ckt
20 /1TORCH CONTACTOR ON *
RELAY PCB (J3) – PILOT PCB (J42)
21 /PLASMA ENABLE RELAY
22 COMMON
23 PILOT CURRENT SIG1,2
24 VDC
24 NC
3,4,7,10 COMMON
25 PILOT CURRENT SIG+
5
PILOT ENABLE +
26 COMMON
6
PILOT ENABLE –
27 WORK CURRENT SIG8
PILOT CURRENT SIG –
28 WORK CURRENT SIG+
9
PILOT CURRENT SIG +
29 NC
30 AMBIENT TEMP
31 COOLANT TEMP
* Used with 1 Torch Option
D
E
Art # A-13077
Revision
Rev
00
Initial Design
AA
AB
ECO-B2687
By
Date
DAT
10/03/2012
DAT
9/16/2014
DAT
Revision
Rev
By
Date
Thermal Dynamics Corporation
2800 Airport Rd.
Denton, Texas 76207 USA
10/17/2014
The information contained herein is proprietary to Thermal Dynamics.
Not for release, reproduction or distribution without written consent.
Size
Drawing Number
SCHEMATIC
Manual 0560956456
6
7
8
APPENDIX
9
10/04/2012
DAT
Title
Ultra-Cut XT 200A CE 380-415 VAC
5
F
Date Printed
Date Revised
11/20/2014
12/16/2014
Drawn
Date
C
Sheet
1 of
2
042X1353
10
A-43
iSERIES 100 /200 /300 /400
APPENDIX 24: System Schematic 200A, 380-415V PG 2
(89)
2
1
5
2
6
3
7
4
8
J12
3
T1
24V RET
BLUE
RED
24V
B
YELLOW
BLUE
120V_2 RET
400V
RED
220V
4
3
2
YELLOW
120V_2
5
120V-1 RET
1
(77)
(78)
CB2 5 A (76)
(74)
(75)
CB3 5 A (73)
(71)
(72)
CB4 5 A
1 TORCH INTERFACE
Refer to 1 Torch Module Schematic for Details
120VAC_1
BIAS TRANSFORMER
MC3A
J16
(66)
M1
1
2
3
(65A)
J72
(69)
(64A)
230 VAC _ SW _ RET
(A9)
1
2
3
(70)
MC2B
FAN2
1
2
3
J34 - 30 CKT RIBBON
J35 - 30 CKT RIBBON
J36 - 30 CKT RIBBON
E
1
2
3
J85
CPU PCB (CPU)
BK
(53)
(55)
1
2
3
4
5
6
7
8
I / O PCB TEST POINTS
------------------------------------TP1 PCB COMMON
TP2 COOLANT FANS ON
TP3 PUMP ON
TP4 LOW FLOW (SW)
TP5 FLOW SIGNAL (pulse, Ultracut only)
TP6 +15VDC_ISO (ref to TP10)
TP7 -15VDC_ISO (ref to TP10)
TP8 +16-18 VDC_ISO (ref to TP10)
TP9 ANALOG CURRENT SIGNAL
(remote & Autocut only)
TP10 ISOLATED VOLTAGE COMMON
TP11 1 TORCH CONTACTOR ON
TP12 +5 VDC
TP13 -15 VDC
TP14 +15 VDC
TP15 +24 VDC
TP18 +5 VDC_ISO (ref to TP10)
230 VAC_SW
goes to J70
for HE 400
(Sht 1 F2)
24 VDC
24 VDC
MISSING PHASE a
MISSING PHASE b
AC V HIGH a
AC V HIGH b
AC V LOW a
24 VDC_RET
24 VDC_RET
AC V LOW b
VAC_IDA a
/ VAC_IDA b
VAC_IDB a
/ VAC_IDB b
FAN1
BN
BL
R
(29)
(30)
(31)
(32)
(33)
(34)
(35)
(36)
(37)
(38)
(39)
(40)
(41)
(42)
1
2
3
4
5
6
7
8
9
10
11
I / O PCB DIP SW
--------------------------------------------SW6 OK TO MOVE
(CONTACTS, VOLTS)
SW11 ANALOG CC SOURCE
SW12 DIVIDED ARC VOLTAGE
(50:1, 16.7:1, 30:1, 40:1, 25:1)
12
13
14
J27
.
J62-12 (/VAC_IDAb)
J62-14 (/VAC_IDBb)
230V
0
0
J28 30 CKT PIN HEADER
I / O PCB LEDS
---------------------------------------------D2 CNC PLASMA ENABLE
D3 E-STOP_PS
D4 GAS ON (Auto-cut, PAK)
D6 CNC START
D8 HOLD START
D12 PREFLOW ON
D13 CSD (corner current reduction)
D18 MARK
D20 SPARE
D25 EXP METAL
D33 OK_CNC
D37 PSR
D41 SPARE OUT 2
D43 SPARE OUT 1
Harness from System Bias PCB
Alternate fan.
100 & 200A units may use either this
single larger fan (same as 300 & 400A
units) or the 2 smaller fans shown above.
C4
J84
J28 30 CKT RECEPTACLE - BOTTOM ENTRY
I-O PCB (CCM)
230 VAC _ SW
(A9)
J72
J32 - 30 CKT RIBBON
J33 - 30 CKT RIBBON
J24
(70)
CHASSIS GND
FAN1
(51)
J73
(69)
(70)
(Sht 1, B8)
TIP VOLTS
(69)
MC2A
Harness from Pilot PCB J45
WORK
230 VAC
Torch Coolant Pump
(67)
ARC VOLTS
(64B)
R
019X501700
J11
19X501100
D
Test Points
TP1, GND
TP2, -15V
TP3, +5VDC
TP4, +12V
TP5, +24V
TP6, +15V
TP7, +5VDC
1
2
(64A)
(64B)
(65A)
(65B)
3
24VAC
J31 - 30 CKT RIBBON
MC3BCHASSIS GND
J13 to CB5
and to MC2
& MC3, also
J14, J16
all 18 AWG
TEMP SENSORS
D2, GREEN, 1TORCH GAS ON
D7, GREEN, PILOT ENABLED
D11, GREEN, PILOT CURRENT
D12, GREEN, WORK CURRENT
D22, GREEN, CONTACTORS ON
D23, GREEN, RF ON
D24, GREEN, FANS ON
D25, GREEN, PLASMA ENABLED
D26, GREEN, 1TORCH ON
D27, GREEN, COOLANT ON
To J100 of IM #1B
To J100 of IM #1A
(Sht 1, C,D6)
To J100 of IM #2A
(Sht 1, B,C6)
4
120VAC_2
J9
J14
120V_1
C
TORCH FLOW SENSOR
12
11
10
9
8
7
6
5
4
3
2
1
0V
J13
SIGNAL (pulse)
J6
(79)
6
J2
RELAY & INTERFACE PCB
+5VDC
1
2
3
4
(81)
(82)
J49
460V
1 2 3 4
5 6 7 8
J1
(95)
COOLANT FLOW SW LEVEL SENSORS WORK CURRENT SENSOR
(80)
1
2
3
4
J7
(94)
3
2
1
r
b
g
1
8
7
6
5
4
3
2
1
J5
FL1
(87)
(93)
14
13
12
11
10
9
8
7
6
5
4
3
2
1
4.7 30W
2
1
0.7 GPM
R2
(92)
TS1
5
4
3
2
1
(83)
COOLANT
6
5
4
3
2
1
(84)
1
2
1
J74
TS2
(59)
(58)
(57)
(56)
COOLANT
MC1A
AMBIENT
COMMON
SIG (+)
-15 VDC
+15 VDC
FS1
(44A)
4
J71
Sht 1, C8)
COOLANT LEVEL
TO HCT1 (Work)
(90)
2
3
From Sys Bias J63
(Sht 1, F2)
(43A)
1
LS1
5
2
J12 = Mini-Fit Jr
400 VAC -- Single 18 AWG in pins 1 & 4
480 VAC -- Single 18 AWG in pins 1 & 8
230 VAC -- 18 AWG wires in pins 1,5,2,6
A
4
3
3
2
4
1
400V 480V ERR
1
0
1
0
1
1
19X501200
Measure relative to TP1 (24VDC_RET)
"0" = 10-12V
"1" = 24V
F
Art # A-13078
1
A-44 2
3
APPENDIX
4
5
Manual 0560956456
iSERIES 100 /200 /300 /400
6
MC3
SA4
(96)
(98)
(99)
(97)
24 VAC
J59 - RAS
ARC_SUPPRESSOR
(60)
120 VAC_1
HMI/GCM
J4 -- 40 CKT RIBBON CABLE
(101)
(102)
(103)
(104)
(106)
(113)
(61)
(62)
AC 120V - GCM
AC 24V - RET - GCM2
AC 120V- Ret- GCM
AC 120V- Ret- TB4-3
J39
USB
PORT
1
2
3
4
(60)
J18
GND
GND
4 WIRE
RxTx+
Rx+
Tx-
(108)
(115)
AC 24V Ret- GCM1
Harness
AC 24V- Ret -TB4-1
(62) 1
(116)
(117)
(118)
K1
(119)
(120)
2
J29
J37
J23- 40 ckt ribbon cable
ENABLE
PLAS_ENABLE SW
PLAS_ EN_SW_RET
/ GAS PRESS OK
/ BASIC ID
TB1
OK2 (contact)
12
+10V (CC Pot Hi) 11
CC Pot Wiper
10
CC Pot Low
9
Div Arc V (+)
8
Div Arc V (-)
7
/Start - Stop (+) 6
/Start - Stop (-)
5
Stop Mom NC
4
OK2 (contact)
3
/ CNC Enable (+) 2
/ CNC Enable (-) 1
CPU PCB TEST POINTS
-------------------------------------------TP1 GND (PCB common)
TP2 +5V_ISO (REF TP5)
TP3 +24 VDC
TP4 +3.3V
TP5 GND_ISO
TP6 +5.0 V
TP7 TOTAL DEMAND
(3.3V = 400A)
TP9 /WR
TP10 /RD
TP11 CPU TEMP SENSE
TP12 +3.3VA
TP13 -15VDAC
TP14 PC2
TP15 +15VDAC
TP16 CLKO
TP18 OSC_CLOCK
12
11
10
9
8
7
6
5
4
3
2
1
PILOT is ON
PILOT is ON
Preflow ON (+)
Preflow ON (-)
Hold Start (+)
Hold Start (-)
CPU PCB DIP SW
--------------------------------------------SW1 AUTO PILOT RESTART
SW3 PREFLOW TIME
SW4 POSTFLOW TIME
SW5 FUNCTION
SW8 SYSTEM CONTROL
(pilot time, etc.)
SW9
RESERVED (future)
SW10 ADDRESS (default = 0)
SW13 UNIT TYPE (AC / UC)
SW14 LINE TERMINATION
(serial comm.)
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
GND
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
TB2
OK to MOVE (-)
+10V
GND
GND
(121)
(122)
(123)
(124)
(125)
(126)
(127)
(128)
(129)
(130)
(131)
(130)
(131)
(112)
(114)
(121)
(122)
(124)
(129)
(128)
(123)
AC 24V Ret - GCM1
AC 24V-GCM2
AC 24V Ret-GCM2
TB3
PSR
SPARE #1a
(167)
AC 120V - GCM
AC 120V- Ret- GCM
00
Initial Design
AA
AB
ECO-B2687
By
Date
DAT
10/03/2012
DAT
9/16/2014
DAT
Revision
Rev
(113)
(140)
(141)
(136)
(135)
(132)
(153)
(143)
(144)
(145)
(144)
(145)
(146)
(147)
(148)
(149)
(150)
(151)
(146)
(147)
(148)
(149)
(150)
(151)
(152)
(154)
(155)
(132)
(152)
(153)
(154)
(155)
(156)
(157)
(158)
(159)
(156)
(157)
(158)
(159)
Manual 0560956456
J55 - GCM
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
1- PLAS_ENABLE SW *
2- PLAS_ EN_SW_RET
3- GAS PRESS OK RET
4- / GAS PRESS OK
5- POT HIGH (GCM 1000)
6- POT WIPER (GCM 1000)
7- POT LOW (GCM 1000)
8- BASIC ID RET
9- / BASIC ID **
1011-
C
GCM 1000 XT
Jumper
1415- 24 VAC - RET
* Plasma Enable SW
in GCM 2010.
Jumpered in
GCM 1000 XT
and DMC 3000.
** Jumper in
GCM 1000 XT
27- GAS SEL SW RET
28- GAS SEL SW
D
J15-1 to chassis used for
SC-11 cable shield
J15-13 connects SC-11
chassis to PS chassis.
The COMM Ref at pin 8
is also for the SC-11
3- / CNC Start (+)
4- / CNC Start (-)
5- Divided Arc V (-)
6- Divided Arc V (+)
7- / Preflow ON (+)
8- COMM Ref (1K Ohm)
9- / Preflow ON (-)
10- / Spare Digital Input (+)
11- / Spare Digital Input (-)
12- OK to Move (-)
14- OK to Move (+)
15 - Key Plug
16- / Hold Start (+)
17- / Hold Start (-)
E
21- / Plasma Mark (+)
22- / Plasma Mark (-)
23- / Spare Digital Input(+)
24- / Spare Digital Input (-)
25- / CNC Plasma Enable (+)
26- / CNC Plasma Enable (-)
29- Remote CC Pot High
30- Remote CC (analog)
31- Remote CC Pot Low
32- Stop SW (momentary) *
33- Stop SW Ret
34- Pilot is ON (a)
35- Pilot is ON (b)
36- Spare OUT #1 (a)
37- Spare OUT #1 (b)
* Used with Momentary CNC Start SW
Date
Thermal Dynamics Corporation
2800 Airport Rd.
Denton, Texas 76207 USA
F
Date Printed
Date Revised
11/20/2014
12/16/2014
Drawn
Date
10/17/2014
Size
Drawing Number
SCHEMATIC
7
8
APPENDIX
9
10/4/2012
DAT
The information contained herein is proprietary to Thermal Dynamics.
Not for release, reproduction or distribution without written consent.
Title
Ultra-Cut XT 200A CE 380-415 VAC
6
12 - Tx13 - Rx+
14 - Rx-
J15-CNC
(133)
(134)
(135)
(136)
(137)
(138)
(139)
(140)
(141)
(142)
J22
By
(106)
CHASSIS GND
Art # A-13078
Revision
Rev
(111)
J69
2
1
(133)
(134)
(137)
(139)
(138)
(143)
(104)
(166)
(125)
(126)
(127)
(142)
(112)
(114)
(103)
(110)
AC 24V-GCM1
J21
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
Spare
Digital
Inputs
12
11
10
9
Spare #1b NO 8
7
6
Spare
5
Digital
4
Inputs
3
/ Plasma Marking (-) 2
/ Plasma Marking (+) 1
B
Comm
019X501800
16 CKT RIBBON
J26
OK
OK to MOVE (+)
5-HMI Plasma Enable SW
6-HMI Plasma Enable SW
7 - Key Plug
8 - Tx+
9 - GND
RS 485
10 - GND / 422
Harness
GAS ON
30 CKT PIN HEADER
1 - 24 VAC
2 - 24 VAC Ret
3- Jumper to 24 VAC
Display PCB
J29 30 CKT RECEPTACLE - BOTTOM ENTRY
CPU PCB LEDs
---------------------------D2 RXD (red)
D3 TXD (red)
D4 CAN BUS (slave)
D7 CAN BUS (MAIN)
D11 5 VDC POWER
D17 STATUS CODE
D18 INITIALIZING /
PROGRAMMING (red)
2
3
4
5
6
7
8
9
10
11
12
13
14
J17
J20
J19
3 - Key Plug
3
INRUSH CONTROL
(116)
(117)
(120)
(115)
(119)
(118)
1
2
3
4
5
6
J30
2 WIRE
NORMAL PROGRAM
PROG
USB IC
(109)
AC 120V- TB4-4
(63)
A
J54 - Remote HMI & CNC COMM
(100)
1
(101)
(102)
AC 24V-TB4-2
(63) 5
J47
1
2
3
4
1
2
3
4
5
6
7
8
9
1
2
3
4
5
6
(98)
1
2
3
4
5
6
7
8
9
10
11
12
13
14
4
USB Cable to Front Panel
1
2
3
4
5
6
7
8
9
10
11
12
120 VAC Ret
MC1
J10
1
2
3
4
5
6
7
8
9
10
11
12
(99)
AC 24V GCM1
AC 24V GCM2
(108)
(109)
(110)
(111)
120 VAC to RAS
120VAC
(100)
18
17
16
15
14
13
12
11
10
9
8
7
6
5
4
3
2
1
120 VAC_2
RS 232 D-SUB
SERIAL PROG
PORT
1
2
3
4
5
6
7
( 69)
230 VAC Ret
W1
CONTROL OUTPUTS
J38
230 VAC to HE 400 (70)
( 69)
CHASSIS GND
24 VDC
GND
10
J70 - HE
(D2)
SA1
Pump Motor Control
16
15
14
13
12
11
10
9
8
7
6
5
4
3
2
1
2
1
J8
(70)
(163)
(162)
(D2)
(161)
SA3
(160)
10 CKT RIBBON
4
3
PILOT A SIG Vin+
PILOT A SIG Vin-
/ PILOT ENABLE
/ PILOT ENABLE RET
5
6
7
8
9
10
230 VAC _ SW
230 VAC _ SW _ RET
ARC_SUPPRESSOR
PILOT PCB
9
MC2 Fan Control
ARC_SUPPRESSOR
J3
8
7
TO PILOT PCB
Sht 1, B8)
C
Sheet
2 of
2
042X1353
10
A-45
iSERIES 100 /200 /300 /400
APPENDIX 25: System Schematic 300A, 380-415V PG 1
1
2
(1)
(2)
(3)
A
1
2
IN1
EMI
FILTER
PCB
(5)
2
1
IN2
1
2
OUT2
GND2B
1
2
IN1
(2)
B
380-415
VAC
INPUT
(Customer
supplied
power cord
must pass
through
ferrite core
assembly.)
