Thermal Dynamics ULTRA-CUT 130, 200, 300, 400 XT® PLASMA CUTTING SYSTEM AUTOMATED GAS CONTROL Operating Manual
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ULTRA-CUT 130, 200,
300, 400 XT®
PLASMA CUTTING
SYSTEM AUTOMATED
GAS CONTROL
Operating
Manual
Revision: AB Issue Date: 10 June, 2020 Manual No.: 0-5578
Art # A-14323_AB
Thermal-Dynamics.com
®
WE APPRECIATE YOUR BUSINESS!
Congratulations on your new Thermal Dynamics product. We are proud to have you as our customer and will strive to provide you with the best service and reliability in the industry. This product is backed by our extensive warranty and world-wide service network. To locate your nearest distributor or service agency call 1-800-752-7622, or visit us on the web at www.thermal-dynamics.com.
This Operating Manual has been designed to instruct you on the correct use and operation of your
Thermal Dynamics product. Your satisfaction with this product and its safe operation is our ultimate concern. Therefore please take the time to read the entire manual, especially the Safety Precautions.
They will help you to avoid potential hazards that may exist when working with this product.
YOU ARE IN GOOD COMPANY!
The Brand of Choice for Contractors and Fabricators Worldwide.
Thermal Dynamics is a Global Brand of manual and automation Plasma Cutting Products.
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, Ultra-Cut XT ™ 130/200/300/400
Operating Manual No. 0-5578
Published by:
Thermal Dynamics Corporation.
2800 Airport Rd.
Denton, Texas 76207 www.thermal-dynamics.com
© Copyright 2019 by
Thermal Dynamics Corporation.
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.
For Printing Material Specification refer to document 47x1966.
Original Publication Date: 16 January, 2019
Revision Date: 10 June, 2020
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 0-5407. 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 0-5407. 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
DECLARATION OF CONFORMITY
According to
The Low Voltage Directive 2014/35/EU, entering into force 20 April 2016
The EMC Directive 2014/30/EU, entering into force 20 April 2016
The RoHS Directive 2011/65/EC, entering into force 2 January 2013
Type of equipment
PLASMA CUTTING POWER SUPPLY
Type designation etc.
UC130, UC200, UC300, and UC400 Plasma Systems, from serial number MX1723XXXXXX
Brand name or trade mark
Thermal Dynamics
Manufacturer or his authorised representative established within the EEA
Name, address, telephone No:
Thermal Dynamics
2800 Airport Rd
Denton TX 76207
Phone: +01 800 426 1888, FAX +01 603 298 7402
The following harmonised standard in force within the EEA has been used in the design:
IEC/EN 60974-1:2017 / AMD1:2019 Arc Welding Equipment - Part 1: Welding power sources.
IEC/EN 60974-10:2014 / AMD1:2015 Published 2015-06-19 Arc Welding Equipment - Part 10: Electromagnetic compatibility (EMC) requirements
Additional Information: Restrictive use, Class A equipment, intended for use in location other than residential.
By signing this document, the undersigned declares as manufacturer, or the manufacturer’s authorised representative established within the EEA, that the equipment in question complies with the safety requirements stated above.
Date Signature Position
1 March 2019
2019
John Boisvert Vice President
Global Cutting
Mechanized Cutting
TABLE OF CONTENTS
1.02 Précautions de sécurité - FRENCH CANADIAN ............................................... 1-6
3.08 Connect Work Cable and Pilot and Negative Leads ......................................... 3-9
3.11 Connect Cables for CNC, Remote Arc Starter, DMC-3000 and HE 400.......... 3-14
3.13 Connect DMC-3000 Fiber Optic Cable to CCM .............................................. 3-19
3.14 Set Switches on the Command - Control Module ......................................... 3-21
3.19 Fiber Optic Cable Installation from CCM to DMC-3000 ................................. 3-34
3.20 Fiber Optic Cable Installation From DMC-3000 to DPC-3000 ........................ 3-36
TABLE OF CONTENTS
4.08 Back up and Restoration of Custom Processes .............................................. 4-9
SECTION 6: REPLACEMENT ASSEMBLIES & PARTS ................................................. 6-1
6.07 Power Supply Replacement Parts - Upper Right Side ..................................... 6-7
6.08 Power Supply Replacement Parts - Lower Right Side ................................... 6-8
6.09 Power Supply Replacement Parts - Rear Panel .............................................. 6-9
6.11 Step Up/StepDown Transformer Replacement Parts ..................................... 6-11
6.12 DFC-3000 Automated Gas Control System Replacement Components ......... 6-12
6.13 DMC-3000 Gas Control Module Replacement Parts ..................................... 6-13
6.14 DPC-3000 Gas Control Module Replacement Parts ...................................... 6-14
6.15 TSC-3000 Touch Screen Control Remote and Internal Replacement Parts ... 6-15
6.16 Remote Arc Starter (RAS-1000 XT) Replacement Parts ............................... 6-16
6.17 HE400XT Heat Exchanger - Replacement Parts ............................................ 6-17
TABLE OF CONTENTS
APPENDIX 1: CNC - CONTROL MODULE PCB CONNECTIONS ....................................... A-1
APPENDIX 2: SERIAL COMMUNICATIONS ............................................................. A-2
APPENDIX 4: DMC-3000 CONTROL PCB LAYOUT ....................................................A-12
APPENDIX 5: DPC-3000 CONTROL PCB LAYOUT ....................................................A-13
APPENDIX 6: DMC-3000 / DPC-3000 POWER SUPPLY PCB LAYOUT .............................A-14
APPENDIX 11: RELAY AND INTERFACE PCB LAYOUT ...............................................A-22
APPENDIX 13: SYSTEM BIAS PCB LAYOUT ...........................................................A-26
APPENDIX 14: MAIN INVERTER BOTTOM PCB LAYOUT ............................................A-28
APPENDIX 15: MAIN INVERTER TOP PCB LAYOUT ..................................................A-30
APPENDIX 16: CONTROL AND FAULT PCB LAYOUT .................................................A-32
APPENDIX 17: CAP BIAS BOTTOM PCB LAYOUT .....................................................A-34
APPENDIX 18: CAP BIAS TOP PCB LAYOUT ..........................................................A-35
APPENDIX 19: SUPPRESSION PCB LAYOUT ..........................................................A-36
APPENDIX 21: REMOTE ARC STARTER SCHEMATIC ................................................A-38
APPENDIX 22: SCHEMATIC, DFC-3000 AUTO GAS BOX SYSTEM ..................................A-40
APPENDIX 23: SYSTEM SCHEMATIC 130A, 380-415V PG 1 ........................................A-42
TABLE OF CONTENTS
APPENDIX 24: SYSTEM SCHEMATIC 130A, 380-415V PG 2 ........................................A-44
APPENDIX 25: SYSTEM SCHEMATIC 200A, 380-415V PG 1 ........................................A-46
APPENDIX 26: SYSTEM SCHEMATIC 200A, 380-415V PG 2 ........................................A-48
APPENDIX 27: SYSTEM SCHEMATIC 300A, 380-415V PG 1 ........................................A-50
APPENDIX 28: SYSTEM SCHEMATIC 300A, 380-415V PG 2 ........................................A-52
APPENDIX 29: SYSTEM SCHEMATIC 400A, 380-415V PG 1 ........................................A-54
APPENDIX 30: SYSTEM SCHEMATIC 400A, 380-415V PG 2 ........................................A-56
APPENDIX 31: ADVANCED TROUBLESHOOTING .....................................................A-58
APPENDIX 32: SL100 INTERCONNECTION .......................................................... A-101
APPENDIX 33: HE 400 XT CONNECTION ............................................................ A-104
INTERNATIONAL CONTACT INFORMATION ................................................. BACK COVER
ULTRA-CUT 130 XT/200 XT/300 XT/400 XT
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:
Always wear safety glasses with side shields in any work area, even if welding helmets, face shields, and goggles are also required.
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.
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.
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.
Protect other personnel from arc rays and hot sparks with a suitable non-flammable partition or curtains.
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:
Remove all combustible materials well away from the work area or cover the materials with a protective nonflammable covering. Combustible materials include wood, cloth, sawdust, liquid and gas fuels, solvents, paints and coatings, paper, etc.
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.“
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.
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.
Do not use equipment beyond its ratings. For example, overloaded welding cable can overheat and create a fire hazard.
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.
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.
0-5578 SAFETY INSTRUCTIONS 1-1
ULTRA-CUT 130 XT/200 XT/300 XT/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.
Be sure the power source frame (chassis) is connected to the ground system of the input power.
Connect the work piece to a good electrical ground.
Connect the work cable to the work piece. A poor or missing connection can expose you or others to a fatal shock.
Use well-maintained equipment. Replace worn or damaged cables.
Keep everything dry, including clothing, work area, cables, torch/electrode holder, and power source.
Make sure that all parts of your body are insulated from work and from ground.
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.
Put on dry, hole-free gloves before turning on the power.
Turn off the power before removing your gloves.
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:
Welders having pacemakers should consult their physician before welding. EMF may interfere with some pacemakers.
Exposure to EMF may have other health effects which are unknown.
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:
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.
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.
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.
Refer to ANSI/ASC Standard Z49.1 (see listing below) for specific ventilation recommendations.
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 0-5578
ULTRA-CUT 130 XT/200 XT/300 XT/400 XT
CYLINDER HANDLING -- Cylinders, if mishandled, can rupture and violently release gas. Sudden rupture of cylinder, valve, or relief device can injure or kill. Therefore:
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.
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.
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.
Locate cylinders away from heat, sparks, and flames. Never strike an arc on a cylinder.
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:
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.
Before performing any maintenance work inside a power source, disconnect the power source from the incoming electrical power.
Maintain cables, grounding wire, connections, power cord, and power supply in safe working order. Do not operate any equipment in faulty condition.
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.
Keep all safety devices and cabinet covers in position and in good repair.
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:
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.”
CSA Standard - W117.2 = Safety in Welding, Cutting and Allied Processes.
0-5578 SAFETY INSTRUCTIONS 1-3
ULTRA-CUT 130 XT/200 XT/300 XT/400
Meaning of symbols - As used throughout this manual: Means Attention! Be Alert! Your safety is involved.
DANGER
CAUTION
Means immediate hazards which, if not avoided, will result in immediate, serious personal injury or loss of life.
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 0-5578
ULTRA-CUT 130 XT/200 XT/300 XT/400 XT
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0-5578 SAFETY INSTRUCTIONS 1-5
ULTRA-CUT 130 XT/200 XT/300 XT/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:
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.
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.
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.
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.
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.
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 :
1-6
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.
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.
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.
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.
Assurez-vous de ne pas excéder la capacité de l’équipement. Par exemple, un câble de soudage surchargé peut surchauffer et provoquer un incendie.
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.
SAFETY INSTRUCTIONS 0-5578
ULTRA-CUT 130 XT/200 XT/300 XT/400 XT
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.
Assurez-vous que le châssis de la source d’alimentation est branché au système de mise à la terre de l’alimentation d’entrée.
Branchez la pièce à traiter à une bonne mise de terre électrique.
Branchez le câble de masse à la pièce à traiter et assurez une bonne connexion afin d’éviter le risque de choc
électrique mortel.
Utilisez toujours un équipement correctement entretenu. Remplacez les câbles usés ou endommagés.
Veillez à garder votre environnement sec, incluant les vêtements, l’aire de travail, les câbles, le porteélectrode/ torche et la source d’alimentation.
Assurez-vous que tout votre corps est bien isolé de la pièce à traiter et des pièces de la mise à la terre.
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.
Avant de mettre l’équipement sous tension, isolez vos mains avec des gants secs et sans trous.
Mettez l’équipement hors tension avant d’enlever vos gants.
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 :
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.
L’exposition à des champs électriques et magnétiques peut avoir des effets néfastes inconnus pour la santé.
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.
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 :
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
0-5578 SAFETY INSTRUCTIONS 1-7
ULTRA-CUT 130 XT/200 XT/300 XT/400 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.
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.
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.
Consultez ANSI/ASC Standard Z49.1 (à la page suivante) pour des recommandations spécifiques concernant la ventilation.
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 :
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.
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.
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.
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.
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 :
1-8
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.
Avant de procéder à une tâche d’entretien à l’intérieur de la source d’alimentation, débranchez l’alimentation
électrique.
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.
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.
Laissez en place tous les dispositifs de sécurité et tous les panneaux de la console et maintenez-les en bon état.
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.
SAFETY INSTRUCTIONS 0-5578
ULTRA-CUT 130 XT/200 XT/300 XT/400 XT
Les publications suivantes sont également recommandées et mises à votre disposition par l’American Welding Society,
550 N.W. LeJuene Road, Miami, FL 33126 :
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.”
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
Signifie un danger potentiel qui peut entraîner des blessures graves ou mortelles.
AVERTISSEMENT
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
Ce produit a été conçu pour la découpe au plasma seulement.
Toute autre utilisation pourrait causer des blessures et/ou endommager l’appareil.
0-5578 SAFETY INSTRUCTIONS 1-9
ULTRA-CUT 130 XT/200 XT/300 XT/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 0-5578
ULTRA-CUT 130 XT/200 XT/300 XT/400 XT
SECTION 2: SPECIFICATIONS
2.01 General Description Of The System
A typical Ultra-Cut XT™system configuration includes:
• One Power Supply
• Remote Arc Starter
• Gas Control - Digital manifold Control (DMC)
• Gas Control - Digital Pressure Control (DPC)
• Precision Plasma Cutting Torch
• Set Of Connecting Leads
• Torch Spare Parts Kit
• Touch Screen Control (TSC) Optional
• Heat Exchanger (Standard with 400A, optional for all others)
The components are connected at installation.
2.02 Plasma Power Supply
The power supply provides the necessary current for cutting operations. The power supply also monitors system performance, and cools and circulates the liquid coolant for the torch and leads.
2.03 Remote Arc Starter
This unit produces a temporary HF pulse to start the pilot arc. The pilot arc creates a path for the main arc to transfer to the work.
When the main arc is established, the pilot arc shuts off.
2.04 Gas Control Module
This module allows automatic remote setting of gas selection, pressures, and flows together with setting of cutting current.
2.05 Precision Plasma Cutting Torch
The torch delivers the controlled current to the work through the main arc, causing the metal to be cut.
0-5578 SPECIFICATIONS 2-1
ULTRA-CUT 130 XT/200 XT/300 XT/400 XT
2.06 Specifications & Electrical Requirements
130 Amp System
Input
Voltage
(Volts)
208
230
380
400
480
600
Input
Voltage
(Volts)
400
480
600
208
230
380
Freq.
(Hz)
50/60
50/60
50/60
50/60
50/60
50/60
Freq.
(Hz)
50/60
50/60
50/60
50/60
50/60
50/60
200 Amp System
Ultra-Cut 130 XT™ Specifications & Design Features
Max OCV (U0)
Minimum Output Current
425vdc (400 vdc CE / CCC)
5 Amps
Max Output Current
Output Voltage
Duty Cycle Rating
Ambient Temperature for Duty Cycle Rating
130 Amps
60 - 180 vdc
100% @ 130A, 200V, (20kW),
104F° (40°C)
Operating range
Power Factor
Cooling
14°F to 122°F (-10°C to + 50°C)
0.94 @ 130 A DC Output
Coolant and Forced Air (Class F)
Ultra-Cut 130 XT™ Power Supply
Power Input Current Suggested Sizes (See Note)
3-Ph
(kVA)
3-Ph
(Amps)
Fuse
(Amps)
3-Ph
Wire
(AWG)
3-Ph
21
21
25
28
27
21
78
70
33
31
26
25
80
70
40-45
40-45
35-40
30
#4
#6
#12
#12
#12
#12
Wire
(mm2)
3-Ph
25
16
4
4
4
4
Ultra-Cut 200 XT™ Specifications & Design Features
Max OCV (U0)
Minimum Output Current
425vdc (400 vdc CE / CCC)
5 Amps
Max Output Current
Output Voltage
Duty Cycle Rating
Ambient Temperature for Duty Cycle Rating
200 Amps
60 - 180 vdc
100% @ 200A, 200V, (40kW),
104F° (40°C)
Operating range
Power Factor
Cooling
14°F to 122°F (-10°C to + 50°C)
0.94 @ 200 A DC Output
Coolant and Forced Air (Class F)
Ultra-Cut 200 XT™ Power Supply
Power Input Current Suggested Sizes (See Note)
3-Ph
(kVA)
3-Ph
(Amps)
Fuse (Amps)
3-Ph
Wire
(AWG)
3-Ph
42
42
47
47
42
45
133
121
65
62
52
45
175
150
100
100
100
60
#2
#2
#6
#6
#8
#8
10
10
16
16
Wire
(mm2)
3-Ph
35
35
2-2 SPECIFICATIONS 0-5578
ULTRA-CUT 130 XT/200 XT/300 XT/400 XT
IEC
IEC
Input
Voltage
(Volts)
208
230
400
400
480
480
600
300 Amp System
50/60
50/60
50/60
50/60
50/60
50/60
50/60
Freq.
(Hz)
Ultra-Cut 300 XT™ Specifications & Design Features
Max OCV (U0)
Minimum Output Current
Max Output Current
425vdc (400 vdc CE / CCC)
5 Amps
300 Amps
Output Voltage / IEC
Duty Cycle Rating
Ambient Temperature for Duty Cycle Rating
Operating range
Power Factor
Cooling
60 - 180 vdc / 60 - 200 vdc
100% @ 300A, 200V, (60kW),
104F° (40°C)
14°F to 122°F (-10°C to + 50°C)
0.94 @ 300 A DC Output
Coolant and Forced Air (Class F)
Ultra-Cut 300 XT™ Power Supply
Power Input Current
3-Ph
(kVA)
3-Ph
(Amps)
Fuse
(Amps)
3-Ph
Suggested Sizes (See Note)
Wire
(AWG)
3-Ph
63
72
75
63
72
76
76
215
194
93
106
77
88
73
250
225
150
150
150
150
90
3/0
2/0
#4
#4
#4
#4
#6
Wire
(mm2)
3-Ph
25
25
95
70
25
25
16
0-5578 SPECIFICATIONS 2-3
ULTRA-CUT 130 XT/200 XT/300 XT/400 XT
400 Amp System
Max OCV (U0)
Ultra-Cut 400 XT™ Specifications & Design Features
425vdc (400 vdc CE / CCC)
Minimum Output Current
Max Output Current
Output Voltage
Duty Cycle Rating
Ambient Temperature for Duty Cycle Rating
Operating range
Power Factor
Cooling
5 Amps
400 Amps
60 - 200 vdc
100% @ 400A, 200V, (80kW),
104F° (40°C)
14°F to 122°F (-10°C to + 50°C)
0.94 @ 400 A DC Output
Coolant and Forced Air (Class F)
Voltage
(Volts)
380
400
480
600
Input
Freq.
(Hz)
50/60
50/60
50/60
50/60
Ultra-Cut 400 XT™ Power Supply
Power Input Current Suggested Sizes (See Note)
3-Ph
(kVA)
3-Ph
(Amps)
Fuse
(Amps)
3-Ph
Wire
(AWG)
3-Ph
93
98
93
93
144
137
114
96
200
200
175
125
#1
#1
#3
#4
Wire
(mm2)
3-Ph
50
50
35
25
NOTE!
* Suggested wire size based on United States NFPA 70 National Electrical Code 2011 edition published by the National Fire Prevention Association. Listings are from table
400.5(A)(2) for flexible cord of certain types rated for 75 deg C in ambient temperatures up to 30 deg C. Using wires of lower temperature rating or different insulation type may require larger wire size. De rate for higher ambient.
These are suggestions only. Always refer to your local and national codes that apply to your region for final determination of correct wire type and size.
2-4 SPECIFICATIONS 0-5578
2.07 Power Supply Dimensions
380V - 480V Input Voltage
ULTRA-CUT 130 XT/200 XT/300 XT/400 XT
47.77 inch
(1213 mm)
0-5578
27.6 inch
(701 mm)
208-230V / 600V Input Voltage
35.97 inch
(914 mm)
130A_420 lb / 190 kg
200A_465 lb / 211 kg
300A_560 lb / 254 kg
400A_580 lb / 263 kg
Art # A-11487_AE
230V
130A_740 lb / 336 kg
200A_1001 lb / 455 kg
300A_1220 lb / 555 kg 65.27 inch
(1658 mm)
600V
130A_652 lb / 296 kg
200A_718 lb / 326 kg
300A_783 lb / 356 kg
400A_849 lb / 386 kg
27.6 inch
(701 mm)
SPECIFICATIONS
35.97 inch
(914 mm)
Art # A-14616
2-5
ULTRA-CUT 130 XT/200 XT/300 XT/400 XT
2.08 Power Supply Rear Panel Features
Customer
Optional
Ports
TSC/Comm
Circuit Breakers
GCM Connector
CNC Connector
J55 - GCM
USER INPUT
C.C.M.
J15 - CNC
HEIGHT CONTROL
Arc Starter Connector
H.E. Connector
J54 - TSC /COMM
J59 - RAS
J70 - HE
F1 - 8A SB 230 VAC
CB2 - 5A 120 VAC
CB3 - 5A 24 VAC
CB4 - 5A 120 VAC
F2 - 8A SB 230 VAC
Fuse
Coolant Return
Coolant Supply
AC Power Lamp
Pilot Lead
Work Lead
Negative Return
Coolant Filter
Input Power
Ports
Art # A-11842_AB
2-6 SPECIFICATIONS 0-5578
2.09 Gas Requirements
ULTRA-CUT 130 XT/200 XT/300 XT/400 XT
The customer will provide all gases and pressure regulators. Gases must be of high quality. Pressure regulators shall be double stage and installed within 3 meters from the Gas Console.