L1
1
L2
1
1
2
(5)
2
1
(6)
OUT3
IN3
W2A
W2B
(7)
(7)
(8)
(8)
1
2
L8
1
2
019X502700
J105A
1
2
1
2
J103A
1
2
Toriod Core
019X502000
CHASSIS GND
INVERTER MODULE (IM) #2 (middle)
AC SUPPRESSION
PCB
J50 019X504000 J51
1
2
3
4
5
6
7
8
9
10
11
12
13
14
1
(3)
1
(10)
1
2
3
4
LT1
(11)
PANEL AC INDICATOR
(12)
J52
LT2
1
2
3
4
GND
(23)
(13)
LT1 & LT2
INPUT POWER
NEON INDICATORS
Rear Panel & Internal
CHASSIS GND
C
L6
J105A
1
2
(25)
AC INPUT
1
2
J103A
1
2
Toriod Core
019x502000
W1A
(1)
1
2
IN1
(2)
EMI
FILTER
PCB
OUT1
1
2
1
2
OUT2
GND2B
IN3
W1B
(21)
2
1
IN2
(3)
INVERTER MODULE (IM) #`1 (bottom)
(20)
2
1
(22)
2
1
W1C
(23)
(23)
(24)
(24)
(25)
(25)
(1)
1
2
IN1
(2)
EMI
FILTER
PCB
(23)
IN2
GND2B
TEST POINTS
TP1 SECONDARY GND
TP2 24VDC
TP3 DC INPUT POSITIVE
TP4 VCC1
TP5 VCC2
TP6 GATE
TP7 PRIMARY GND
TP8 +12V PRIMARY
TP9 P ISOL GND
SYSTEM BIAS
SUPPLY PCB
F2
8A, 500V, SB
+24VDC
+V
019X501900
(27A)
(85A)
(86B)
(27B)
(85B)
AC INPUT
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
GND
K1A
K1B
J63
(43A)
Art # A-13079
1
A-46 1
2
3
4
5
6
7
8
9
10
11
12
J60
F
TO AUX TRANSFORMER
TO J12
(44A)
T1 PRIMARY
(Sht 2, A1)
480V-ID
400V-ID
208-230V-ID
COM
(86A)
L4
J105A
019x502700
D6, GREEN, -12V
D11, GREEN, +12VP
D13, GREEN, +12V
IM #1 Section B (upper)
CONTROL PCB LEDS
D1, RED, INV FLT
D14, RED, OVER TEMP
D24, GREEN, PWM ON
D32, RED, PRI OC
1
2
IM #1 Section A (lower)
AC INPUT
J104A
1
2
J103A
System Bias LEDs & Test Points
OUT3
4
3
2
1
(28)
(26)
F1
8A, 500V, SB
1
2
MAIN PCB LEDS
D3, RED, CAP
IMBALANCE
D4, GREEN, READY
CAP BIAS PCB LEDS
1
2
WORK (+)
019x502000
2
1
(FRONT PANEL)
(27A&B)
E
J103B
Toriod Core
CHASSIS GND
CB1
1
2
(25)
(1-20)
(2-21)
(3-22)
ON / OFF
16 A
J104B
OUT2
IN3
AC INPUT
1
2
(24)
2
1
OUT1
2
1
1
2
J105B
OUT3
1
2
(3)
L5
Toriod Core
CHASSIS GND
D
IM #2 Section A (lower)
J104A
(24)
INTERNAL AC INDICATOR
AC LINE
CHASSIS GND
IM #3 Section A
AC INPUT
J104A
(9)
W2C
IM #3 Section B
J103B
Toriod Core
(9)
OUT2
GND2B
(2)
Earth
OUT1
2
1
IN2
(3)
(4)
2
1
1
2
(1)
L3
EMI
FILTER
PCB
1
2
AC INPUT
J104B
(9)
CHASSIS GND
(1)
J105B
(8)
OUT3
IN3
L9
(7)
(6)
2
1
5
INVERTER MODULE (IM) #3 (top)
(4)
2
1
OUT1
1
2
4
3
(48)
LEDS
D3, RED, MISSING PHASE
D4, RED, AC V HIGH
D14, RED, AC V LOW
D26, GREEN, +12V PRI
D30, GREEN, 24VDC
D44, GREEN, T1 ON
Component Locations (not including PCB components)
Capacitor, fan starting, 8uf 440VAC (Sht 2, D2)
Circuit Breaker /ON/OFF SW, 15A 480V
(Sht 1, E1)
CB2-4
Circuit Breaker, 5A, 250V (Sht 2, B3)
F1, 2
Fuse, 8A, 500V, S.B. (Sht 1,E1)
FAN1
Fan, Heat Exchanger , 230 VAC (Sht 2, D2)
FL1
Flow meter, pulse output (Sht 2, B2)
FS1
Flow SW, 0.5 GPM (3.8 lpm), N.O. (Sht 2, A2)
To J27 on CCM I/O PCBHCT1
Current Sensor, Hall Effect 200A, Work Lead
(Sht 1, C8)
(Sht 2, E3)
K1
Relay,
24VAC, Inrush Control, (Sht2, B9)
J62
L1
Inductor, (Sht 1, B7)
24
VDC
(29)
1
L3-9
Toriod
Core Common Mode Ind (Sht1 B8, A-D3)
24 VDC
(30)
2
LS1
Level Switch, Coolant Tank (Sht 2, A3)
MISSING PHASE a (31)
3
LT2
Indicator,
Neon, 250V, AC Volts Present
LT1,
MISSING
PHASE
b
(32)
4
AC V HIGH a
(33)
(Sht 1, B2 & C2)
5
(34)
AC
V
HIGH
b
M1
Motor,
Pump,
½ hp 230VAC, 50/60 Hz, 1Ph
6
AC V LOW a
(35)
(Sht 2, C2)
7
24
VDC_RET
(36)
MC1
Relay,
120VAC,
Inrush, coil (Sht2, B9)
8
24 VDC_RET
(37)
contact (Sht2, A1)
9
AC V LOW b
(38)
MC2
Relay, 120 VAC, Fan Control, coil
10
VAC_IDA a
(39)
11
(Coil at Sht 2, A7)(Contacts at Sht 2, D1)
(40)
/ VAC_IDA b
12
MC3
Relay, 120 VAC, Pump Motor Control, coil
VAC_IDB
a
(41)
13
(Coil at Sht 2, A7)(Contacts at Sht 2, C1)
/
VAC_IDB
b
(42)
14
R2
Inrush, 4.7 Ohm, 30W (Sht2, A1)
230V 400V 480V ERR
R3,4
Ext RC, 100 ohm 55W (Sht1, A7)
/VAC_IDAb 0
1
0
1
SA1-4
Snubber, Contactor & Relay coils
/VAC_IDBb 0
0
1
1
(Sht 2, A8 & A9)
Measure relative to TP1 (24VDC_RET)
T1
Aux
Transformer (Sht 2, B2)
"0" = 10-12V
"1" = 24V
J61
TB4
Terminal Block (Sht 1, C9)
VOLTAGE SELECTION
TS1
Temperature Sensor, NTC, Coolant Return
Wire #48 from J61-1 to:
(Sht 2, A5)
J61-2 for 208-230 VAC
TS2
Temperature Sensor, NTC, Ambient (Sht 2, A5)
J61-3 for 400 VAC
W1
Contactor , Input (Coil Sht 2, A8), (Contacts C2)
J61-4 for 480 VAC
W2
Contactor , Input (Coil Sht 2, A8), (Contacts A2)
2
3
APPENDIX
C4
CB1
4
5
Manual 0560956456
iSERIES 100 /200 /300 /400
7
6
8
9
10
TO CCM
CPU PCB J36
(Sht 2, C3)
(51F)
D2 PILOT ENABLE
D11 +5V
J102B
TO CCM
CPU PCB
J35
WORK (+)
1
J41 (J87)
J58C
(50)
J41
5
4
3
2
1
(51F)
TIP
J40
INVERTER
019X501600
To / From Optional
1 Torch Module
(Refer to 1 Torch
section for details.)
J45
10 ckt Ribbon
TO J3 on RELAY PCB
(Sht 2, A5)
To J24 on I-O PCB
(Sht 2, D3)
TO CCM
CPU PCB
J33
Tip
WORK
(53)
B
Work
1
(+)
TIP VOLTS
(51)
WORK
ARC VOLTS
(55)
HCT1
3
4
3
4
Hall Effect Sensor
2
4
3
2
1
1
(51)
(51)
2
(51C)
J102A
(49C)
5
1
WORK (+)
(+)
SHIELD
L1
(Sht 2, C3)
ELECTRODE (-)
(-)
CHASSIS GND
1
2
J42
J100 -- 30 CKT RIBBON
1
(52)
CHASSIS GND
J102A
OUTPUT
PILOT RAS
To TB4-6TIP
PILOT PCB J44
R3 & R4
(49E)
A
Electrode
ELECTRODE (-)
5
4
3
2
1
(51E)
J100 -- 30 CKT RIBBON
J43
ELECTRODE
1
L3
(49)
J58A
(Sht 2, C3)
TORCH
(49)
TEST POINTS
TP1 GND
TP2 PILOT GATE
TP3 +5V
PILOT BOARD LED'S
2
1
OUTPUT
(49)
1
WORK (+)
TORCH
To TB4-7
(49F)
5
4
3
2
1
1
2
3
4
5
6
7
8
9
10
ELECTRODE (-)
1
2
3
4
5
6
7
8
J100 -- 30 CKT RIBBON
ELECTRODE (-)
WORK (+)
OUTPUT
4
3
2
1
TO J1 on RELAY PCB
(Sht 2, B9)
AC 120V- TB4-4
(57) b
AC 120V- Ret- TB4-3
(58) g
AC 24V-TB4-2
(59) w
AC 24V- Ret -TB4-1
(49)
(52)
(51)
(60)
7
ARC VOLTS (TORCH)
6
TIP VOLTS (PILOT)
5
WORK
4
(61)
3
(62)
2
(63)
1
120 VAC @ 100 ma.
24 VAC @ 1A
(J10 Sht 2, B8)
(Sht 2, C3)
RIBBON CABLE 30 ckt.
CCM (J31-36) - INVERTER (J100)
J100 -- 30 CKT RIBBON
J102A
(49A)
WORK (+)
TORCH
(Sht 1, A9)
TIP
(Sht 1, A9)
(56) o
TO CCM
CPU PCB
J31
ELECTRODE (-)
C
TB4
COMMON
J46-F
SIG (+)
+15 VDC
2
1
J102B
(49B)
5
J46-M
(51B)
J100 -- 30 CKT RIBBON
(Sht 2, C3)
2
1
J16
TO CCM
CPU PCB
J32
-15 VDC
OUTPUT
5
4
3
2
1
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
(50)
OUTPUT
RIBBON CABLE 40 ckt CCM (J23) - RELAY PCB (J4)
32 COMMON
1 COMMON
33 -15 VDC
2 /1TORCH START *
34 COMMON
3 NA
35 24 VDC
4 /1TORCH GAS SOL ON *
36 COMMON
5 /MAIN TORCH IDLE *
37 24 VDC
6 /1TORCH PRESS OK *
38 COMMON
7 FLOW SENSOR (pulses)
39 24 VDC
8 LOW COOLANT FLOW
40
COMMON
9 COOLANT LEVEL OK
10 COMMON
RIBBON
CABLE 16 ckt
11 NA
CCM ( J37) - DISPLAY
12 /PLASMA ENABLE-HMI
PCB
(J17)
13 /COOLANT PUMP ON
14 COMMON
1,3,5,7
24 VDC
15 /PILOT ENABLE
2,4,6,8
COMMON
16 /RAS ON
9,10
NC
17 /CONTACTORS ON
11-16
SERIAL DATA
18 COMMON
19 /COOLANT FANS ON
20 /1TORCH CONTACTOR ON *
RIBBON CABLE 10 ckt
21 /PLASMA ENABLE RELAY
RELAY PCB (J3) – PILOT PCB (J42)
22 COMMON
23 PILOT CURRENT SIG24 NC
1,2
24 VDC
25 PILOT CURRENT SIG+
3,4,7,10 COMMON
26 COMMON
5
PILOT ENABLE +
27 WORK CURRENT SIG6
PILOT ENABLE –
28 WORK CURRENT SIG+
8
PILOT CURRENT SIG –
29 NC
9
PILOT CURRENT SIG +
30 AMBIENT TEMP
31 COOLANT TEMP
* Used with 1 Torch Option
READY +
READY INVERTER_FLT +
INVERTER_FLT OVERTEMP_FLT +
OVERTEMP_FLT PWR_PRESENT +
PWR_PRESENT OUT_COM (+3 to 5VDC)
VAC_SELA
VAC_SELB
IS_IDA
IS_IDB
IS_IDC
ENABLE +
ENABLE START2 +
START2 SPARE
SYNC_IN +
SYNC_IN NC
NC
47 OHM to COMM
DEMAND +
DEMAND 47 OHM to COMM
CURRENT +
CURRENT 47 OHM to COMM
D
E
Art # A-13079
Rev
00
Revision
Initial Design
AA
AB
ECO 1 Torch Option
By
Date
DAT
10/03/2012
DAT
9/16/2014
DAT
10/17/2014
Revision
Rev
By
Date
2800 Airport Rd.
Denton, Texas 76207 USA
Size
Drawing Number
SCHEMATIC
Manual 0560956456
7
8
9
APPENDIX
10/04/2012
DAT
The information contained herein is proprietary to Thermal Dynamics.
Not for release, reproduction or distribution without written consent.
Title
iSeries XT 300A CE 380-415 VAC
6
F
Date Printed
Date Revised
10/20/2014
12/16/2014
Drawn
Date
C
Sheet
1 of
2
042X1352
10
A-47
iSERIES 100 /200 /300 /400
APPENDIX 26: System Schematic 300A, 380-415V PG 2
2
COOLANT LEVEL
(89)
COMMON
SIG (+)
-15 VDC
+15 VDC
J49
460V
1 2 3 4
5 6 7 8
1
2
3
4
(81)
(82)
24V RET
BLUE
RED
24V
B
YELLOW
BLUE
120V_2 RET
400V
RED
220V
4
(74)
(75)
CB3 5 A(73)
3
120V-1 RET
(71)
(72)
CB4 5 A
1
8
7
6
5
4
3
2
1
1 TORCH INTERFACE
Refer to 1 Torch Module Schematic for Details
120VAC_1
BIAS TRANSFORMER
MC3A
J16
(66)
M1
1
2
3
(67)
(69)
MC2A
J72
(69)
MC2B
(64A)
230 VAC _ SW _ RET
(A9)
1
2
3
(70)
FAN2
1
2
3
J35 - 30 CKT RIBBON
J36 - 30 CKT RIBBON
Alternate fan.
100 & 200A units may use either this
single larger fan (same as 300 & 400A
units) or the 2 smaller fans shown above.
1
2
3
J85
CPU PCB (CPU)
BK
FAN1
BN
BL
R
(55)
1
2
3
4
5
6
7
8
I / O PCB TEST POINTS
------------------------------------TP1 PCB COMMON
TP2 COOLANT FANS ON
TP3 PUMP ON
TP4 LOW FLOW (SW)
TP5 FLOW SIGNAL (pulse, Ultracut only)
TP6 +15VDC_ISO (ref to TP10)
TP7 -15VDC_ISO (ref to TP10)
TP8 +16-18 VDC_ISO (ref to TP10)
TP9 ANALOG CURRENT SIGNAL
(remote & Autocut only)
TP10 ISOLATED VOLTAGE COMMON
TP11 1 TORCH CONTACTOR ON
TP12 +5 VDC
TP13 -15 VDC
TP14 +15 VDC
TP15 +24 VDC
TP18 +5 VDC_ISO (ref to TP10)
230 VAC_SW
goes to J70
for HE 400
Harness from System Bias PCB
(Sht 1 F2)
24 VDC
24 VDC
MISSING PHASE a
MISSING PHASE b
AC V HIGH a
AC V HIGH b
AC V LOW a
24 VDC_RET
24 VDC_RET
AC V LOW b
VAC_IDA a
/ VAC_IDA b
VAC_IDB a
/ VAC_IDB b
(29)
(30)
(31)
(32)
(33)
(34)
(35)
(36)
(37)
(38)
(39)
(40)
(41)
(42)
1
2
3
4
5
6
7
8
9
10
11
I / O PCB DIP SW
--------------------------------------------SW6 OK TO MOVE
(CONTACTS, VOLTS)
SW11 ANALOG CC SOURCE
SW12 DIVIDED ARC VOLTAGE
(50:1, 16.7:1, 30:1, 40:1, 25:1)
12
13
14
J27
.
J62-12 (/VAC_IDAb)
J62-14 (/VAC_IDBb)
230V
0
0
400V
1
0
480V ERR
0
1
1
1
J28 30 CKT PIN HEADER
I / O PCB LEDS
---------------------------------------------D2 CNC PLASMA ENABLE
D3 E-STOP_PS
D4 GAS ON (Auto-cut, PAK)
D6 CNC START
D8 HOLD START
D12 PREFLOW ON
D13 CSD (corner current reduction)
D18 MARK
D20 SPARE
D25 EXP METAL
D33 OK_CNC
D37 PSR
D41 SPARE OUT 2
D43 SPARE OUT 1
230 VAC _ SW
(A9)
CHASSIS GND
C4
J84
J28 30 CKT RECEPTACLE - BOTTOM ENTRY
I-O PCB (CCM)
J24
(70)
J72
J32 - 30 CKT RIBBON
J34 - 30 CKT RIBBON
(53)
(51)
J73
(69)
(70)
FAN1
TIP VOLTS
(Sht 1, B8)
WORK
230 VAC
Torch Coolant Pump Harness from Pilot PCB J45
ARC VOLTS
(64B)
(65A)
E
019X501700
J33 - 30 CKT RIBBON
19X501100
R
Test Points
TP1, GND
TP2, -15V
TP3, +5VDC
TP4, +12V
TP5, +24V
TP6, +15V
TP7, +5VDC
1
2
3
(64A)
(64B)
(65A)
(65B)
4
24VAC
J31 - 30 CKT RIBBON
MC3BCHASSIS GND
D
TEMP SENSORS
D2, GREEN, 1TORCH GAS ON
D7, GREEN, PILOT ENABLED
D11, GREEN, PILOT CURRENT
D12, GREEN, WORK CURRENT
D22, GREEN, CONTACTORS ON
D23, GREEN, RF ON
D24, GREEN, FANS ON
D25, GREEN, PLASMA ENABLED
D26, GREEN, 1TORCH ON
D27, GREEN, COOLANT ON
J11
To J100 of IM #2A
(Sht 1, B,C6)
J13 to CB5
and to MC2
& MC3, also
J14, J16
all 18 AWG
J2
To J100 of IM #1B
To J100 of IM #1A
(Sht 1, C,D6)
0V
C
120VAC_2
J9
J14
120V_1
J13
TORCH FLOW SENSOR
12
11
10
9
8
7
6
5
4
3
2
1
(77)
(78)
CB2 5 A(76)
5
2
YELLOW
120V_2
(79)
6
(95)
RELAY & INTERFACE PCB
+5VDC
SIGNAL (pulse)
J6
(93)
3
2
1
1
5
2
6
3
7
4
8
3
T1
J1
TS1
(94)
COOLANT FLOW SW LEVEL SENSORS WORK CURRENT SENSOR
(80)
1
2
3
4
J7
(92)
COOLANT
5
4
3
2
1
r
b
g
1
2
J12
2
1
J5
FL1
(87)
TS2
14
13
12
11
10
9
8
7
6
5
4
3
2
1
4.7 30W
1
(59)
(58)
(57)
(56)
(83)
2
(84)
1
2
0.7 GPM
R2
AMBIENT
J74
3
COOLANT
MC1A
4
J71
FS1
(44A)
(43A)
(90)
3
From Sys Bias J63
(Sht 1, F2)
A
1
LS1
6
5
4
3
2
1
J12 = Mini-Fit Jr
400 VAC -- Single 18 AWG in pins 1 & 4
480 VAC -- Single 18 AWG in pins 1 & 8
230 VAC -- 18 AWG wires in pins 1,5,2,6
5
4
Sht 1, C8)
3
TO HCT1 (Work)
2
4
1
19X501200
Measure relative to TP1 (24VDC_RET)
"0" = 10-12V
"1" = 24V
F
Art # A-13080
1
A-48 2
3
APPENDIX
4
Manual 0560956456
iSERIES 100 /200 /300 /400
6
7
TO PILOT PCB
Sht 1, B8)
MC3
SA4
SA1
(96)
(98)
(99)
(97)
24 VAC
J59 - RAS
ARC_SUPPRESSOR
120 VAC_1
(101)
(102)
(103)
(104)
(106)
(62)
AC 120V - GCM
(108)
(109)
(110)
(111)
(113)
(61)
AC 24V - RET - GCM2
AC 120V- Ret- GCM
AC 120V- Ret- TB4-3
1
2
3
4
1
2
3
4
4 WIRE
RxTx+
Rx+
Tx-
Harness
(62) 1
(116)
(117)
(118)
K1
(119)
(120)
2
J29
J37
ENABLE
PLAS_ENABLE SW
PLAS_ EN_SW_RET
/ GAS PRESS OK
/ BASIC ID
TB1
CPU PCB TEST POINTS
-------------------------------------------TP1 GND (PCB common)
TP2 +5V_ISO (REF TP5)
TP3 +24 VDC
TP4 +3.3V
TP5 GND_ISO
TP6 +5.0 V
TP7 TOTAL DEMAND
(3.3V = 400A)
TP9 /WR
TP10 /RD
TP11 CPU TEMP SENSE
TP12 +3.3VA
TP13 -15VDAC
TP14 PC2
TP15 +15VDAC
TP16 CLKO
TP18 OSC_CLOCK
12
11
10
9
8
7
6
5
4
3
2
1
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
OK to MOVE (+) 12
PILOT is ON
PILOT is ON
Preflow ON (+)
Preflow ON (-)
Hold Start (+)
Hold Start (-)
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
GND
TB2
11
10
9
8
7
6
5
4
3
2
1
+10V
GND
TB3
CPU PCB DIP SW
12
Spare
--------------------------------------------11
Digital
SW1 AUTO PILOT RESTART
10
Inputs
SW3 PREFLOW TIME
9
SW4 POSTFLOW TIME
Spare #1b NO 8
7
SW5 FUNCTION
6
Spare
5
Digital
SW8 SYSTEM CONTROL
4
Inputs
(pilot time, etc.)
3
/ Plasma Marking (-) 2
SW9
RESERVED (future)
/ Plasma Marking (+) 1
SW10 ADDRESS (default = 0)
SW13 UNIT TYPE (AC / UC)
SW14 LINE TERMINATION
(serial comm.)
(121)
(122)
(123)
(124)
(125)
(126)
(127)
(128)
(129)
(130)
(131)
(130)
(131)
(112)
(114)
(121)
(122)
(124)
(129)
(128)
(123)
AC 24V-GCM1
AC 24V Ret - GCM1
AC 24V-GCM2
AC 24V Ret-GCM2
GND
SPARE #1a
(167)
AC 120V - GCM
AC 120V- Ret- GCM
(106)
(113)
(153)
(143)
(144)
(145)
(144)
(145)
(146)
(147)
(148)
(149)
(150)
(151)
(146)
(147)
(148)
(149)
(150)
(151)
(152)
(154)
(155)
(132)
(152)
(153)
(154)
(155)
(156)
(157)
(158)
(159)
(156)
(157)
(158)
(159)
J22
00
Revision
Initial Design
AA
AB
ECO-B2687
By
DAT
Date
Revision
Rev
By
9/16/2014
DAT
10/17/2014
6
Manual 0560956456
C
GCM 1000 XT
Jumper
1415- 24 VAC - RET
* Plasma Enable SW
in GCM 2010.
Jumpered in
GCM 1000 XT
and DMC 3000.
** Jumper in
GCM 1000 XT
27- GAS SEL SW RET
28- GAS SEL SW
D
J15-1 to chassis used for
SC-11 cable shield
J15-13 connects SC-11
chassis to PS chassis.