Gas
O2 (Oxygen)
N2 (Nitrogen)
Compressed or Bottled Air
H35 (Argon-Hydrogen)
H35 = 35% Hydrogen,
65% Argon
H2O (Water)
Ultra-Cut 130 XT™ Power Supply: Gas Pressures, Flows, and Quality Requirements
Quality Minimum Pressure
99.5% Purity
(Liquid recommended)
120 psi
8.3 bar / 827 kPa
99.5% Purity
(Liquid recommended) <1000 ppm
O2, <32 ppm H2O)
Clean, Dry,
Free of Oil (see Note 1)
99.995% Purity
(gas recommended)
120 psi
8.3 bar / 827 kPa
120 psi
8.3 bar / 827 kPa
120 psi
8.3 bar / 827 kPa
Flow
70 scfh (33 lpm)
200 scfh (95 lpm)
250 scfh (118 lpm)
90 scfh (42.5 lpm)
See Note 2 55 psi (3.8 bar)
Note 1: The air source must be adequately filtered to remove all oil or grease consistent with 8573-1:2010 Class 1.4.2 Oil or grease contamination from compressed or bottled air can cause fires in conjunction with oxygen.
10 gph (0.6 lpm)
For filtering, a coalescing filter able to filter to 0.01 microns should be placed as close as possible to the gas inlets on the Gas Control Module.
Note 2: The tap water source does not need to be deionized, but in water systems with extremely high mineral content a water softener is recommended.
Tap water with high levels of particulate matter must be filtered. Soft tap water with an allowable water hardness of <10 ppm as CaCO3 or less, filtered at 5 microns. Resistivity must be at least 15 k ohm per cm. Total disolved solids < 61 PPM. Calcium + magnesium < 40 PPM. Silica < 5 PPM and pH 6.5 - 8.0
.
Note 3: Water Pressure Regulator No. 8-6118 is recommended to ensure proper water pressure.
O
2
Gas
(Oxygen)
Ultra-Cut 200 XT™ Power Supply: Gas Pressures, Flows, and Quality Requirements
Quality Minimum Pressure
99.5% Purity
(Liquid recommended)
120 psi
8.3 bar / 827 kPa
Flow
200 scfh (95 lpm)
N
2
(Nitrogen)
99.5% Purity
(Liquid recommended) <1000 ppm O
<32 ppm H
2
O)
2
,
120 psi
8.3 bar / 827 kPa
200 scfh (95 lpm)
Compressed or Bottled Air
Clean, Dry,
Free of Oil (see Note 1)
120 psi
8.3 bar / 827 kPa
450 scfh (212.4 lpm)
H35 (Argon-Hydrogen)
H35 = 35% Hydrogen,
65% Argon
99.995% Purity
(gas recommended)
120 psi
8.3 bar / 827 kPa
H
2
O (Water) See Note 2 55 psi (3.8 bar)
Note 1: The air source must be adequately filtered to remove all oil or grease.
Oil or grease contamination from compressed or bottled air can cause fires in conjunction with oxygen.
For filtering, a coalescing filter able to filter to 0.01 microns should be placed as close as possible to the gas inlets on the Gas Control Module.
200 scfh (95 lpm)
10 gph (0.6 lpm)
Note 2: The tap water source does not need to be deionized, but in water systems with extremely high mineral content a water softener is recommended.
Tap water with high levels of particulate matter must be filtered. Soft tap water with an allowable water hardness of <10 ppm as CaCO3 or less, filtered at 5 microns. Resistivity must be at least 15 k ohm per cm. Total disolved solids < 61 PPM. Calcium + magnesium < 40 PPM. Silica < 5 PPM and pH 6.5 - 8.0.
Note 3: Water Pressure Regulator No. 8-6118 is recommended to ensure proper water pressure.
0-5578 SPECIFICATIONS 2-7
ULTRA-CUT 130 XT/200 XT/300 XT/400 XT
N
O
2
2
Gas
(Oxygen)
(Nitrogen)
Compressed or Bottled Air
Ultra-Cut 300 XT™ Power Supply: Gas Pressures, Flows, and Quality Requirements
Quality Minimum Pressure Flow
99.5% Purity
(Liquid recommended)
120 psi
8.3 bar / 827 kPa
200 scfh (95 lpm)
99.5% Purity
(Liquid recommended) <1000 ppm O
2
, <32 ppm H
2
O)
Clean, Dry,
Free of Oil (see Note 1)
120 psi
8.3 bar / 827 kPa
120 psi
8.3 bar / 827 kPa
300 scfh (141.6 lpm)
450 scfh (212.4 lpm)
H35 (Argon-Hydrogen)
H35 = 35% Hydrogen,
65% Argon
99.995% Purity
(gas recommended)
120 psi
8.3 bar / 827 kPa
H
2
O (Water) See Note 2 55 psi (3.8 bar)
Note 1: The air source must be adequately filtered to remove all oil or grease. Oil or grease contamination from compressed or bottled air can cause fires in conjunction with oxygen.
For filtering, a coalescing filter able to filter to 0.01 microns should be placed as close as possible to the gas inlets on the Gas Control Module.
200 scfh (94.4 lpm)
10 gph (0.6 lpm)
Note 2: The tap water source does not need to be deionized, but in water systems with extremely high mineral content a water softener is recommended.
Tap water with high levels of particulate matter must be filtered. Soft tap water with an allowable water hardness of <10 ppm as CaCO3 or less, filtered at 5 microns. Resistivity must be at least 15 k ohm per cm. Total disolved solids < 61 PPM. Calcium + magnesium < 40 PPM. Silica < 5 PPM and pH 6.5 - 8.0.
Note 3: Water Pressure Regulator No. 8-6118 is recommended to ensure proper water pressure.
Gas
O2 (Oxygen)
N2 (Nitrogen)
Compressed or Bottled Air
H35 (Argon-Hydrogen)
H35 = 35% Hydrogen,
65% Argon
Ultra-Cut 400 XT™ Power Supply: Gas Pressures, Flows, and Quality Requirements
Quality Minimum Pressure
99.5% Purity
(Liquid recommended)
99.5% Purity
(Liquid recommended) <1000 ppm O2,
<32 ppm H2O)
Clean, Dry,
Free of Oil (see Note 1)
99.995% Purity
(gas recommended)
Ar (Argon)
H2O (Water)
99.995% Purity
(gas recommended)
See Note 2
Note 1: The air source must be adequately filtered to remove all oil or grease. Oil or grease contamination from compressed or bottled air can cause fires in conjunction with oxygen.
For filtering, a coalescing filter able to filter to 0.01 microns should be placed as close as possible to the gas inlets on the Gas Control Module.
120 psi
8.3 bar / 827 kPa
120 psi
8.3 bar / 827 kPa
120 psi
8.3 bar / 827 kPa
120 psi
8.3 bar / 827 kPa
120 psi
8.3 bar / 827 kPa
55 psi (3.8 bar)
Flow
200 scfh (95 lpm)
300 scfh (141.6 lpm)
500 scfh (236 lpm)
200 scfh (95 lpm)
150 scfh (70.8 lpm)
10 gph (0.6 lpm)
Note 2: The tap water source does not need to be deionized, but in water systems with extremely high mineral content a water softener is recommended.
Tap water with high levels of particulate matter must be filtered. Soft tap water with an allowable water hardness of <10 ppm as CaCO3 or less, filtered at 5 microns. Resistivity must be at least 15 k ohm per cm. Total disolved solids < 61 PPM. Calcium + magnesium < 40 PPM. Silica < 5 PPM and pH 6.5 - 8.0
.
Note 3: Water Pressure Regulator No. 8-6118 is recommended to ensure proper water pressure.
2-8 SPECIFICATIONS 0-5578
2.10 Gas Applications
ULTRA-CUT 130 XT/200 XT/300 XT/400 XT
MATERIAL MILD STEEL
GAS TYPE
STAINLESS STEEL
GAS TYPE
ALUMINUM
GAS TYPE
OPERATION PREFLOW PLASMA SHIELD PREFLOW PLASMA SHIELD PREFLOW PLASMA SHIELD
30A Cut
Air O2 O2 Air Air Air Air Air Air
50A Cut
Air O2 Air
N2
Air
N2
Air
H20
Air
N2
Air
N2
Air
H20
Air
70A Cut
Air O2 Air
N2
Air
N2
Air
H20
Air
N2
Air
N2
Air
H20
Air
100A Cut
130A Cut
150A Cut
200A Cut
Air
Air
Air
O2
O2
O2
Air
Aire
Air
N2
N2
N2
N2
N2
N2
N2
N2
N2
N2
H35
N2
H35
N2
H35
N2
H35
N2
H20
N2
H20
N2
H20
H20
N2
H20
N2
N2
N2
N2
N2
N2
N2
N2
N2
N2
N2
H35
N2
H35
N2
H35
N2
H35
N2
H20
N2
H20
N2
H20
H20
N2
H20
N2
250A Cut
300A Cut
400A Cut
Air
Air
Air
O2
O2
O2
Air
Air
Air
N2
N2
N2
N2
H35
N2
H35
N2
N2
H20
N2
H20
N2
N2
N2
N2
H35
N2
H35
N2
N2
H20
N2
H20
0-5578 SPECIFICATIONS 2-9
ULTRA-CUT 130 XT/200 XT/300 XT/400 XT
2.11 XT Torch Specifications
A. Torch Dimensions
End Cap
3.5”
88.9 mm
Mounting
Tube
15.5"
393.8 mm
15.75"
(400 mm)
168.5 mm
6.6”
50.8 mm
2”
109.1 mm
4.3”
61 mm
2.4”
34.5 mm
1.4” 70°
Art # A-14327_AB 12.7 mm
.5”
B. Torch Leads Lengths
Torch Lead Assembly
Lengths
Feet
10
Meters
3.05
15
25
50
75
100
4.6
7.6
15.2
22.9
30.4
2-10 SPECIFICATIONS 0-5578
C. Torch Parts (Generic Parts Shown)
Art # A-04741_AB
Shield Gas
Distributor
ULTRA-CUT 130 XT/200 XT/300 XT/400 XT
Plasma Gas
Distributor
Shield Cap Tip Electrode
Shield Cup Cartridge
D. Parts - In - Place (PIP)
The torch is designed for use with a power supply which senses coolant return flow to confirm that torch parts are in place. If coolant return flow to the power supply is absent or insufficient the power supply will not provide power to the torch. Coolant leakage from the torch also indicates that torch parts are absent or installed improperly.
E. Type of Cooling
Combination of gas stream through torch and liquid cooling.
F. XT Torch Data
Ambient
Temperature
Duty Cycle
Maximum Current
Voltage (Vpeak)
Arc Striking Voltage
Current
Plasma Gases:
Shield Gases:
Operating Pressure
Maximum Input Pressure
Gas flow
XT Torch Ratings for use with Ultra-Cut XT™ Power Supply
104° F
40° C
100% @ 400 Amps
400 Amps
500V
10kV
Up to 400 Amps, DC, Straight Polarity
XT Torch Gas Specifications
Compressed Air, Oxygen, Nitrogen, H35, Ar
Compressed Air, Oxygen, Nitrogen, Water, H35
125 psi ± 10 psi
8.6 bar ± 0.7 bar
135 psi / 9.3 bar
10 - 500 scfh
0-5578 SPECIFICATIONS 2-11
ULTRA-CUT 130 XT/200 XT/300 XT/400 XT
This Page Intentionally Blank
2-12 SPECIFICATIONS 0-5578
ULTRA-CUT 130 XT/200 XT/300 XT/400 XT
SECTION 3: INSTALLATION
3.01 Installation Requirements
Electric Supply
The electrical supply network, the gas and water supply system must meet local safety standards. This conformity shall be checked by qualified personnel.
Input
Voltage
(Volts)
208
230
380
400
480
600
Input
Voltage
(Volts)
208
230
380
400
480
600
Freq.
(Hz)
50/60
50/60
50/60
50/60
50/60
50/60
Freq.
(Hz)
50/60
50/60
50/60
50/60
50/60
50/60
Ultra-Cut 130 XT™ Power Supply
Power Input Current Suggested Sizes (See Note)
3-Ph
(kVA)
28
27
21
3-Ph
(Amps)
78
70
33
Fuse (Amps)
3-Ph
80
70
40-45
Wire (AWG)
3-Ph
#4
#6
#12
21
21
25
31
26
25
40-45
35-40
30
#12
#12
#12
Ultra-Cut 200 XT™ Power Supply
Power Input Current Suggested Sizes (See Note)
3-Ph
(kVA)
3-Ph
(Amps)
Fuse (Amps)
3-Ph
Wire (AWG)
3-Ph
47
47
42
42
42
45
133
121
65
62
52
45
175
150
100
100
100
60
#2
#2
#6
#6
#8
#8
Wire (mm2)
3-Ph
25
16
4
4
4
4
Wire (mm2)
3-Ph
35
35
16
16
10
10
IEC
IEC
Input
Voltage
(Volts)
380
400
480
600
Input
Voltage
(Volts)
208
230
400
400
480
480
600
Freq.
(Hz)
50/60
50/60
50/60
50/60
Freq.
(Hz)
50/60
50/60
50/60
50/60
50/60
50/60
50/60
Ultra-Cut 300 XT™ Power Supply
Power Input Current Suggested Sizes (See Note)
63
72
63
72
3-Ph
(kVA)
76
76
75
3-Ph
(Amps)
213
194
93
106
77
88
73
Fuse (Amps)
3-Ph
250
225
150
150
150
150
90
Wire (AWG)
3-Ph
3/0
2/0
#4
#4
#4
#4
#6
Ultra-Cut 400 XT™ Power Supply
Power Input Current Suggested Sizes (See Note)
3-Ph
(kVA)
93
93
3-Ph
(Amps)
144
137
Fuse (Amps)
3-Ph
200
200
Wire (AWG)
3-Ph
#1
#1
93
98
114
96
175
125
#3
#4
Wire (mm2)
3-Ph
95
70
25
25
25
25
16
Wire (mm2)
3-Ph
50
50
35
25
0-5578 INSTALLATION 3-1
ULTRA-CUT 130 XT/200 XT/300 XT/400 XT
NOTE!
* Suggested wire size based on United States NFPA 70 National Electrical Code 2011 edition published by the
National Fire Prevention Association. Listings are from table 400.5(A)(2) for flexible cord of certain types rated for
75 deg C in ambient temperatures up to 30 deg C. Using wires of lower temperature rating or different insulation type may require larger wire size. Derate for higher ambient.
These are suggestions only. Always refer to your local and national codes that apply to your region for final determination of correct wire type and size.
Gas Supply
The customer must supply all gases and pressure regulators. Gases must be of high quality. Pressure regulators must be double-stage and installed as close as possible to the gas console. Contaminated gas can cause one or more of the following problems:
• Reduced cutting speed
• Poor cut quality
• Poor cutting precision
• Reduced consumables life.
• Oil or grease contamination from compressed or bottled air can cause fires in conjunction with oxygen.
WARNING
Oil or grease contamination from compressed or bottled air can cause fires in conjunction with oxygen!
Cooling System Requirements
Coolant must be added to the system on installation. The amount required varies with torch leads length.
Thermal Dynamics recommends the use of its coolants 7-3580 and 7-3581 (for low temperatures).
Coolant Capabilities
Cat. Number and Mixture Mixture
7-3580 ‘Extra-Cool™’
7-3581 ‘Ultra-Cool™’
25 / 75
50 / 50
7-3582 ‘Extreme Cool™’
* For mixing with D-I Cool™ 7-3583
Concentrate*
Protects To
10° F / -12° C
-27° F / -33° C
-76° F / -60° C
3-2 INSTALLATION 0-5578
ULTRA-CUT 130 XT/200 XT/300 XT/400 XT
3.02 System Layout 130 - 300 Amp
Refer to section 3.08 and 3.10 for ground connections and ground cables.
225’ / 68.6 m Maximum Length
F1
Primary power
220’ / 61 m Maximum Length
Pilot Return
Negative
Coolant Supply
Coolant Return
Control Cable E
F1
A
B
C
D
Remote
Arc
Starter
100’ / 30.5 m Maximum Length
Pilot Return
Shield
Ultra-Cut
Power
Supply
Coolant Supply
Coolant Return
Shield
F
CNC
Touch
Screen
Controller
W
P
V
Fiber Optic
Control Cable
Ground Cable
to PS Only
When DMC
Mounted On
Top Of PS
-If not - Earth-
L
K
F
DMC-3000
Gas
Console
Plasma Gas
Fiber Optic
Shield Gas
Preflow
Control Cable
Water Shield
Marking
S
T
U
Q
R
H
L
DPC-3000
Gas
Control
Plasma Gas
Shield Gas
F
I
J
Positioning Tube
G
Torch
Work
Work Cable O
Art # A-11995_AC
0-5578 INSTALLATION 3-3
ULTRA-CUT 130 XT/200 XT/300 XT/400 XT
3.03 System Layout 400 Amp
Refer to section 3.08 and 3.10 for ground connections and ground cables.
225’ / 68.6 m Maximum Length
F
CNC
F1
Primary power
Touch
Screen
Controller
W
P
C
C
M
Ultra-Cut
Power
Supply
220’ / 61 m Maximum Length
Pilot Return #8
Negative 2/0
Control Cable
Coolant Supply 10’
Coolant Return 10’
Control Cable
C
D
Y
HE 400
Heat
Exchanger
Coolant Supply
Coolant Return
A
B
E
F1
C
D
V
Fiber Optic
Control Cable
Ground Cable
to PS Only
When DMC
Mounted On
Top Of PS
-If not - Earth-
L
K
F
DMC-3000
Gas
Console
Plasma Gas
Fiber Optic
Shield Gas
Preflow
Control Cable
Water Shield
Marking
S
T
Q
R
U
H
L
Remote
Arc
Starter
DPC-3000
Gas
Control
50’ / 15.25 m Maximum Length
Pilot Return
Shield
Coolant Supply
Coolant Return
Shield
Plasma Gas
Shield Gas
F
I
J
Positioning Tube
G
Torch
Work
Work Cable O
Art # A-11996_AC
3.04 Recommended Gas Supply Hose
Item # Qty
1
Description
3/8”Gray Synflex Hose. No fittings included. Catalog number per foot 9-3616
Catalog #
3-4 INSTALLATION 0-5578
3.05 Leads and Cables All Amperage
#8 AWG Cable
A
4/0 AWG Cable (120 mm 2 )
B
I
C
D
E,Y
14/7
F
F1
G
Green
Red
ULTRA-CUT 130 XT/200 XT/300 XT/400 XT
Green
Red
Green / Yellow # 4 AWG
Pilot Return, Power Supply to Arc Starter
Negative Lead, Power Supply to Arc Starter
Coolant Supply Lead,
Power Supply to Arc Starter
Coolant Return Lead,
Power Supply to Arc Starter
E - Control Cable, Power Supply to Arc Starter
Y - Control Cable to Heat Exchanger
Ground Cable
Ground Cable,
Remote Arc Starter
To Earth Ground
Shielded Torch Lead
Assembly, Remote
Arc Starter to Torch
Plasma Gas Lead,
Torch Valve to Torch
J
K 37
L
H, Q,
R,T, U
Shield Gas Lead,
Torch Valve to Torch
Control Cable,
Power Supply to
Gas Control Module
Fiber Optic Cable,
Power Supply to
Gas Control Module
For use with
DFC-3000
S,V
16 pin
S - Control Cable,
DMC-3000 to DPC-3000
V - TSC-3000 to PS
O
P,W
37/11
Work Cable
CNC Cable (37 Wire)
W - CNC Communitcation
Cable (11 Wire)
0-5578 INSTALLATION 3-5
ULTRA-CUT 130 XT/200 XT/300 XT/400 XT
3.06 Lift the Power Supply
WARNING
Do not touch live electrical parts.
Disconnect input power conductors from de-energized supply line before moving unit.
FALLING EQUIPMENT can cause serious personal injury and equipment damage.
Use a forklift, crane, or hoist to lift the unit off the shipping pallet as shown. Keep the power supply steady and vertical.
Do not lift it any further than necessary to clear the shipping pallet. Ensure all panels and screws are secure prior to lifting.
Art # A-11531_AC
Set the power supply on a solid, level surface. The installer may fasten the power supply to the floor or a supporting fixture with hardware passing through the horizontal parts of the power supply feet.
3-6 INSTALLATION 0-5578
3.07 Connect Input Power and Ground Cables
ULTRA-CUT 130 XT/200 XT/300 XT/400 XT
380-480 V Systems
Connect Input Power and System Ground Cables
1. Remove the input power cover to the right of the coolant filter at the rear of the power supply. To do this remove the two screws then lift up and pull away.
2. Carefully cut back the outer sheath on the primary input power cable to expose the individual wires. Cut back the insulation on the individual wires. Route the cable upward through Input Power Port at the bottom of the panel.
There are 2 extra plates included at the cable entrance. Discarding one or both allows changing the opening size for larger cable/strain relief.
3. Install stripped end of 3 phase wires into the terminal block L1, L2 and L3 and connect the individual cables as shown.
4. Connect the power cable ground wire to the ground terminal block.
5. Route a system ground cable (F1) through the last opening in the connections cover support panel next to the input power cable. Connect the cable to the ground terminal block on the power supply rear panel. Refer to the
Ground Connections Section for full details and procedures on proper system grounding.
Ground Terminals
Ground
Input Power
Art # A-11942
0-5578 INSTALLATION 3-7
ULTRA-CUT 130 XT/200 XT/300 XT/400 XT
208-230 / 600 V systems
Connect Input Power and System Ground Cables
1. Remove rear access panel and side panel. Requires T25 driver or 8mm wrench.
Art # A-14617
2. Carefully cut back the outer sheath on the primary input power cable to expose the individual wires. Cut back the insulation on the individual wires. Route the power cable through the strain relief and attach the 3 phases to L1,
L2, L3 and the green/yellow earth ground wire to ground terminal accessible through the side panel.
L1 L2 L3
Art # A-14618
3. Reinstall the access panel and tighten the strain relief around the power cord. Replace the side panel.
3-8 INSTALLATION 0-5578
ULTRA-CUT 130 XT/200 XT/300 XT/400 XT
3.08 Connect Work Cable and Pilot and Negative Leads
1. Remove the output power cover to the left of the coolant filter at the rear of the power supply. To do this remove the two screws then lift up and pull away.