The COMM Ref at pin 8
is also for the SC-11
3- / CNC Start (+)
4- / CNC Start (-)
5- Divided Arc V (-)
6- Divided Arc V (+)
7- / Preflow ON (+)
8- COMM Ref (1K Ohm)
9- / Preflow ON (-)
10- / Spare Digital Input (+)
11- / Spare Digital Input (-)
12- OK to Move (-)
14- OK to Move (+)
15 - Key Plug
16- / Hold Start (+)
17- / Hold Start (-)
E
21- / Plasma Mark (+)
22- / Plasma Mark (-)
23- / Spare Digital Input(+)
24- / Spare Digital Input (-)
25- / CNC Plasma Enable (+)
26- / CNC Plasma Enable (-)
29- Remote CC Pot High
30- Remote CC (analog)
31- Remote CC Pot Low
32- Stop SW (momentary) *
33- Stop SW Ret
34- Pilot is ON (a)
35- Pilot is ON (b)
36- Spare OUT #1 (a)
37- Spare OUT #1 (b)
Thermal Dynamics Corporation
2800 Airport Rd.
Denton, Texas 76207 USA
10/03/2012
DAT
1- PLAS_ENABLE SW *
2- PLAS_ EN_SW_RET
3- GAS PRESS OK RET
4- / GAS PRESS OK
5- POT HIGH (GCM 1000)
6- POT WIPER (GCM 1000)
7- POT LOW (GCM 1000)
8- BASIC ID RET
9- / BASIC ID **
1011-
* Used with Momentary CNC Start SW
Date
F
Date Printed
Date Revised
11/20/2014
12/16/2014
Drawn
Date
Size
Title
Drawing Number
SCHEMATIC
7
8
APPENDIX
9
10/4/2012
DAT
The information contained herein is proprietary to Thermal Dynamics.
Not for release, reproduction or distribution without written consent.
Ultra-Cut XT 200A CE 380-415 VAC
5
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
(133)
(134)
(135)
(136)
(137)
(138)
(139)
(140)
(141)
(142)
(140)
(141)
(136)
(135)
(132)
J55 - GCM
J15-CNC
CHASSIS GND
J21
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
PSR
(111)
J69
2
1
(133)
(134)
(137)
(139)
(138)
(143)
(104)
(166)
(125)
(126)
(127)
(142)
(112)
(114)
(103)
(110)
Art # A-13080
Rev
Comm
12 - Tx13 - Rx+
14 - Rx-
019X501800
16 CKT RIBBON
J26
OK
OK to MOVE (-)
B
Harness
GAS ON
J23- 40 ckt ribbon cable
OK2 (contact)
+10V (CC Pot Hi)
CC Pot Wiper
CC Pot Low
Div Arc V (+)
Div Arc V (-)
/Start - Stop (+)
/Start - Stop (-)
Stop Mom NC
OK2 (contact)
/ CNC Enable (+)
/ CNC Enable (-)
5-HMI Plasma Enable SW
6-HMI Plasma Enable SW
7 - Key Plug
8 - Tx+
9 - GND
RS 485
10 - GND / 422
Display PCB
J20
30 CKT PIN HEADER
1 - 24 VAC
2 - 24 VAC Ret
3- Jumper to 24 VAC
J17
J29 30 CKT RECEPTACLE - BOTTOM ENTRY
CPU PCB LEDs
---------------------------D2 RXD (red)
D3 TXD (red)
D4 CAN BUS (slave)
D7 CAN BUS (MAIN)
D11 5 VDC POWER
D17 STATUS CODE
D18 INITIALIZING /
PROGRAMMING (red)
2
3
4
5
6
7
8
9
10
11
12
13
14
3
INRUSH CONTROL
(116)
(117)
(120)
(115)
(119)
(118)
1
2
3
4
5
6
J30
2 WIRE
NORMAL PROGRAM
(115)
AC 24V- Ret -TB4-1
(63) 5
J47
GND
GND
J19
(108)
AC 24V Ret- GCM1
(63)
A
3 - Key Plug
4
J39
USB
PORT
1
2
3
4
5
6
7
8
9
J18
(109)
AC 120V- TB4-4
J10
1
2
3
4
5
6
7
8
9
10
11
12
(101)
(102)
AC 24V-TB4-2
(60)
1
2
3
4
5
6
7
8
9
10
11
12
13
14
J54 - Remote HMI & CNC COMM
(100)
1
AC 24V GCM1
AC 24V GCM2
USB Cable to Front Panel
PROG
USB IC
(98)
120VAC
(100)
18
17
16
15
14
13
12
11
10
9
8
7
6
5
4
3
2
1
J4 -- 40 CKT RIBBON CABLE
1
2
3
4
5
6
(99)
120 VAC Ret
(60)
HMI/GCM
1
2
3
4
5
6
7
8
9
10
11
12
120 VAC to RAS
MC1
120 VAC_2
RS 232 D-SUB
SERIAL PROG
PORT
1
2
3
4
5
6
7
( 69)
230 VAC Ret
CHASSIS GND
CONTROL OUTPUTS
J38
230 VAC to HE 400 (70)
( 69)
W1
Pump Motor Control
24 VDC
GND
10
J70 - HE
(D2)
16
15
14
13
12
11
10
9
8
7
6
5
4
3
2
1
2
1
J8
(70)
(163)
(162)
(D2)
(161)
SA3
(160)
10 CKT RIBBON
4
3
PILOT A SIG Vin+
PILOT A SIG Vin-
/ PILOT ENABLE
/ PILOT ENABLE RET
5
6
7
8
9
10
230 VAC _ SW
230 VAC _ SW _ RET
ARC_SUPPRESSOR
PILOT PCB
9
MC2 Fan Control
ARC_SUPPRESSOR
J3
8
C
Sheet
2 of
2
042X1353
10
A-49
iSERIES 100 /200 /300 /400
APPENDIX 27: System Schematic 400A, 380-415V PG 1
1
2
(1)
1
2
IN1
(2)
2
1
IN2
OUT2
GND2B
CHASSIS GND
(1)
1
2
IN1
(2)
B
380-415
VAC
INPUT
(Customer
supplied
power cord
must pass
through
ferrite core
assembly.)
L1
(3)
Earth
(5)
2
1
IN2
1
2
W2B
(7)
(7)
(8)
(8)
2
1
(6)
OUT3
L8
1
2
019X502700
J105A
1
2
1
2
J103A
Toriod Core
1
2
019X502000
CHASSIS GND
INVERTER MODULE (IM) #2 (middle)
AC SUPPRESSION
PCB
J50 019X504000 J51
1
2
3
4
5
6
7
8
9
10
11
12
13
14
1
1
1
(3)
1
(10)
1
2
3
4
GND
Toriod Core
(23)
(13)
LT1 & LT2
INPUT POWER
NEON INDICATORS
Rear Panel & Internal
CHASSIS GND
C
L6
1
2
019X502700
J105A
1
2
AC INPUT
1
2
IN1
(2)
EMI
FILTER
PCB
J103A
(25)
Toriod Core
1
2
019x502000
OUT1
1
2
1
2
OUT2
GND2B
IN3
W1B
(21)
2
1
IN2
(3)
INVERTER MODULE (IM) #`1 (bottom)
(20)
2
1
(22)
2
1
W1C
(23)
(23)
(24)
(24)
(25)
(25)
(1)
1
2
IN1
(2)
EMI
FILTER
PCB
(23)
2
1
OUT1
2
1
IN2
1
2
OUT2
GND2B
IN3
2
1
(20)
(21)
8A, 500V, SB
+24VDC
+V
019X501900
(27A)
(85A)
(86B)
(27B)
(85B)
AC INPUT
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
GND
480V-ID
400V-ID
208-230V-ID
COM
(86A)
J63
(43A)
Art # A-13081
1
A-50 1
2
3
4
5
6
7
8
9
10
11
12
J60
F
L4
019x502700
IM #1 Section B (upper)
CONTROL PCB LEDS
D1, RED, INV FLT
D14, RED, OVER TEMP
D24, GREEN, PWM ON
D32, RED, PRI OC
J105A
1
2
IM #1 Section A (lower)
AC INPUT
J104A
1
2
J103A
System Bias LEDs & Test Points
1
2
WORK (+)
TO AUX TRANSFORMER
(44A)
TO J12
T1 PRIMARY
(Sht 2, A1)
2
(48)
Component Locations (not including PCB components)
Capacitor, fan starting, 8uf 440VAC (Sht 2, D2)
Circuit Breaker /ON/OFF SW, 15A 480V
(Sht 1, E1)
CB2-4
Circuit Breaker, 5A, 250V (Sht 2, B3)
F1, 2
Fuse, 8A, 500V, S.B. (Sht 1,E1)
FAN1
Fan, Heat Exchanger , 230 VAC (Sht 2, D2)
FL1
Flow meter, pulse output (Sht 2, B2)
FS1
Flow SW, 0.5 GPM (3.8 lpm), N.O. (Sht 2, A2)
To J27 on CCM I/O PCB
HCT1
Current Sensor, Hall Effect 200A, Work Lead
(Sht 1, C8)
(Sht 2, E3)
J62
K1
Relay, 24VAC, Inrush Control, (Sht2, B9)
24 VDC
(29)
L1
Inductor, (Sht 1, B7)
1
24 VDC
(30)
L3-9
Toriod Core Common Mode Ind (Sht1 B8, A-D3)
2
MISSING PHASE a (31)
LS1
Level Switch, Coolant Tank (Sht 2, A3)
3
MISSING PHASE b (32)
LT1, LT2 Indicator, Neon, 250V, AC Volts Present
4
AC V HIGH a
(33)
(Sht 1, B2 & C2)
5
AC V HIGH b
(34)
6
M1
Motor, Pump, ½ hp 230VAC, 50/60 Hz, 1Ph
AC V LOW a
(35)
7
(Sht 2, C2)
(36)
24
VDC_RET
8
MC1
Relay, 120VAC, Inrush, coil (Sht2, B9)
(37)
24 VDC_RET
9
contact (Sht2, A1)
(38)
AC
V
LOW
b
10
MC2
Relay, 120 VAC, Fan Control, coil
(39)
VAC_IDA a
11
(Coil at Sht 2, A7)(Contacts at Sht 2, D1)
(40)
/ VAC_IDA b
12
Relay, 120 VAC, Pump Motor Control, coil
MC3
(41)
VAC_IDB
a
13
(Coil at Sht 2, A7)(Contacts at Sht 2, C1)
(42)
/
VAC_IDB
b
14
R2
Inrush, 4.7 Ohm, 30W (Sht2, A1)
230V 400V 480V ERR
R3,4
Ext
RC,
100 ohm 55W (Sht1, A7)
/VAC_IDAb 0
1
0
1
/VAC_IDBb 0
0
1
1
SA1-4
Snubber, Contactor & Relay coils
(Sht 2, A8 & A9)
Measure relative to TP1 (24VDC_RET)
"0" = 10-12V
"1" = 24V
T1
Aux Transformer (Sht 2, B2)
J61
TB4
Terminal Block (Sht 1, C9)
VOLTAGE SELECTION
TS1
Temperature Sensor, NTC, Coolant Return
Wire #48 from J61-1 to:
(Sht 2, A5)
J61-2 for 208-230 VAC
J61-3 for 400 VAC
TS2
Temperature Sensor, NTC, Ambient (Sht 2, A5)
J61-4 for 480 VAC
W1
Contactor , Input (Coil Sht 2, A8), (Contacts C2)
W2
Contactor , Input (Coil Sht 2, A8), (Contacts A2)
TEST POINTS
TP1 SECONDARY GND
TP2 24VDC
TP3 DC INPUT POSITIVE
TP4 VCC1
TP5 VCC2
TP6 GATE
TP7 PRIMARY GND
TP8 +12V PRIMARY
TP9 P ISOL GND
OUT3
SYSTEM BIAS
SUPPLY PCB
F2
1
2
MAIN PCB LEDS
D3, RED, CAP
IMBALANCE
D4, GREEN, READY
CAP BIAS PCB LEDS
D6, GREEN, -12V
D11, GREEN, +12VP
D13, GREEN, +12V
019x502000
(22)
4
3
2
1
(28)
(26)
F1
8A, 500V, SB
J103B
Toriod Core
(FRONT PANEL)
(27A&B)
E
1
2
(25)
(1-20)
(2-21)
(3-22)
ON / OFF
16 A
AC INPUT
1
2
J104B
(24)
CHASSIS GND
CB1
J105B
OUT3
1
2
(3)
L5
Toriod Core
CHASSIS GND
D
IM #2 Section A (lower)
1
2
W1A
(1)
IM #2 Section B
J104A
(24)
INTERNAL AC INDICATOR
AC INPUT
J103B
LT2
1
2
3
4
1
2
1
2
(9)
(12)
J105B
J104B
(8)
(11)
J52
L7
(7)
LT1
PANEL AC INDICATOR
AC LINE
CHASSIS GND
IM #3 Section A
AC INPUT
J104A
(9)
W2C
IM #3 Section B
AC INPUT
1
2
Toriod Core
(9)
OUT2
GND2B
IN3
(2)
L3
2
1
OUT1
1
2
(1)
L2
EMI
FILTER
PCB
(4)
1
2
J103B
(9)
W2A
J105B
J104B
(8)
OUT3
IN3
L9
(7)
(6)
2
1
5
INVERTER MODULE (IM) #3 (top)
(5)
2
1
1
2
4
3
(4)
OUT1
1
2
(3)
A
EMI
FILTER
PCB
LEDS
D3, RED, MISSING PHASE
D4, RED, AC V HIGH
D14, RED, AC V LOW
D26, GREEN, +12V PRI
D30, GREEN, 24VDC
D44, GREEN, T1 ON
C4
CB1
4
3
APPENDIX
5
Manual 0560956456
iSERIES 100 /200 /300 /400
6
8
7
9
10
TO CCM
CPU PCB J36
(Sht 2, C3)
TORCH
To TB4-7
J100 -- 30 CKT RIBBON
(50)
J100 -- 30 CKT RIBBON
(51D)
Tip
WORK
B
Work
1
2
3
4
5
6
7
8
1
WORK
(+)
(51)
ARC VOLTS
(55)
HCT1
Hall Effect Sensor
4
4
3
2
1
(51)
(51)
4
J102A
(49C)
5
3
WORK (+)
(+)
L1
(51C)
ELECTRODE (-)
SHIELD
TIP VOLTS
(Sht 2, D3)
TO CCM
CPU PCB
J33
To / From Optional
1 Torch Module
(Refer to 1 Torch
section for details.)
(53)
To J24 on I-O PCB
J102B
J45
TO I/O BOARD
10 ckt Ribbon
TO J3 on RELAY PCB
(Sht 2, A5)
(Sht 2, C3)
J100 -- 30 CKT RIBBON
J42
019X501600
2
OUTPUT
5
4
3
2
1
TIP
J40
(51F)
(-)
CHASSIS GND
1
2
INVERTER
(Sht 2, C3)
WORK (+)
J41
5
4
3
2
1
J102A
Electrode
(51E)
CHASSIS GND
J58C
TO CCM
CPU PCB
J34
ELECTRODE (-)
1
2
1
J41 (J87)
(49E)
(49D)
PILOT RAS
(52)
1
R3 & R4
1
OUTPUT
A
To TB4-6TIP
PILOT PCB J44
J58A
3
WORK (+)
5
4
3
2
1
J43
ELECTRODE
1
L3
(49)
1
TO CCM
CPU PCB
J35
(Sht 2, C3)
ELECTRODE (-)
TEST POINTS
TP1 GND
TP2 PILOT GATE
TP3 +5V
PILOT BOARD LED'S
D2 PILOT ENABLE
D11 +5V
J102B
J100 -- 30 CKT RIBBON
TORCH
(49)
(51F)
2
OUTPUT
(49F)
1
WORK (+)
5
4
3
2
1
1
2
3
4
5
6
7
8
9
10
ELECTRODE (-)
WORK (+)
OUTPUT
4
3
2
1
TO J1 on RELAY PCB
(Sht 2, B9)
TO CCM
CPU PCB
J31
(Sht 2, C3)
WORK (+)
SIG (+)
(56) o
AC 120V- TB4-4
(57) b
AC 120V- Ret- TB4-3
(58) g
AC 24V-TB4-2
(59) w
AC 24V- Ret -TB4-1
(49)
(52)
(51)
(60)
7
ARC VOLTS (TORCH)
6
TIP VOLTS (PILOT)
5
WORK
4
(61)
3
(62)
2
(63)
1
120 VAC @ 100 ma.
24 VAC @ 1A
RIBBON CABLE 40 ckt CCM (J23) - RELAY PCB (J4)
RIBBON CABLE 30 ckt.
CCM (J31-36) - INVERTER (J100)
J102A
(49A)
5
4
3
2
1
TORCH
(Sht 1, A9)
TIP
(Sht 1, A9)
(J10 Sht 2, B8)
J100 -- 30 CKT RIBBON
ELECTRODE (-)
C
TB4
COMMON
J102B
(49B)
5
J46-F
(51B)
ELECTRODE (-)
2
1
(Sht 2, C3)
J100 -- 30 CKT RIBBON
J46-M
+15 VDC
2
1
J16
TO CCM
CPU PCB
J32
-15 VDC
OUTPUT
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
(50)
OUTPUT
1 COMMON
2 /1TORCH START *
3 NA
4 /1TORCH GAS SOL ON *
5 /MAIN TORCH IDLE *
6 /1TORCH PRESS OK *
7 FLOW SENSOR (pulses)
8 LOW COOLANT FLOW
9 COOLANT LEVEL OK
10 COMMON
11 NA
12 /PLASMA ENABLE-HMI
13 /COOLANT PUMP ON
14 COMMON
15 /PILOT ENABLE
16 /RAS ON
17 /CONTACTORS ON
18 COMMON
19 /COOLANT FANS ON
20 /1TORCH CONTACTOR ON *
21 /PLASMA ENABLE RELAY
22 COMMON
23 PILOT CURRENT SIG24 NC
25 PILOT CURRENT SIG+
26 COMMON
27 WORK CURRENT SIG28 WORK CURRENT SIG+
29 NC
30 AMBIENT TEMP
31 COOLANT TEMP
* Used with 1 Torch Option
READY +
READY INVERTER_FLT +
INVERTER_FLT OVERTEMP_FLT +
OVERTEMP_FLT PWR_PRESENT +
PWR_PRESENT OUT_COM (+3 to 5VDC)
VAC_SELA
VAC_SELB
IS_IDA
IS_IDB
IS_IDC
ENABLE +
ENABLE START2 +
START2 SPARE
SYNC_IN +
SYNC_IN NC
NC
47 OHM to COMM
DEMAND +
DEMAND 47 OHM to COMM
CURRENT +
CURRENT 47 OHM to COMM
32
33
34
35
36
37
38
39
40
COMMON
-15 VDC
COMMON
24 VDC
COMMON
24 VDC
COMMON
24 VDC
COMMON
D
RIBBON CABLE 16 ckt
CCM ( J37) - DISPLAY
PCB (J17)
1,3,5,7
2,4,6,8
9,10
11-16
24 VDC
COMMON
NC
SERIAL DATA
RIBBON CABLE 10 ckt
RELAY PCB (J3) – PILOT PCB (J42)
1,2
3,4,7,10
5
6
8
9
E
24 VDC
COMMON
PILOT ENABLE +
PILOT ENABLE –
PILOT CURRENT SIG –
PILOT CURRENT SIG +
Art # A-13081
Rev
00
Revision
Initial Design
AA
AB
By
DAT
DAT
ECO-B2687
DAT
Date
Revision
Rev
By
Date
2800 Airport Rd.
Denton, Texas 76207 USA
10/03/2012
9/16/2014
10/17/2014
Size
Drawing Number
SCHEMATIC
Manual 0560956456
8
7
APPENDIX
9
10/03/2012
DAT
The information contained herein is proprietary to Thermal Dynamics.
Not for release, reproduction or distribution without written consent.
Title
iSeries XT 400A CE 380-415 VAC
6
F
Date Printed
Date Revised
11/20/2014
12/16/2014
Drawn
Date
C
Sheet
1 of
2
042X1341
10
A-51
iSERIES 100 /200 /300 /400
APPENDIX 28: System Schematic 400A, 380-415V PG 2
1
3
2
(1)
1
2
IN1
(2)
2
1
(5)
2
1
IN2
1
2
OUT2
GND2B
1
2
IN1
(2)
B
380-415
VAC
INPUT
(Customer
supplied
power cord
must pass
through
ferrite core
assembly.)
L1
1
2
L3
(5)
1
2
W2A
W2B
(7)
(7)
(8)
(8)
2
1
(6)
OUT3
L8
1
2
019X502700
J105A
1
2
1
2
J103A
1
2
Toriod Core
019X502000
CHASSIS GND
INVERTER MODULE (IM) #2 (middle)
AC SUPPRESSION
PCB
J50 019X504000 J51
1
2
3
4
5
6
7
8
9
10
11
12
13
14
1
1
1
(3)
1
(10)
1
2
3
4
GND
(23)
C
1
2
L6
(25)
019X502700
J105A
1
2
AC INPUT
1
2
J103A
1
2
Toriod Core
019x502000
W1A
(1)
1
2
IN1
(2)
EMI
FILTER
PCB
OUT1
1
2
1
2
OUT2
GND2B
IN3
W1B
(21)
2
1
IN2
(3)
INVERTER MODULE (IM) #`1 (bottom)
(20)
2
1
(22)
2
1
W1C
(23)
(23)
(24)
(24)
(25)
(25)
(1)
1
2
IN1
(2)
EMI
FILTER
PCB
(23)
2
1
OUT1
2
1
IN2
1
2
OUT2
GND2B
IN3
2
1
(20)
(21)
8A, 500V, SB
TEST POINTS
TP1 SECONDARY GND
TP2 24VDC
TP3 DC INPUT POSITIVE
TP4 VCC1
TP5 VCC2
TP6 GATE
TP7 PRIMARY GND
TP8 +12V PRIMARY
TP9 P ISOL GND
+24VDC
+V
019X501900
(27A)
(85A)
(86B)
(27B)
(85B)
AC INPUT
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
GND
480V-ID
400V-ID
208-230V-ID
COM
(86A)
J63
(43A)
Art # A-13082
1
A-52 1
2
3
4
5
6
7
8
9
10
11
12
J60
F
1
2
L4
019x502700
D6, GREEN, -12V
D11, GREEN, +12VP
D13, GREEN, +12V
IM #1 Section B (upper)
CONTROL PCB LEDS
D1, RED, INV FLT
D14, RED, OVER TEMP
D24, GREEN, PWM ON
D32, RED, PRI OC
J105A
1
2
IM #1 Section A (lower)
AC INPUT
J104A
1
2
J103A
System Bias LEDs & Test Points
OUT3
SYSTEM BIAS
SUPPLY PCB
F2
J103B
MAIN PCB LEDS
D3, RED, CAP
IMBALANCE
D4, GREEN, READY
CAP BIAS PCB LEDS
1
2
WORK (+)
019x502000
(22)
TO AUX TRANSFORMER
(44A)
TO J12
T1 PRIMARY
(Sht 2, A1)
2
4
3
2
1
(28)
(26)
F1
8A, 500V, SB
1
2
Toriod Core
(FRONT PANEL)
(27A&B)
E
J104B
(25)
(1-20)
(2-21)
(3-22)
CB1
AC INPUT
1
2
(24)
CHASSIS GND
ON / OFF
16 A
J105B
OUT3
1
2
(3)
L5
Toriod Core
CHASSIS GND
D
IM #2 Section A (lower)
J104A
(24)
LT1 & LT2
INPUT POWER
NEON INDICATORS
Rear Panel & Internal
IM #2 Section B
J103B
LT2
(13)
AC INPUT
1
2
Toriod Core
INTERNAL AC INDICATOR
CHASSIS GND
1
2
J104B
(9)
(12)
1
2
3
4
J105B
(8)
(11)
J52
L7
(7)
LT1
PANEL AC INDICATOR
AC LINE
CHASSIS GND
IM #3 Section A
AC INPUT
J104A
(9)
W2C
IM #3 Section B
AC INPUT
1
2
Toriod Core
(9)
OUT2
GND2B
IN3
(2)
Earth
OUT1
2
1
IN2
(3)
(4)
2
1
1
2
(1)
L2
EMI
FILTER
PCB
J105B
J103B
(9)
CHASSIS GND
(1)
5
J104B
(8)
(6)
2
1
L9
(7)
OUT3
IN3
4
INVERTER MODULE (IM) #3 (top)
(4)
OUT1
1
2
(3)
A
EMI
FILTER
PCB
(48)
LEDS
D3, RED, MISSING PHASE
D4, RED, AC V HIGH
D14, RED, AC V LOW
D26, GREEN, +12V PRI
D30, GREEN, 24VDC
D44, GREEN, T1 ON
Component Locations (not including PCB components)
C4
CB1
Capacitor, fan starting, 8uf 440VAC (Sht 2, D2)
Circuit Breaker /ON/OFF SW, 15A 480V
(Sht 1, E1)
CB2-4
Circuit Breaker, 5A, 250V (Sht 2, B3)
F1, 2
Fuse, 8A, 500V, S.B. (Sht 1,E1)
FAN1
Fan, Heat Exchanger , 230 VAC (Sht 2, D2)
FL1
Flow meter, pulse output (Sht 2, B2)
FS1
Flow SW, 0.5 GPM (3.8 lpm), N.O. (Sht 2, A2)
To J27 on CCM I/O PCB
HCT1
Current Sensor, Hall Effect 200A, Work Lead
(Sht 1, C8)
(Sht 2, E3)
J62
K1
Relay, 24VAC, Inrush Control, (Sht2, B9)
(29)
24 VDC
L1
Inductor, (Sht 1, B7)
1
(30)
24 VDC
L3-9
Toriod Core Common Mode Ind (Sht1 B8, A-D3)
2
MISSING PHASE a (31)
LS1
Level Switch, Coolant Tank (Sht 2, A3)
3
MISSING PHASE b (32)
LT1, LT2 Indicator, Neon, 250V, AC Volts Present
4
(33)
AC V HIGH a
(Sht 1, B2 & C2)
5
(34)
AC V HIGH b
6
M1
Motor, Pump, ½ hp 230VAC, 50/60 Hz, 1Ph
(35)
AC V LOW a
7
(Sht 2, C2)
(36)
24
VDC_RET
8
MC1
Relay, 120VAC, Inrush, coil (Sht2, B9)
(37)
24 VDC_RET
9
contact (Sht2, A1)
(38)
AC
V
LOW
b
10
MC2
Relay, 120 VAC, Fan Control, coil
(39)
VAC_IDA a
11
(Coil at Sht 2, A7)(Contacts at Sht 2, D1)
(40)
/ VAC_IDA b
12
Relay, 120 VAC, Pump Motor Control, coil
MC3
(41)
VAC_IDB
a
13
(Coil at Sht 2, A7)(Contacts at Sht 2, C1)
(42)
/
VAC_IDB
b
14
R2
Inrush, 4.7 Ohm, 30W (Sht2, A1)
230V 400V 480V ERR
R3,4
Ext
RC,
100 ohm 55W (Sht1, A7)
/VAC_IDAb 0
1
0
1
/VAC_IDBb 0
0
1
1
SA1-4
Snubber, Contactor & Relay coils
(Sht 2, A8 & A9)
Measure relative to TP1 (24VDC_RET)
"0" = 10-12V
"1" = 24V
T1
Aux Transformer (Sht 2, B2)
J61
TB4
Terminal Block (Sht 1, C9)
VOLTAGE SELECTION
TS1
Temperature Sensor, NTC, Coolant Return
Wire #48 from J61-1 to:
(Sht 2, A5)
J61-2 for 208-230 VAC
J61-3 for 400 VAC
TS2
Temperature Sensor, NTC, Ambient (Sht 2, A5)
J61-4 for 480 VAC
W1
Contactor , Input (Coil Sht 2, A8), (Contacts C2)
W2
Contactor , Input (Coil Sht 2, A8), (Contacts A2)
3
4
APPENDIX
5
Manual 0560956456
iSERIES 100 /200 /300 /400
6
8
7
9
10
TO CCM
CPU PCB J36
(Sht 2, C3)
TORCH
To TB4-7
J100 -- 30 CKT RIBBON
D2 PILOT ENABLE
D11 +5V
J41 (J87)
CHASSIS GND
(50)
INVERTER
(51F)
J100 -- 30 CKT RIBBON
B
Work
(+)
(51)
(55)
ARC VOLTS
HCT1
4
3
2
1
Hall Effect Sensor
(51)
(51)
4
J102A
(49C)
5
3
WORK (+)
Tip
WORK
L1
(51C)
ELECTRODE (-)
(+)
1
WORK
(Sht 2, D3)
(Sht 2, C3)
J100 -- 30 CKT RIBBON
SHIELD
TIP VOLTS
To J24 on I-O PCB
J102B
TO CCM
CPU PCB
J33
To / From Optional
1 Torch Module
(Refer to 1 Torch
section for details.)
(53)
4
OUTPUT
5
4
3
2
1
J45
TO I/O BOARD
10 ckt Ribbon
3
WORK (+)
J42
TO J3 on RELAY PCB
(Sht 2, A5)
(51D)
ELECTRODE (-)
TIP
019X501600
1
2
3
4
5
6
7
8
TO CCM
CPU PCB
J34
(Sht 2, C3)
(-)
CHASSIS GND
1
2
J40
(49D)
J41
5
4
3
2
1
J102A
Electrode
J58C
2
OUTPUT
R3 & R4
(49E)
1
WORK (+)
1
(52)
1
(51E)
ELECTRODE (-)
5
4
3
2
1
PILOT RAS
To TB4-6TIP
PILOT PCB J44
J58A
(Sht 2, C3)
J100 -- 30 CKT RIBBON
J43
ELECTRODE
A
2
1
J102B
TO CCM
CPU PCB
J35
1
L3
(49)
1
(51F)
2
OUTPUT
TORCH
(49)
TEST POINTS
TP1 GND
TP2 PILOT GATE
TP3 +5V
PILOT BOARD LED'S
1
WORK (+)
5
4
3
2
1
1
2
3
4
5
6
7
8
9
10
ELECTRODE (-)
(49F)
ELECTRODE (-)
WORK (+)
OUTPUT
4
3
2
1
TO J1 on RELAY PCB
(Sht 2, B9)
TO CCM
CPU PCB
J31
(Sht 2, C3)
WORK (+)
SIG (+)
(56) o
AC 120V- TB4-4
(57) b
AC 120V- Ret- TB4-3
(58) g
AC 24V-TB4-2
(59) w
AC 24V- Ret -TB4-1
(49)
(52)
(51)
(60)
7
ARC VOLTS (TORCH)
6
TIP VOLTS (PILOT)
5
WORK
4
(61)
3
(62)
2
(63)
1
120 VAC @ 100 ma.
24 VAC @ 1A
RIBBON CABLE 40 ckt CCM (J23) - RELAY PCB (J4)
RIBBON CABLE 30 ckt.
CCM (J31-36) - INVERTER (J100)
J102A
(49A)
5
4
3
2
1
TORCH
(Sht 1, A9)
TIP
(Sht 1, A9)
(J10 Sht 2, B8)
J100 -- 30 CKT RIBBON
ELECTRODE (-)
C
TB4
COMMON
J102B
(49B)
5
J46-F
(51B)
J100 -- 30 CKT RIBBON
2
1
(Sht 2, C3)
J46-M
+15 VDC
2
1
J16
TO CCM
CPU PCB
J32
-15 VDC
OUTPUT
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
(50)
OUTPUT
1 COMMON
2 /1TORCH START *
3 NA
4 /1TORCH GAS SOL ON *
5 /MAIN TORCH IDLE *
6 /1TORCH PRESS OK *
7 FLOW SENSOR (pulses)
8 LOW COOLANT FLOW
9 COOLANT LEVEL OK
10 COMMON
11 NA
12 /PLASMA ENABLE-HMI
13 /COOLANT PUMP ON
14 COMMON
15 /PILOT ENABLE
16 /RAS ON
17 /CONTACTORS ON
18 COMMON
19 /COOLANT FANS ON
20 /1TORCH CONTACTOR ON *
21 /PLASMA ENABLE RELAY
22 COMMON
23 PILOT CURRENT SIG24 NC
25 PILOT CURRENT SIG+
26 COMMON
27 WORK CURRENT SIG28 WORK CURRENT SIG+
29 NC
30 AMBIENT TEMP
31 COOLANT TEMP
* Used with 1 Torch Option
READY +
READY INVERTER_FLT +
INVERTER_FLT OVERTEMP_FLT +
OVERTEMP_FLT PWR_PRESENT +
PWR_PRESENT OUT_COM (+3 to 5VDC)
VAC_SELA
VAC_SELB
IS_IDA
IS_IDB
IS_IDC
ENABLE +
ENABLE START2 +
START2 SPARE
SYNC_IN +
SYNC_IN NC
NC
47 OHM to COMM
DEMAND +
DEMAND 47 OHM to COMM
CURRENT +
CURRENT 47 OHM to COMM
32
33
34
35
36
37
38
39
40
COMMON
-15 VDC
COMMON
24 VDC
COMMON
24 VDC
COMMON
24 VDC
COMMON
D
RIBBON CABLE 16 ckt
CCM ( J37) - DISPLAY
PCB (J17)
1,3,5,7
2,4,6,8
9,10
11-16
24 VDC
COMMON
NC
SERIAL DATA
RIBBON CABLE 10 ckt
RELAY PCB (J3) – PILOT PCB (J42)
1,2
3,4,7,10
5
6
8
9
E
24 VDC
COMMON
PILOT ENABLE +
PILOT ENABLE –
PILOT CURRENT SIG –
PILOT CURRENT SIG +
Art # A-13082
Rev
00
Revision
Initial Design
DAT
AA
AB
By
ECO-B2687
Date
Revision
Rev
By
Date
2800 Airport Rd.
Denton, Texas 76207 USA
10/03/2012
DAT
9/16/2014
DAT
10/17/2014
Size
Drawing Number
SCHEMATIC
Manual 0560956456
7
8
APPENDIX
9
10/03/2012
DAT
The information contained herein is proprietary to Thermal Dynamics.
Not for release, reproduction or distribution without written consent.
Title
iSeries XT 400A CE 380-415 VAC
6
F
Date Printed
Date Revised
11/20/2014
12/16/2014
Drawn
Date
C
Sheet
1 of
2
042X1341
10
A-53
iSERIES 100 /200 /300 /400
APPENDIX 29: ADVANCED TROUBLESHOOTING
System Overview
The iSeries 100, 200, 300 & 400 power supplies include
one, two or three inverter modules (IM). Each IM may
have either 1 or 2 inverter sections designated A or
B sections. The IMs are mounted one over the other
numbered from bottom to top. The sections are also
designated from bottom to top with section A being on
the bottom of each module. An IM with one section is
considered to be a ½ or “partial” module with the upper
or “B” section missing. ½ modules are used with the
200A & 300A power supplies and will always be in the
middle position. IMs with 2 sections are considered to
be “full” modules.
Each inverter section can supply up to 67A but does not
do so in all configurations:
A 400A unit uses 6 sections. 400A / 6 = 66.67A per section.
A 300A unit uses 5 sections. 300A / 5 = 60A per section.
A 200A unit uses 3 sections. 200/3 = 66.67A per section.
A 100A unit uses 2 sections. 100/2=50A per section.
Unit configurations.
Art # 12299
With the exception of the AC 200 XT and PAK200i all
other units have the same chassis with room for up to
3 IMs. The unused areas have blank panels filling the
empty locations which are required for proper air flow.
A 100A system uses 1 full IM; 200A uses 1 and ½ modules
with a full module in the bottom location and a ½ module
in the middle position. A 300A unit has full modules top
and bottom with the ½ module in the middle location.
The AC 200 XT and PAK200i have only the bottom and
middle locations for IMs. An internal Arc Starter and Gas
Control are located in the place of the 3rd or upper IM.
Inverter module cooling.
The power semiconductors of the inverter modules
are liquid cooled allowing us to get more power in a
smaller area and at lower cost. Each IM has a liquid
cooled heatsink or “cold plate” shared by the 2 inverter
sections. The magnetic components, transformers and
inductors, are air cooled and mounted on the back side
of the IMs where they are exposed to high volumes of
air flow from the cooling fans whose air also cools liquid
coolant in the radiator or heat exchanger. It is important
that lower right side panel be in place or the air flow will
not be proper for cooling the magnetics.
Art # 12300
Inverter control.
The inverter sections are operated as separate inverters
whose outputs are connected in parallel. They are controlled independently from the Command and Control
Module (CCM) which is the “brains” of the system. Each
inverter section has a separate ribbon cable connected
A-54 APPENDIX
Manual 0560956456
iSERIES 100 /200 /300 /400
to it coming from the CCM which has 6 connectors, J31 – J36 corresponding to the inverter sections 1A through 3B.
The ribbon cables are labeled on the inverter ends as INV with the number and section (INV 1A, INV 1B, etc.). A
100A unit will only have ribbon cables in J31 & J32; a 200A will have J31-J33 filled with the others empty. 300A will
have J34 missing with the others filled.
Other boards in the system include the System Bias Supply, the Relay & Interface PCB, Display PCB, Pilot PCB
and AC Suppression PCB. The CCM has 2 boards, the I/O (input/output) and the CPU (central processing unit)
board. The CE units will also have one or more EMI Filter boards on the input power.
System Bias supply PCB is powered from the 3 phase AC input and works from about 150V to over 600V covering
all the normal voltage ranges. It can operate from 2 phases (single phase) so it still provides bias power and can
report a fault if a phase is missing. The supply’s output is 24 VDC which powers the Relay board, the Display, the
Pilot board and the 2 boards in the CCM. System Bias also contains circuits to detect missing phase and determine
if the AC voltage is within the correct range, not too high or too low. It also signals to the CCM what voltage the
unit is configured for. The System Bias supply PCB includes a relay, K1, which only applies voltage to Auxiliary
transformer, primary,T1, primary when the input voltage is in the correct range.
The Relay and Interface PCB Accepts and distributed the output of the Aux Transformer. It has relay to control
the pump, fans, input contactors, the Arc Starter and the Inrush relays. A circuit on the Relay board accepts input
from the Work current sensor, HCT1, and Pilot current sensor (on the Pilot PCB) and sends the Enable signal to the
Pilot boards IGBT switches via the J3 to J42 ribbon cable. Other inputs on the Relay board include those from the
Negative Temperature Coefficient (NTC) ambient and coolant temperature sensors. Coolant tank level switch and
coolant flow switch, which determines if the flow is above the required minimum rate, also send signals to the Relay
Board. ISeries units include a flow sensor whose output to the Relay Board is a series of pulses whose frequency
indicates the flow rate and can detect the presence of gas bubbles in the coolant. All these signals pass to the CCM
via a 40 conductor ribbon cable going to the CCM I/O board.
The Display Board Has LEDs for AC, TEMP, GAS & DC. It also has a 4 digit 7 segment display for status and fault
information. AC LED indicates the input contactors to the inverters have been commanded to close, but does not
mean they are closed. TEMP means one or more inverters or the coolant has exceeded the allowed temperature.
GAS means gas is flowing and coolant flow is OK. DC means the inverters output voltage is above 60 VDC.
The first digit of the 7 segment display shows the letter, “C”; “E”; “L” or is blank. During the initial power up sequence the letter “C” followed by the other 3 digits, indicates the CCM code revision. Status or Fault codes which
may occur during the power up sequence or any time thereafter are preceded by letters “E” for an active fault or
“L” for a “latched” or “last” fault that stopped the process but is no longer active. When there is no Fault or active
Status code, the output current setting is displayed with the first digit blank. If the system is an iSeries using the
Auto Gas Control, Automatic Gas Control, the display will show “0” until a process has been loaded. If there is a
fault or other status showing the display will alternate between the current setting and the fault.
The Pilot PCB contains a pair of parallel IGBT transistors working as an electronic switch to connect and disconnect
the torch tip from the 1st inverter section.
When the pilot electronic switch is closed and the pilot is ignited by the Arc Starter, current from the 1st section
flows between electrode and tip. Then as transfer begins, a small current from the 2nd inverter flows from electrode
to work. When transfer is detected the pilot switch is opened and current from the 1st section is free to flow to the
work through the diode which is also on the Pilot board. The PAK200i and the optional 1Torch are exceptions in
that the second section is not enabled during piloting. Both pilot and initial transfer come from the first section.
Other sections are phased in as the current ramps up to the final level. The Pilot PCB also contains a pilot current
sensor to detect and measure the level of pilot current. Additional resistor/capacitor (RC) circuits on the pilot PCB
assist and stabilize the pilot and transferred arcs.
Manual 0560956456
APPENDIX
A-55
iSERIES 100 /200 /300 /400
PILOT SW (IGBT)
1st INVERTER SECTION
(INV 1 A)
(+)
ELECTRODE
2nd INVERTER SECTION
(INV 1 B)
TIP
WORK
Art # 12301
(+)
The AC Suppression PCB has capacitors and other transient suppression components to protect the system from
transients on the AC lines. It also provides power for the neon AC present indicators which illuminate when AC
power is connected even when the ON-OFF switch, CB1, is off.
Status codes.
The codes for the power supply are displayed on the Display PCB 4 digit numerical display. Some codes refer to
the Gas Controls but more detailed Gas Control codes will be found on the individual gas controls. The gas controls used with the XT family of plasma supplies have not changed. They have their own set of status codes which
should be covered in another section. This guide assumes you have first considered the Status Code Tables in the
Operation Section of the unit manual. Individual codes will point to different inverter sections while this guide
groups similar codes together. For example code E (or L) 249 indicates an inverter fault in Inverter 2A. This guide
covers codes 247-252 in one section as they are all the same, varying only by which inverter and section they refer to.
The codes are separated into 7 groups.
Group 1
Plasma Process -- Relating to pilot, transfer, torch voltages, etc.
Group 2
Plasma Power Supply -- Primarily the Inverter Sections
Group 3
Interface to Gas controls -- Mainly the Automatic Gas Control
Group 4
Cooling System -- The liquid cooling system for the torch and inverters
Group 5
CCM -- Communications port to the gas controls
Group 6
CCM -- Status
For the XT units we are using a 3 digit code with group 1 codes in the 100’s, group 2 in the 200s etc. These correspond to the older codes used in previous units, where 1-1 is now 101. For the most part the codes have the
same meaning. Where an older code no longer applies to the XT system we don’t use it over again and have left it
reserved to avoid confusion. For example the code 204 (2-4) which meant the inverter module wasn’t ready. We
now detect that error in a different way that has a somewhat different meaning so we have reserved the 204 Code.
While most of the codes indicate a fault has occurred, a few of them, such as 304 (formerly 3-4), simply refer to
the current status. 304 indicates either “priming” where the pump is filling the system with coolant or more often
“purging” where the gas is flowing to dry the consumables after replacing them or purging the gas lines when a
different gas type has been selected.
A-56 APPENDIX
Manual 0560956456
iSERIES 100 /200 /300 /400
Troubleshooting (General)
In many cases where the cause may be listed as a cable or wire disconnected but also includes loose or broken.
All Ribbon cables have an extra receptacle near one end for measuring signals on the cable.
A number of the measurements will require probing of some small connectors or measuring signal on ribbon cables.