2. Route the ends of the work cable, pilot and negative/torch leads upward through the leads strain relief at the bottom edge of the left rear panel.
3. Refer to the illustration. Connect the leads as shown. Tighten securely. Do not overtighten.
+ -
Pilot
Work Cable
Torch
Art # A-11533
4. Reinstall the cover on the power supply. Snug the hardware securely by hand. Do not overtighten.
3.09 Ground Connections
Star Ground on Cutting Table
Remote Arc
Starter (RAS-1000)
Cutting Machine / Gantry iCNC
Lifter
Torch
#4 AWG
(25mm2)
Ground
Gas Control Module
Primary location
#4 AWG
(25mm2)
Ground
(F)
#4 AWG
(25mm2)
Ground
1/0 (70mm2)
Ground Cable
(F1)
Power Supply
Note: The gas control module can be mounted on top of the power supply.
If it is, it should be grounded directly to the power supply with #4 AWG
(25mm2) ground, (F).
Any location requires grounding the power supply to the ‘Star’ ground with the 1/0 (70mm2)
Ground Cable (F1).
Cutting Table
Earth Ground
Rod
1/0 (70mm2)
Ground Cable
Customer supplied
A good ground will be less than 3 ohm. Ideal 1.
3/0 (95mm2)
Work Cable
1/0 (70mm2)
Ground Cable
Art # A-11875.AD
0-5578
0 - 10 ft (0 - 3 m) Ideal
20 ft (6 m) Maximum
‘Star’
Ground
INSTALLATION 3-9
ULTRA-CUT 130 XT/200 XT/300 XT/400 XT
A. Electromagnetic Interference (EMI)
Pilot arc starting generates a certain amount of electromagnetic interference (EMI), commonly called RF noise. This RF noise may interfere with other electronic equipment such as CNC controllers, remote controls, height controllers, etc. To minimize
RF interference, follow these grounding procedures when installing automation (mechanized) systems:
B. Grounding
1. The preferred grounding arrangement is a single point or “Star” ground. The single point, usually on the cutting table, is connected with 1/0 AWG (European 50 mm 2 ) or larger wire to a good earth ground measuring less than 3 ohms; an ideal ground measures 1 ohm or less. Refer to paragraph ‘C’, Creating An Earth Ground. The ground rod must be placed as close as possible to the cutting table, ideally less than 10 ft (3.0 m), but no more than 20 ft (6.1 m) from the cutting table.
NOTE!
All ground wires should be as short as possible. Long wires will have increased resistance to RF frequencies. Smaller diameter wire has increased resistance to RF frequencies, so using a larger diameter wire is better.
2. Grounding for components mounted on the cutting table (CNC controllers, height controllers, plasma remote controls, etc.) should follow the manufacturer’s recommendations for wire size, type, and connection point locations.
For Thermal Dynamics components (except Remote Arc Starter and Gas Control Module) it is recommended to use a minimum of 10 AWG (European 6 mm 2 ) wire or flat copper braid with cross section equal to or greater than 10 AWG connected to the cutting table frame. The Remote Arc Starter uses 1/0 earth ground wire and the Gas Control Module should use minimum # 4 AWG wire. The connection point must be to clean bare metal; rust and paint make poor connections. For all components, wires larger than the recommended minimum can be used and may improve noise protection.
3. The cutting machine frame is then connected to the “Star” point using 1/0 AWG (European 50 mm 2 ) or larger wire.
4. The plasma power supply work cable (see NOTE) is connected to the cutting table at the single point “Star” ground.
NOTE!
Do Not connect the work cable directly to the ground rod. Do not coil up excess ground or power cables. Cut to proper length and reterminate as needed.
5. Make sure work cable and ground cables are properly connected. The work cable must have a solid connection to the cutting table. The work and ground connections must be free from rust, dirt, grease, oil and paint. If necessary grind or sand down to bare metal. Use lock washers to keep the connections tight. Using electrical joint compound to prevent corrosion is also recommended.
6. The plasma power supply chassis is connected to the power distribution system ground as required by electrical codes.
If the plasma supply is close to the cutting table (see NOTE) a second ground rod is not usually needed, in fact it could be detrimental as it can set up ground loop currents that cause interference.
When the plasma power supply is far away from the ground rod and interference is experienced, it may help to install a second earth ground rod next to the plasma power supply. The plasma power supply chassis would then be connected to this ground rod.
NOTE!
It is recommended that the Plasma Power Supply be within 20 - 30 ft (6.1 – 9.1 m) of the cutting table, if possible.
7. The plasma control cable should be shielded with the shield connected only at the cutting machine end. Connecting the shield at both ends will allow ground loop currents which may cause more interference than with no shield at all.
3-10 INSTALLATION 0-5578
Creating An Earth Ground
ULTRA-CUT 130 XT/200 XT/300 XT/400 XT
1. To create a solid, low resistance, earth ground, drive a 1/2 in (12 mm) or greater diameter copper clad ground rod at least
6 - 8 ft (1.8 - 2.4 m) into the earth so that the rod contacts moist soil over most of its length. Depending on location, a greater depth may be required to obtain a low resistance ground (see NOTE). Ground rods, typically 10 ft (3.0 m) long, may be welded end to end for greater lengths. Locate the rod as close as possible to the work table. Install a ground wire, 1/0 AWG (European 50 mm2) or greater, between the ground rod and the star ground point on the cutting table.
NOTE!
Ideally, a properly installed ground rod will have a resistance of three ohms or less.
D. Low Cost Ground Rod Tester
1. A key component of reduced EMI is a good low resistance earth ground rod. There are several very expensive instruments to measure the ground but cost from several hundred to a few thousand dollars. Below is a low cost alternative which can be constructed by qualified personnel familiar with established electrical construction and safety practices.
Previously suggested method using an incandescent light bulb will not work with GFCI outlets which are increasingly being used and the bulbs are becoming obsolete.
2. This method, as well as the light bulb method and some of the expensive instruments, assumes the utility ground is perfect, Zero ohms. It connects the rod being tested in series with the utility ground and measures the resistance of both in series. If the utility ground is not zero ohms, no matter how good your rod is, you won’t get a low reading due the higher resistance of the utility ground. Fortunately this is rare. Also if your rod is right next to another earth grounded structure you may get a false lower reading of only resistance between that structure and your rod rather than to gnd.
NOTE!
In the United States most standard AC outlets are 120 VAC 60 Hz. Elsewhere most outlets are 220 VAC 50Hz.
3. Obtain a transformer rated for at least 25 VA with primary voltage and frequency matching your standard outlets. The transformer should have an isolated secondary of either 220 VAC (220 -240 is OK) or 120 VAC (110-120 is OK) and be rated for at least 100 ma. The transformer could also have dual 115VAC primaries wired in series for 220V or in parallel for 120 VAC. An example is Triad N-68X, shown below, rated 50VA, 50/60 Hz.
Obtain a power resistor of either 1200 (1.2K) ohms, 15-25W min, if using a 120V secondary or 2200 (2.2K) ohms, 25 -30W for a 220V secondary.
4. Assemble the transformer and power resistor in a metal box. Connect a 3 wire (w/gnd) power cord with ground wire attached to the metal box for safety. If a plastic box is used instead, connect the transformer core and the resistor mounts to the power cord ground wire. There should be a fuse ¼ - ½ A, in series with the transformer primary. From the transformer secondary connect one wire to the utility safety ground. This could be the cutting table frame, the ground terminal of the 120 or 220 VAC outlet or the test box if grounded as indicated.
0-5578 INSTALLATION 3-11
ULTRA-CUT 130 XT/200 XT/300 XT/400 XT
An excellent ground measures 1 ohm or less. Up to 3 ohms is often acceptable, higher reduces the effectiveness of the
EMI suppression.
R = 1.2K, 15W
Ground Rod with other connec ti ons removed
Triad N-68X Triad N-68X
F
F
0.1 VAC = 1 OHM,
0.3 VAC = 3 OHM, etc.
GND
220 VAC
GND
120 VAC
Utility (building) GND
Art # A-12710_AB
5. Increasing the ground rod length beyond 20 - 30 ft (6.1 – 9.1 m) does not generally increase the effectiveness of the ground rod. A larger diameter rod which has more surface area may help. Sometimes keeping the soil around the ground rod moist by continuously running a small amount of water into it will work. Adding salt to the soil by soaking it in salt water may also reduce its resistance. You may also try a chemical ground rod devise. When these methods are used, periodic checking of the ground resistance is required to make sure the ground is still good.
E. Routing Of Torch Leads
1. To minimize RF interference, position torch leads as far as possible from any CNC components, drive motors, control cables, or primary power lines. If cables have to pass over torch leads, do so at an angle. Do not run the plasma control or other control cables in parallel with the torch leads in power tracts.
2. Keep torch leads clean. Dirt and metal particles bleed off energy, which causes difficult starting and increased chance of RF interference.
3-12 INSTALLATION 0-5578
3.10 Connect Coolant Leads
ULTRA-CUT 130 XT/200 XT/300 XT/400 XT
1. Connect the color-coded coolant hoses to the coolant connections on the power supply rear panel. The supply line (out) is flagged green, the return line (in) is flagged red.
Coolant Connections
J55 - GCM
USER INPUT
J15 - CNC
HEIGHT CONTROL
J54 - TSC /COMM
J59 - RAS
J70 - HE
F1 - 8A SB 230 VAC
CB2 - 5A 120 VAC
CB3 - 5A 24 VAC
CB4 - 5A 120 VAC
F2 - 8A SB 230 VAC
COOLANT
RETURN SUPPLY
RED
GREEN
To RAS 1000 Arc Starter or
HE-400 Heat Exchanger if used
Art # A-11534_AB
0-5578 INSTALLATION 3-13
ULTRA-CUT 130 XT/200 XT/300 XT/400 XT
3.11 Connect Cables for CNC, Remote Arc Starter, DMC-3000 and HE 400
1. Connect one end of each cable to the power supply.
2. Connect the other end of the CNC cable to the CNC device .
3. The CNC cable shield must be attached to ground at the CNC end.
J55 To DMC-3000
J15 To CNC Control
J55 - GCM
USER INPUT
J15 - CNC
HEIGHT CONTROL
J54 - TSC /COMM
J59 - RAS
J70 - HE
F1 - 8A SB 230 VAC
CB2 - 5A 120 VAC
CB3 - 5A 24 VAC
CB4 - 5A 120 VAC
F2 - 8A SB 230 VAC
J54 TSC/
Comm
J59 To Remote
Arc Starter
J70 To Heat
Exchanger
Art # A-11994
3-14 INSTALLATION 0-5578
3.12 Handling and Installation of Fiber Optics
ULTRA-CUT 130 XT/200 XT/300 XT/400 XT
General Information
This kit is for proper handling and installation of Fiber Optic Cables used in Thermal Dynamics Ultra-Cut ® automated gas boxes and Gas Control Modules.
Fiber Optic cable is used in place of wire because it offers far superior immunity to electrical noise but it is more delicate and requires careful handling. With fiber optics, electrical signals are converted to light with a transmitter LED. The light passes down the fiber where it is converted back to an electrical signal at the receiver end. Any damage to the fiber from sharp bends or pulling that stretches the fiber can reduce its ability to transmit light. We run the fiber inside a hose for most of its length to protect it from abrasion, burning from hot metal or sharp bends, but the ends are exposed and must be handled with care.
Art # A-09416
Strain Relief Hose Fiber
Remove fiber optic end covers and plugs.
Connector with Latch Protective End Covers
WARNING
Disconnect primary power at the source.
Art # A-12015
0-5578 INSTALLATION 3-15
ULTRA-CUT 130 XT/200 XT/300 XT/400 XT
Avoid the following:
1. If you need to pull the cable through a power track do not fold the fiber back on itself making a sharp bend where it exits the hose.
Art # A-09417
2. Do not hook onto the fiber to pull on the cable.
Art # A-09418
3. Once the fiber cable is installed in the CCM or gas control make sure the strain relief nut is securely tightened onto the hose so the hose can’t pull out of it like this:
Hose not secured in the Strain Relief
Art # A-09677_AB
3-16 INSTALLATION 0-5578
Correct installation:
ULTRA-CUT 130 XT/200 XT/300 XT/400 XT
Correct way to pull the cable is to use a snake or a wire or another cable and attach it securely to the hose behind the strain relief. Then secure the fiber connector to the pulling device leaving some slack in the fiber. Keep the protective end covers on the fiber until you are ready to connect it to the PCB in the CCM or gas control.
Art # A-09420
Correct installation in CCM or Gas Control leaves a loop of fiber so there is no stress on the fiber where it exits the connector or the hose.
CCM
No sharp bends
Art # A-12014
Correct routing of fiber optic cable. No sharp bends going into connectors.
Art # A-09678_AB
0-5578 INSTALLATION 3-17
ULTRA-CUT 130 XT/200 XT/300 XT/400 XT
Unplugging the fiber optic connector.
Do not pull on the fiber cable!
Art # A-09423
For the CCM grip the fiber connector front and back squeezing the latch lever and remove from the socket.
Art # A-09424_AB
3-18 INSTALLATION 0-5578
ULTRA-CUT 130 XT/200 XT/300 XT/400 XT
3.13 Connect DMC-3000 Fiber Optic Cable to CCM
1. Remove the bottom plastic plug in the CCM at the rear of the Power Supply.
J55 - GCM
USER INPUT
J15 - CNC
HEIGHT CONTROL
TSC-3000 Cable
J54 - TSC /COMM
J59 - RAS
J70 - HE
CB2 - 5A 120 VAC
CB3 - 5A 24 VAC
CB4 - 5A 120 VAC
F1 - 8A SB 230 VAC F2 - 8A SB 230 VAC DMC-3000 Fiber
Optic Cable
J55 - GCM
USER INPUT
J15 - CNC
HEIGHT CONTROL
J54 - TSC /COMM
J59 - RAS
J70 - HE
F1 - 8A SB 230 VAC
CB2 - 5A 120 VAC
CB3 - 5A 24 VAC
CB4 - 5A 120 VAC
F2 - 8A SB 230 VAC
COOLANT
RETURN SUPPLY
!
!
Art # A-11991
CAUTION
Avoid kinking, twisting, or bunching the fiber optic cable. The cable can be damaged by being forced into tight-radius turns.
0-5578 INSTALLATION 3-19
ULTRA-CUT 130 XT/200 XT/300 XT/400 XT
2. Remove outer thin nut from through hole protector at one end of Fiber Optic Cable (L) that connects between the
CCM portion of the Power Supply and the DMC-3000.
3. Feed the Fiber Optic Cable plug and wires through the hole where the plastic plug was removed labeled GCM/DMC and slide the thin nut back over the Fiber Optic Cable.
4. Secure the thin nut on the through hole protector so both nut faces are tight against the sheet metal inside and out.
5. Plug the Fiber Optic Cable into the PCB as shown below. Make sure the locking tabs are engaged. Fiber Optic for the DMC-3000 goes into the lower pair of fiber optic receptacles (U31 & U37).
Fiber Optic
Cable
Plug
Thin nut securing the through hole protector
Art # A-11998
3-20 INSTALLATION 0-5578
ULTRA-CUT 130 XT/200 XT/300 XT/400 XT
3.14 Set Switches on the Command - Control Module
Remove the power supply upper right side. Set switches on the CCM (Command-Control Module) per the illustrations. Switch settings and connection details are provided in the Appendix. Any changes made require a restart of the power supply.
!
!
CAUTION
Printed circuit boards in the Command - Control Module are static - sensitive. Discharge any built-up static charges in your body or surroundings before touching the printed circuit boards.
USB
Future Use
O
N
SW8 SW1 SW5 SW9 SW4 SW3 O
N
1 2 3 4 1 2 3 4 1 2
Switches shown in OFF position
1 2 1 2 1 2
Actual orientation
SW 8-1: Pilot Time 1 = OFF = Short (85 ms.) (Factory default setting).
1 = ON = Long (3 s.)
SW 8-2: Remote Current 1 = OFF = Disabled (Factory default setting).
1 = ON = (Remote Analog Current Control) Also set SW11 to “A” position
*SW 8-3: Auto Transfer Retry1 = OFF = Enabled Up to 3 tries (Factory default setting).
SW 8-4:
1 = ON = Disabled
OFF = Disabled (Factory default setting).
ON = Remote Marking SW Enabled at TB3-1&2
SW-1-1: Auto Pilot Restart. 1 = ON = Auto Pilot Function enabled.
1 = OFF = Auto Pilot Function disabled (Factory default setting).
SW-1-2: Pilot Delay 2 = OFF, 3 = OFF, 4 = OFF: 0 Seconds (Factory default setting).
SW-1-3: Pilot Delay 2 = ON, 3 = OFF, 4 = OFF: 0.1 Seconds
SW-1-4: Pilot Delay 2 = OFF, 3 = ON, 4 = OFF: 0.2 Seconds
2 = ON, 3 = ON, 4 = OFF: 0.4 Seconds
2 = OFF, 3 = OFF, 4 = ON: 0.8 Seconds
2 = ON, 3 = OFF, 4 = ON: 1.0 Seconds
2 = OFF, 3 = ON, 4 = ON: 1.5 Seconds
2 = ON, 3 = ON, 4 = ON: 2.0 Seconds
SW-5-1: Tip Saver Reserved for Factory use.
SW-5-2: Off Plate Reserved for Factory use.
SW-4: Postflow Time 1 = OFF, 2 = OFF: 10 Seconds (Factory default setting).
1 = ON, 2 = OFF: 20 Seconds
1 = OFF, 2 = ON: 5 Seconds
1 = ON, 2 = ON: 0 Seconds
Active only when
SW-1-1 is set to ON.
SW-3: Gas Preflow Time 1 = Off, 2 = OFF: 3 seconds
1 = ON, 2 = OFF: 4 seconds
1 = OFF, 2 = ON: 6 seconds
1 = ON, 2 = ON: 8 seconds Art # A-11890_AB
0-5578 INSTALLATION 3-21
ULTRA-CUT 130 XT/200 XT/300 XT/400 XT
!!
CAUTION
Printed circuit boards in the Command - Control Module are static - sensitive. Discharge any built-up static charges in your body or surroundings before touching the printed circuit boards.
SW11
SW6
SW12
SW13
SW-6: OK-to-Move: Contact closure, 120VAC @ 1A (Factory default setting) or
DC Volts (16-18vdc@ up to 100 ma.)
SW-11: Set “B” position, (up) for default
SW-11: Set “A” position (down) for remote analog current control. SW-8-2 must be set to “ON”.
SW-12-1/2/3/4: Divided Arc signal All = OFF = 50:1 (Factory default setting)
1 = ON = 16.6:1
2 = ON = 30:1
3 = ON = 40:1
4 = ON = 25:1
Only 1 on at a time.
SW13: Ultra-Cut Switch positions
Art # A-12016_AC
SW13 (Note position 4 is_ not yet used)
3-22 INSTALLATION 0-5578
2 - Wire and 4 - Wire settings
ULTRA-CUT 130 XT/200 XT/300 XT/400 XT
When used with the TSC-3000 the plug should be in the 2 wire (2W) position shown below. For other CNC controls using
4 wire communication such as the iCNC, place the jumper in the 4W position.
NOTE!
Failure to set in the correct position will result in no communication with the device.
4W - 2W
0-5578 INSTALLATION 3-23
ULTRA-CUT 130 XT/200 XT/300 XT/400 XT
3.15 Height Control Connections
The terminal strip provides connections to negative Arc Volts (Torch or electrode), Tip Volts (Pilot) and Work. These are for a height control that requires connection to the full non-divided arc voltage. Also available on the terminal strip are
120VAC and 24 VAC. The allowable current draw is 100ma @ 120VAC and 1Amp @ 24 VAC.
Art # A-11900
NOTE!
Wires from TB4 must not be routed between the CCM and the side panel.
TB4 1 2 3 4 5 6 7
24 VAC
@ 1A
120 VAC
@ 100 ma.
Work
Tip Volts
(Pilot)
Arc Volts
(Torch)
Art # A-11954
NOTE!
There are holes added in the rear panel for customer wiring. This, rather than the one in the
CCM will be the preferred place for customer added wiring (and strain relief) for connections to height controls, etc..
3-24 INSTALLATION 0-5578
3.16 HE400XT COOLER
ULTRA-CUT 130 XT/200 XT/300 XT/400 XT
Used in series with the existing cooling system of the Ultra-Cut XT™ series power supplies, the HE400XT Cooler provides necessary additional water cooling for the torch head when cutting at over 300amps. The HE400XT fan is thermally controlled to operate whenever the Ultra-Cut fan and pump is on and the coolant temperature is above a predetermined level.
It may come on anytime while the main pump is operating.
!
!
WARNING
Do not disassemble the Cooler with the power applied or the coolant flowing. Dangerous 220 AC voltages and high pressure liquid are present.
Locate the Cooler so that there is adequate ventilation in front of and behind the unit and do not place or stack anything on top of the unit.
0-5578
2’ (0.6 m)
3”
(76 mm)
3”
(76 mm)
2’ (0.6 m)
Art # A-12813_AB
NOTE!
Ensure the four coolant lines described below are connected and leak free before connecting power to J71.
INSTALLATION 3-25
ULTRA-CUT 130 XT/200 XT/300 XT/400 XT
Included with the HE400XT are two 10’ hoses, supply (green) and return (red), that are to be connected to the matching colors on left side of the HE400XT and to the supply and return fittings on the rear of the Ultra-Cut XT power supply. Hoses to the RAS1000XT connect on the right side of the HE400XT.
!
!
CAUTION
Do NOT cross the coolant lines as this will not provide cooling for the XT™ plasma torch as designed and void the warranty.
Attach and tighten all #6 JIC fittings with 11/16” (18mm) wrench. Do not overtighten as it will strip the fitting threads and will cause a leak. Do not start the Ultra-Cut XT™ without coolant in the reservoir. An additional gallon (3.78l) of coolant is required to compensate for the HE400XT being attached to the system. Monitor the fluid level while filling the Ultra-Cut
XT. Do not allow the coolant reservoir level to drop below minimum.