For probing the small connectors, standard meter probes are usually too big. We suggest making a couple probes
using steel wire. Copper buss wire isn’t stiff enough. A paper clip is a little too big. One idea is take a socket from
an Amp mate-n-loc or similar connector into which your meter probe will fit and crimp a small piece of steel wire,
(0.020 to 0.025” dia.; (0.5-0.6 mm) works best), into where wire would normally be crimped. The wire should be
soldered and crimped. The steel wire may be found in hobby stores that cater to model building.
Art # 12302
Art # 12303
Insulate all but the end of the wire and slide these onto your meter probe. If your meter has alligator clip adaptors
you could hold the wire in these as well, be sure they don’t short together.
Not all problems are caused by the plasma system. If extra wires or other components have been added that were
not part of the original system, if possible, remove them to see if they are causing the problem.
Connections to TB4 or the other TBs on the CCM may be bringing in noise or forming unexpected current paths
that change how the system operates.
Problems that do not set Status or Fault codes:
Coolant Problems
1. Blinking Gas Indicator. At power on the GAS indicator on the front panel blinks continuously. No code is
showing. The actual Real problem is no, or low coolant flow but it takes 4 minutes before the code is set
and most people don’t wait that long. Go to code 404 to troubleshoot.
2. Pump doesn’t start. The R2 Inrush resistor is open which prevents power from being applied to the T1
transformer. This will not allow the pump to start. This will set 404 code after 4 minutes but most people
won’t wait that long.
Pilot Problems.
3. Failure to start pilot. This actually sets failure code 102 after 15-18 seconds but it seems as though no code
was set if you don’t wait that long. Go to code 102 to troubleshoot.
4. A weak pilot that will only transfer with the torch very close to the work may be caused by the 30 pin ribbon
cables being reversed on the A and B sections of inverter 1.
Start problems also reported as failure to pilot problems.
5. No response to the CNC Start or Pak200i torch trigger. Check on the CCM I/O board for the D6 CNC START
LED being on all the time. If it is on, either the external CNC Start signal is on or the CCM is faulty. Remove
the CNC cable from J15 or if Start is applied via the TB terminal strip on the CCM remove that. If D6 is still
on replace the CCM.
6. No response to the optional 1Torch trigger (Start). Go to the beginning of the 700 code group to troubleshoot.
Communication problems.
7. Failure to communicate with the TSC 3000 or the cutting table controller over the RS 485 could be due to
not having the J14 _ 4W / 2W (4 wire / 2 wire) jumper set right. TSC3000 needs 2W. The iCNC controller
needs 4W. Refer to section _____ in the manual.
Manual 0560956456
APPENDIX
A-57
iSERIES 100 /200 /300 /400
Power Supply Status Codes
Group 1, Process Codes
101
Plasma Enable Is Disabled
Code 101 is activated by either an open circuit between TB1-1 & 2 on CCM I/O PCB or Plasma Enable switched
off on the GCM 2010 or on the TSC 3000. TB1-1 & 2 comes from the factory with a jumper installed. An installer
may remove the jumper and connect a separate Plasma Enable switch or use the Plasma Enable wires included
in the 37 pin CNC cable used with the iSeries. These may be used to connect to the cutting table E-Stop switch.
In either case the jumper would be removed from TB1-1 & 2. 101 is not a latched code, it clears as soon as the
condition is fixed.
Causes for 101 code other than one of the Enable switches being off (see detailed descriptions below):
• Gas Control Cable from J55 to gas control not connected.
• Ribbon cable from Relay board to I/O board not connected.
• CNC cable not connected (if using a Plasma Enable switch or output from the cutting table or robot).
• Defective Relay PCB
• Defective CCM I/O PCB
Special case: Display alternates between E101 and ----. This happens when there is both a missing phase and
Plasma enable is off. It is probably a bug in the code, it should be showing E101 & E201 (missing phase code).
We will likely fix this in a later code release but be aware of it for now.
Input voltage too high is detected on the System Bias PCB which will light its D4 (red LED) and will not energize
it’s K1 relay thus T1 transformer receives no power and any AC powered components including gas controls
will not have power.
External or CNC Plasma Enable D2, CNC PLASMA ENABLE LED, is not on.
• LED D2 on the CCM will be on if this input is satisfied either with the jumper on TB1- 1 & 2 or an external
or CNC switch. If the jumper is in place and the LED is not on, the CCM is most likely defective.
• If the jumper at CCM TB1-1 & 2 has been removed to use an external switch, install a jumper as a test. If
D2 illuminates the problem is with the switch or it’s wiring.
• If Plasma Enable is wired through the CNC cable remove the cable and jumper J15 pins 25 & 26. If D2
still not on there may be a problem in the wiring inside the power supply.
102
Pilot Ignition Failure
Code 102 is activated when there is no pilot current after 15 seconds of firing the Arc Starter. Pilot ignition
requires the Pilot board to be enabled, pilot switch (IGBT) turned on and high voltage pulses (HF) from the arc
Starter (either the Remote Arc Starter RAS) applied between the tip and the electrode of the torch.
Possible Causes for 102 code:
XT Automation Torch ONLY:
• No HF to the torch due to broken pilot wire connection in the torch leads.
• No HF to the torch due to defective Arc Starter.
• Arc Starter not receiving power.
Troubleshooting:
1. Determine if the problem is a lack of HF (Arc Starter) or if it’s due to the pilot circuit.
A-58 APPENDIX
Manual 0560956456
iSERIES 100 /200 /300 /400
Arc starter without Spark Gap (ISeries)
1. Check for power to the RAS’s Ignition Module during the 15 seconds following preflow (ignition phase).
Arc starter power comes through the rear panel circuit breaker CB4, make sure it isn’t tripped.
a. During the ignition phase, measure for 120 VAC at the input terminals marked 120 VAC on the Ignition
module, a gray rectangular box with screw terminals on one side.
WARNING
Do not let the meter probes (or your hands) come in contact with the other terminals
marked Hb and Ho or the other end of the wires connected to them. These can have
10,000 volt pulses which can cause physical harm and will damage your meter.
2. If 120 VAC is not present go to step 3.
a. If 120 VAC is present and still no spark, the Ignition Module may be bad.
3. 120 VAC to the remote Arc Starter comes from J59-7 & 9 on the power supply rear panel and connects to
J58-7 & 9 on the RAS1000XT. Remove the cable from J59 and during the ignition phase measure for 120 VAC
between pins 7 & 9.
a. If 120 VAC is present problem is in the cable to the RAS or the J58 connector and internal harness in the
Arc Starter.
b. If 120 VAC is present proceed to the next step.
4. 120 VAC to J59 comes from the relay board J8-3 with return on pin 11. On the Relay board, RF ON LED,
D23, should be on during the igniting phase. If it is not skip to the next step.
a. If D23 is on and there is not 120 VAC at J8-3 & 11 then the Relay board is bad.
Either Arc Starter
5. /RAS ON signal not on. CCM sends active low signal “ /RAS ON” over the 40 pin ribbon cable on pin
16 to the Relay & Interface board. On the relay board RAS Control relay (K2) closes (RF ON LED, D23 on)
sending 120 VAC to J8-3 with return on J8-11. From here it either goes to the HF transformer T2 (AC200XT)
or to J59 as described above.
a. Measure the signal “/RAS ON” on pin 16 of the 40 pin ribbon cable relative to TP1 on either the CCM
I/O board or the Relay board. If it is low (less than 1V) skip to step 6. Otherwise continue this step.
NOTE!
If the CCM thinks there is already a pilot it would not enable the HF. Pilot board has a current sensor
that sends a differential analog pilot current level signal to the Relay board which in turn passes that
signal to the CCM. On the Relay board D11 LED “Pilot Current Detected” or just “PILOT” lights if it
sees a signal from the pilot board.
Reasons why RAS Control relay would not close:
6. Pilot current flowing. There actually is pilot current flowing somewhere. Unlikely as it would normally set
the 208 fault but we have to rule it out.
a. Disconnect J41 on the Pilot board, if HF still doesn’t fire and the Relay board Pilot LED, D11, is still
on, it’s due to a fault in the detection circuits.
7. Faulty detection circuit. There isn’t any pilot current but a fault in the circuits measuring pilot current is
indicating there is current.
a. Measure between pins 8 (-) and 9 (+) on the Pilot ribbon cable from Relay board J3 to Pilot board J42. If
there is no pilot current it should be zero. Anything else indicates the Pilot board current sensor is faulty
causing the Relay board D11 to be on. Replace the Pilot board assembly.
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APPENDIX
A-59
iSERIES 100 /200 /300 /400
b. If the Pilot current signal on the pilot ribbon cable was zero, measure between pins 23 (-) and 25 (+) on
the 40 pin ribbon cable between the Relay board and the CCM. This would also normally be zero if there
is no pilot current. Anything else would indicate the Relay board is faulty.
Relay & Interface Board
TO RELAY BOARD
/ RAS ON
TP1
GND
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
J4
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
120 VAC_RET
From J9-7
120 VAC_1
From J9-1
From I/O PCB
24VDC_SW
D21
1
120 VAC RET
J23
120 VAC
CCM I/O Board
K2
3
D23
GREEN
4
120 VAC to RAS
5
J8
J59 - RAS
(Rear Panel)
16
15
14
13
12
11
10
9
8
7
6
5
4
3
2
1
1
2
3
4
5
6
7
8
9
10
11
12
13
14
(99)
(98)
RAS CONTROL
RF ON
(99)
T2
6.5K 1W
(98)
6.5K 1W
AC200XT only
120 / 6000 VAC
TP1
GND
Art # 12307
8. If “ /RAS ON” signal is low on pin 16 of the 40 pin ribbon cable, relative to TP1 on the CCM I/O board,
during the ignition time then we need to determine if the Relay board is defective. If /RAS ON signal is
not low the CCM or the 40 pin ribbon cable may be defective.
a. If the Relay board RF ON LED, D23, is not on while the /RAS ON signal is low, then the Relay board is
defective.
b. Is D23 is on, measure for 120 VAC on J8-3 to J8-11. If not present the Relay board is defective.
c. If 120 VAC is present at J8 during the ignition time go back and perform steps 2-4.
Troubleshooting Pilot Board problems.
1. The Pilot board is behind the CCM in the iSeries has two LEDs. The first one, D11, a green LED, indicates
the board has bias power and should be on all the time when the unit is turned on. The second LED, D2,
also green, is on when the pilot is enabled, that is the pilot IGBT switch is turned on. The pilot is enabled
near the end of preflow time and remains on until the transfer is established or for 15 seconds after which a
102 code is displayed. If D2 performs as expected you know the CCM, Relay board and work current sensor
are not causing the problem.
2. Test pilot IGBT operation. D2 on shows the pilot is enabled but you don’t know if the pilot switch (IGBT
transistor) actually closes the circuit. To test attach a jumper, 18 AWG or larger as follows:
a. iSeries: connect a jumper wire from TB4-7 (arc volts) to TB4-6 (tip volts).
A-60 Apply CNC Start. If the pilot switch closes as it should, you’ll get either 106 or 208 fault code within 3-5
seconds. If not, keep the CNC Start on for up to 20 seconds. The front panel DC LED will stay on for 15
seconds then shows 102 code again. This likely indicates the Pilot board is bad but If the XT supply includes
the 1Torch option it could be the W4 contactor is not closing. Go to the 700 group instructions to bypass the
W4 contactor.
APPENDIX
Manual 0560956456
iSERIES 100 /200 /300 /400
3. If D11 on the Pilot board is not on check if the 10 pin ribbon cable is connected between the Pilot board (J42)
and the Relay board (J3). Measure for 24 VDC on the Pilot ribbon cable test connector pin 2 (+) and pin 10
(-). If 24V is present and neither D11 nor D2 lights then the Pilot board may be defective. Pilot board end
of the ribbon cable could also be the cause.
What should happen on the Relay board is LEDs D12, work Current Detected & D11, Pilot Current Detected
should both be off. When you apply START after 2 seconds (Preflow time) D7, Pilot Enable, should come on.
Also D23, RF ON, should come on indicating the Arc Starter is being enabled. Normally D23 would only
be on for a moment until pilot current is detected. Then D11 would be on (and D23 off) until arc transfer or
pilot timeout (15 sec.) Since a pilot has not been detected D11 should not come on.
4. If the work current sensor is defective it could be telling the relay board (and thus the CCM) that there is
already a transferred arc so no need for pilot. D12, a green LED on the Relay board, is on if work current is
detected. If D12 is not on skip to step 5, otherwise disconnect J1, the work sensor connector. If D12 is still
on the Relay board is defective.
5. If D12 goes out when J1 is disconnected, plug it back in and measure voltage from TP1 (common) to J1-1,
should be positive 12-15VDC. Now measure J1-2, should be negative 12-15VDC. Now measure J1-3, should
be 0 +/- 0.05V. If any of these are wrong disconnect J1 and measure again (on the relay board, not the harness). If still wrong the relay board is defective. Otherwise it’s the work sensor.
6. Pilot Enable signal comes from the CCM on pin 15 of the 40 pin ribbon cable between the Relay board (J4)
and the CCM (J23). It should be low, less than 2V relative to TP1 on either the CCM I/O board or the Relay
board. You can also measure this on TP11 of the I/O board. If the signal does not go low when the pilot
should be enabled at the end of preflow time then the CCM is probably defective. You can also jumper
TP11 on the CCM I/O board to TP1, also on the I/O, to see if that will light D7, the Pilot Enable LED, on the
Relay board. If it does, that further confirms the CCM is bad. If jumping TP11 to TP1 does not light D7 on
the Relay board, the problem is likely the Relay board or possibly the ribbon cable.
103
Lost Pilot
Code 103 occurs when Pilot has ignited as sensed by the pilot current sensor on the Pilot board , but went out
on its own while CNC Start is still active before the pilot timeout (85 ms. or 3 sec.).
Possible causes:
• Preflow gas pressure too high, for manual gas controls check cut charts for proper setting. For Automatic
Gas Control check that the process is correct for the consumables.
• Cutting current set too low for the torch parts being used. Pilot current level is automatically set based on
the cutting current. A low cutting current results in a lower pilot current that may not be able to sustain
a pilot for higher current torch parts.
• Remote Analog Current Control switches set wrong can also result in lower than normal pilot current
setting. See section on these switch settings under next section for code 104.
• Broken torch pilot wire.
• Defective Inverter module puts out less current than it’s set for.
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A-61
iSERIES 100 /200 /300 /400
104
Transfer Lost
Arc transferred to metal for at least 50 ms. then went out.
Causes for 104 code:
• Cut demand set much lower than recommended for torch parts, i.e. 100A consumables in torch but cut
current set for 30 or 50A (or zero). Current may be too low to keep arc on.
• Torch standoff too high for cutting process being used.
• Plasma gas flow too low due to a leak somewhere between the plasma regulator or the DPC and the torch.
Check for leaks.
• Coolant flow goes too low while cutting causing the unit to shut the arc off. This normally should set 402
fault but for reasons currently unknown sometimes the fault is 104.
o One cause of low flow is defective O-ring in the torch check valve assembly. Replacing the O-ring is the
solution.
• Remote analog current control switches set wrong.
o If remote analog current control is being used, SW8-2 (CCM CPU PCB) is on and SW11 (CCM I/O
PCB) is set to “A” (down) position, but no analog voltage connected to TB1-10 or J15-30 (CNC cable)
then cut demand will be zero, pilot will be weak, depending on torch height it may still transfer but
will immediately go out.
o If remote analog current control is not being used but either SW11 is set to the down position or SW8-2
is on also results in zero cut demand.
105
Not Used. This is one of the reserved codes from the earlier product.
106
Pilot Timeout, no Transfer
Pilot time is limited to either 0.085 seconds (85 ms.) with CCM SW8-1 off (default for pierce starting) or 3 seconds
with SW8-1 on (used for cutting over holes, expanded metal, etc.). Arc must transfer before pilot time ends.
Code 106 is set if no arc transfer (current in work lead) was sensed before pilot timed out. If the unit does not
detect pilot current the arc starter will operate up to 15 seconds then set the 102 code. If you are getting 106 there
is pilot current somewhere. If it’s not visible perhaps it’s inside the consumables or following some other part.
Causes for 106 code:
No Pilot Visible:
• Pilot inside the consumables
Visible Pilot:
• First the obvious, make sure the work lead is connected both to the work and the power supply. Also
make sure the work itself is making good electrical contact with cutting table. If rusty or painted metal,
you may need to clean a spot and attach the work lead directly to the metal.
• Torch too far from work.
• Cut current set too low for torch parts being used. Pilot current is set based on cut current. If cut current
is too low pilot current will be lower and may not transfer at the height used for higher current consumables.
• Preflow pressure/flow too low.
• Remote Analog Current Control switches set wrong can also result in lower than normal pilot current
setting. See section on these switch settings under section for code 104.
• Defective work lead current sensor circuit. If transfer is not sensed cut current remains at the lower starting level and pilot timer (85 ms. or 3 sec) will time out.
A-62 APPENDIX
Manual 0560956456
iSERIES 100 /200 /300 /400
108
Tip to Electrode Voltage Fault
The Pilot voltage, measured between tip and electrode varies with different current and gas type, flow rate and
consumable design.
Once the arc is transferred the pilot switch opens leaving the tip basically floating. The voltage then is determined by how much of a cold gas barrier surrounds the arc. Too much current or too little gas and the arc
starts to contact the tip reducing the voltage difference between tip and electrode and leading to a double arc
that destroys the consumables.
The CCM measures both electrode and tip voltage and calculates the difference. If the difference between tip
and electrode is found to be less than a minimum voltage we stop cutting and set a fault for the 108 code. The
normal tip to electrode voltage is different for different processes so the min value for each process is embedded
in the cut charts when using the Automatic Gas Control.
During piloting and ramping (the time from transfer until the current reaches full cut current), we lower the
allowed tip to electrode voltage to about 80% of that allowed during cutting because the current is lower and
the gas flow is lower during that time.
Causes for 108 code:
• Gas Flow/pressure too low for consumable parts being used.
o If gas source pressure is not well regulated it is possible pressure may be OK at times and drop too
low at other times such as during a cut.
o A leak of the preflow/plasma gas after the pressure/flow control (DPC) can reduce the pressure/flow
to the torch because some if it is bypassing the torch, while seeming to have enough pressure/flow at
the gas control.
• Cut current set too high for consumable parts being used.
• With Automatic Gas Control a faulty component would be expected to set a fault code in either the DPC
or GSC. However, if a wrong process is selected which doesn’t match the consumable type or if using
a custom process where pressure has been set too low or current too high that could cause 108 without
setting any faults in the Automatic Gas Control.
•A broken pilot wire in the torch lead making intermittent contact can allow piloting or sometimes the
torch can transfer using only HF (high frequency). This intermittent connection will upset the tip voltage
measurement and can result in the 108 code. Symptom is - it may cut for a short time then fault. Check
for an open/broken torch lead pilot wire.
• Physically shorted torch body between anode (tip) and cathode (electrode).
The fault resulting in a 108 code is measured while cutting. It is more likely a shorted torch body, depending
on the resistance of the short, it will set code 208 (Unwanted Current) as that is measured prior to starting cut
However, it must be considered as a last resort.
109
Part Process not Configured.
This represents a status, not a fault. This is used with the Automatic Gas Control only. It means the operator
hasn’t loaded the cutting process from the program embedded in the cutting table CNC controller. The solution is to load a process. The code will continue to be displayed until the CNC Start is applied at which time
the code will clear.
110
Device locked.
This means the DPC or GSC is still in the process of downloading a new cutting process. This should only occur
with the Automatic Gas Control if you apply CNC Start before the download process is finished.
Manual 0560956456
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Group 2 – Plasma Power Supply codes
General:
LEDS
Several LEDs are used as indicators on the different inverter module boards. RED LEDs indicate faults. Green
LEDs should be on for the most part. Green LEDs are: On the main board, D4-READY; On the Cap Bias Board,
D6, -12V, D11 +12VP (primary referenced), D13, +12V; On the Control board D24, PWM will only be on when
the inverter is enabled and its brightness varies with the duty cycle of the PWM.
Signals:
General description of some Inverter Signals passed to the CCM that can generate fault codes in Group 2.
“Ready” also called AC IN FLT (D4, READY LED, green, on Main Inverter board)
On the inverter main board we measure the input voltage. The 3 phases are rectified and lightly filtered to
achieve an average voltage. Due to the light filtering a missing phase will also lower the average voltage so it
will be detected. Voltage in the correct range turns on the READY LED D4 (on the far left of the main boards,
in the upper part of the “B” section or lower part of the “A” section). Voltage outside the correct range or missing phase will turn D4 off.
An AC Input Fault by itself (no other faults occurring at the same time) will set codes in the 241-246 group
depending on which inverter sees the problem.
INV FLT (D1, INV FLT LED, red, on the Inverter Control and Fault board)
Several things can cause Inv Flt (Inverter Fault). Inverter fault is indicated by an LED, D1 on the Inverter Control and Fault board. Inverter Fault, when it occurs, is latched on. The latch is reset next time the inverter is
enabled unless it is still active in which case it is immediately latched again. Inverter Fault will set the codes
247-252 unless it’s in conjunction with another fault in which case that fault code may be set.
Things that can set the inverter fault:
• The local (to the inverter) + 12V & -12V bias supplies out of tolerance. There are LEDs on the Cap/Bias
board that light indicating these bias supplies are present but don’t verify they are in tolerance. It’s not
likely this would happen. More likely that fault related to the +/-12V the supply would be missing and
it’s LED not on.