Attach the cable from J70 on the power supply to J71 on the HE400XT after the Cooler and coolant lines have been determined to be leak free.
Under low power plasma cutting the HE400XT may not come on. This is normal operation.
Periodically check obstructions in the radiator and remove them by vacuuming the fins. Do not use cleaners or fluids to remove debris, they may affect the radiator integrity.
3-26 INSTALLATION 0-5578
ULTRA-CUT 130 XT/200 XT/300 XT/400 XT
3.17 DMC-3000 Gas Manifold Control Installation
The DMC-3000 Gas Control must be installed in a suitable location where it is easily accessible to the system operator. The unit must be mounted to a flat horizontal surface. If the Module is mounted to any support subject to vibration or motion, the installer must fasten the module to the support securely.
The Module should be located as far away as possible from the Arc Starter due to possible electromagnetic interference.
It is acceptable to locate the control cable in the same track as the cables from the Arc Starter and away from torch leads.
The Module includes feet which lift the bottom panel of the mounting surface. Louvers on the back panel of the module must remain unblocked, for the free passage of ventilating air.
Mounting Dimensions
DMC-3000 Profile
DMC-3000 Top
13.60 in
[345.6 mm]
7.08 in
[179.8 mm]
5.00 in
[127.0 mm]
.30 in
[7.62 mm] 11.44 in
[290.6 mm]
12.18 in
[309.4 mm]
Art # A-09459
0-5578 INSTALLATION 3-27
ULTRA-CUT 130 XT/200 XT/300 XT/400 XT
Preparation
1. Remove the screws securing the Cover Panel to the Module.
Remove 2 Screws
Loosen or remove 2 screws
Cover Removal
2. Carefully remove the cover from the module noting the attached wire harness that connects to J1. Remove the wire harness and then set the cover to the side.
Art # A-09140
3-28 INSTALLATION 0-5578
ULTRA-CUT 130 XT/200 XT/300 XT/400 XT
3. Attach all hoses and cables to the front of the DMC-3000 except the Fiber Optic cable which will be covered a little later. Avoid turning any fittings already mounted in the unit by placing a wrench on it before tightening the hose fitting to it.
Art # A-09141_AB
NOTE!
Argon must be used for the “Marking” gas. If replacing existing fittings in the base, apply thread sealant to the fitting threads, according to manufacturer’s instructions. Do not use Teflon tape as a thread sealer, as small particles of the tape may break off and block the small air passages in the torch.
NOTE!
If you need to replace a gas or water fitting all inlets and outlets of the aluminum manifold are 1/4”
NPT (United States National Pipe Thread) into which are screwed the various adapters.
4. Connect the ground cable to rear of DMC-3000 shown in previous illustration.
5. Connect Control cable from the Power Supply to J56 on the front of the DMC-3000 as shown below. The Fiber Optic cable will be covered a little later.
0-5578 INSTALLATION
Art # A-09142_AB
3-29
ULTRA-CUT 130 XT/200 XT/300 XT/400 XT
6. Install WMS Water Softener Kit in the line that feeds the inlet side of the DMC-3000. Mount the softener and bracket on the power supply where the provided 2’ hose can reach to the DMC-3000. Mounting in another location is possible with a customer provided hose. Below is typical customer added hose and installation.
7. Make sure that the hose going to the DMC-3000 is connected to the port on the WMS Water Softener marked “OUT” and the incoming water supply connected to the port marked “IN”. Do not mount over any electronics or outlets in case of leaks during operation or spills when changing the element at a later date.
3-30 INSTALLATION 0-5578
ULTRA-CUT 130 XT/200 XT/300 XT/400 XT
3.18 DPC-3000 Gas Pressure Control Installation
The DPC-3000 Gas Control must be installed in a suitable location close to the Torch such as the gantry. The unit must be mounted to a flat horizontal surface. If the Module is mounted to any support subject to vibration or motion, the installer must fasten the module to the support securely.
The Module should be located as far away as possible from the Arc Starter due to possible electromagnetic interference. It is acceptable to locate the control cable in the same track as the cables from the Arc Starter and away from torch leads.
The Module includes feet which lift the bottom panel off the mounting surface. Louvers on the back panel of the module must remain unblocked, for the free passage of ventilating air.
The Module also comes with non metallic isolation grommets for mounting. These must be used in all four mounting slots to raise the Module so there is no metal to metal contact between the Module and the mounting surface in order to reduce the chance of EMI interference.
Mounting Dimensions
DPC-3000 Profile DPC-3000 Top
10.90 in
[276.86 mm]
6.64in
[168.7mm]
4.00 in
[101.6 mm]
.30 in
[7.62mm]
Art # A-09143
10.45 in
[265.4 mm]
11.00 in
[279.4 mm]
0-5578 INSTALLATION 3-31
ULTRA-CUT 130 XT/200 XT/300 XT/400 XT
Preparation
1. Remove the screws securing the Cover Panel to the Module.
Remove 2 Screws
Loosen or remove 2 screws
2. Carefully remove the cover from the module noting the attached wire harness that connects to J4. Remove the wire harness and then set the cover to the side.
Art # A-09145
3-32 INSTALLATION 0-5578
ULTRA-CUT 130 XT/200 XT/300 XT/400 XT
3. Attach all hoses and cables to the back of the DPC-3000 except the Fiber Optic cable which will be covered a little later. Avoid turning any fittings already mounted in the unit by placing a wrench on it before tightening the hose fitting to it.
Do not connect Fiber Optic cable until later
Art # A-09146_AB
4. Connect hoses from the front of the DMC-3000 where shown below to the torch.
NOTE!
One fitting with the notches is left hand thread and the other is standard right hand thread.
0-5578
Do Not Block Vent
Art # A-09147_AB
INSTALLATION 3-33
ULTRA-CUT 130 XT/200 XT/300 XT/400 XT
3.19 Fiber Optic Cable Installation from CCM to DMC-3000
!
!
CAUTION
Avoid kinking, twisting, or bunching the fiber optic cable. The cable can be damaged by being forced into tight-radius turns. Review section 3.10 for proper handling and installation of fiber optic cable.
1. Remove outer thin nut from through hole protector at the end of Fiber Optic Cable (L) that is connected to the CCM.
2. Ensure that the cable is exposed beyond the through hole protector approximately 1” (as shown below) and secure by tightening the wide nut with the rounded end while holding the other nut in place. Normal hand tightening is not enough.
3. Feed the Fiber Optic Cable plug and wires through the hole where shown then slide the thin nut back over the
Fiber Optic Cable.
Art # A-09148_AB
3-34 INSTALLATION 0-5578
ULTRA-CUT 130 XT/200 XT/300 XT/400 XT
4. Secure the thin nut on the through hole protector so both nut faces are tight against the sheet metal inside and out.
Art # A-09149_AB
5. Plug the Fiber Optic Cable into the PCB as shown below. Make sure the locking tabs are engaged.
Fiber Optic Cable to/from
CCM plugs in here
Art # A-11999
0-5578 INSTALLATION 3-35
ULTRA-CUT 130 XT/200 XT/300 XT/400 XT
3.20 Fiber Optic Cable Installation From DMC-3000 to DPC-3000
1. Remove outer thin nuts from through hole protector at both ends of Fiber Optic Cable (L) that connects between the DCM-3000 and DPC-3000.
!
!
CAUTION
Avoid kinking, twisting, or bunching the fiber optic cable. The cable can be damaged by being forced into tight-radius turns.
2. Ensure that the outer protective hose/cable is exposed beyond the through hole protector approximately 1” and secure by tightening the wide nut with the rounded end while holding the other nut in place. Normal hand tightening is not enough.
3. Feed the Fiber Optic Cable plug and wires through the back of each module (DMC-DPC) where indicated and slide the thin nut back over the Fiber Optic Cable.
Fiber Optic for
DMC-3000 goes here
Insert Fiber Optic cable here
Art # A-09152_AB
Art # A-09153_AB
4. Secure each of the thin nuts on the through hole protectors so both nut faces are tight against the sheet metal inside and out.
3-36 INSTALLATION 0-5578
ULTRA-CUT 130 XT/200 XT/300 XT/400 XT
5. Plug the Fiber Optic Cable into the PCB as shown below for the DMC-3000. Make sure the locking tabs are engaged.
Plug Fiber Optic cable to/from DPC-3000 here
Art # A-09154
6. Plug the Fiber Optic Cable into the PCB as shown below for the DPC-3000. Make sure the locking tabs are engaged.
Fiber Optic to/from DMC-3000 plugs in here
7. Reinstall the Cover Panels making sure the wire harnesses are attached.
Art # A-09155
0-5578 INSTALLATION 3-37
ULTRA-CUT 130 XT/200 XT/300 XT/400 XT
3.21 Install TSC-3000 Touch Screen Control
Mounting Dimensions
TSC-3000 Top
TSC-3000 Profile
1.11 in
[28.2 mm]
2.35 in
[59.69 mm]
5.58 in
[141.7 mm]
.25 in
[6.35 mm]
6.99 in
[177.5 mm]
10.83 in
[275.0 mm]
11.80 in
[299.7 mm]
12.45 in
[316.2 mm]
Art # A-09156
Preparation
1. Select a clean, dry location with good ventilation and adequate working space around all components. Review the safety precautions in the front of this manual to be sure that the location meets all safety requirements. The
TSC-3000 mounting brackets allow for mounting on or under a horizontal surface as well as left or right of a vertical surface. Choose which ever works best for protection against moving equipment and flying metal/cutting debris etc..
2. Once the unit has been secured to a flat surface, attach Communication cable (“V” which is already attached to J54 on the unit’s rear panel done in sub section 3.10) and ground cable (“F”) to the rear of the unit.
NOTE!
Make sure the CCM CPU jumper is set to 2 Wire (2W) noted earlier in section 3.15 and in the
Appendix.
Art # A-09157_AC
Ground Cable to/from
“Star” ground on table
Communication Cable to/from
CCM rear of power supply
3-38 INSTALLATION 0-5578
3.22 Install Remote Arc Starter
ULTRA-CUT 130 XT/200 XT/300 XT/400 XT
Site Location
Select a clean, dry location with good ventilation and adequate working space around all components.
Review the safety precautions in the front of this manual to be sure that the location meets all safety requirements.
Interconnecting cables and hoses attach to the Arc Starter. There must be adequate space around the Arc Starter for these connections without excessive kinking or bending.
Mounting Dimensions
NOTE!
Height not shown is 7.375” ( 187mm )
38.10mm
1.50in
190.50mm
7.50in
50.80mm
2.00in
203.20mm
8.00in
Art # A-12058
50.80mm
2.00in
38.10mm
1.50in
0-5578 INSTALLATION 3-39
ULTRA-CUT 130 XT/200 XT/300 XT/400 XT
Installation
The Remote Arc Starter must be installed in a suitable location near the torch head. If the Arc Starter is mounted to a gantry or to any other support subject to motion or vibration, fasten the Arc Starter to the support securely.
1. Loosen, but do not remove, the lower screws securing the cover to the Arc Starter. Remove the upper screws securing the Cover Panel to the Arc Starter.
NOTE!
A ground wire connects the cover to the Arc Starter base. This wire must remain in place.
2. Remove the Cover Panel from the Arc Starter.
Upper screws (2 per side)
Cover
Ground Wire
Lower screws
(2 per side)
Art # A-12059
Cover Removal
3. Position the Arc Starter on a flat, horizontal mounting surface.
4. Use pre-drilled holes in at least two of the feet on the bottom of the Arc Starter to secure the Arc Starter to the mounting surface.
Minimum 2
Art # A-12060
3-40 INSTALLATION 0-5578
Input Connections
ULTRA-CUT 130 XT/200 XT/300 XT/400 XT
1. Refer to the illustrations. Make the following input connections to the Arc Starter.
• Coolant Supply and Return Hoses (from HE-400 Heat Exchanger). Hoses and connectors are color-coded; Red for Return, Green for Supply.
Art # A-12061
Coolant Supply and Return Hoses
(from power supply)
Return
Supply
Art # A-12062
Red
Coolant Return (Red)
Coolant Supply (Green)
Green
0-5578 INSTALLATION 3-41
ULTRA-CUT 130 XT/200 XT/300 XT/400 XT
2. Refer to illustration. Connect the Pilot wire and Negative cables using a star washer on each.
NOTE!
* Slave and Master refer to only those set ups using two power supplies in parrallel. Slave is not used in single system operations.
*Negative (Slave)
Pilot
*Negative (Master)
Torch Lead
Art # A-12063_AB
Negative Master, Negative Slave and Pilot Cables (from Power Supply )
Art # A-12064
Control Cable from Power Supply rear panel
3-42 INSTALLATION 0-5578
Output Connections
ULTRA-CUT 130 XT/200 XT/300 XT/400 XT
1. Refer to the illustrations. Make the following output connections to the Arc Starter.
Pilot Lead
Coolant Return (Red)
Coolant Supply (Green)
Red
Green
Art # A-12065
Pilot Return Cable, Coolant Supply and Return Hoses (from Torch)
2. Reinstall the Arc Starter Cover. Ensure that the ground wire is not crimped between the cover and the base.
Upper screws (2 per side)
Cover
Ground Wire
Lower screws
(2 per side)
Art # A-12059
0-5578 INSTALLATION 3-43
ULTRA-CUT 130 XT/200 XT/300 XT/400 XT
3. The Arc Starter must be grounded; the grounding terminal is marked . Minimum of 1/O size wired directly to the star ground. Refer to the previous section for grounding details.
Art # A-04758
Torch Leads
1 Nut and 1 Washer
Remain in Place
Ground Cable
4. Use a clamp to secure the Torch Lead Shield braid brass ring to the port on the Remote Arc Starter as shown.
Art # A-04759
Torch Leads Shield
Shield Clamp
Coolant and Pilot Leads to Torch Valve Assembly
3-44 INSTALLATION 0-5578
ULTRA-CUT 130 XT/200 XT/300 XT/400 XT
Connect Control Cable
1. Connect the Remote Arc Starter cable to the Remote Arc Starter receptacle.
J55 - GCM
USER INPUT
J15 - CNC
HEIGHT CONTROL
J54 - TSC /COMM
J59 - RAS
J70 - HE
F1 - 8A SB 230 VAC
CB2 - 5A 120 VAC
CB3 - 5A 24 VAC
CB4 - 5A 120 VAC
F2 - 8A SB 230 VAC
Art # A-12067
0-5578 INSTALLATION 3-45
ULTRA-CUT 130 XT/200 XT/300 XT/400 XT
3.23 Connecting Torch
Connect the Torch as follows:
Coolant Supply,
Coolant Return, and Pilot Leads
Leads Cover
Torch Leads End Cap
Groove for O-Ring
Pilot Lead
Shield Gas
(Right Hand Thread)
Mounting Tube
Plasma Gas
(Left Hand Thread)
To Torch Valve
Coolant Supply
&
Power Lead (-)
Pilot Lead Connector
Torch Head Assembly
Art # A-09198_AB
1. Lay out the torch leads on a clean, dry working surface.
2. Hold the Torch Leads End Cap stationary. Pull approximately 18” (0.5 m) of leads through the End Cap.
3. Remove and discard the protective end caps from the Mounting Tube.
4. Install the O-ring in the groove at the upper end of the Mounting Tube.
5. Install the Mounting Tube as follows: a. Position the Mounting Tube at the end of the leads assemblies as shown. b. Slide the Mounting Tube upward onto the leads assemblies.
c. Press the upper end of the Mounting Tube into the lower end of the Torch Leads End Cap. Ensure that the O-
Ring on the Tube engages the mating groove inside the Torch Leads End Cap.
d. Ensure that the Mounting Tube is free to rotate within the Torch Leads End Cap.
6. Connect the gas and coolant leads to the Torch Head. a. Coolant supply and return connections to the Torch Head are of different lengths.
b. Plasma and secondary gas connections to the Torch Head are threaded differently; the plasma gas connection is left-hand thread, the shield gas connection is right-hand thread.
c. Hold the Torch Head leads connectors stationary; turn the leads fittings with a wrench to secure the leads to the Torch Head. Do not overtighten.
!!
CAUTION
The gas and coolant leads include compression fittings. Do not use sealant on these connections.
Slowly apply pressure to the gas lines. Check for leaks at all connections before continuing. If there are no leaks, shut off the gas supplies and continue with installation.
3-46 INSTALLATION 0-5578
ULTRA-CUT 130 XT/200 XT/300 XT/400 XT
7. Connect the pilot lead to the Torch Head. Press the two ends of the connector firmly together. Thread the plastic lead cover/connector onto the mating Torch Head connector.
8. Press the Torch Head Assembly upward to connect to the Mounting Tube. Pull the leads back as needed to ensure a proper fit through the Mounting Tube and Torch Leads End Cap. Hold the Torch Head Assembly stationary; rotate the Mounting Tube to thread it onto the Torch Head.
!
!
CAUTION
Ensure that the leads do not twist within the mounting tube. Leads must lie as shown in the installation sketch
9. The lower end of the Mounting Tube includes four threaded holes. Install an Allen set screw in any of the threaded holes to secure the Torch Head Assembly to the Mounting Tube.
10. Install the appropriate consumable parts as shown on the following pages. The torch manual includes diagrams showing the correct parts to install, depending on the metal to be cut and the gases in use.
3.24 Install Consumable Torch Parts
Install the consumable parts as follows to ensure proper operation. These steps will help ensure that parts are seated correctly.
WARNINGS
Do not install consumables into the Cartridge while the Cartridge is attached to the Torch Head.
Keep foreign materials out of the consumables and Cartridge.
Handle all parts carefully to avoid damage, which may affect torch performance.
Art # A-03887
Consumable Assembly Video Links
15-150A MS, 30-300 SS and AL
200A MS
300/400 A MS, 150A/200A bevel parts https://www.youtube.com/watch?v=JLkgjJ8F5eE https://www.youtube.com/watch?v=kgi_qf6a9i0 https://www.youtube.com/watch?v=5Se_YOX3DGM
1. Check the appropriate cut chart for the right combination of parts for the cutting application.
2. Check that the shield cup is properly secured to the cartridge
3. Stack the consumable parts together.
Art # A-14052
Shield
Retainer
Shield
Shield G
Distr as ibut or
Tip as
Plasma G ibut or
Elec trode
Shield C up
Car tridge
0-5578
A
1 - Tighten “C” .
2 - Assemble “B”.
B
3 - Assemble “B” to “C”.
C
4 - Assemble “A” to “B-C” assembly.
INSTALLATION 3-47
ULTRA-CUT 130 XT/200 XT/300 XT/400 XT
4. Insert the stack of consumable parts into the cartridge. Half of the flat portion of the outer most part of the Shield
Gas Distributor should be hidden when parts are properly seated.
5. Use the cartridge tool to hold the cartridge assembly, while turning the shield cup onto the cartridge assembly.
Turn the shield retainer onto the shield cup. When this group is fully assembled, the shield should protrude from the front of the shield retainer. Without this protrusion the shield cup is not properly tightened onto the cartridge assembly.
6. Take the cartridge tool off the cartridge. Fit the cartridge assembly onto the torch head.
7. Align and install the torch cartridge onto the torch body. Turn the locking collar by hand only. Stop anywhere within the length of that slot.
Art # A-14038
3-48 INSTALLATION 0-5578
ULTRA-CUT 130 XT/200 XT/300 XT/400 XT
8. Slide the ohmic clip over the shield cup if using ohmic torch height control sensing.
Ohmic Clip
Art # A-03393_AB
9. Connect the wire lead from the height finder to the ohmic clip.
3.25 Voltage Divider for iHC Torch Height Control
For best plasma cutting performance it is necessary to maintain a constant height (standoff) above the metal while cutting. Cutting tables use a Torch Height Control (THC), also called a Z axis control, most of which use feedback from the arc voltage to control the height. Several of these, including the iHC, part of the Victor Technologies XT CNC Controller, come with a Voltage Divider Printed Circuit Board that has to be installed inside the plasma power supply to divide the high arc voltage down to lower levels for use with control circuits.
There is a space for mounting the V-D Board located on the upper portion of an internal vertical panel near the rear of the power supply. Predrilled holes for mounting the iHT V-D board as well as another popular height control are provided.
!!
CAUTION
If using another board that doesn’t align with the existing holes, remove the panel if possible before drilling. If not possible then every precaution must be taken to keep metal filings from being deposited inside the power supply.
Install the V-D Board.
1. Locate the V-D Board which should be with the iCNC.
2. Inside the Power Supply, locate and remove the mounting panel’s 2 screws and panel.
3. Install the V-D board standoffs and the V-D Board from the XT iCNC then reattach the panel with the 2 screws, securing the V-D board in place. If using another V-D Board, follow the instructions provided mounting it in this same location.
Space for V-D Board Ohmic clip cable port
V-D Board installed
0-5578
V-D Board connection
V-D Board shown with optional wire harness for iHC controller
Art # A-12079
INSTALLATION 3-49
ULTRA-CUT 130 XT/200 XT/300 XT/400 XT
Control Cable.
The iHC board can be supplied with a wire harness and connector (shown in previous image), to be installed in the rear panel hole labeled “Height Control” . The connector mates with a cable from the iHC. For other height control V-D boards a strain relief can be installed in this hole for those cables. Refer to Appendix for wiring diagram.
J55 - GCM
USER INPUT
J15 - CNC
HEIGHT CONTROL
Ohmic clip cable port
V-D Board connection
J54 - TSC /COMM
J59 - RAS
J70 - HE
F1 - 8A SB 230 VAC
CB2 - 5A 120 VAC
CB3 - 5A 24 VAC
CB4 - 5A 120 VAC
F2 - 8A SB 230 VAC
Art # A-12080
Arc Voltage Connections.
The XT plasma supplies provide a terminal strip, TB4, on the right side ahead of the CCM module for connections to Arc
V- (Torch); Tip V (Pilot); Arc V + (Work). If the V-D board requires separate power, 24 VAC and 120 VAC is available on the terminal strip TB4. Refer to the wiring diagram in the Appendix for more information.