• Capacitor imbalance. In a cap imbalance condition D3, red Led on the main board (lower left corner of
bottom or “A” section and upper left corner of the upper or “B” section), will latch on.
• Primary over current. This is an over current condition in main switching transformer’s primary. This will
latch on but is cleared when the inverter is enabled unless it is still active in which case it is immediately
latched again.
•Inverter over temperature sets the Fault signal and LED but has its own fault signal to the CCM. See OT
Flt below.
OT FLT (D14, OT FLT, Inverter Control and Fault board)
• Inverter over temperature lights LED D14 on the Inverter Control and Fault board and will latch the fault
signal and it’s LED but also has its own separate fault so that will be reported as a code in the range of
253-258 or 259-264.
PWR Present
• When power is first applied to the inverter (contactor closed) CCM checks for presence of the +12V bias
on the Inverter Control and Fault board. If not present will set codes in the range of 265-270.
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201
Missing AC Phase
The System Bias Supply board contains circuits to detect if one of the 3 AC input phases is missing. Along with
that it can also detect if the AC voltage is too low or too high. Three phase voltage is supplied from the input
terminals through the ON/OFF Switch / circuit breaker CB1 to the System Bias board. The System Bias can
operate on any 2 of the 3 phases to supply control power and fault detection.
SYSTEM BIAS PCB
1
2
3
4
5
6
7
8
9
10
11
12
13
14
+V
CB1
F1
3 phase AC
J60-9,18
J60-5,14
F2
I/O PCB
J62
J60-1,10
ON / OFF
GND
J27
Missing Phase a
Missing Phase b
1
2
3
4
5
6
7
8
9
10
11
12
13
14
1
U?
2
HCPL-817
4
Missing Phase
3
To CPU PCB
J29-16
GND
Art # 12310
Normally when the phase is not missing the transistor is on which turns on the opto-isolator making the signal
“Missing Phase” low.
Causes for 201, missing phase code:
Codes are displayed two different ways, with an “L” meaning “Latched” or “Last”, before the number meaning
it was a problem but isn’t right now or with an “E” meaning the problem exists now.
L201 :
Most likely cause is an intermittent problem with the incoming power or possibly a loose connection on the
power cord at the back or the iSeries plasma supply.
E201:
• Phase missing from the wall fuse box, blown fuse.
• F1 or F2, 8A 500V slow blow fuses blown.
• CB1 one phase open.
• System Bias board defective.
• I/O board defective.
Troubleshooting:
1. System Bias board has a red LED, D3, that lights if it detects a missing phase. If D3 is on, check J60 for all 3
phases.
a. If all 3 phases are not present at J60 check for incoming power, then the F1 & F2 fuses. Finally the CB1.
b. If all 3 phases present and about equal voltage then change the System Bias board.
2. If D3, Missing Phase LED, is not on check for voltage at J27-3 & 4 on the CCM. Normal voltage, with no
missing phase, at J27 (or J62 on the System Bias board) pin 3 and pin 4, relative to I/O PCB ground. (TP1)
should be between 10-14VDC with pin 3 being a couple volts higher than pin 4. If this is normal, problem
may be in the CCM.
3. If the voltage at J27-3 & 4 is higher than 10-14VDC and up to 20-24VDC, make the same measurement at
J62 pin 4. If still high there and you have confirmed all 3 phases are present at J60 then the System Bias is
defective.
4. If the voltage at J62-4 is not high the wires between J27 and J62 may be broken.
202-204Not used. Reserved codes from the earlier product.
205
DC Output Low
DC output (voltage) low means one or more inverter sections are enabled but the output voltage is below a
preset voltage. Shortly after receiving the Start signal from the CNC, but before the end of preflow, both sections
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of IM#1 are enabled and CCM measures the power supply output voltage between negative (Torch) to positive
(Work) at the output terminals. If this is less than a set value during preflow or if at any time during piloting
or cutting it drops to below that value for a short time, the inverters are shut off and code 205 is set. 205 will
almost always be indicated as an “L”, not an “E” fault because as soon as it’s detected the inverters are shut off
and so no longer have the fault of low output voltage. Currently the low voltage value is -60VDC.
Causes of 205 code can include shorts outside the plasma power supply, shorts inside the plasma power supply
and measurement errors.
a. Short external to the plasma power supply:
• Cable pinched in or exiting the power track
• Short inside the Arc Starter such as a wire coming loose and grounding to the chassis.
• Short inside the torch mounting tube.
• Trouble shoot for external negative lead shorts by removing the lead from the rear of the power supply
and try to start. It won’t start but if you get the same 205 code the problem is inside the unit.
b. Short inside the supply:
• All the inverters outputs except that of IM1A are in parallel. If any inverter’s output is shorted it will
appear as a short across the power supply output.
Troubleshoot by removing all (or one at a time) of the inverter output connectors except those on IM1A.
Then apply Start to the unit. If it starts now one of the other inverters had shorted output. To find the
defective one reconnect one at a time until the fault reappears.
206
Not used. Reserved codes from the earlier product.
207
Unexpected Current in the Work Lead.
HCT1, a Hall Effect current sensor on the positive (work buss bar) measures the work lead current. Inverter
section 1A is enabled during preflow time but there should be no current in the work lead before the pilot is
ignited and before the arc is transferred to the work. If current greater than 8A is detected before or during
preflow something is wrong.
1. 207 code before START applied:
• Defective work current sensor, HCT1.
• Defective Relay PCB
• Defective CCM
Defective Sensor
• The work current sensor, HCT1, receives power, +15VDC and -15VDC from the Relay PCB. Both must
be present for the sensor to work properly. Measure between Relay PCB TP1 (or J1-4) to J1-1 for +15VDC
and to J1-2 for -15VDC.
• If either + or – 15VDC not present remove the J1 connector and repeat the measurement at J1-1 & 2 on the
Relay board. If the voltage is now present the sensor is defective or shorted (the harness may be shorted).
If voltages still not present, the Relay board is defective.
Relay PCB
• Relay board LED D12, Work Current Detected, will light if the current sensor signal exceeds 0.05V. If
D12 is on, measure the sensor output signal at J1-3 with signal common on J1-1. This signal should be
0V +/- 0.04VDC. If greater than +/- 0.04VDC with no work lead current, the sensor is defective. If the
signal voltage is within the limits and D12 is on, then the Relay board is defective.
• If D12 is not on and the 207 code is still active, either the Relay board or the CCM is defective.
CCM or ribbon cable
• The work current signal leaving the relay board is on the 40 pin ribbon cable (Relay J4 to CCM J23) pins
27 (-) & 28 (+). If the voltage here exceeds 0.1VDC with no work current the Relay board is likely defec-
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tive. Another possibility is in the 40 pin ribbon cable either pin 27 or 28 is shorted to an adjacent pin.
Otherwise the CCM is defective.
2. 207 code after START applied (during preflow):
• Short between power supply negative output and Work circuit.
• Short between power supply negative output and earth ground.
• Defective or incorrectly installed user supplied equipment such as torch height controls that make connections to power supply output.
Shorts are more likely to cause DC output voltage low (code 205). However, if the short has enough resistance
it is possible to show code 207. To test, remove negative output cable and reapply Start. If 207 code does not
appear problem is a short somewhere outside the power supply.
User Installed Equipment
For user installed equipment to cause 207 code it would have to be connected on the output (to the rear) of the
current sensors. To test, disconnect user equipment and apply CNC START. If code 207 is gone user equipment
was defective or connected incorrectly.
208
Unexpected current in Pilot Circuit
The Pilot board includes a current sensor to measure the pilot current. There should not be any pilot current
until the inverters and the pilot board are enabled and the arc starter has fired to ignite the pilot. Pilot current
or the signal indicating pilot current should not be present until the arc starter has fired.
Unwanted current signal due to defective sensor or defective circuit boards will most likely be present as soon
as the power up sequence completes and will be indicated as an active fault, E208. An actual short allowing real
current to flow in the pilot circuit will not occur until the inverter and pilot board are enabled near the end of
preflow. This will result in the inverters immediately being shut off and displaying a “last” or “latched” fault,
L208. An LED, D2, on the Pilot board lights when the Pilot Board is enabled.
1. 208 code before START applied:
• Defective Pilot board (current sensor circuit).
• Defective Relay PCB
• Defective CCM
Pilot PCB
Pilot current signal is on the 10 pin ribbon cable (Pilot J42, Relay PCB J3) between pins 8 (-) and 9 (+). With no
current, the signal should be zero +/- 0.05 V. Also the Relay board has an LED, D11, “Pilot Current Detected”,
which will light if the pilot current signal exceeds 0.15V. If the signal is not zero V.Pilot PCB is likely the cause.
To be sure, disconnect the Pilot board ribbon cable from the Relay board at J3. If D11 goes out, the Pilot board
was the cause. Double check by measuring pin 8 & 9 again. If it’s zero V. now, the Pilot board is defective. If
D11 is still on or pin 8 & 9 voltage still high check the Relay board.
Relay Board or CCM
If D11 on the Relay PCB is still on after the previous tests, measure the output to the CCM on the 40 pin ribbon
cable (Relay J4 to CCM J23) between pins 23 (-) and 25 (+). It should be less than 0.1V. If not, the Relay board
is bad. If voltage is zero then the CCM is defective.
2. 208 code comes on during preflow:
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IM#1 and the Pilot board are enabled near the end of preflow. To have unwanted current there must be a path
(short) for current to flow between the inverter negative output (negative cable/torch electrode) and the Pilot
return/tip before the arc starter is enabled for pilot ignition.
Possible causes are:
• Short between electrode and tip due to mismatch of consumables, damaged consumables or foreign matter between tip and electrode. An electrode at the end of its life may lose material that can short between
electrode and tip.
• Defective or incorrectly installed user supplied equipment such as torch height controls that make connections to power supply output.
• Short between power supply negative output cable and pilot cable.
• Shorted torch body.
Troubleshooting:
1. Remove and insulate (may have voltage on it) the pilot cable from the rear of the unit. Attempt to pilot. If
no 208 code shows, it confirms problem is outside the power supply.
2. Remove and check consumable for damage, cleanliness and missing (gas dist, etc.) or wrong components.
3. Disconnect user supplied equipment and see if fault still exists.
4. Inspect Arc Starter for broken/disconnected wires or burnt components.
5. Inspect inside the torch mounting tube for shorts.
6. If all else fails disconnect the pilot wire from the back of the torch head. Insulate it well or keep it away from
any metal, it may have HF (high frequency) on it when you try to start. Try to start, if the 208 is gone now
the torch head is shorted.
209
Not used. Reserved codes from the earlier product.
210–211Output current, measured by the work lead current sensor, is too high (210) or too low (211).
These are warnings and do not shut down the process but may explain poor cut quality or poor parts life.
Individual inverter sections have their own current sensors and the work lead has a current sensor whose
signal should equal the sum of the individual inverter sections. Each section is set to output a certain current
based on its ”demand” signal. If the current differs from the total “demand”, sum of the individual demands,
the individual sections are checked to determine if their output is correct compared with their demand signals.
If the individual sections are correct but the work current sensor signal differs from the total demand by more
than 16% code 210 (too high) or 211 (too low) is displayed.
If an individual inverter section was found to be in error causing the total current to be wrong, a different code
would be displayed in the range of 212 to 223 depending on which section was at fault.
Possible causes for work current signal too high:
• HCT1 Work Current Sensor
• Relay PCB
•CCM
Possible cause for work current to low.
• All the above plus a short to chassis caused by:
o User installed equipment connect behind the current sensor that makes a connection to work or earth
allowing current flow to bypass work sensor.
o Inverter + output shorted to chassis.
Troubleshooting:
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1. For current too low due to a short disconnect work lead from back of unit. Check for continuity to chassis,
there should be none. Inspect for incorrectly connected user equipment.
2. If no shorts were found or if fault was current signal too high see section on code 207 for detailed description
of the power and signal paths for the work lead current sensor.
3. In the section on code 207 for Relay PCB it describes measuring the work current sensor signal when there
is no current. The signal should be zero and we assume it is or else you should have gotten the 207 code. If
the zero current signal is correct but there is an error while cutting, measure the signal on the 40pin ribbon
cable (Relay board J4 to CCM J23) pins 27 (-) & 28 (+). The signal voltage should equal the cutting current
* 0.0266. For example for 100A (100*0.0266) =2.66V.
• If this signal is correct the fault is the CCM
• If it’s not correct the error may be in the Relay board or sensor. Follow the instructions for code 207 to
measure the voltage to and signal from the current sensor at J1 on the Relay board. The signal voltage
should equal the cutting current * 0.0133. For example for 100A (100*0.0133) =1.33V. For 400A would be
400*0.013 3= 5.33V.
• If power and signal are correct Relay board is faulty. If not correct the HCT1 work current sensor is bad.
212-223 Incorrect output from an inverter section.
Work current high or low due to wrong output from one inverter section. Individual code indicates which section.
Causes may be:
• The named inverter section output connector, J102 A or B, is not plugged in or is damaged.
• Ribbon cable with bad connection, perhaps not fully locked in place at either the inverter or the CCM.
• Defective inverter section.
Troubleshooting:
1. If it reports the current of an individual inverter section is too high, the problem is the inverter.
2. If the report is current too low (which included no current) check the connections.
3. The ribbon cable for the first inverter section (IM#1A) must connect to that section only but if there are 2
additional sections, unit is 200A or greater, swap the ribbon cable going into those sections.
a. If it now reports a different section as bad, the one whose cable was moved, then the original section was
bad.
b. If it still reports the original section the ribbon cable or the CCM is bad (unlikely).
c. Swap both ends of the ribbon cable with one next to it. If still reports the original section then the problem
is with the CCM if not then it’s the ribbon cable.
4. If it’s the first inverter section or it’s a 100A unit so there’s no other inverter to swap cables with, replace the
inverter.
Additional hint: Inverter control PCBs have a green LED, D24, PWM ON, that lights when that section is enabled
and has a demand signal. The LED brightness is relative to the output so may be very dim if output is low. If
that LED doesn’t light may indicate a defective inverter (control board).
224 Inverter 1 not found.
There must be an inverter connected in the 1st section, 1A, to be able to pilot. During the power up sequence,
before power is connected to the inverters, the CCM does a continuity test to see if its section 1A ribbon cable
(J31 on CCM) is connected.
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Causes & troubleshooting:
• As this is just a continuity test it is very unlikely to be a bad inverter. Most likely a poor connection or
defective ribbon cable.
o Check ribbon cable connections at both ends of INV1A to CCM J31 (1A) cable. Make sure it is plugged
into J31, the top connector, on the CCM.
o Plug a different inverter cable into J31, doesn’t matter which one for this test as long as it’s plugged
into an inverter on the other end. If still gives 224, “Inverter 1 not found” fault, it’s a bad CCM. Otherwise it’s the ribbon cable.
225-230Inverter Revision and CCM incompatible.
If sometime in the future we should make a change to the inverter making it incompatible with older CCM we
have included a hardware key that would change to indicate this. During the power up sequence, before power
is connected to the inverters, the CCM does a continuity test to determine what is the hardware key configuration. The key uses 3 lines of the CCM to inverter ribbon cable which are named IS_ID_A, IS_ID_B, IS_ID_C (on
pins 12, 13 & 14) and checks for continuity to a 4th line OUTCOM (pin 9). The test consists of applying voltage
to OUTCOM and looking for that voltage coming back on the 3 ID pins. The present configuration has all 3
lines connected to OUTCOM so all 3 should be high.
To get the 225-230 code now when we don’t have any incompatible revisions would most likely be a bad connection in the ribbon cable between the CCM and the inverter or a defective CCM (unlikely).
• On the inverter section swap the ribbon cable with that of a different inverter section. If fault remains
unchanged, still calls out the original inverter section, the problem is with either ribbon cable or CCM.
• On the inverter end put the ribbon cables back in their original positions. Now swap suspect ribbon
cable with another one on the CCM. If the fault now moves to a different section it’s the ribbon cable. If
it remains with the original section the problem is the CCM.
231-236Inverter VAC Mismatch.
Different inverter modules are manufactured for 480VAC, 380-415VAC & 208-230VAC operation voltages. There
is a key, called inverter ID, read through the inverter’s ribbon cable, to identify which voltage range the inverter
is designed for. The unit itself is wired differently for the different input voltages and part of that includes a
jumper at J61 on the System Bias board that indicates to the System Bias board what voltage the unit is wired
to accept.
At power on, the System Bias board measures the incoming voltage, determines what input voltage range it
fall into and sends that range information to the CCM. Before Appling power to the inverters by turning on
the input contactors, the CCM checks that each connected inverter is of the correct voltage matching that of the
System Bias board. The inverter ID’s are read from the lowest section to the highest so in all cases if it truly is a
wrong voltage inverter it should call out the A section whose code is read first. A VAC mismatch of a B section
is likely another problem.
Possible causes:
• Wrong voltage inverter (very unlikely but easy to check).
• System Bias board wrong J61 jumper (unlikely but easy to check)
• Defective inverter.
• Ribbon Cable
•CCM
• System Bias board defective.
Troubleshooting:
1. If System Bias board has either the wrong jumper or is defective it will call out the first inverter section, code
231, because all the inverters won’t match the incorrect signal and 1A is checked first.
a. For the jumper Wire #48 should be connected from J61-1 to:
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i. J61-2 for 208-230 VAC
ii. J61-3 for 400 VAC
iii. J61-4 for 480 VAC
Check for proper connection and continuity.
b. System Bias may be defective reporting the wrong voltage ID. On the output of the System Bias board
at J62 measure relative to TP1 or ( J62-8, 24VDC_RET) to J62-12 for signal /VAC_IDAb and J62-14 for
signal /VAC_IDBb. The 2 signals should read according to this table. “0” = 10-12V; “1” = 24V.
signal
230V
400V
480V ERR
/VAC_IDAb
0
1
0
1
/VAC_IDBb
0
0
1
1
2. Defective inverter, ribbon cable or CCM.
a. On the inverter section swap the ribbon cable of the inverter section whose fault was indicated with that
of a different inverter section. If fault remains unchanged, still calls out the original inverter section, the
problem is with either ribbon cable or CCM. If fault changes to the different section, the one the ribbon
cable was swapped with, then it’s the inverter that’s defective.
b. If the fault remained unchanged in Step A, on the inverter end, put the ribbon cables back in their original
positions. Now swap suspect ribbon cable with another one on the CCM. If the fault now moves to a
different section it’s the ribbon cable. If it remains with the original section the problem is the CCM.
237
Too Few Inverters Found
There must be a minimum of 2 inverter sections present to operate. We know the ribbon cable for inverter section 1A is connected or else we would have code 224. During the power up sequence, before power is connected
to the inverters, the CCM does a continuity test through the ribbon cable to see if an inverter is connected. If it
doesn’t see continuity with at least one other inverter it assumes none are connected.
Possible causes:
• Ribbon cable disconnected or defective.
• Inverter defective
• CCM defective.
Troubleshooting:
1. Check that all cables are connected, latches locked down, at both the inverter and CCM ends.
2. If this fault occurs it’s most likely on a 100A unit which only has one section (1B) in addition to the 1A section. If there were 2 or more additional sections it’s extremely unlikely all ribbon cables or CCM connectors
would be defective.
a. Swap the ribbon cables of the inverter section 1A and 1B. If fault remains unchanged, still 237, problem
is with either ribbon cable or the CCM. If fault changes from 237 to 224 indicating inverter 1A missing,
then it’s the inverter that’s defective.
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b. If the fault remained unchanged in step a., on the inverter end put the ribbon cables back in their original
positions. Now swap suspect ribbon cables on the CCM. If the fault now changes it’s the ribbon cable.
If it remains the same it is the CCM.
c. If there are 2 or more ribbon cables in addition to the one on section 1A then CCM is seeing none of them
connected which indicates the CCM is faulty.
238
System Bias voltage identification is invalid.
At power up the System Bias board measures the input voltage and sends signals to the CCM indicating which
range of voltage it has detected. See section 231-236 for details. If one of the 3 voltage ranges, 208-230V, 380415V or 480V isn’t identified then both ID signals are high resulting in an invalid signal.
Possible causes:
• Unit is connected to voltage below the 208-230V range or above the 480V range. (unlikely unless there is
a problem with the incoming voltage.)
• Defective System Bias board
• Bad connection between System Bias output J62 and CCM input J27 on the I/O board.
• Defective CCM
Troubleshooting:
1. Measure all 3 phases of the input voltage and confirm they are within the tolerance specified in the unit
manual.
2. Refer to section 231-236 Inverter VAC Mismatch and perform troubleshooting in step 1.b. If the 2 signals
don’t match the incoming voltage, if both are high, then the System Bias is defective.
3. If step 2 was OK make the same measurement at J27 on the CCM I/O PCB. If OK here the CCM is defective.
Otherwise inspect the connections at J62 and J27.
239
AC Voltage High
Voltage OK -- At power up the System Bias board measures the input voltage and determined if it is within the
range of voltage set by the J16 jumper. See section 231-236 Inverter VAC Mismatch Troubleshooting step 1.a
for details of the jumper. Normally when the input voltage is OK the System Bias board turns on a relay K1
on the left die of the board to apply power to the T1 Auxiliary transformer. D44, a green “Transformer ON”
LED, will light when K1 is energized. T1 provides power to the gas controls and the TSC 3000 as well as the
pumps and fans.
Voltage High -- If the AC voltage is determined to be too high it lights D4, ACV HIGH, a red LED on the System
Bias board, and sets the signal “AC V HIGH b” on J62-6 to a “high” about 24VDC (normal for a “low” here is
10-14VDC). To prevent the possibility of excessive voltage applied to several items (gas controls, pumps, fans
etc.) K1 is opened removing power from T1 and D44 goes off. If it’s more than a momentary glitch the gas
controls will reset. Communication with the cutting table may be interrupted. With the Automatic Gas Control
Auto Gas Control and perhaps the cutting table control, the process will have to be reloaded.
D4 is on and the signal “AC V HIGH b” is high only while the voltage is actually high. The signal “AC V HIGH
b” does not latch on.
If the fault is E239 that means it is currently active, that is, currently detected as being too high. If it’s L239 that
means the voltage too high previously but it is not too high now. Applying START will clear the fault unless
it becomes active again.
The voltage that triggers an AC Voltage High fault is above 550V for 480VAC line; above 470V for a 380, 400 or
415V nominal line; above 270V for a 208 or 230VAC line.
Possible causes:
• Incoming voltage is or was too high.
• Bad connection at J62 or J27
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• Bad connection at J61 jumper
• System Bias board defective
• CCM defective.
Troubleshooting:
1. If the fault is L239 applying START will clear the fault unless it becomes active again. An occasional problem may be due to incoming voltage swells (voltage increases lasting from ½ cycle to as much as a minute).
Usually, if the plasma is at fault the problem will be present all the time.
2. It is unlikely that an open connection on the J61 jumper would result in a 239 fault, more likely to be a Voltage Mismatch fault. However, if it’s intermittent at exactly the right time, perhaps not fully plugged in, it
could possibly show up as 239. Check J61.
3. If the incoming voltage is OK and the problem persists it may be the System Bias board, the CCM or the
connection between J62 and J27.
a. If the incoming voltage is OK and D4 is on or signal “AC V HIGH b” on J62-6 is “high” (about 24VDC,
relative to TP1 or J62-8 ) the System Bias board is defective.
b. If D4 is not on and the signal “AC V HIGH b” on J62-6 is “low” (about 10-14VDC, relative to TP1 or J628) then System Bias is OK and problem is in the CCM.
c. If J62-6 is near zero volts there may be bad connection between J62-6 and J27-6 or J62-7 and J27-6.
240
AC Voltage Low
Refer to the first paragraph for code 239 for explanation of what should happen when the input voltage is correct.
Voltage Low -- If the System Bias board determines AC voltage is too low it lights a red LED, D14, ACV LOW,
and sets the signal “AC V LOW b” on J62-10 to a “high”, about 24VDC (normal for a “low” here is 10-14VDC).
Power is not removed from T1 as low voltage won’t damage anything, However, if it’s too low for too long,
some things like contactors, AC solenoids, the gas controls or TSC 3000 may stop working. A low voltage, if it’s
low enough, may also light D3, the red Missing Phase LED. This does not indicate the phase is actually missing.
The voltage that triggers an AC Voltage Low fault is 380V for a 480VAC nominal line; 300V for a 380, 400 or
415VAC nominal line; 175V for a 208 or 230 VAC line.
Possible cause:
• Incoming voltage is now, or was previously, too low.
o Power distribution wires or power cord too small for the load.
o Loose or high resistance connection somewhere in the power distribution or power cord connection.
• Bad connection at J62 on the System Bias board or J27 on the CCM.
• Bad connection at J61 jumper on the System Bias board.
• System Bias board defective.
• CCM defective.
Troubleshooting:
1. If the fault is L240, applying START will clear the fault unless it becomes active again. An occasional problem
may be due to incoming voltage dips or sags (voltage drops lasting from ½ cycle to as much as a minute).
Usually, if the plasma is at fault, the problem will be present all the time. After ruling out everything else
we may have to attach a monitor to the power input to determine if this is the problem.
2. Voltage can be OK when not cutting or cutting at lower currents but at higher current too much voltage may
be lost due to undersize power cord or distribution wires.
a. Measure the voltage while cutting at higher current to determine if the drop is excessive.
b. Verify all power connections are clean and secure.
c. Verify correct wires size for the current draw per the recommendations in our manual as well as the local
electrical codes.
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3. It is unlikely that an open connection on the J61 jumper would result in a 240 fault, it is more likely to cause
a Voltage Mismatch fault. However, if it’s intermittent at exactly the right time, perhaps not fully plugged
in, it possibly could show up as 240. Check the jumper at J61.
4. If the incoming voltage is OK and the problem persists it may be System Bias, CCM or connection between
J62 and J27.
a. If the incoming voltage is OK and D14, ACV LOW, is on or the signal “AC V LOW b” on J62-10 is “high”
(about 24VDC, relative to TP1 or J62-8 ) the System Bias board is defective.
b. If D14 is not on and signal “AC V HIGH b” on J62-10 is “low” (about 10-14VDC, relative to TP1 or J62-8)
then System Bias is OK and problem is in the CCM.
c. If J62-10 is near zero volts there may be a bad connection between J62-10 and J27-10 or J62-7 and J27-7.
241-246Inverter Section Input Voltage Error.
The System Bias board checks for input voltage high, low or missing a phase from the power coming in from the
power cord. It is unlikely but not impossible that a problem with the incoming power could result in 241-246
codes. The 241-246 codes more likely point to problems with the power into or within a single inverter section
or in the case of missing phase it may be the contactor that supplies up to 3 inverter sections.
Once the input contactors close, applying voltage to the inverters, they test for input too high or too low and
for missing phase. When the input voltage is in the correct range, a green LED, D4, named READY, lights on
the left side of the main inverter board. If D4 is not on, either the input voltage is out of range or the inverter
is defective.
You can still get the 241-246 code with a missing phase with the READY LED on. The LED will be going on
and off rapidly but appears to the eye to be on. In this case you can measure the signal on the ribbon cable.
The signal previously called READY is now called AC_INPUT_FLT. It is a differential signal on pins 1(+) &
2(-) of the inverters 30 pin ribbon cable. If the AC input is correct you should read 5-6V between the pins. If
AC_INPUT_FLT is true voltage on pins 1 & 2 will be less than 2V.
Some of the other faults such as Inverter Fault and Over Temperature also set the AC_INPUT_FLT (not Ready).
However, they will latch on associated LEDs or set different fault codes. In the event of an Input Voltage Fault
the CCM does not remove power from the inverter.
Things that can cause Input Voltage Fault codes:
1. Intermittently having the power drop out on one or more phases for at least 1 ms. a longer term loss would
more likely trigger a different fault. If it’s the incoming power it would be likely not always be the same
inverter.
2. Phase missing or intermittent to a specific inverter the fault would always call out that inverter.
3. Intermittent connections on the fault signal internal to the inverter.
247-252Inverter Fault
Once the input contactors close applying voltage to the inverters several tests are performed. The Inverter Fault
signal latches on so even if the cause has gone away you can see that there was a fault as indicated by red LED
D1, INV FLT on the inverter Control & Fault PCB. It is reset by applying start signal or cycling power. If the
fault is still present it will come back on.
Things that cause an inverter fault:
• One or more of the local bias supplies (+/-12VDC) failed or out of spec. Green LEDs on Cap Bias board
labeled +12V (D13) & -12V (D6) indicate the supplies are present but not necessarily that they are in tolerance.
• Input capacitor voltage imbalance indicated by D3 CAP IMBALANCE LED (red) on left side of main
inverter board. Applies to units with series connected capacitors (380-480V units).
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• Too much current in the main transformer (switching transformer) primary, D32, PRI OC LED (red), on
inverter control board.
INV_FLT is a differential signal on pins 3(+) & 4(-) of the inverters 30 pin ribbon cable. If there is not a fault you
should read 5-6V between the two pins. If INV_FLT is true voltage on pins 3 & 4 will be less than 2V.
253-258Inverter Over Temperature.
Each inverter section (IS) contains one or more temperature sensors. If any of these detect an over temperature
condition it activates the signal “OVERTEMP_FLT going to the CCM over the inverter sections ribbon cable.
Inverters semiconductors (transistors and diodes) are liquid cooled. Anything that increases the coolant temperature too high can cause overheating of the inverters. The inverters magnetics (transformer & inductors)
are air cooled by the same fan(s) that cool(s) the liquid.
Possible causes:
• Cooling fan(s) not operating.
• Disrupted air flow.
• Defective inverter module.
• Inverter Ribbon cable bad connection.
• Defective CCM.
Originally 100 and 200A units had 2 smaller fans while 300 & 400A used a single larger fan along with a larger
radiator. More recently, the single larger fan may be used in the 100 & 200A as well. Replacement fans for all
units are a single fan kit.
Troubleshooting:
1. Confirm that air is exhausting from both the top (top fan)and bottom (bottom fan of units with 2 fans) of the
opening in the right side panel. As the fan(s) are behind the radiator it’s hard to see them to confirm they
are turning but perhaps you can use an inspection mirror. Refer to section for code 403 for troubleshooting
defective fans.
!
WARNING
Fan blades can be moving and accidental contact with a mirror or other
inspection devise can cause personal injury or damage to the machine.
2. Leaving the side panels and cover off, especially the left lower side or the top cover will reduce the air flow.
Also if the radiator fins become clogged with dust it will reduce air flow. Clean the radiator periodically by
blowing air into it to clear dirt from the fins.
259-264Inverter Over Temperature due to high Ambient.
The CCM measures the ambient temperature where the cooling air enters the louvers on the left side of the
front panel. If an inverter goes over temperature and we have determined that the ambient exceeds 40 deg C
we will get one or more of the high ambient codes, 252-264. The sensor, TS2, is a NTC (Negative Temperature
Coefficient) resistor whose resistance varies with temperature. It is mounted on the inside of the front panel
next to the louvers on the left. To access it requires removing one or more of the inverter modules. If the ambient is high but no inverter is too hot there is no fault.
Possible causes:
• Ambient is too high.
• Cooling fan(s) not operating.
• Disrupted air flow.
• TS2, Ambient temperature sensor, shorted (very unlikely) or otherwise defective.
• Defective Relay board.
• Defective CCM.
• Defective Relay board.
Troubleshooting:
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1. If room temperature exceeds 40 deg C, cool the room, or operate the unit at reduced duty cycle or lower
current.
2. Confirm that air is exhausting from opening in the right side panel. As the fan(s) are behind the radiator
it’s hard to see them to confirm they are turning but perhaps you can use an inspection mirror. Be careful
not to get the mirror or your hands into the blades. 100 & 200A units have 2 smaller fans, 300 & 400A have
one larger one.
3. It is unlikely these high ambient temperature codes would be set before some other temperature related code
but just in case we’ll note that leaving the side panels and cover off, especially the left lower side or the top
cover will reduce the air flow. Also the radiator fins clogged with dust will reduce air.
4. To test TS2 remove J2 from the Relay board and measure the resistance between pins 4 & 6 of the J2 harness
connector. The resistance varies from about 33K ohms at 0 degrees C to about 12K ohms at 20C to 5.3K ohms
at 40C.
5. If TS2 is within the correct range the problem may be with the Relay board or the CCM.
a. The output from the relay board going to the CCM is on pin 30 of the 40 pin ribbon cable (J4 of Relay
board to J23 of the CCM I/O board). It is an analog voltage that should range between 0.44V at 0 deg
C to 1.6V at 40C. If it is confirmed that the room ambient is not above 40C and Ambient temperature
signal at pin 30 is higher than 1.6V then the Relay board is defective.
b. If Ambient temperature signal at pin 30 is OK, less than 1.6V, and the room ambient is not above 40C
then the CCM is bad.
265-270Inverter No Input Power
There are several digital signals on the ribbon cables between the inverter sections and the CCM that involve
some level of voltage. These include AC_INPUT_FLT\, INVERTER _FLT\, OVERTEMP_FLT\ and POWER_
PRESENT. Normally all of these should be high. Before power is applied to the inverter modules the CCM
has already performed a continuity check to see if that section is in place and it’s ribbon cable connected (code
224 & 237). As soon as power is applied to the inverter modules the CCM checks these 4 signals and, having
already confirmed there is an inverter whose ribbon cable is connected. If it finds none of the signals have voltage, it assumes there is no power into the section or something is wrong with that inverter section’s bias power.
Possible causes:
• The 3 input phases, J103-105 to that inverter section not connected.
• The circuit breaker CB2 providing the 120 VAC to the contactor (and Remote Arc Starter) has tripped.
• The contactor powering that section (and others) defective.
• Relay board defective.
• Inverter defective.
• CCM defective.
Troubleshooting:
1. Check that the input power cables are connected to the inverters.
2. Check if the contactor for that section (W1 for 1A, 1B, 2A; W2 for 2B, 3A, 3B) is energized.
a. There is a rectangular section in the middle of each contactor top that can be used to attach auxiliary contacts. This can also be an indicator of contactor operation as it pulls in when the contactor is energized.
b. Check for CB2 on the rear panel being tripped. The white button marked “5” indicating it’s 5 amps, will
pop out if tripped. Reset it and if it pops out again something (contactor coil?) may be shorted.
c. Measure for 120 VAC on the contactor coil. If present, but the contactor isn’t pulled in, it’s probably a
defective contactor.
3. On the Relay board D22, CONTACTOR ON LED (green) next to relay K1 lights if K1 is being told to energize.
a. If it’s on check for 120 VAC between J8-1 and J8-9. If present the relay board is OK.
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b. If D22 is on but 120 VAC is not present at J8-1 and J8-9 (make sure meter is set for ACV) then the relay
board is defective.
c. D22 is not on, go to the 40 pin ribbon cable test connector and measure voltage on pin 17 (relative to
TP1 on either the Relay board or the CCM I/O Board). It should be low, less than 1 volt. If it is the relay
board is likely bad. If it’s high, about 24VDC then the CCM may be bad, not telling the contactor to turn
on.
4. The inverter section may be defective with a bad bias supply. Swap the inverter end of the ribbon cable with
one next to it.
a. If it now reports a different code, that of the inverter that was swapped with, then the original section is
bad.
b. If it still reports the same section even though the ribbon cable was swapped then the CCM is bad.
271
Inverter ID Reading Fault.
Refer to section for codes 225-230 for a description of the ID signals. If this code appears it means one of these
ID signals has gone false some time after power up.
Possible causes:
• An intermittent ribbon cable or one not fully latched in place.
• EMI interference.
Troubleshooting:
1. First recycle power to see if the fault is still there. It may now show up as one of the 225-230 codes which
will indicate which inverter.
2. Determine when the code shows up. If it is EMI it may not happen every time but if, when it happens, it is
always at the beginning of piloting, it may be EMI interference. Check the system ground cables and if an
AC200XT check the torch shield connection to the unit rear panel.
3. If it happens intermittently during cutting or idling it might be an intermittent ribbon cable. This code does
not say which inverter section so you have to check each ribbon cable for proper connection on each end. It’s
highly unlikely for a ribbon cable to be intermittent but if you have more than 2 sections try disconnecting
one section at a time and cut at lower current. See if you find one that causes the problem and if so replace
that ribbon cable.
Group 3 codes relate to the GAS Controls Status and Communication Protocol
301
Gas Control Communication Fault
No signal detected over the fiber-optic link from the gas control. In the case where there are additional devices
other than Gas Control connected to the CANBUS this code would indicate the Gas Control is having communication problems while the other CANBUS devices are OK. We don’t currently have any other devices on the
CANBUS so it is more likely that code 501 will be what is set. In any case troubleshooting is the same as for 501.
Possible cause:
• Most likely cause is dirty or defective fiber-optic cable or connector.
• Cable to GSC or DPC not connected or broken.
• Defective control board or power supply in the Gas Control
• Defective CCM
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Troubleshooting:
1. Check that the fiber-optic cable is fully plugged in to both sockets. Clean the cable ends with a soft cloth
and blow out the sockets with air.
2. Check gas control cables. If any of the gas control cables are not connected there will be no communication
as there will be no power to the control. This may show up as a 301 or 501 code. Also if the cable is broken
or defective such that the gas control is not enabled it may have power but in the case of the GSC or DPC
its fault light will blink error 101 while the CCM will only detect that there is no communication and it will
show 301 or possibly 501.
302
Gas Control communications reply fault
Communication has been established but Gas Control did not reply to a request from the CCM in the time allowed. Likely cause is Fiber-optic problems (see code 501) or if problem persists defective Gas Control main PCB.
303
Gas Pressure fault
Gas pressure faults only show up when you try to start the torch, not during purging or setting flows .
304
Gas Control not ready
This is the normal code when the gas control is conducting a purge at start up or when the process is loaded or
changed or when the plasma system has been disabled and is returned to “Enable”.
305
Gas Control Protocol Error
Application error or firmware incompatibility fault. Consult factory for latest firmware update. Possible electromagnetic interference from the Arc Starter; inspect grounding, bonding, and isolation.
306
Not Used. This is one of the reserved codes from the earlier product.
307
Gas Control returns wrong command sequence.
Firmware incompatibility. Consult factory for latest firmware update. Possible electromagnetic interference
from the Arc Starter; inspect grounding; bonding; and isolation.
309
Gas Control Communication reply fault.
Relay doesn’t match what was requested. Possible firmware incompatibility. Consult factory for latest firmware update.
Possible electromagnetic interference from the Arc Starter; inspect grounding; bonding; and isolation.
310-313 Automatic Gas Control Auto Gas Faults.
These different codes displayed on the power simply indicate one of the Auto Gas modules (DPC for codes
310 or 311; GSC for 312 and 313 could be either) is reporting a fault. You need to refer to the specific modules
blinking red LED status indicator and the Status code tables for more information.
Group 4 codes relate to the Liquid Cooling System
Cooling system description. System includes a reservoir, a pump, one or more heat exchangers, flow switch,
level switch and flow sensor on some models. Also included are a filter and various fittings and hoses. New
coolant is installed into the reservoir or “tank” from an opening in the unit’s front panel where there is a visual
level indicator. Coolant flows to the pump inlet from the bottom of the tank, is pumped through a pressure
relief or “bypass” valve which limits MAX pressure to 150 PSI bypassing excess flow back into the reservoir.
The coolant temperature sensor, TS1, a linear NTC sensor, is mounted on the bypass valve.
From the bypass valve in most systems coolant is plumbed to the rear panel coolant supply fitting where it goes
to the torch via the RAS, the remote arc starter, The UC 400 XT had an additional external heat exchanger, the
HE 400 in the supply line between the power supply and the remote arc starter. Coolant from the Torch returns
to the RAS and on to the return fitting on the rear of the power supply. Coolant returning from the torch is
routed through the rear panel filter then through the radiator (internal heat exchanger) and through the flow
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switch. iSeries models also have a flow sensor in series the flow switch that can detect bubbles in the coolant.
Upon leaving the radiator, coolant goes into the bottom inverter “cold plate” or liquid cooled heat sink. It flows
through the inverters in series and returns to the tank. detect bubbles in the coolant. Upon leaving the radiator,
coolant goes into the bottom inverter “cold plate” or liquid cooled heat sink. It flows through the inverters in
series and returns to the tank.
401
Coolant Level Low
The coolant reservoir (tank) has a normally open (tank dry) float type level switch, LS1. When the coolant level
in the tank is below about ½ full this fault will signal the need to add coolant. It will not stop the process during a cut but will instead show the 405 fault as a warning. As soon as the cut stops it will not allow another to
start until the issue is corrected.
Possible causes:
• Coolant is low
• Level switch defective, disconnected or installed upside down.
• Relay board defective or J7 disconnected.
• CCM defective.
Troubleshooting:
1. Confirm visually that the level switch float is below the coolant, if not add more coolant to the tank.
2. Check J7 on the Relay board.
a. If properly connected remove J7 and check continuity between pins 2 and 4 (pins 2 & 3 of J71 on the
switch itself).
b. If no continuity at J71 on the switch, if it is still open, replace the switch.
3. If there was continuity at J7 plug it back in and measure voltage on pin 9 of the 40 pin ribbon cable (Relay
board J4 to CCM J23). Common is TP1 on either the Relay or the I/O board.
a. Pin 9 should be high, about +10 to +15V. If it’s not the relay board is bad or the ribbon cable is shorted.
b. To test the ribbon cable remove both ends, J4 on the Relay board and J23 on the I/O board and measure
from pin 9 of the ribbon cable to both pin 8 and pin 10 of the cable. Both should be open. If not replace
the ribbon cable. Otherwise it’s the Relay board.
4. If pin 9 of the 40 pin ribbon cable was high in step 3.a the CCM is defective.
402
Low coolant Flow
The flow switch FS1 is positioned in series with the radiator where it measures the flow returning from the
torch. The flow switch serves two purposes, one to insure there is adequate flow for cooling needs and two,
it insures the torch consumables are in place so the negative output of the power supply is not exposed. This
function is called “Parts in Place” or PIP. The output cannot be enabled if parts are not in place. The normally
open flow switch requires 0.7 GPM (2.65 liter/min.) +/- about 10% to close.
When the system is turned on and enabled and fails to achieve proper coolant flow after 4 minutes code 404
will be set. Getting code 402 means it initially had enough flow but something has caused the flow to be reduced. Listed here are things that might happen during cutting to cause reduced flow. For other causes like
component failures refer to code 404.
Possible causes for low flow:
• Coolant filter clogged.
• Defective O-ring in torch check valve.