NOTE!
Wires from TB4 must not be routed between the CCM and the side panel.
TB4 1 2 3 4 5 6 7
24 VAC
@ 1A
120 VAC
@ 100 ma.
Work
Tip Volts
(Pilot)
Arc Volts
(Torch)
Art # A-11954
“Ohmic” or Shield (cup) cable.
Some height controls including the iHC find the plate using an electrical or resistance measurement, thus “ohmic”, contact between the conductive end of the torch and the metal or “plate” being cut. A wire, usually a single highly flexible wire that withstands the reflective heat from the arc, is connected between the V-D board and the torch shield cup. The XT torch includes a metal spring clip which slips into a groove in the shield cup allowing easy removal for parts change. The Ohmic wire can be connected to this clip with a ¼” female push-on terminal.
Significant amounts of high frequency (HF) energy causing electromagnetic interference (EMI) can be conducted along this wire due to it’s close coupling to the torch. This is the reason for mounting the V-D board away from the CCM and close to the rear panel where the Ohmic wire does not need to pass near other sensitive electronics. It is especially recommended that the Ohmic wire not be routed near the CCM module or along the torch leads.
Refer to Appendix for wiring diagram.
Ferrite cores.
It is recommended that the Ohmic Sensing wire be wrapped through a ferrite core with several turns, at least 3 but more is better, to reduce the energy conducted to the V-D board and into the plasma supply. The ferrite core should be located
3-50 INSTALLATION 0-5578
ULTRA-CUT 130 XT/200 XT/300 XT/400 XT on the wire where it enters the plasma supply. A second ferrite core added several feet (couple of meters) from the torch will further reduce the conducted EMI that may couple to other cable/wires and cause interference.
Refer to Appendix for wiring diagram.
3.26 Complete the Installation
1. Remove the cap from the coolant tank. Fill the coolant tank to the level shown, with Thermal Dynamics coolant.
The coolant level is visible through the translucent coolant tank. The amount of coolant required varies with torch leads length.
Cat. Number and Mixture
7-3580 ‘Extra-Cool™’
7-3581 ‘Ultra-Cool™’
7-3582 ‘Extreme Cool™’
Coolant Capabilities
Mixture
25 / 75
50 / 50
Concentrate*
* For mixing with D-I Cool™ 7-3583
Protects To
10° F / -12° C
-27° F / -33° C
-76° F / -60° C
Coolant Tank
Fill Range
Art # A-11536
2. After the complete system has been installed, check that the coolant has been pumped through the system as follows (see NOTE):
NOTE!
Depending on the length of the torch leads, the system may require more coolant after turning the system ON for the first time.
a. Place the ON/OFF Switch to ON.
b. After about 4 minutes the system may shut down if the leads are not full of coolant.
c. Place the ON/OFF switch to OFF. Add more coolant if needed d. After 10 seconds place the ON/OFF switch to ON again.
0-5578 INSTALLATION 3-51
ULTRA-CUT 130 XT/200 XT/300 XT/400 XT e. Repeat steps ‘b’ through ‘d’ until the system no longer shuts down. Depending on the length of the torch leads this sequence may need to be repeated.
f. After the system stays operational allow the pump to operate for ten minutes to properly purge any air from the coolant lines before using the system.
3. Refill the reservoir and reinstall the filler cap.
4. Purge coolant from the torch before firing the torch. Ensure there are no leaks before use. If leaks are evident, consult the coolant leak troubleshooting guide in the maintenance section of this manual.
3-52 INSTALLATION 0-5578
ULTRA-CUT 130 XT/200 XT/300 XT/400 XT
SECTION 4: OPERATION
4.01 Power Supply Control Panel
AC Indicator Gas Indicator
Temp Indicator DC Indicator
A/ Status Indicator
A/
Art # A-11541_AC
AC Power Lamp
Indicates unit has passed the input power tests and AC power is being supplied to the inverter modules via the input contactor when the ON/OFF switch is in ON position.
TEMP Lamp:
Normally OFF. Lamp will come ON when the internal temperature sensors detect temperatures above normal limits.
Let the unit cool before continuing operation.
GAS Lamp:
Flashing during start up gas purge/pump priming, then steady whenever gas is flowing. Indicates adequate gas pressure and coolant flow for operation.
DC Lamp:
Indicates the power supply is generating output DC voltage.
A/
Status Indicator:
Shows CCM code version on start up followed by the Current Control setting and system status. Refer to Section 4.05 and Status Code Section for details.
Rear Panel AC Power Lamp
Indicates AC power is present inside the unit.
0-5578 OPERATION 4-1
ULTRA-CUT 130 XT/200 XT/300 XT/400 XT
4.02 System Operation
This section contains operating information which is specific to the power supply.
WARNING
Review the safety precautions in Section 1.
If the power supply cord has a plug or is not permanently connected to power, be sure the power to the outlet is disconnected when inserting the plug into the outlet.
Disconnect primary power at the source before assembling or disassembling power supply, torch parts, or torch and leads assemblies, or adding coolant.
It is not enough to simply move the ON/OFF switch on the unit to OFF position when cutting operations have been completed. Always open the power supply disconnect switch five minutes after the last cut is made.
NOTE!
Prior to starting the system determine the process to be used. The process is determined by the type and thickness of the metal to be cut. Select and install the required consumables, connect the required gasses to the system.
1. Connect system to primary input power. An indicator will light on the rear panel when AC power is applied to the unit. Place the Plasma Enable Switch (TSC 3000; user installed Plasma Enable/E-Stop) in the “Enable” position
2. Turn ON/OFF switch to ON (up) position. System goes through the “Start up Sequence”.
• For about 10 seconds the decimal points of the 4 digit display blink from right to left.
• Next the 4 rectangular LED indicators and the 4 status display digits illuminate all segments as a test.
• Then for about 6 seconds the display shows the letter “C” (code) followed by the CCM code version. Example
“C1.2.0” . During this time various input voltage tests are being performed. If a fault is found its code is displayed and the start up sequence halts. Faults will show “E” or “L”. If Plasma hasn’t been Enabled by this point, E101 will be displayed and the startup sequence will not proceed.
• The coolant pump starts, the Gas LED indicator blinks and the display shows “0” indicating no cutting process has been loaded.
• If the unit is disabled, Plasma Enable shut off, the pump doesn’t start and display alternates between status code
E101 and “0”.
• Assuming the unit is not disabled, as soon as adequate coolant flow is detected, usually in about 5 seconds, the
Gas LED stops blinking and the contactors close and the AC LED Indicator lights.
• If there are bubbles in the coolant code E406 may be displayed alternating with “0” until the bubbles clear up.
This is a warning and you can continue.
• If flow is not detected, the pump will run and the Gas LED blinks until flow is detected or for up to 4 minutes at which time the pump stops and the display shows E404 indicating proper coolant flow was not obtained.
• Now select and load the cutting process using the TSC 3000 or the program included in the CNC control. Once the process is loaded a gas purge begins. Purge time varies with the torch lead length and the cutting process.
See section 4.03 to 4.08 for details of using the TSC 3000 or the CNC manual for embedded programs. Also refer to section 4.09 for a more detailed Sequence of Operation.
4-2
ULTRA-CUT 130 XT/200 XT/300 XT/400 XT
• During the gas purge the Gas LED will blink and the display will show E304 alternating with the cutting current indicating a gas purge is in progress. E304 goes away and the Gas LED stops blinking at the end of the gas purge.
A purge is also initiated, with E304 and blinking Gas LED, when the unit is enabled following a disable. Does not require loading the process again.
I
POWER
OFF
O
O
OFF
O
OFF
O
ON
OFF
Art # A-11542
4.03 TSC-3000 Navigation Functions
PAGE HEADER
Art # A-09158
SELECTION NAVIGATION
:
MOVES CURSOR / SELECTION UP
AND DOWN ON THE PAGE OR
SCROLLS TEXT IN DIALOG BOX
WINDOW
+
System Status: IDLE
BACK BUTTON
:
REVERSES TO THE PREVIOUS PAGE
INCREMENTS / DECREMENTS THE
DISPLAYS SYSTEM STATUS IN ALL SCREENS SELECTED VALUE
ACCEPTS ENTRIES AND MOVES TO THE
NEXT PAGE
0-5578 OPERATION 4-3
ULTRA-CUT 130 XT/200 XT/300 XT/400 XT
4.04 TSC-3000 Initial Setup ONLY
Initial steps required before First operation only. Note 400 Amp system requires a Height Controller with Elevation Height
(EH) feature.
HOME ENTER/CHANGE PASSWORD
When power is turned on
TSC 3000 goes to the Home screen. For new installation it is required to perform initial SETUP.
Press SETUP button (1).
Enter Initial default
PASSWORD 00000 (2)
1
2
SETUP
1a
Select language and measurement units.
Enter SYSTEM UTILITY
(3).
To change Password press
SET PASSWORD enter new 5 digit password (1a).
Press green arrow to accept new password and return to
SETUP screen (2).
3
UTILITY 1 of 3
Enter XT lead (DPC to Torch); only 4’ currently allowed.
Enter DFC 3000 lead length (DMC to DPC);
Set Elevation Height Support to “Yes” if height control supports that feature.
Elevation Height Feature is required for the
Ultra-Cut 400
4
UTILITY 2 of 3
UTILITY 3 of 3
Utility Screen 2 is for information only.
Displays Device and
Cutchart IDs, setting of options switches etc.
5
Utilit y screen 3 (5) allows viewing consumable statistics,
Starts, Hours, Errors.
Return to Home Screen.
Art # A-09656
4-4
4.05 TSC-3000 Selecting New Process
ULTRA-CUT 130 XT/200 XT/300 XT/400 XT
Select new standard process by material; thickness; amperage (1) or enter process # using pop-up number pad (2).
HOME
SELECT MATERIAL, THICKNESS
Material –
Scroll to select,
Thic kness –
Scroll to select,
2
SELECT PROCESS NUMBER
A ccept & advance (1).
1
Select process by # (2) or by name (3).
If by name, first select process type; best cut, fastest, MAX Pierce, etc.
Then press
To accept &
advance to Torch
Consumables. (4
).
3
SELECT PROCESS
TORCH CONSUMABLES
4
Confirm the listed torch consumables are installed in the torch.
Go to THC / CNC settings for cutting (5).
5
6
THC / CNC Settings (Cutting)
PROCESS MONITOR
THC / CNC Settings (Marking)
Toggle between Cut &
Marking settings (6).
Proceed to Process Monitor
(7).
7
Now you are ready to start cutting. Displayed Amps Demand is the output current setting, not the actual current.
As soon as Start is applied Process Monitor shows output voltage, gas pressures, status of Start, OK to Move and Gas On signals. Here you can toggle between Plasma
Marking with the selected consumables and cutting.
0-5578 OPERATION 4-5
ULTRA-CUT 130 XT/200 XT/300 XT/400 XT
4.06 TSC-3000 Selecting Recently Used Process
Home screen shows some of the most recently used processes with the last one used highlighted. Select the highlighted process by pressing the Green arrow or scroll with up/down arrows to select another recent process then press the green arrow.
HOME
Check that you have the correct torch consumables. (1)
If yo u already know the settings and consumables you can go directly to
Process Monitor using
CUT MONITOR button.
(1a).
1a
THC / CNC Settings
Use SHOW CUTTING
& SHOW MARKING to toggle between views of cutting & marking settings.
Proceed to
Cut Monitor (3)
3
Go to THC / CNC Setting to see recommended Torch
Height Control and CNC settings; (2)
2
Art # A-09161
CUT MONITOR
N ow you are ready to start cutting. Displayed Amps Demand is the output current setting, not the actual current.
As soon as Start is applied Process Monitor shows output voltage, gas pressures, status of Start, OK to Move and Gas On signals. Here you can toggle between Plasma
Marking with the selected consumables and cutting.
4-6
4.07 TSC-3000 Creating a Custom Process
ULTRA-CUT 130 XT/200 XT/300 XT/400 XT
Considerable effort has been made to define the best parameters for each cutting and marking process. However for various reasons, variations in material composition, variations in cutting table performance, user preferences, etc. you may desire to modify one or more processes. Or perhaps you want to keep the same cutting current and gas pressures but save different
THC / CNC parameters such as cutting speed, arc voltage, pierce height, etc. That will still be treated as a custom process.
Creating a Custom Process starts with an existing standard process. From there you may adjust the cutting current and the gas pressures. It’s up to you to determine and enter the correct values. There no limits in these values, if you change too far it may cause faults.
You may also change the values displayed on THC/CNC Settings screen. THC / CNC settings on the TSC-3000 at this time are for information only. They do not connect to the THC or CNC so do not automatically modify setting in those devices.
Still, when you determine the correct values for your modified (custom) process you may want to record them here.
The custom process will have the same name as the standard base process but it will be automatically assigned a new number and the whole name and number will be in red text wherever it appears.
You cannot change the gas type. If you want a different gas types find a standard process that uses those types and edit it.
0-5578 OPERATION 4-7
ULTRA-CUT 130 XT/200 XT/300 XT/400 XT
First step is to select a standard process. Usually you want a process that is for the same metal type and thickness that you want to cut. From the HOME screen you may select a recent process (sect 4.06, Selecting Recently Used Process) or a new process (sect 4.05, Selecting New Process).
HOME CUSTOM PROCESS SETUP
Customize Recent Cut.
Highlight the process closest to what you want to use then press CUSTOM CUTS button.
Or
Select NEW CUT then
MATERIAL & THICKNESS.
SELECT MATERIAL/THICKNESS
SELECT CUT
Select value to change using UP/DN arrows. Change value with +/- buttons.
Shows
List of consumables to use.
If the custom process requires different setting, speed, arc voltage, etc. , edit it here.
Editing the THC / CNC
SETTING is for reference only, does not change the actual THC or CNC setting.
That must be done on the
THC or CNC.
TORCH CONSUMABLES LIST
CUSTOM THC/CNC SETTINGS
CUT MONITOR
Art # A -09162
Going to the Cut Monitor loads the new custom process with its name/number in red. Following purging of the new process you are ready to cut. Your custom process will appear in the recent cuts menu in red.
4-8
ULTRA-CUT 130 XT/200 XT/300 XT/400 XT
4.08 Back up and Restoration of Custom Processes
Users can create their own custom cut processes. These can be lost by accidentally deleting them on the TDC 3000 or they can be over written when updating programs. They can also be lost if the DSC 3000 should be replaced. We recommend you back up your custom processes every time a new one is created. To back up you will need a USB Flash drive.
Backing Up Custom Process:
1. For the remotely mounted DSC 3000 insert the flash drive in the USB connector on the back. If using the TSC 3000 mounted in the plasma supply front panel the USB connector is in the front under the clear plastic protective screen.
2. Go to the HOME screen. Select SETUP. Enter the 5 digit password (00000) unless you’ve changed it.
3. Press button “Back Up Custom>USB”
4. Very quickly, depending on how many custom processes there are, you should see along the bottom of the screen the message “Copy to D:\TD\CustomFiles\Complete” at which point you can remove the flash drive.
Art # A-09234_AB
0-5578 OPERATION 4-9
ULTRA-CUT 130 XT/200 XT/300 XT/400 XT
Restoring Custom Processes:
During file backup (see previous process) a folder and sub folders called “TD” were placed on your flash drive. You should copy this folder with its subfolders to some secure place. Making more than one copy is advised. If the need arises to restore from this backup, place the entire TD folder in the root directory (not in another folder) on a USB flash drive and plug it into the USB port on the TDC 3000.
1. For the remotely mounted DSC 3000 insert the flash drive in the USB connector on the back. If using the TSC 3000 mounted in the plasma supply front panel the USB connector is in the front under the clear plastic protective screen.
2. Go to the HOME screen. Select SETUP. Enter the 5 digit password (00000) unless you’ve changed it.
3. Press the “Restore Custom <USB.
Art # A-09235_AB
4. Shortly, almost instantly if only a few files, you should see at the bottom “Status: Copy to .\Files\Custom/Complete” then you can remove the USB flash drive.
4-10
Renaming Custom Files
ULTRA-CUT 130 XT/200 XT/300 XT/400 XT
You cannot rename the files while on the TSC 3000 but once you backup a file on the flash drive you can use a computer to rename the file on the flash drive and perform the restore to put the renamed file back on the TSC 3000.
1. Use Windows Explorer to find the folder TD in the root directory of the flash drive. Then find and open the folder
CustomFiles. Here you will find all the custom processes saved.
Art # A-09236
2. Use Windows Rename to change the file name to whatever you want. Do not change the file extension (.cus) or the file number in the brackets! Suggest not making the name too long as the TSC 3000 screen is limited in the number characters on one line. Here I’ve renamed the top file.
Art # A-09237
3. Now put the flash drive with the renamed file back into the TSC 3000 and perform the file restore.
4. Go back to the Home screen. You will find your new file name (John Doe’s) and the old name with the same file number [20392]. They are the same process, either one will work. You can delete the file with the old name if you don’t want both of them showing.
0-5578 OPERATION 4-11
ULTRA-CUT 130 XT/200 XT/300 XT/400 XT
4.09 Sequence of Operation
Ultracut with DFC 3000 using TSC 3000
The purpose of this section is to explain the steps an operator should follow when using the DFC 3000 with the TSC 3000 touch screen control panel for a specific cutting process. Also included are steps to follow for changing torch consumables.
NOTE!
For units not using the TSC 3000 where control is embedded into the cutting table controller most of this sequence still applies except for the parts that are specific to the TSC 3000. For those sections refer to the cutting table controller documentation.
NOTE!
When the TSC 3000 is installed, J14 on the CCM must be set for 2 Wire communication. For units not using a TSC 3000, determine if the communication requires 2 wire or 4 wire communication and set accordingly. The XT iCNC controller requires 4 wire setting. See section 3.13 and the Appendix.
This assumes the system setup; language and units, lead lengths, etc., have already been performed by the installer and the system is confirmed as operational.
1. Before Applying power: a) Ensure that the required gasses are connected to the DMC 3000 inlet and gasses are turned on and set for required inlet pressure.
b) Ensure you have a torch cartridge with consumables installed on the torch.
If you don’t know what consumables you need to use and need to select the cutting process in order to read the consumables list on the TSC 3000, you can start up with Plasma Disabled. In this case the operation sequence will skip to step 3.
c) Set Plasma Enable SW on the TSC 3000 to Enabled.
2. Turn on 3 phase power at the main disconnect (Plasma Enable on TSC 3000 on). Turn ON/OFF switch to the ON position (up). System will then go through the start up sequence.
a) For about 10 seconds the decimal points of the 4 digit display blink from right to left. b) Next the 4 rectangular LED indicators and the 4 status display digits illuminate all segments as a test.
c) Then for about 6 seconds the display shows the letter “C” (code) followed by the CCM code version. Example
“C1.2.0” . During this time various input voltage tests are being performed. If a fault is found its code is displayed and the start up sequence halts. Faults will show “E” or “L”. If Plasma hasn’t been Enabled by this point, E101 will be displayed. If disabled the pump will not start, the gas LED doesn’t blink and the contactors don’t close (steps d & e). However the events of steps f & g will continue and you can select and load the cutting process. Until the process is loaded, the display shows “0” indicating no process has been loaded. If a fault exists the display alternates between “0” and the fault code.
d) The coolant pump starts and the Gas indicator blinks, and the display shows E304, while the cutting gasses are purged. Purge time varies with the torch lead length and the cutting process. See section 4.04 for setting lead length. When the gas purge ends the E304 goes away but the gas LED may continue blinking if the coolant flow hasn’t been satisfied. e) Once coolant flow is detected, usually within 5 seconds after the pump starts, the input contactor(s) W1 (W2) close and the AC indicator lights.
f) At the same time the DMC & DPC, both Green & Red LEDs, also blink their firmware version. g) Following the firmware version indication, while CCM establishes communication with the gas control (Step e.), the coolant pump and fans come on to “prime” the system. The “gas” indicator on the front panel blinks until correct coolant flow is detected. Normally this takes only a few seconds but can last up to 4 minutes if there is a problem. Should there be a problem with priming the coolant system, after 4 minutes the Status indicator will show code 404 and the pump will stop until you rectify the problem and recycle the power.
4-12
ULTRA-CUT 130 XT/200 XT/300 XT/400 XT
NOTE!
If communication is not established in step g, the pump will not strart and the gas indicator will not blink. The fault code E501 (DMC) or E301 (DPC) will be displayed.
h) Once communication with the DFC components is established the Green power indicator on both DMC & DPC will be on and their Red indicator will be off.
3. At power on while all the items in step 2 are going on the TSC 3000 has been starting up Windows XP™ which takes about 2 ¼ minutes. Another 15 sec the application starts and displays the HOME screen.
4. Now you must select the cutting (and plasma marking) process. Refer to sections 4.05, 4.06 and 4.07 for step by step instructions in selecting New, Recently Used or Creating Custom Processes.
5. During process selection you will come to the “Torch Consumables” screen. At this point if you have not installed correct consumables and “Plasma” is not already disabled, shut off (disable) the Plasma Enable SW. Install the consumables, Set the Plasma Enable SW to “Enable”.
a) Coolant Pump starts up to prime the torch cooling system. The “Gas” indicator on the front panel blinks until correct coolant flow is detected. Normally only a few seconds. See step 2 d and 2 e. for full details.
6. The next screen following Torch Consumables is a table of recommended CNC and THC (Torch Height Control) settings. You may toggle between cutting and marking settings using the “Show Marking / Show Cutting” button.
Set your cutting table controller and height control to the recommended setting.
a) If you prefer other settings for cutting you can create a “Custom” process where you edit the cutting CNC/THC setting if you want. Currently, modifying the marking CNC/THC settings is not allowed. A custom process does not have to change the cutting current or gas pressures unless you want to. You can use customs to modify the recommended CNC/THC settings as well.
7. Continue the process selection until you reach the Cut Monitor screen. If you have not set the Plasma Enable SW to “Enable” do so now. a) Purging of the gasses used for the selected process begins. Depending on your lead length and consumable type this can take some time. While the gas purge is being performed the display will show E304 and the Gas
LED will blink. If the plasma was not enabled before this step the coolant pump will start and when the coolant flow is satisfied the contactors will turn on. Once the gas purge is finished E304 will go away and if the the coolant flow is OK the Gas LED stops blinking.
Purge times for different lead lengths have been set to allow time to fully pressurize the leads and to remove any coolant that gets into the consumables during a parts change. Make sure that during setup the correct lead length has been selected, the default time is for max lead length and may be longer than you require.
8. Once purge is complete you are ready to start cutting. a) If marking is desired press button “Go to Marking”. The screen will show recommended CNC/THC setting. Green arrow takes you back to the Cut Monitor set up for Marking. b) To return to cutting on the Cut Monitor press button “Got to Cutting”. Same as with the marking this takes you to the CNC/THC screen except this displays the cutting settings.
9. Upon applying CNC Start the fan(s) will come on and run during cutting and continue for 4 minutes after the last cut. Then both pump and fan(s) will shut off. With CNC Start the Gas LED will come on steady indicating gas should be flowing and gas preflow begins. Near the end of the preflow time the DC LED will come on indicating the inverters are enabled and we have DC Voltage at the output. At the end of the cut the Gas indicator remains one for the post flow time then goes out.
0-5578 OPERATION 4-13
ULTRA-CUT 130 XT/200 XT/300 XT/400 XT
10. Changing torch consumables:
Following a consumables change or inspection the system will initiate a purge of the gas. This serves two purposes: a) Remove the coolant that gets into the consumables when they have been removed.
b) If the gas type has changed “Purge” removes the old gas from the lines and replaces it with the new gas. If the gas type has changed from a fuel gas like H35 to an oxidizing gas like oxygen or air the purge inserts a buffer of inert gas, nitrogen, so the H35 and oxygen don’t mix.
You can change consumables by removing power or using the “Plasma Disable” SW.
If you remove power the system does not remember what gasses were last used so you have to select the process again and it will do a complete purge including nitrogen buffer even if you do not change gas types.
With “Plasma Disable” the system remembers what was used last and does only the amount of purge necessary possibly saving time.
11. Use “Plasma Disable”.
a) You may use the Plasma Disable when removing the torch cartridge to change or inspect consumables. Plasma disable stops coolant pump, shuts off all gas solenoids, removes power from the inverter (power supply) and pilot circuits, inhibits the arc starter ignition (HF) circuit. It does not remove power from the TSC 3000 or the systems logic and communications circuits so you do not need to go through as long a power up process after replacing the consumables.
b) If changing to a process with a different gas type you may want to select it before enabling the plasma otherwise it will start purging the old process and when you do select the new one it will purge again taking more time. c) If you are not changing gas type you may want to turn on the Enable first to start the purge while you enter the process.
12. Shutting off power.
a) If you chose to shut off power for inspecting or changing consumables, or any other purpose, the system does not remember what you were doing last so you will have to go through the complete sequence from the beginning starting with step 1.
Operational Suggestions
1. Wait four minutes before setting the ON/OFF switch to OFF after operation. This allows the cooling fans to remove operating heat from the power supply.
2. For maximum parts life, do not operate the pilot arc any longer than necessary.
3. Use care in handling torch leads and protect them from damage.
4. When using water as the shield note the following:
• Use clean drinking quality tap water to help prevent particulate build-up within the system water shield plumbing.
• Particulate contamination and build-up can cause reduced consumable parts life and premature torch failure.
• A cartridge type particulate water filter may help achieve optimum cutting performance.
4-14
4.10 Gas Selection
ULTRA-CUT 130 XT/200 XT/300 XT/400 XT
A. Plasma Gases
1. Air Plasma
• Provides satisfactory results on stainless steel and aluminum materials only.
2. Argon/Hydrogen (H35) Plasma
• Recommended for use on 3/4 in (19 mm) and thicker stainless steel. Recommended for 1/2 inch (12 mm) and thicker nonferrous materials. Ar/H2 is not normally used for thinner nonferrous materials because less expensive gases can achieve similar cut quality.
• Poor cut quality on ferrous materials.
• Provides faster cutting speeds and high cut quality on thicker materials to offset the higher cost.
• A 65% argon / 35% hydrogen mixture should be used.
3. Oxygen (O2) Plasma
• Oxygen is recommended for cutting ferrous materials.
• Provides faster cutting speeds.
• Provides very smooth finishes and minimizes nitride buildup on cut surface (nitride buildup can cause difficulties in producing high quality welds if not removed).
4. Nitrogen (N2) Plasma
• Provides better cut quality on nonferrous materials such as stainless steel and aluminum.
• A good clean welding grade nitrogen should be used.
• When used with a water mist secondary it produces superior cut speeds and cut quality on stainless steel and aluminum.
B. Shield Gases
1. Compressed Air Shield
• Air shield is normally used when operating with air or oxygen plasma.
• Used with air plasma on stainless steel and aluminum.
• Improves cut quality on some ferrous materials.
• Inexpensive - reduces operating costs.
2. Nitrogen (N2) Shield
• Nitrogen shield is used with Ar/H2 (H35) plasma.
• Provides smooth finishes on nonferrous materials.
• May reduce smoke when used with Ar/H2 plasma.
3. Water Shield, for use with Non Ferrous Metals.
• Normally used with nitrogen plasma.
• Provides very smooth cut surface.
• Reduces smoke and heat input to the workpiece.
• Effective when used with N2 up to 2 inch (50mm) maximum material thickness for stainless steel and aluminum.
• Tap water provides low operating expense.
0-5578 OPERATION 4-15
ULTRA-CUT 130 XT/200 XT/300 XT/400 XT
Operational Suggestions
1. Wait four minutes before setting the ON/OFF switch to OFF after operation. This allows the cooling fans to run to dissipate operating heat from the power supply.
2. For maximum parts life, do not operate the pilot arc any longer than necessary.
3. Use care in handling torch leads and protect them from damage.
4. When using water as the shield note the following:
• Use clean drinking quality tap water to help prevent particulate build-up within the system water shield plumbing.
• Particulate contamination and build-up can cause reduced consumable parts life and premature torch failure.
• A cartridge type particulate water filter may help achieve optimum cutting performance.
4-16
104
105
106
107
108
4.11 CCM Status Codes
ULTRA-CUT 130 XT/200 XT/300 XT/400 XT
NOTE!
See the Appendix for Advanced Troubleshooting
On start-up and during operation, the power supply control circuitry performs various tests. If the circuitry detects a condition requiring operator attention, the status display on the front panel shows a 3 digit number code preceded by either letter “E” (currently active fault) or letter “L” (last or latched fault) meaning a fault occurred during the process but is not currently active.
Some conditions can be active indefinitely, while others are momentary. The power supply latches momentary conditions; some momentary conditions can shut down the system. The indicator may show multiple conditions in sequence; it is important to recognize all possible conditions that may be displayed.
NOTE!
These tables cover units up to 400A, Lower current units won’t have all the inverter sections referred to in Group 2. Codes for those sections should not appear.
Code
101
102
103
109
110
Message
Plasma Disabled
Pilot Ignition Failure
Lost Pilot
Transfer Lost
Not used
Pilot Timeout, no Transfer
Tip Saver Fault
Tip to Electrode voltage fault.
Part process not configured.
Devise Locked
CCM Status Code
Group 1 -- Plasma Process
Remedy / Comments
Plasma Enable Off ; Disable activated on TSC3000 or GCM 2010 or external
SW disabled (CNC); CCM TB1-1&2 jumper missing; 40 circuit ribbon cable from Relay PCB to CCM disconnected or defective;
Pilot did not start within 15 seconds. Torch consumable parts worn? Ensure correct process selected or manual setting including current control setting matches consumables; Plasma pressure too high; Defective Arc Starter;
Defective Pilot PCB; defective Inverter section 1A. Ribbon cables reversed on
INV1 sections 1A and 1B.
Pilot went out while Start active. Torch consumable parts worn? Ensure cut process or current control setting setting matches consumables; Plasma pressure too high;
Arc was transferred to work then went out while Start still active. Arc lost contact with work (run off edge, over hole, etc.); Standoff too high; Ensure cut process or manual settings (current control, gas pressures) matches consumables;
Reserved for legacy product
Must transfer from Pilot to Cutting Arc in 0.085 seconds (SW8-1 OFF) or 3 sec.
(SW8-1 ON). Standoff too high or void in work under torch; Wrong cut process selected or wrong manual settings (current control set too low or wrong gas pressure).
Tip remained in contact with work in excess of 15 seconds. ( Pak200i).
Tip voltage too close to electrode voltage; Torch consumable parts worn out;
Wrong consumables installed causing tip to electrode short; Wrong process selected or wrong manual setting of plasma gas or cutting current.; Leak in
Plasma hose to torch; Defective Pilot PCB; Shorted torch body .
Applies only to DFC 3000 Auto Gas Control. Select and load a cutting process.
DFC 3000: Process loading; wait until finished
0-5578 OPERATION 4-17
ULTRA-CUT 130 XT/200 XT/300 XT/400 XT
Code
201
202
203
204
205
206
207
208
209
Message
Missing AC Phase
Not used
Not used
Not used
DC Output Low
Not used
Unexpected current in work lead
Unexpected current in pilot circuit
CCM Status Code
Group 2 -- Plasma Power Supply
Remedy / Comments
Blown wall fuse, Blown unit fuse F1 or F2 or rear panel, Bad power cable connection;
Defective System Bias PCB.
Reserved for legacy product
Reserved for legacy product
Reserved for legacy product
Less than 60 VDC; Negative lead short to work or ground; Defective inverter (output shorted); CCM voltage sense (J24) disconnected or wire broken; Defective CCM.
Reserved for legacy product
Current above 8A in work lead prior to pilot ignition or transfer. Negative lead short to ground or arcstarter chassis; Defective HCT1 work lead current sensor; Defective Relay
PCB.
Current above 6A in pilot circuit prior to ignition. Wrong or mismatched consumables causing tip - electrode short; Pilot lead shorted to negative in torch tube; Defective Relay
PCB; Defective Pilot PCB; Possible shorted torch.
Reserved for legacy product
210
Not used
Work Current Too
High
Work lead current detected greater than 16% above process setting. Possible defective
HCT1 Work lead current sensor or Relay PCB; Defective CCM.
211
Work Current Too
Low
Work current detected more than 16% below process setting. Possible defective HCT1
Work lead current sensor or Relay PCB; Possible defective pilot PCB (shorted IGBT);
212
213
214
215
216
217
218
219
220
Inverter 1A Output
Current Low
Inverter 1B Output
Current Low
Inverter 2A Output
Current Low
Inverter 2B Output
Current Low
Inverter 3A Output
Current Low
Inverter 3B Output
Current Low
Inverter 1A Output
Current High
Inverter 1B Output
Current High
Inverter 2A Output
Current High
Plasma work current low during cutting and attributed to Inverter Module 1 Section A output low; Inverter output disconnected; Possible defective ribbon cable; If problem persists replace Inverter Module 1
Plasma work current low during cutting and attributed to Inverter Module 1 Section B output low; Inverter output disconnected; Possible defective ribbon cable; If problem persists replace Inverter Module 1
Plasma work current low during cutting and attributed to Inverter Module 2 Section A output low; Inverter output disconnected; Possible defective ribbon cable; If problem persists replace Inverter Module 2
Plasma work current low during cutting and attributed to Inverter Module 2 Section B output low; Inverter output disconnected; Possible defective ribbon cable; If problem persists replace Inverter Module 2
Plasma work current low during cutting and attributed to Inverter Module 3 Section A output low; Inverter output disconnected; Possible defective ribbon cable; If problem persists replace Inverter Module 3
Plasma work current low during cutting and attributed to Inverter Module 3 Section B output low; Inverter output disconnected; Possible defective ribbon cable; If problem persists replace Inverter Module 2
Plasma work current high during cutting and attributed to Inverter Module 1 Section A output high; If problem persists replace Inverter Module 1
Plasma work current high during cutting and attributed to Inverter Module 1 Section B output high; If problem persists replace Inverter Module 1
Plasma work current high during cutting and attributed to Inverter Module 2 Section A output high; If problem persists replace Inverter Module 2
4-18
232
233
234
235
236
237
238
Code
221
226
227
228
229
230
222
223
224
225
231
Message
Inverter 2B Output
Current High
Inverter 3A Output
Current High
Inverter 3B Output
Current High
Inverter 1 Not
Found
Inverter 1A Incompatible Revision
Inverter 1B Incompatible Revision
Inverter 2A Incompatible Revision
Inverter 2B Incompatible Revision
Inverter 3A Incompatible Revision
Inverter 3B Incompatible Revision
Inverter 1A VAC
Mismatch
Inverter 1B VAC
Mismatch
Inverter 2A VAC
Mismatch
Inverter 2B VAC
Mismatch
Inverter 3A VAC
Mismatch
Inverter 3B VAC
Mismatch
Too Few Inverters
Found
BIAS VAC Invalid
ULTRA-CUT 130 XT/200 XT/300 XT/400 XT
CCM Status Code
Group 2 -- Plasma Power Supply
Remedy / Comments
Plasma work current high during cutting and attributed to Inverter Module 2 Section B output high; If problem persists replace Inverter Module 2
Plasma work current high during cutting and attributed to Inverter Module 3 Section A output high; If problem persists replace Inverter Module 3
Plasma work current high during cutting and attributed to Inverter Module 3 Section B output high; If problem persists replace Inverter Module 3
Inverter Module 1 Section A required for Piloting; Bad ribbon cable connection to CCM
J31 to Inverter Module 1 Section A.
Unsupported Inverter Revision; Ribbon cable CCM J31 to Inverter Module 1 Section A damaged; CCM code version incompatible with Inverter revision or model
Unsupported Inverter Revision; Ribbon cable CCM J32 to Inverter Module 1 Section B damaged ; CCM code version incompatible with Inverter revision or model
Unsupported Inverter Revision; Ribbon cable CCM J33 to Inverter Module 2 Section A damaged; CCM code version incompatible with Inverter revision or model
Unsupported Inverter Revision; Ribbon cable CCM J34 to Inverter Module 2 Section B damaged; CCM code version incompatible with Inverter revision or model
Unsupported Inverter Revision; Ribbon cable CCM J35 to Inverter Module 3 Section A damaged; CCM code version incompatible with Inverter revision or model
Unsupported Inverter Revision; Ribbon cable CCM J36 to Inverter Module 3 Section B damaged; CCM code version incompatible with Inverter revision or model
Inverter AC Voltage rating incompatible with Power Supply voltage rating; Bad ribbon cable connection CCM J31 to Inverter Module 1 Section A; Wrong voltage Inverter Module 1 installed; Defective Inverter module
Inverter AC Voltage rating incompatible with Power Supply voltage rating; Bad ribbon cable connection CCM J32 to Inverter Module 1 Section B; Wrong voltage Inverter Module 1 installed; Defective Inverter module
Inverter AC Voltage rating incompatible with Power Supply voltage rating; Bad ribbon cable connection CCM J33 to Inverter Module 2 Section A; Wrong voltage Inverter Module 2 installed; Defective Inverter module
Inverter AC Voltage rating incompatible with Power Supply voltage rating; Bad ribbon cable connection CCM J34 to Inverter Module 2 Section B; Wrong voltage Inverter Module 2 installed; Defective Inverter module
Inverter AC Voltage rating incompatible with Power Supply voltage rating; Bad ribbon cable connection CCM J35 to Inverter Module 3 Section A; Wrong voltage Inverter Module 3 installed; Defective Inverter module
Inverter AC Voltage rating incompatible with Power Supply voltage rating; Bad ribbon cable connection CCM J36 to Inverter Module 3 Section B; Wrong voltage Inverter Module 3 installed; Defective Inverter module
Two or more Inverter Sections required to operate; Ribbon cable from CCM to Inverter
Section damaged or disconnected;
Invalid AC Voltage Selection; Damaged or loose connection at J61 of System Bias Supply;
Defective System Bias PCB
0-5578 OPERATION 4-19
ULTRA-CUT 130 XT/200 XT/300 XT/400 XT
Code
239
240
Message
AC Voltage High
AC Voltage Low
CCM Status Code
Group 2 -- Plasma Power Supply
Remedy / Comments
System Bias PCB detected AC Voltage is higher than Power Supply rated Voltage; System Bias Supply J61 Voltage Selection connection damaged or disconnected; Defective
System Bias PCB; Defective CCM
System Bias PCB detected AC Voltage is lower than Power Supply rated Voltage; System
Bias Supply J61 Voltage Selection connection damaged or disconnected; Defective
System Bias PCB; Defective CCM
241
Inverter 1A Input
Voltage Error
Inverter Input Voltage fault; voltage out of range or missing phase at AC Input of
Inverter Module 1 Section A; Poor AC Power Quality; Defective W1 contactor; Loose or open connection between input terminals and W1 contactor or contactor and input of
Inverter Section; Defective Inverter module
242
243
Inverter 1B Input
Voltage Error
Inverter 2A Input
Voltage Error
Inverter Input Voltage fault; voltage out of range or missing phase at AC Input of
Inverter Module 1 Section B; Poor AC Power Quality; Defective W1 contactor; Loose or open connection between input terminals and W1 contactor or contactor and input of
Inverter Section; Defective Inverter module
Inverter Input Voltage fault; voltage out of range or missing phase at AC Input of
Inverter Module 2 Section A; Poor AC Power Quality; Defective W1 contactor; Loose or open connection between input terminals and W1 contactor or contactor and input of
Inverter Section; Defective Inverter module
244
245
246
Inverter 2B Input
Voltage Error
Inverter 3A Input
Voltage Error
Inverter 3B Input
Voltage Error
Inverter Input Voltage fault; voltage out of range or missing phase at AC Input of
Inverter Module 2 Section B; Poor AC Power Quality; Defective W2 contactor; Loose or open connection between input terminals and W2 contactor or contactor and input of
Inverter Section; Defective Inverter module
Inverter Input Voltage fault; voltage out of range or missing phase at AC Input of
Inverter Module 3 Section A; Poor AC Power Quality; Defective W2 contactor; Loose or open connection between input terminals and W2 contactor or contactor and input of
Inverter Section; Defective Inverter module
Inverter Input Voltage fault; voltage out of range or missing phase at AC Input of
Inverter Module 3 Section B; Poor AC Power Quality; Defective W2 contactor; Loose or open connection between input terminals and W2 contactor or contactor and input of
Inverter Section; Defective Inverter module
247
248
249
250
251
252
253
254
Inverter 1A Circuit
Fault
Inverter 1B Circuit
Fault
Inverter 2A Circuit
Fault
Inverter 2B Circuit
Fault
Inverter 3A Circuit
Fault
Inverter 3B Circuit
Fault
Inverter 1A Over
Temp
Inverter 1B Over
Temp
Inverter Module 1 Section A detected a circuit fault; Damaged Inverter Module 1
Inverter Module 1 Section B detected a circuit fault; Damaged Inverter Module 1
Inverter Module 2 Section A detected a circuit fault; Damaged Inverter Module 2
Inverter Module 2 Section B detected a circuit fault; Damaged Inverter Module 2
Inverter Module 3 Section A detected a circuit fault; Damaged Inverter Module 3
Inverter Module 3 Section B detected a circuit fault; Damaged Inverter Module 3
Inverter Module 1 Section A is over temperature; Operating with side panels removed,
Check for restricted air flow, clogged radiator; Defective fan; If problem persists replace inverter module.
Inverter Module 1 Section B is over temperature; Operating with side panels removed,
Check for restricted air flow, clogged radiator; Defective fan; If problem persists replace inverter module.
4-20
Code
255
256
257
258
262
263
264
265
266
267
268
269
270
271
259
260
261
Message
Inverter 2A Over
Temp
Inverter 2B Over
Temp
Inverter 3A Over
Temp
Inverter 3B Over
Temp
Inverter 1A Over
Temp Ambient
Inverter 1B Over
Temp Ambient
Inverter 2A Over
Temp Ambient
Inverter 2B Over
Temp Ambient
Inverter 3A Over
Temp Ambient
Inverter 3B Over
Temp Ambient
Inverter 1A No
Input Power
Inverter 1B No
Input Power
Inverter 2A No
Input Power
Inverter 2B No
Input Power
Inverter 3A No
Input Power
Inverter 3B No
Input Power
Inverter ID reading fault
ULTRA-CUT 130 XT/200 XT/300 XT/400 XT
CCM Status Code
Group 2 -- Plasma Power Supply
Remedy / Comments
Inverter Module 2 Section A is over temperature; Operating with side panels removed,
Check for restricted air flow, clogged radiator; Defective fan; If problem persists replace inverter module.
Inverter Module 2 Section B is over temperature; Operating with side panels removed,
Check for restricted air flow, clogged radiator; Defective fan; If problem persists replace inverter module.
Inverter Module 3 Section A is over temperature; Operating with side panels removed,
Check for restricted air flow, clogged radiator; Defective fan; If problem persists replace inverter module.
Inverter Module 3 Section B is over temperature; Operating with side panels removed,
Check for restricted air flow, clogged radiator; Defective fan; If problem persists replace inverter module.
Inverter circuitry is over temperature likely cause is ambient greater than 40 deg C;
Reduce power supply cutting Duty Cycle; Reduce ambient air temperature; Add auxiliary cooler.
Inverter circuitry is over temperature likely cause is ambient greater than 40 deg C;
Reduce power supply cutting Duty Cycle; Reduce ambient air temperature; Add auxiliary cooler.
Inverter circuitry is over temperature likely cause is ambient greater than 40 deg C;
Reduce power supply cutting Duty Cycle; Reduce ambient air temperature; Add auxiliary cooler.
Inverter circuitry is over temperature likely cause is ambient greater than 40 deg C;
Reduce power supply cutting Duty Cycle; Reduce ambient air temperature; Add auxiliary cooler.