• External pump bypass valve incorrect adjustment or defective. Call the factory for instructions.
• Defective pump.
• Coolant supply or return hose twisted or pinched reducing flow.
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If coolant flow is not low but code is being set, possible causes:
• Flow switch disconnected or defective.
• Relay PCB.
•CCM.
Troubleshooting:
1. First note whether the fault is an “E” meaning it’s currently low or an “L” meaning it was low but isn’t now.
Flow that remains low could indicate a failed component or a blockage such as clogged filter or pinched
hose. It also means you should be able to measure the flow to determine if it is really low or the sensor has
a problem.
2. First recycle power. If flow is still low or a component is defective the code should change to 404. Go to
that section for further troubleshooting.
3. If after recycling power there is no code, continue cutting to see if it occurs again. Take note of when it occurs, for example if it’s with the torch at one end of the table, perhaps the leads get pinched there? In any
case go to code 404 section for more information.
403
Coolant overheated.
TS1 is a linear negative temperature coefficient (NTC) resistor sensor attached to the brass fitting at the exit of
the bypass valve. Here we determine the coolant being supplied to the torch is below the required temperature
which is currently 75 deg C (167F). The radiator is on the lower right side of the unit. The fan is behind it and
blow out through the radiator.
Fans operate during cutting and for 4 minutes after last cut then shut off. The external heat exchanger, HE400,
fan is thermostatically controlled so it only comes on when coolant is over 60 deg C. It will shut off when the
other fans shut off.
Possible reasons for coolant overheated:
Coolant fan(s) failed or defective fan control relay MC2.
• Radiator fins clogged with dirt.
• Duty cycle exceeded (ambient temperature above 40 deg C and operating at high duty cycle).
• Operating with an object placed in close proximity to the air outlet (right side of the unit) or the front
panel inlet openings.
• Operating for extended time with right lower side panel removed.
• Defective Relay board.
• Defective CCM.
Troubleshooting:
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1. Check for air blowing out of the unit. Remember, the fans only run when CNC START is applied and for 4
minutes after cutting, you may have to apply start again to restart the 4 minute time. Fans may be forced
on by jumping TP2 on the CCM I/O board to TP1 (ground).
a. If using the external HE400XT heat exchanger, standard for 400A, check for air blowing out of it. Note
that the HE400XT fan, controlled by a thermal switch in the HE400XT, only runs if the coolant is over 60
deg C and the internal fans are operating. With the 100 & 200A if it has 2 fans make sure both fans are
operating by checking for air both top and bottom of the opening. The fans are difficult to see, perhaps
you can use an inspection mirror. Be careful not to get the mirror or your hands into the blades.
2. Fans are powered by 230 VAC. The 230 VAC for the fan(s) is switched by the MC2 control relay.
To J70-3
1
TP1
2
TP2
J13
3
To test fan relay jump TP2 to TP1.
4
230 VAC from T1
CCM I/O PCB
(65A)
Relay PCB
J4-19
+24
1
K4
D24
2
4
5
MC2B
J8
24 VAC
3
Fan Bias Control
R
MC2A
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
(64A)
(70)
1
2
3
BK
C4
FAN1
BN
BL
R
(69)
(70)
(161)
SA3
(69)
J72
MC2
J73
1
2
3
(70)
Fan Control
To J70-2
CHASSIS GND
ARC_SUPPRESSOR
(160)
Art # 12311
3. Check for 230 VAC at either of the fan connectors, J72 & J73. It may also be measured at the rear panel connector J70 for the HE400XT fan.
a. If the fans are not getting 230 VAC, measure for 24 VAC on the coil of MC2. If present and the relay
contacts aren’t closed the relay is defective. Note, the coil is rectified so you won’t measure continuity
of even a good coil.
b. If 24 VAC is not on the MC2 coil check for D24 on the relay board being ON. If it’s on, the Relay board
should be providing the 24 VAC so if it’s not the Relay board must be defective.
c. If D24 is not on, measure on the CCM I/O board between TP2 and the common at TP1. It should be low,
near zero volts. If not the CCM is probably defective. Jumper TP2 (I/O board) to TP1. If the fans now
come on replace the CCM.
d. If jumping TP2 to TP1 does not turn the fans on then the Relay board or the 40 pin ribbon cable pin 19
is at fault.
404
Coolant System Not Ready
When power is applied to the system with External Plasma Enable satisfied and Plasma Power Supply Enabled,
assuming there is enough coolant in the tank, after some initial tests taking about 15-20 seconds (see manual
section 4 for details of the Start-Up Sequence) the pump will start. Coolant will be pumped through the system.
Flow is measured by the FS1 flow switch placed in the torch coolant return path just before the radiator (see
plumbing diagram). If the flow doesn’t reach at least 0.75 GPM (2.8 lpm) within 4 minutes it will set the 404
fault. The reason for the 4 minutes is a new dry system especially one with long torch leads will take some time
before the leads, hoses, radiator and cold plates are full of coolant. More coolant may have to be added. On a
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system that has been run before it normally takes only a few seconds to establish proper flow. In any case the
pump will run for 4 minutes before setting the 404 fault.
First determine if the pump motor is running and if so is there any coolant flowing. With the right lower side
panel removed touch the pump and feel for vibration to indicate if the motor is running. Observe the clear
coolant hoses to see if they are full of coolant. There are two hose fittings on the back of the tank. The upper
one is the coolant return. Remove the tank filler cover. You should see a fairly strong stream of coolant from
that fitting. The lower fitting is from the pump bypass valve. If the pump is operating some coolant may be
exiting that fitting as well. If these fittings are below the coolant level you may have to drain out some of the
coolant to see this. If a strong stream is exiting the bypass (lower) fitting but nothing from the upper fitting,
you probably have some kind of blockage.
Reasons for 404 faults (Coolant not flowing):
• In new installation, coolant has not circulated all the way through the leads. Add more coolant if necessary and recycle the power to restart the pump and 4 minute timer.
• Coolant supply & return leads are reversed, check valve in torch coolant return prevents reverse flow.
• Torch parts removed or are wrong style so torch check valve shuts off flow.
• Torch coolant tube damaged or the tube extension (if required) missing.
• No power to pump motor.
• Pump/motor failure.
• Bypass valve defective or adjusted incorrectly.
Damaged Coolant Tube
Coolant tube includes a check valve at its upper end. When cartridge with consumables is not installed the
spring loaded coolant tube is fully extended closing the check valve preventing coolant from leaking out.
When consumables are in place they push the tube inward, opening the check valve, allowing coolant to flow.
The coolant tube has fingers on the end to contact the inside of the electrode and allow coolant to flow through
the openings between the fingers.
The fingers can be bent over or broken if reasonable care is not taken when the cartridge is not in place. If the
fingers are bent or broken it shortens the tube so the consumables may not push the tube in enough to open
the check valve resulting in no coolant flow. The coolant tube assembly may be replaced separately from the
torch head.
Some consumables use an extension on the coolant tube. A missing extension will not allow the check valve
to open.
Internal Check Valve
Fingers
Coolant Tube Extension
Art # 12312
No Power to the Pump Motor
The pump motor is powered by 230 VAC controlled by the MC3 control relay. During the 4 minutes after turning
on power, before the 404 fault code is displayed, measure for 230 VAC at the motor connector J16 pin 1 to pin 3.
A-82 APPENDIX
Manual 0560956456
iSERIES 100 /200 /300 /400
a. If the pump motor is not getting 230 VAC, measure for 24 VAC on the coil of MC3. If present and the relay
contacts aren’t closed the relay is defective. Note, the coil is rectified so you won’t measure continuity of
even a good coil.
b. If 24 VAC is not on the MC3 coil check for D27 on the relay board being ON. If it’s on the Relay board should
be providing the 24 VAC so if it’s not the Relay board may be defective. Measure for 24 VAC at J9-6 to J9-12
on the Relay board. If 24 VAC is present and D27 is on, the Relay board or the wire harness is defective.
c. If D27 is not on, measure on the CCM I/O board between TP3 and the common at TP1. It should be low,
near zero volts. If not the CCM is probably defective. Jumper TP3 (I/O board) to TP1. If the pump comes
on now replace the CCM.
d. If jumping TP3 to TP1 does not turn the fans on then the Relay board or the 40 pin ribbon cable pin 13 is at fault.
TP3
1
2
J13
3
230 VAC from T1
To test Pump relay jump TP3 to TP1.
4
CCM I/O PCB
TP1
MC3A
(65B)
Relay PCB
J4-13
J8
24 VAC
+24
1
D27
K5
2
4
5
3
Coolant Pump Control
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
(64B)
(66)
MC3B CHASSIS GND
(67)
J16
M1
1
2
3
Torch Coolant Pump
(162)
SA4
MC3
Coolant pump Control
ARC_SUPPRESSOR
(163)
Art # 12313
Coolant flows but flow is less than the required minimum:
Test and adjust the pump/bypass valve:
This test measures the “dead head” or blocked flow pressure at the rear panel coolant supply fitting. Perform
this test only after the coolant system is fully primed, that is after the coolant is circulated throughout the system
and is mostly free of bubbles. It requires a pressure gauge with #6 JIC fitting.
The gauge needs to be able to read at least 173 PSI. Remove the coolant supply hose and connect the pressure
gauge in its place.
NOTE!
Do not put the gauge in-line and attempt to pinch off the hose to block the flow. It is very difficult to
totally block the flow and failure to do so will result in incorrect setting of the bypass.
Turn the on the unit. You will have 4 minutes to perform the test/adjustment before the system times out with
a coolant flow fault. If that happens recycling the power gives you another 4 minutes.
1. The pressure on the gauge should be close to 173 (170-175) PSI. If it is the pump and the bypass are OK.
2. If the pressure is less than 173 PSI adjust the bypass screw clockwise to raise the pressure. If you can
change the pressure with the bypass screw but cannot reach 173 PSI it is likely the pump is worn out or
damaged. If the pressure does not change using the bypass screw it is likely the bypass is defective.
3. If the pressure is above 173 reduce the pressure by adjusting the bypass valve screw counter clockwise.
Coolant flow test:
Manual 0560956456
APPENDIX
A-83
iSERIES 100 /200 /300 /400
In addition to the pressure test or in place of it if you don’t have a gauge, determine if the flow returning from
the torch (the flow that passes through the FS1), is greater than the required minimum. With the unit switched
off remove the return hose from the back of the power supply. Place it in a container of a known volume. Turn
the unit on and let the pump run exactly 30 seconds. It should pump at least 3/8 gal. (1.4 l). Use a larger container in case the flow is greater and it overflows.
If the flow is lower than 0.75 GPM (0.25 GPM for PAK200i):
• Look for restrictions such as sharp bends or something pinching the coolant hoses or torch leads.
• Other possibilities are the bypass valve has been adjusted wrong (someone may have turned the adjustment screw) see pressure test/adjustment above
• The pump is worn out (may be the case with an older unit).
Coolant flow is correct but system doesn’t detect it due to defective components:
• Defective or disconnected FS1 flow switch.
• Relay board.
•CCM.
Flow Switch FS1 disconnected – FS1 comes with wire about 1 ft. long and a connector that connects to a 3 wire
harness. This could be disconnected at either end, J74 or J5 on the relay board.
Defective FS1– The flow switch, normally open, closes when flow through it exceeds 0.75 GPM, could be open.
Easiest place to measure the switch is at the J5 harness connector that plugs into the Pilot board. Assuming you
have previously determined flow is sufficient, disconnect J5 from the Pilot board, start the unit so the coolant
is flowing and measure continuity between the 2 pins of J5.
• If there is no continuity either the switch is open or the harness between J5 and J74 at FS1 is open.
• If there is continuity between the J5 pins with sufficient coolant flow then either relay board or the CCM
is faulty.
405
Low Coolant Level Warning
If the coolant level becomes low while cutting it is not necessary to immediately stop the cut as there is still
enough coolant to continue so we display E405 as a warning. Once the cut stops if the coolant is still low the
display changes to E401 and prevents starting another cut. Refer to the section for code 401 for troubleshooting.
406
Coolant Flow Low Warning
This code is a warning, it does not prevent cutting but if it persists the cause should be investigated. iSeries
XT units, in addition to a coolant flow switch, include a turbine flow sensor FL1, referred to in the plumbing
diagram as a “bubble sensor”, with a pulse output that accurately measures coolant flow and in addition can
detect the presence of gas bubbles in the coolant. Gas bubbles from leaking seals in the torch or hose fittings
have been proven to reduce consumable life. This code is a warning, it does not prevent cutting but if it persists
the cause should be investigated.
407
Coolant Overheated due to High Ambient
As described in the section for codes 259-264 the CCM measures the ambient temperature using sensor TS2 and,
like with the inverters, if the coolant is over temperature we first check the ambient and if it is above 40 deg C
we attribute the cause of the coolant over temperature to high ambient and of course the solution is to lower
the ambient or reduce the duty cycle.
The other possibility is the ambient measuring circuit is defective and the coolant is overheated. In that case
you would have to go to the section for code 403 to find the cause of the coolant overheating and go to section
for codes 259-264 to determine what is wrong with the TS2 circuit.
A-84 APPENDIX
Manual 0560956456
iSERIES 100 /200 /300 /400
The 5 Group relates to CANBUS (Fiber optic) communication errors
501
CANBUS Failure to Acknowledge fault.
The CCM communicates with the gas controls over a fiber-optic cable using the CANBUS protocol. The CCM
is looking for a signal from the gas control over the fiber-optic link. No signal has been detected. Communication with the DPC which is relayed through the GSC sets a different code, 301, if there is a problem with it.
Possible causes:
• CANBUS / Fiber-optic problem to the GSC (part of Automatic Gas Control).
• Control Cable to GSC defective.
• Gas control (GSC) main PCB blown fuse or defective.
• GSC power supply PCB blown fuse or defective.
• CCM defective.
Troubleshooting:
1. Automatic Gas Control. If the gas control does not have power it will not communicate. Check for power
to the gas control boards.
a. When using Auto Gas (DFC3000) with GSC & DPC if there is no power to the GSC main board, the green
power light on the GSC front panel will not be lighted. The main board receives several voltages from
its separate power supply board. For communication it needs +5VDC. There is a green LED, D17 (first
on the left of the row of LEDs.) that lights when the main board has +5V power.
b. The GSC power supply board has several blue LEDs that light when it has power. If none of these are on
check for the control cable being connected or the circuit breaker, CB2, on the plasma supply rear panel
may be tripped in which case there is probably a short somewhere.
c. The GSC power supply which supplies several voltages could be missing one or more and still have
some blue LEDs lighted. Check for voltages.
2. CANBUS / Fiber-optic communication errors can be difficult to troubleshoot, especially when they are
intermittent. See “Test the Fiber” below. Things to look for are:
a. The connectors not locked in place at either end of the fiber.
b. The fiber is damaged or bent sharply. This should not be the case if the fiber is inside the protective hose
and the hose properly secured in the strain relief but that is not always the case.
c. Dirt on the ends of the fiber or in the receiver/transmitter where the fiber plugs in. Blow out gently with
clean dry air such as is used to clean a camera lens.
d. Excessive electrical interference. While the fiber is immune to EMI it can bother circuits at either end.
Check that all the grounding connections are connected per the manual and are clean and tight. Check
the resistance of the ground rod (with all wires disconnected from it). It may have increased due to dryer
weather conditions. See the instructions in the Plasma Installation manual.
e. Defective receiver/transmitter or other circuits on either CCM or Gas Control main board. Otherwise
replace either (or both) Gas Control main board or CCM.
Transmitter / Receiver Tests. The transmitter/receiver pair on the PCB and the fiber cable looks like this:
Art # 12314
502
CANBUS off due to excessive errors.
See 501 code for troubleshooting CANBUS faults.
503
CANBUS Data Error Warning.
Manual 0560956456
APPENDIX
A-85
iSERIES 100 /200 /300 /400
This is a warning, does not shut the system down but is an indication that it probably will shut down soon (502
code). Troubleshooting is same as for 501.
504
Reserved for future use.
Should not get this but if it happens may be due to EMI. Contact customer service.
Group 6 codes relate to the CCM and program updates. One exception is 619 which is a
coolant flow switch FS1 fault.
601-611Various CCM CPU board internal faults.
For most of these faults try recycling the power but if the problem returns only thing to do is replace the CCM.
Exceptions are:
1. 603 This is one of the reserved codes from the earlier product. Not used so it should never appear, if it does
contact customer service.
2. 607 Processor over temperature could occur if the ambient in the area of the CCM is too high. Try opening
the upper right side panel, perhaps blow some air to cool it off. If that doesn’t help or the ambient was not
too hot to begin with, replace the CCM.
3. 611 Code has various causes most of which require replacing the CCM. However, one possible cause is
the programming jumper on the CPU board (under the Static suppression PCB) has been left in the PROG
position. This is a factory setting used during initial programming and should never be found in the field.
It is NOT used for application code updates However, if someone did move it 611 will be the result.
612
USB port power fault.
USB port supplies +5V to power some USB devices such as the flash drive (thumb drive, memory stick), used for
program updates. A flash drive is the only device currently being used with this USB port. This fault detected
no or low voltage to the port. This could be a shorted flash drive or some other device that draws too much
current exceeding the limits of the USB power supply.
Try another flash drive or if you know this one is OK (it works with a computer), then replace the CCM.
613
USB Log File Creation Fault
When updating the CCM, GSC and DPC programs from a flash drive, a log file called CCM_LOG.TXT is created
on the flash which reports on the results of the update including any problems. If that log file can’t be created
you get 613. This may be a problem with the flash drive having too many other files on it or a problem with its
format that may not be compatible with the CCM.
1. Try putting the update files on a different, preferably empty, flash drive.
2. Or save all the flash drive files in another place on your computer, then delete all the files on the flash drive.
Now copy onto the flash drive only the files required for program updates.
3. If the above doesn’t work, making sure you still have copies of the files, format your flash drive which erases
everything on it. Now load only the files required for program update.
614
No USF File
The file VTCCMFW.USF is required on the flash drive along with the program files when performing a program
update. If it’s either missing or corrupted the display will show b614. The “b” indicates the fault is generated
by the Bootloader program rather than the normal application program code. Note that each new revision of
the program files is supplied with a new VTCCMFW.USF. Even though the name is the same it requires the
new version of this file that is supplied with the application code.
1. Install the correct VTCCMFW.USF on the flash drive.
2. If you already have the correct version of VTCCMFW.USF perhaps the flash drive is the problem. Follow
the instructions for code 613.
A-86 APPENDIX
Manual 0560956456
iSERIES 100 /200 /300 /400
615-617No Update File for CCM, DPC or GSC found
Program files for the CCM, GSC & DPC may be updated through the plasma supply’s USB port. Program
update files are in the format Cx_x_0.S (CCM); Mx_x_0.S (GSC) and Px_x_0.S (DPC).
If the Bootloader finds there are 3 devices, CCM, GSC & DPC on the CANBUS but the flash drive doesn’t have
all 3 update files it will go ahead and update those it has but will show a code indicating that one or more are
missing (615 for CCM; 616 for GSC; 617 for DPC).
Try another flash drive or if you know this one is OK (it works with a computer), then replace the CCM.
Manual 0560956456
APPENDIX
A-87
iSERIES 100 /200 /300 /400
APPENDIX 30: HE 400 CONNECTION
1
2
3
4
5
6
A
A
FAN ASSEMBLY
B
B
R
1
2
3
4
5
6
7
(2)
(3)
FAN1
C4
J72
(6)
1
2
3
(6A)
J71
BN
G/Y
BL
R
TS1
GND
BK
GND
130F
C
C
Art # A-13083
Revision
Rev
AA
By
ECO-B2687
DAT
Date
8/20/2014
2800 Airport Rd.
Denton, Texas 76207 USA
D
Date Printed
Date Revised
11/25/2014
12/16/2014
Drawn
Date
Size
Title
Drawing Number
SCHEMATIC
A-88 2
3
4
APPENDIX
A
Sheet
1 of
1
042X1667
HE400XT
1
8/20/2014
DAT
The information contained herein is proprietary to Thermal Dynamics.
Not for release, reproduction or distribution without written consent.
D
5
6
Manual 0560956456
iSERIES 100 /200 /300 /400
Manual 0560956456
APPENDIX
A-89
iSERIES 100 /200 /300 /400
A-90 APPENDIX
Manual 0560956456
iSERIES 100 /200 /300 /400
This Page Intentionally Blank
Manual 0560956456
APPENDIX
A-91
iSERIES 100 /200 /300 /400
APPENDIX 31: PUBLICATION HISTORY
Cover Date
Rev
A-92
Change(s)
First issue
APPENDIX
Manual 0560956456
iSERIES 100 /200 /300 /400
Manual 0560956456
APPENDIX
A-93
iSERIES 100 /200 /300 /400
Customer // Technical Support
(843) 664-4405
(800) ESAB-123 (372-2123)
ESAB Welding and Cutting Products
PO BOX 100545 Ebenezer Road
Florence, SC 29501-0545
http://www.esab.com
ESAB Cutting Systems – Canada
6010 Tomken Road
Mississauga, Ontario Canada L5T 1X9
Phone: (905) 670-0220
Fax: (905) 670-4879
ESAB Cutting Systems GMBH
Robert-Bosch-Strasse 20
Postfach 1128
D-61184 Karben 1
Phone 011-49-6039-400
Fax 011-49-6039-403-02
http://www.esab.de
A-94 APPENDIX
Manual 0560956456
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