Inverter circuitry is over temperature likely cause is ambient greater than 40 deg C;
Reduce power supply cutting Duty Cycle; Reduce ambient air temperature; Add auxiliary cooler.
Inverter circuitry is over temperature likely cause is ambient greater than 40 deg C;
Reduce power supply cutting Duty Cycle; Reduce ambient air temperature; Add auxiliary cooler.
Inverter section may have no input power. Contactor W1 not closed; Defective contactor or CB4 tripped; Inverter section input not connected; Defective Inverter.
Inverter section may have no input power. Contactor W1 not closed; Defective contactor or CB4 tripped; Inverter section input not connected; Defective Inverter.
Inverter section may have no input power. Contactor W1 not closed; Defective contactor or CB4 tripped; Inverter section input not connected; Defective Inverter.
Inverter section may have no input power. Contactor W2 not closed; Defective contactor or CB4 tripped; Inverter section input not connected; Defective Inverter.
Inverter section may have no input power. Contactor W2 not closed; Defective contactor or CB4 tripped; Inverter section input not connected; Defective Inverter.
Inverter section may have no input power. Contactor W2 not closed; Defective contactor or CB4 tripped; Inverter section input not connected; Defective Inverter.
CCM found ID values inconsistent during reading. CCM to an Inverter section ribbon damaged or disconnected; Improper ribbon cable routing.
0-5578 OPERATION 4-21
ULTRA-CUT 130 XT/200 XT/300 XT/400 XT
Code
301
302
303
304
305
306
307
308
309
Message
CCM Status Code
Group 3 -- Gas Controller Status & Protocol
Remedy / Comments
Gas control communication fault
Gas Control reply fault
Problem with fiber optic cable to GCM 2010 or DMC or DPC; Dirt on fiber ends or in connectors; blow out with clean dry air. Fiber not locked into connector; Sharp bends in fiber cable; Fiber defective; GCM 2010 circuit board defect; DMC or DPC power supply defective; DMC or DPC circuit board defect
Problem with fiber optic cable to GCM 2010 or DMC or DPC; Dirt on fiber ends or in connectors; blow out with clean dry air. Fiber not locked into connector; Sharp bends in fiber cable; Fiber defective; GCM 2010 circuit board defect; DMC or DPC power supply defective; DMC or DPC circuit board defect
Gas Supply Pressure out of range.
Gas Control Purging
GCM 2010 inlet plasma or shield pressure low or defective pressure sensors
PS3 & PS4; Defective GCM 2010 PCB; For DFC 3000 see DPC for pressure faults.
Normal following power up or returning from Plasma Disable. Wait for purge to finish.
Gas Control protocol error
Not used
Gas Control sequencing error
Gas Control Type Mismatch
Gas Control command fault
Verify Firmware revision for compatibility with GCM 2010 or DMC and
DPC
Reserved for other future use.
Verify Firmware revision for compatibility with GCM 2010 or DMC and
DPC
Wrong CCM (Auto-Cut or Pak 200 type?) for Ultra-Cut; Install correct CCM
Verify Firmware revision for compatibility with GCM 2010 or DMC and
DPC; Electromagnetic interference with Arc Starter; inspect grounding; bonding; and isolation
310 * DPC fault
Check DPC status indicator for specific problem
311 * DPC valve control fault
Check DPC status indicator for specific problem
312 *
313 *
DMC fault
Gas Controller not configured.
* Applies to DFC 3000 (Auto Gas) only
Check DMC status indicator for specific problem
DMC or DPC not configured for a process or locked; See DMC and DPC status
4-22
404
405
406
Code
401
402
403
407
Code
501
502
503
504
Message
Coolant Level low
Low coolant flow
Coolant overheated
Coolant System not ready.
Low Coolant Level
Warning
Coolant Flow Low
Warning.
Coolant overheated, high ambient.
ULTRA-CUT 130 XT/200 XT/300 XT/400 XT
CCM Status Code
Group 4 -- Torch Coolant System
Remedy / Comments
Check coolant level, add as needed. Defective or disconnected level sensor.
Coolant flow as measured by flow switch FS1 is less than 0.7 gpm (0.25 for
Pak200i); Clogged filter; Restriction in torch lead or head; Wrong style consumables; Bad O-ring on the torch check valve; broken or defective torch coolant tube/check valve; Defective pump or bypass valve. 402 code along with 104 code is probably a low flow problem.
Coolant supply temperature exceeded 75 degrees Celcius (167 F ). Operating with side panel loose or removed; Air flow blocked at air inlet or exit of power supply; Coolant fan failed; radiator fins clogged with dirt.
Proper coolant flow of 0.7 gpm as measured by flow switch FS1 was not obtained during up to 4 minutes of Priming. New installation can require additional Priming cycle(s) to fill hoses with coolant; cycle power to restart Priming; Coolant hoses or torch hoses reversed; Clogged coolant filter; Restriction in torch lead or head;
Wrong style consumables; broken or defective torch coolant tube/check valve;
Defective or disconnected FS1 flow SW; Defective pump or bypass valve.
Low coolant level during cut, does not stop cut.
Add coolant as required.
This is a warning, does not stop system operation. Coolant flow rate lower than expected. Can be caused by gas bubbles being introduced into the coolant or wrong or mismatched or worn consumable parts; Failed seals in torch cartridge or torch body; Clogged coolant filter; Restriction in torch lead or head; defective or disconnected FL1 flow sensor.
Coolant supply temperature exceeded 75 degrees Celsius (167 F ) likely cause ambient greater than 40 degrees Celsius (104 F ); Reduce cutting duty cycle; Reduce ambient temperature; Add separate coolant cooler.
CCM Status Code
CCM-Group-5 Gas Controller Communication Port
Message Remedy / Comments
CANBUS Acknowledge Fault
CANBUS Off
CANBUS Errors Warning
Reserved
CCM to DMC Fiber-optic Control cable not connected, not properly connected or cable defective. DMC power supply or Control PCB defective. Defective CCM, replace.
Dirt on fiber ends or in connectors; blow out with clean dry air; Fiber not locked into connector; Sharp bends in fiber; Fiber defective
Dirt on fiber ends or in connectors; blow out with clean dry air; Fiber not locked into connector; Sharp bends in fiber; Fiber defective;
No information available; Contact customer service
0-5578 OPERATION 4-23
ULTRA-CUT 130 XT/200 XT/300 XT/400 XT
Code
601
602
603
604
605
606
607
608
609
610
611
612
613
614
615
Message
Analog Voltage Error
ADC or DAC error
Reserved
Data Memory error
Program memory fault
+5V Logic supply low
Processor over temperature
5V supply for RS 485/422 communication low.
Firmware Update Device
Error
Firmware Update Protocol
Error
USB Controller Fault
USB Power Fault
USB Log Creation Fault
No USF File
No CCM Update File
CCM Status Code
Group 6 -- CCM
Remedy / Comments
Defective CCM, replace.
Defective CCM, replace.
No information available; Contact customer service
Defective CCM, replace.
Defective CCM, replace.
Defective CCM, replace.
Reduce ambient temperature; Defective CCM; replace
Defective CCM, replace.
Defective CCM; replace
Defective CCM; replace
Defective CCM; replace
Faulty USB device plugged into USB port, remove; Defective CCM
Unable to create Log file on USB Flash drive last firmware update attempt; Use different USB Flash Drive or Reformat
File VTCCMFW.USF missing from Flash Drive; Add proper files to Flash Drive for
Firmware Update; Use different USB Flash Drive or Reformat
CCM Firmware file specified in VTCCMFW.USF not found ; Add proper files to Flash
Drive for Firmware updating
616
DPC Update Fault
Fault occurred attempting to update DPC firmware; Add proper files to USB Flash drive for Firmware updating; Refer to CCM_LOG.TXT on Flash Drive for details
617
618
619
620
621
622
DMC Update Fault
ADC Calibration Fault
Flow Switch Fault
Non Volatile Memory Error
USB Format Fault
CCM Code Execution
Fault
Fault occurred attempting to update DMC firmware; Add proper files to USB Flash drive for Firmware updating; Refer to CCM_LOG.TXT on Flash Drive for details
Error too large calibrating ADC; Fault persists defective CCM;
Flow switch reporting coolant flow when pump off;
Non Volatile Memory Storage Corrupted and Erased; Fault persists defective CCM.
A USB flash drive was detected but could not be read by CCM. Backup any files currently on flash drive, reformat the USB flash drive to a FAT or FAT32 file system, replace only the CCM update files and try again. Use different
USB flash drive formatted with FAT or FAT32 file system.
Possible EMI noise problem or code fault. Check for proper grounding and bonding of equipment and routing of torch leads and cables to reduce
Electromagnetic Emission Interference onto CCM module. If problem persists, verify CCM code version is the latest supported revision. Replace
CCM module.
4-24
Code
701
702
703
704
705
Message
Isolation Contactor Fault
Contact Start consumable fault
Contact Start detection circuit fault
Contact Start pressure fault
Contact Start Cartridge fault
ULTRA-CUT 130 XT/200 XT/300 XT/400 XT
CCM Status Code
Group 7 -- Options
Remedy / Comments
1 Torch isolation contactor W5 appears closed when expected to be open. Contacts may fused or, W5 could be energized, 24 VAC on it's coil, when it should not be due to faulty Relay PCB.
Prior to 1 torch preflow there should be continuity from the electrode, through the start cartridge, to the tip. Failure may be due to worn or missing consumable or Start Cartridge. Inspect, clean or replace.
In the 1 Torch module K201 should energize when W5 does. Either it failed to energize or the pressure switch PS2 is failed closed.
Pressure switch PS2 detects less than 35 PSI. Normal pressure is
75-85 PSI. No air connected to the 1 Torch module inlet or it's too low pressure; if using optional single stage filter the element may need cleaning or replacement, refer to maintance section. ;1 Torch pressure regulator set too low; 1 torch module solenoid SOL4 has failed; Relay PCB does not apply 24 VAC to SOL4.
Air pressure should seperate the Start Cartridge from the tip to initiate pilot. Failure may be stuck or damaged cartridge or consumables. Clean or replace. Or no DC output from inverters, front panel
DC LED does not come on.
4.12 DMC-3000 Status Codes
Status Code indicators:
1. At power up, RED & GREEN indicators flash program firmware revision number in a 2 digit code as explained below.
Following the revision code
2. Green indicator
· On steady = OK, communication established.
· Blinking = no communication established with CCM
3. Red indicator
· Off = Status OK
· Rapid blinking = downloading new program
· Blinking 2 digit code = Status (table below)
Status Indicators on the DMC & DPC modules flash a 2-part code. Both green and red flash the firmware version at power up. Only the red flashes for a fault.
First part of the code indicates a code group, the second part a particular condition within that group. DMC and DPM may flash codes at the same time and they may be different codes. For example, a power supply fault, such as 1-3, in the DMC could prevent communicating with the DPM so the DPC would flash one it’s group 2 codes. You have to consider the codes in all the modules, CCM, DMC & DPC before determining which hardware has the fault.
The 2 digit code is separated by a 1.2 second space between digits and a 4 second space before the sequence repeats or flashes another code group. Codes displayed may be currently active or may represent a fault that shut the process down but is no longer active. If the fault that shut down the process is no longer active the first blink of the first digit is extra long.
Example: Indicator flashes 1 long followed by 3 shorter blinks the condition is in group 4. After 1.2 seconds delay, the indicator blinks 3 times; the condition code is 4-3 (the first long blink counts as part of the first digit), indicating the DMC has detected a DPC time-out error and it is not currently active. After a 4 second delay, the indicator repeats the sequence until the condition is corrected.
0-5578 OPERATION 4-25
ULTRA-CUT 130 XT/200 XT/300 XT/400 XT
Code
1-1
1-2
1-3
1-4
1-5
1-6
Message
Plasma Disabled
24 VDC fault
5 VDC fault
No gas process selected
DMC is locked
Gas not Purged
DMC Status Code Key
Group 1 - DMC
Cause/Remedy
Enable Plasma; Defective DMC Power Supply (E-Stop relay)
Check /replace DMC power supply fuse (F2); Replace DMC Power Supply; Replace DMC control PCB
Check /replace DMC power supply; Replace DMC control PCB
Select and send process from TSC 3000 or CNC;
2-1
2-2
2-3
DPC Acknowledge error
DPC Bus off error
Reserved
Process loading, wait until finished
DPC fault prevented purge from occuring, see DPC fault status
Group 2 - DPC Communication Port *
Check DMC to DPC fiber optic cable and connections; Dirty or defective fiber-optic;DPC power supply, fuse or Control PCB. DMC Control PCB
Check DMC to DPC fiber optic cable and connections; Dirty or defective fiber-optic;DPC power supply, fuse or Control PCB. DMC Control PCB.
No information available; Contact customer service
3-1
3-2
3-3
4-1
4-2
4-3
4-4
4-5
4-6
CCM Acknowledge error
CCM Bus off error
Group 3 - CCM Communication Port *
Check DMC to CCM fiber optic cable and connections; Dirty or defective fiber-optic;
Replace DMC Control PCB; Replace CCM.
Check DMC to CCM fiber optic cable and connections; Dirty or defective fiber-optic;
Replace DMC Control PCB; Replace CCM.
Reserved No information available; Contact customer service
Group 4 - Gas Controller Status and Protocol Errors
CCM Connection loss
Loss of communication with either DPC or DMC; check for dirty or defective fiber optic to either DPC or CCM; See DPC and CCM status codes
CCM Timeout
DPC Timeout
DPC error
Reserved
Reserved
Loss of communication with either DPC or DMC, check for dirty or defective fiber-optic to either DPC or CCM. See DPC and CCM status codes.
Loss of communication with DPC, check for dirty or defective fiber-optic to DPC. See
DPC status code.
Loss of communication with DPC, check for dirty or defective fiber-optic to DPC. See
DPC status code.
No information available; Contact customer service
No information available; Contact customer service
4-26
ULTRA-CUT 130 XT/200 XT/300 XT/400 XT
5-1
5-2
5-3
5-4
5-5
5-6
5-7
5-8
5-9
5-10
5-11
5-12
Sol 1 – H35 Plasma
Sol 2 – Oxygen
Plasma
Sol 3 – Air Plasma
Sol 4 – Nitrogen
Plasma
Sol 5 – Aux Plasma
Sol 6 – Oxygen
Shield
Sol 7 – Air Shield
Sol 8 – Nitrogen
Shield
Sol 9 – H2O Shield
Sol 10 – Oxygen
Preflow
Sol 11 – Air Preflow
Sol 12 – Nitrogen
Preflow
Group 5 - Shorted Solenoid Faults
Replace solenoid; Shorted wire harness; Defective DMC Control PCB
Replace solenoid; Shorted wire harness; Defective DMC Control PCB
Replace solenoid; Shorted wire harness; Defective DMC Control PCB
Replace solenoid; Shorted wire harness; Defective DMC Control PCB
Replace solenoid; Shorted wire harness; Defective DMC Control PCB
Replace solenoid; Shorted wire harness; Defective DMC Control PCB
Replace solenoid; Shorted wire harness; Defective DMC Control PCB
Replace solenoid; Shorted wire harness; Defective DMC Control PCB
Replace solenoid; Shorted wire harness; Defective DMC Control PCB
Replace solenoid; Shorted wire harness; Defective DMC Control PCB
Replace solenoid; Shorted wire harness; Defective DMC Control PCB
Replace solenoid; Shorted wire harness; Defective DMC Control PCB
5-13 Sol 13 – Argon
Marking
Sol 14 – Air Marking
Replace solenoid; Shorted wire harness; Defective DMC Control PCB
5-14 Replace solenoid; Shorted wire harness; Defective DMC Control PCB
5-15 Sol 15 – Nitrogen
Marking
Replace solenoid; Shorted wire harness; Defective DMC Control PCB
* Communication faults shown on the DMC can be caused by the device on the other end of the communication line.
Before assuming the DMC is at fault see if either the CCM or the DPC are showing any codes that might indicate they are at fault instead.
0-5578 OPERATION 4-27
ULTRA-CUT 130 XT/200 XT/300 XT/400 XT
4.13 DPC-3000 Status Codes
Code
1-1
1-2
1-7
1-8
1-9
1-3
1-4
1-5
1-6
1-10
Message
Plasma Disabled
24 VDC fault
+12 VDC fault
-12 VDC fault
5 VDC fault
Analog Reference fault
ADC voltage fault
Reserved
Valve not configured
DPC is locked
DPC Status Code Key
Group 1 - DPC
Cause/Remedy
Enable Plasma; DMC Power Supply input fuse F1 blown (no lights on DMC); Defective DMC Power Supply (E-Stop relay). Defective DPC Power Supply (E-Stop relay).
Defective DPC control PCB
Check /replace DPC power supply output fuse (F2); Defective DPC power supply;
Replace DPC control PCB
Check /replace DPC power supply; Replace DPC control PCB
Check /replace DPC power supply; Replace DPC control PCB
Check /replace DPC power supply; Replace DPC control PCB
Replace DPC Control PCB
Replace DPC Control PCB
2-1
2-2
2-3
2-4
2-5
3-1
Acknowledge error
Timeout
Protocol
Bus off
Physical
Resend process from TSC 3000 / CNC
Process loading, wait until finished
Group 2 - Control Communication
Fiber optic cable; DPC Control PCB
Communication loss: Check DMC codes; if DMC 2-1 check DPC to DMC Fiber optic cable, DMC 4-2 check DMC to CCM fiber-optic cable.; DPC Control PCB; DMC Control
PCB; CCM.
Program firmware fault, consult factory
Fiber optic cable; DPC Control PCB
Fiber optic cable; DPC Control PCB
Group 3 - Inlet Pressure Faults
Reduce pressure from gas supply; defective pressure sensor (PS4).
3-2
3-3
3-4
Plasma Gas High (>145
PSI)
Pilot Gas High (>145
PSI)
Shield Gas High (>145
PSI)
Shield H2O High (>145
PSI)
Reduce pressure from gas supply; defective pressure sensor (PS3).
Reduce pressure from gas supply; defective pressure sensor (PS1).
Reduce pressure from gas supply; defective pressure sensor (PS2).
4-28
6-1
6-2
6-3
6-4
6-5
6-6
4-1
4-2
4-3
4-4
4-5
4-6
4-7
4-8
4-9
4-10
4-11
5-1
5-2
5-3
5-4
5-5
ULTRA-CUT 130 XT/200 XT/300 XT/400 XT
Group 4 - Proportional Valves & Solenoids Electrical Faults
Plasma High (V5) shorted
Check for shorted wire harness; Replace valve
Check for shorted wire harness; Replace valve Plasma Low (V4) shorted
Pilot (V3) shorted
Shield Gas (V1) shorted
Shield H2O (V2) shorted
Check for shorted wire harness; Replace valve
Check for shorted wire harness; Replace valve
Check for shorted wire harness; Replace valve
Vent (SOL2) shorted
Cut (SOL3) shorted
Mark (SOL1) shorted
Vent (SOL2) open
Cut (SOL3) open
Check for shorted wire harness; Replace valve
Check for shorted wire harness; Replace valve
Check for shorted wire harness; Replace valve
Check for open connection; Replace valve.
Check for open connection; Replace valve.
Mark (SOL1) open Check for open connection; Replace valve.
Group 5 - Plasma High Proportional Valve (V5)
Valve open Check for open connection; Replace valve.
DPC inlet Supply pressure low
Outlet pressure too low
Raise plasma inlet pressure; check for DMC valve not open; restriction in gas supply
/ hoses.
Valve full open. Leak in plasma hose to torch; defective control valve (V5); defective pressure sensor (PS6); DPC Control PCB
Outlet pressure low
Outlet pressure too high.
Tracking error Leak in plasma hose to torch; defective control valve (V5); defective pressure sensor (PS6); DPC Control PCB
Valve at minimum setting. Restriction in plasma hose, torch, DPC manifold; defective control valve (V5); defective pressure sensor (PS6); DPC Control PCB
Valve open
DPC inlet Supply pressure low
Outlet pressure too low
Outlet pressure low
Outlet pressure Too high
Group 6 - Plasma Low Proportional Valve (V4)
Check for open connection; Replace valve.
Raise plasma inlet pressure; check for DMC valve not open; restriction in gas supply/ hoses.
Outlet pressure high
Valve full open but pressure still too low. Leak in plasma hose to torch; Defective control valve (V4); Defective pressure sensor (PS6); DPC Control PCB
Tracking error. Leak in plasma hose to torch; Defective control valve (V4); Defective pressure sensor (PS6); DPC Control PCB
Valve at minimum setting but pressure still too high. Restriction in plasma hose to torch; torch or DPC manifold; Defective control valve (V4); Defective pressure sensor
(PS6); DPC Control PCB
Tracking error. Restriction in plasma hose; torch or DPC manifold; Defective control valve (V4); Defective pressure sensor (PS6); DPC Control PCB
0-5578 OPERATION 4-29
ULTRA-CUT 130 XT/200 XT/300 XT/400 XT
7-1
7-2
7-3
7-4
7-5
7-6
8-1
8-2
8-3
8-4
8-5
8-6
9-1
9-2
9-3
9-4
9-5
9-6
Valve open
DPC inlet Supply pressure low
Outlet pressure too low
Outlet pressure low
Outlet pressure Too high
Group 7 - Pilot Proportional Valve (V3)
Check for open connection; Replace valve.
Raise plasma inlet pressure; check for DMC valve not open; restriction in gas supply/ hoses.
Valve full open but pressure still too low. Leak in plasma hose to torch; defective control valve; defective pressure sensor (PS6); DPC Control PCB
Tracking error. Leak in plasma hose to torch; defective control valve; defective pressure sensor (PS6); DPC Control PCB
Valve at minimum setting but pressure still too high. Restriction in plasma hose, torch,
DPC manifold; defective control valve; defective pressure sensor (PS6); DPC Control
PCB
Outlet pressure high
Valve open
Tracking error. Restriction in plasma hose, torch, DPC manifold; defective control valve; defective pressure sensor (PS6); DPC Control PCB
Group 8 - Shield Gas Proportional Valve (V1)
Check for open connection; Replace valve.
DPC inlet Supply pressure low
Outlet pressure too low
Raise plasma inlet pressure; check for DMC valve not open; restriction in gas supply/ hoses.
Valve full open but pressure still too low. Leak in plasma hose to torch; defective control valve; defective pressure sensor (PS5); DPC Control PCB
Outlet pressure low
Outlet pressure Too high
Tracking error. Leak in plasma hose to torch; defective control valve; defective pressure sensor (PS5); DPC Control PCB
Valve at minimum setting but pressure still too high. Restriction in plasma hose, torch,
DPC manifold; defective control valve; defective pressure sensor (PS5); DPC Control
PCB
Outlet pressure high Tracking error. Restriction in plasma hose, torch, DPC manifold; defective control valve; defective pressure sensor (PS5); DPC Control PCB
Group 9 - Shield H2O Proportional Valve (V2)
Valve open Check for open connection; Replace valve.
DPC inlet Supply pressure low
Raise plasma inlet pressure; check for DMC valve not open; restriction in gas supply/ hoses.
Outlet flow too low
Outlet flow low
Outlet flow Too high
Outlet flow high
Valve full on but pressure still too low. Leak in shield hose to torch; Defective control valve (V2); Defective pressure sensor (PS5) or flow sensor (FS-1) if equipped; DPC
Control PCB
Tracking error, outlet pressure too low. Leak in shield hose to torch; Defective control valve (V2). Defective pressure sensor (PS5) or flow sensor (FS-1) if equipped; DPC
Control PCB
Valve set to minimum but valve outlet pressure still too high. Mineral build up or other restriction in control valve (V2), DPC manifold, shield hose or torch; Defective control valve (V2)/ Defective pressure sensor (PS5) or flow sensor (FS-1) if equipped;
DPC Control PCB
Tracking error, outlet pressure too high. Mineral build up or other restriction in control valve (V2), DPC manifold, shield hose or torch; Defective control valve (V2); Defective pressure sensor (PS5) or flow sensor (FS-1) if equipped; DPC Control PCB
4-30
4.14 Remote Arc Starter Trouble Shooting
Symptom
No Pilot ignition Neon indicator on
Cap board lights but no ignition.
Symptom
No Pilot ignition: Neon indicator not illuminated.
Arc Starter Trouble Shooting
Cause
Pilot return wire not connected at torch head or broken in torch lead
Coolant has become conductive
High Frequency cap (C4 on Cap PCB) possibly open wires disconnected.
Check
Visual inspection, continuity check
Use conductivity meter
Use capacitance meter
Negative supply cable not connected correctly
Visual inspection
Pilot return wire not connected or loose in arcstarter.
Cause
Visual inspection
Arc Starter Trouble Shooting
Check
No 120V supply, CB4 of plasma rear panel tripped
Electronic Ignition module shorted input
No 120V supply, CB4 not tripped
Reset breaker, check for 120
VAC at the module’s 115V terminals during ignition time.
Resistance measurement, good module measures about 45 ohms check for 120 VAC at the plasma supply’s rear panel connector J59-7 & 9 during ignition time.
Faulty Electronic Ignition module
ULTRA-CUT 130 XT/200 XT/300 XT/400 XT
Check for 120 VAC at the modules 115V terminals during pilot ignition time
Visual inspection
Remedy
Connect Wire or replace leads.
Flush system, replace coolant.
Reconnect or replace.
Reconnect
Connect Wire.
Remedy
Check for shorted cable, defective circuit breaker, shorted ignition module input. (see next symptom)
Replace bad module
120V present - open control cable, 120V not present - fault in plasma power supply
If 120 VAC is present but neon not illuminated, module is defective, replace module
Tighten fittings.
Coolant
Leaks
No cooling or insufficient cooling: No
Coolant Flow
Erratic System
Behavior(EMI
Interference ）
Loose fitting(s)
Damaged or punctured coolant line(s).
Supply & return hose reversed
Blockage in supply/return hoses
Missing or loose ground connection
Torch Lead Shield not connected or loose. F1 gnd cable not connected.
Cap board ground screw not tight or missing.
Cap C5 or C7 (on Cap PCB) open or disconnected wires to Cap board.
Visual inspection
Visual Inspection of color-coded connections
Loosen fitting slightly and check for coolant flow
Visual inspection of ground wire to Arc Starter
Visual inspection of lead shield attachment to Arc
Starter
Visual inspection
Visual inspection / capacitor measurement
Replace Coolant Lines
Match coolant connection colors to arc starter fitting colors.
Flush system or replace blocked hose.
Make or tighten connections to good ground.
Reconnect / tighten lead connectors.
Tighten or replace.
Replace PCB.
0-5578 OPERATION 4-31
ULTRA-CUT 130 XT/200 XT/300 XT/400 XT
This Page Intentionally Blank
4-32
ULTRA-CUT 130 XT/200 XT/300 XT/400 XT
SECTION 5: MAINTENANCE
5.01 General Maintenance
Perform the following checks periodically to ensure proper system performance.
Power Supply Maintenance Schedule
Daily
Check coolant level; add coolant as needed.
Check gas hose connections and pressures.
Check cooling fan; clean as needed.
Weekly
Check O-Rings in Torch and Cartridge
Monthly
Check cooling fan and radiator; clean as needed.
Check gas hoses for cracks, leaks, or abrasion.
Replace as needed.
Check all electrical connections for cracks or abrasion. Replace as needed.
Clean water filter (if using H
2
O Mist)
Six Months
Clean or replace coolant filter.
Clean coolant tank.
Vacuum out any dust buildup inside power supply.
5.02 External Coolant Filter Replacement Procedure
Periodic replacement of the coolant filter ensures maximum coolant flow efficiency. Poor coolant flow causes inefficient torch parts cooling with consequent faster consumable wear.
Replace the coolant filter as follows:
1. Disconnect system from main input power.
2. Unscrew and remove the filter canister by hand. Large canister located at the back of the power supply. Be sure to keep the O-ring.
3. Inspect and replace filter as needed. Re-install the canister, tightening it by hand. Be sure the O-ring is in place.
4. Turn the system on and check for leaks.
0-5578 MAINTENANCE 5-1
ULTRA-CUT 130 XT/200 XT/300 XT/400 XT
5.03 Coolant Replacement Procedure
Replace coolant as follows:
1. Disconnect the system from main input power.
2. Remove the two right side panels.
3. Locate the coupling in the coolant line that comes from the bottom of the coolant tank, #1 in the following illustration. Disconnect the coolant line at this fitting and drain the coolant into a disposable container of sufficient size.
Remember you will be draining more than the contents of the coolant reservoir.
4. Once coolant is draining, disconnect the gray hose coupling #2 in the illustration below. Allow excess coolant to drain, then apply a maximum of 5psi to clear the lines.
!
!
CAUTION
Applying more than 5 psi air pressure to the cooling system will result in damage. Extra caution must be used when performing this task.
2
1
5-2
Coolant overflow will drain through port in bottom of unit via this hose.
Art # A11689_AC
5. Reconnect those two fittings and then remove the filter bowl from the canister at the rear of the power supply.
Pour this remaining coolant into the container and replace the filter bowl.
NOTE!
If you also need to replace the coolant still in the leads, disconnect the leads from the power supply and manually drain them.
6. Fill the tank with fresh coolant until the right level is reached checking for leaks.
7. Turn system on, let it run for a few minutes and check coolant level, refill as needed. Refer to Section 3:26 Complete
Installation on the procedure for this.
8. Install the side panels.
MAINTENANCE 0-5578
ULTRA-CUT 100 XT/200 XT/300 XT/400 XT
SECTION 6: REPLACEMENT ASSEMBLIES & PARTS
6.01 Replacement Power Supply
Complete Unit / Component
Ultra-Cut 130 XT™ Power Supply, 400V +10 -15% (CCC)
Ultra-Cut 130 XT™ Power Supply, 400V +10 -15% (CE)
Ultra-Cut 200 XT™ Power Supply, 400V +10 -15% (CCC)
Ultra-Cut 200 XT™ Power Supply, 400V +10 -15% (CE)
Ultra-Cut 300 XT™ Power Supply, 400V +10 -15% (CCC)
Ultra-Cut 300 XT™ Power Supply, 400V +10 -15% (CE)
Ultra-Cut 400 XT™ Power Supply, 400V +10 -15% (CCC)
Ultra-Cut 400 XT™ Power Supply, 400V +10 -15% (CE)
Ultra-Cut 130 XT™ Power Supply, 208/230V +10 -15% with SL100 interface
Ultra-Cut 130 XT™ Power Supply, 480V +10 -15% with SL100 interface
Ultra-Cut 130 XT™ Power Supply, 400V +10 -15% with SL100 interface (CCC)
Ultra-Cut 130 XT™ Power Supply, 400V +10 -15% with SL100 interface (CE)
Ultra-Cut 130 XT™ Power Supply, 600V +10 -15% with SL100 interface
Ultra-Cut 200 XT™ Power Supply, 208/230V +10 -15% with SL100 interface
Ultra-Cut 200 XT™ Power Supply, 400V +10 -15% with SL100 interface
Ultra-Cut 200 XT™ Power Supply, 480V +10 -15% with SL100 interface (CCC)
Ultra-Cut 200 XT™ Power Supply, 480V +10 -15% with SL100 interface (CE)
Ultra-Cut 200 XT™ Power Supply, 600V +10 -15% with SL100 interface
Ultra-Cut 300 XT™ Power Supply, 208/230V +10 -15% with SL100 interface
Ultra-Cut 300 XT™ Power Supply, 480V +10 -15% with SL100 interface
Ultra-Cut 300 XT™ Power Supply, 400V +10 -15% with SL100 interface (CCC)
Ultra-Cut 300 XT™ Power Supply, 400V +10 -15% with SL100 interface (CE)
Ultra-Cut 300 XT™ Power Supply, 600V +10 -15% with SL100 interface
Ultra-Cut 400 XT™ Power Supply, 480V +10 -15% with SL100 interface
Ultra-Cut 400 XT™ Power Supply, 400V +10 -15% with SL100 interface (CCC)
Ultra-Cut 400 XT™ Power Supply, 400V +10 -15% with SL100 interface (CE)
Ultra-Cut 400 XT™ Power Supply, 600V +10 -15% with SL100 interface
Catalog Number
3-8115-3
3-8115-4
3-8119-3
3-8119-4
3-8118-3
3-8118-4
3-8120-3
3-8120-4
3-8115-1T
3-8115-2T
3-8115-3T
3-8115-4T
3-8115-5T
3-8119-1T
3-8119-2T
3-8119-3T
3-8119-4T
3-8119-5T
3-8118-1T
3-8118-2T
3-8118-3T
3-8118-4T
3-8118-5T
3-8120-2T
3-8120-3T
3-8120-4T
3-8120-5T
Remote Arc Starter (RAS-1000 XT) 3-9130E
OPTIONAL EQUIPMENT:
Wheel Kit (Not for use with Step up/Step down transformers). 9-7378
0-5578 PARTS LISTS 6-1
ULTRA-CUT 100 XT/200 XT/300 XT/400 XT
6.02 System Layout 130 - 300 Amp
Refer to section 3.08 and 3.10 for ground connections and ground cables.
F1
Primary power
220’ / 61 m Maximum Length
Pilot Return
Negative
Coolant Supply
Coolant Return
Control Cable
225’ / 68.6 m Maximum Length
E
F1
A
B
C
D
Remote
Arc
Starter
100’ / 30.5 m Maximum Length
Pilot Return
Shield
Coolant Supply
Coolant Return
Shield
Ultra-Cut
Power
Supply
F
CNC
Touch
Screen
Controller
W
P
V
Fiber Optic
Control Cable
Ground Cable
to PS Only
When DMC
Mounted On
Top Of PS
-If not - Earth-
L
K
F
DMC-3000
Gas
Console
Plasma Gas
Fiber Optic
Shield Gas
Preflow
Control Cable
Water Shield
Marking
H
L
Q
R
S
T
U
DPC-3000
Gas
Control
Plasma Gas
Shield Gas
F
I
J
Positioning Tube
G
Torch
Work
Work Cable O
Art # A-11995_AC
6-2 PARTS LISTS 0-5578
ULTRA-CUT 100 XT/200 XT/300 XT/400 XT
6.03 System Layout 400 Amp
Refer to section 3.08 and 3.10 for ground connections and ground cables.
225’ / 68.6 m Maximum Length
F
CNC
F1
Primary power
Touch
Screen
Controller
W
P
C
C
M
Ultra-Cut
Power
Supply
220’ / 61 m Maximum Length
Pilot Return #8
Negative 2/0
Control Cable
Coolant Supply 10’
Coolant Return 10’
Control Cable
C
D
Y
HE 400
Heat
Exchanger
Coolant Supply
Coolant Return
A
B
E
F1
C
D
V
Fiber Optic
Control Cable
Ground Cable
to PS Only
When DMC
Mounted On
Top Of PS
-If not - Earth-
L
K
F
DMC-3000
Gas
Console
Plasma Gas
Fiber Optic
Shield Gas
Preflow
Control Cable
Water Shield
Marking
S
T
Q
R
U
H
L
Remote
Arc
Starter
DPC-3000
Gas
Control
50’ / 15.25 m Maximum Length
Pilot Return
Shield
Coolant Supply
Coolant Return
Shield
Plasma Gas
Shield Gas
F
I
J
Positioning Tube
G
Torch
Work
Work Cable O
Art # A-11996_AC
6.04 Recommended Gas Supply Hose
Item # Qty
1
Description
3/8”Gray Synflex Hose. No fittings included. Catalog number per foot 9-3616
Catalog #
0-5578 PARTS LISTS 6-3
ULTRA-CUT 100 XT/200 XT/300 XT/400 XT
6.05 Leads And Cables All Amperages
#8 AWG Cable
A
Pilot Return, Power Supply to Arc Starter
4/0 AWG Cable (120 mm 2 )
B
Negative Lead, Power Supply to Arc Starter
E,Y
14/7
I
C
D
F
F1
G
Green
Red
Green
Green / Yellow # 4 AWG
Red
Coolant Supply Lead,
Power Supply to Arc Starter
Coolant Return Lead,
Power Supply to Arc Starter
E - Control Cable, Power Supply to Arc Starter
Y - Control Cable to Heat Exchanger
Ground Cable
Ground Cable,
Remote Arc Starter
To Earth Ground
Shielded Torch Lead
Assembly, Remote
Arc Starter to Torch
Plasma Gas Lead,
Torch Valve to Torch
J
K 37
L
H, Q,
R,T, U
Shield Gas Lead,
Torch Valve to Torch
Control Cable,
Power Supply to
Gas Control Module
Fiber Optic Cable,
Power Supply to
Gas Control Module
For use with
DFC-3000
S,V
16 pin
S - Control Cable,
DMC-3000 to DPC-3000
V - TSC-3000 to PS
O
P,W
37/11
Work Cable
CNC Cable (37 Wire)
W - CNC Communitcation
Cable (11 Wire)
6-4 PARTS LISTS 0-5578
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0-5578 PARTS LISTS 6-5
ULTRA-CUT 100 XT/200 XT/300 XT/400 XT
6.06 Power Supply External Replacement Parts
Item # Qty
5
6
7
3
4
1
2
1
1
1
1
1
1
1
Description Catalog #
Power and Leads Cable Cover 9-7346
Top Panel,
Upper Side Covers
9-7300
9-7301
Lower Left Side Panel 9-7304
Lower Right Side 300A/400A Panel 9-7344
Lower Right Side 130A/200A Panel
Lifting Eye
9-7302
9-9373
Art # A-11543_AC
1 1
2 7
3
4
3
5 Larger 300/400A
6 Smaller 100/200A
6-6 PARTS LISTS 0-5578
ULTRA-CUT 100 XT/200 XT/300 XT/400 XT
6.07 Power Supply Replacement Parts - Upper Right Side
Item # Qty
1 1
5
6
3
4
7
8
10
11
1
1
1
1
1
1
1
1
Description
System Bias PCB
CCM Assembly, 130-400Amp
Relays, Pump / Fan
Relay, Inrush Control
Relay, Inrush
Resistor, Inrush
Display PCB
On/Off Switch Breaker
Relay and Interface PCB
Ref. Des. Catalog #
9-9253
9-9250
9-7334
MC3 / MC2 9-7314
K1
MC1
R2
9-733
9-733
7
6
9-7376
9-9252
T1 9-7315
CB1 9-7316
9-9251
1 2
11
10
9
8
7
6
5
3
4
Art # A-11546_AB
0-5578 PARTS LISTS 6-7
ULTRA-CUT 100 XT/200 XT/300 XT/400 XT
6.08 Power Supply Replacement Parts - Lower Right Side
Item # Qty Description Ref. Des. Catalog #
2 1 Coolant
3 1
Tank
Tank
Coolant level Sensor
4
5
1
1
1
Pump, Coolant, Assembly (with motor)
Pump, Coolant, Assembly (no motor)
Motor, Pump (motor only)
8-5142
9-7306
9-7307
9-7309
9-7422
9-7424
6 1 Cooling
Two smaller for 130A / 200A systems
9-7348
9-7312
7 1 Radiator
300A / 400A systems
130A / 200A systems
9-7349
9-7311
8
9
1
1
Flow, Switch (Not shown)
Current Transducer, 300A (Not shown)
FS1
HCT1
9-7310
W7005324
Art # A-11984_AB
1
3
2
4
7
8
5
6
6-8 PARTS LISTS 0-5578
ULTRA-CUT 100 XT/200 XT/300 XT/400 XT
6.09 Power Supply Replacement Parts - Rear Panel
Item # Qty Description Breaker Rating Circuit Rating Ref. Des.
1
3
4
5
6
7
1
1
1
1
1
1
Coolant Filter Assy
Catalog #
Fuse, 8A SB 500 VAC 9-7377
Circuit Breaker, 250VAC, 5Amp
Input Cable Connector
Pilot Cable Connector
Output Cable Connector
9-7320
9-7321
9-7439
9-7384
9-7386
9-7385
1
J55 - GCM
USER INPUT
J15 - CNC
HEIGHT CONTROL
2
6
7
5
J54 - TSC /COMM
J59 - RAS
J70 - HE
F1 - 8A SB 500 VAC
CB2 - 5A 120 VAC
CB3 - 5A 24 VAC
CB4 - 5A 120 VAC
F2 - 8A SB 500 VAC
4
3
Art # A-11549_AD
0-5578 PARTS LISTS 6-9
ULTRA-CUT 100 XT/200 XT/300 XT/400 XT
6.10 Power Supply Replacement Parts - Left Side
Item # Qty
1
2
3
4 1
1
1
1
1
1
Description Ref. Des. Catalog #
AC Suppresion PCB
Main Contactor (2 total)
Inverter Module, Full 380-415 VAC
Inverter Module, Full 480 VAC
(130 and 200 Amp Systems use 1)
(300 Amp System uses 2)
(400 Amp System uses 3)
Inverter Module, Partial 380-415 VAC (For 200A and 300A ONLY)
Inverter Module, Partial 480 VAC (For 200A and 300A ONLY)
W1, W2
5 1 EMI Filter PCB
(130 Amp Systems use 1)
(200 Amp Systems use 2)
(300 Amp Systems use 3)
(400 Amp Systems use 4)
9-9254
9-7318
9-7317
9-7330
9-7319
9-7331
9-9264
400 Amp Power Supply
200 Amp Power Supply
1
2
5
4
5
3
Art # A-11943
6-10 PARTS LISTS 0-5578
ULTRA-CUT 100 XT/200 XT/300 XT/400 XT
6.11 Step Up/StepDown Transformer Replacement Parts
Item # Qty
1
2
3
4
5
1
1
1
1
1
Description
Transformer 130/200A 230V-480V
Transformer 130/200A 600V-480V
Transformer 300A 230V-480V
Transformer 300A 600V-480V
Transformer 400A 600V-480V
Catalog #
9-7408
9-7411
9-7409
9-7416
9-7417
Art# A-14615
0-5578 PARTS LISTS 6-11
ULTRA-CUT 100 XT/200 XT/300 XT/400 XT
6.12 DFC-3000 Automated Gas Control System Replacement Components
Item # Qty
1
2
3
1
1
1
Description
Assy, DMC-3000, Demo
Assy, DPC-3000, Demo
Assy, TSC-3000, Remote, Demo
Catalog #
9-9491D
9-9443D
9-9490D
Art # A-09135_AC
6-12 PARTS LISTS 0-5578
ULTRA-CUT 100 XT/200 XT/300 XT/400 XT
6.13 DMC-3000 Gas Control Module Replacement Parts
Item # Qty Description
2 1 Solenoid
3 1 Manifold subassembly (includes 15 of item 2)
Catalog #
9-9491D
9-8264
9-7546
9-8263
9-7291
Not shown:
6
7
8
9
10
1
1
1
1
1
WMS Water Softener Kit (includes the following items)
WMS Replacement Filter Cartridge
WMS Filter Housing
WMS Filter Mounting Bracket
WMS Filter Hose and Fitting Assembly
5
9-1068
9-1069
9-1070
9-4523
9-4524
4
1
2
There are 15 total
3
0-5578 PARTS LISTS 6-13
ULTRA-CUT 100 XT/200 XT/300 XT/400 XT
6.14 DPC-3000 Gas Control Module Replacement Parts
Item # Qty Description
1 1 Assy, DPC-3000, Demo
2 1 DPC-PCB
3
4
1
1
SMPS PCB
Shield Gas P Valve
5
6
1
1
Sensor, Pressure, 1/8mnpt (six total)
Solenoid (3 total)
7
8
1
1
Plasma Low, Pre-Flow & H
2
O Shield P Valve (3 total)
DPC Manifold Fully Assembled
2
1
3
Catalog #
9-9443D
9-8262
(V1)
9-8263
9-8267
9-8269
9-8264
(V2, V3, V4) 9-8268
9-7658
4
6
5
7 7
8
6-14 PARTS LISTS 0-5578
ULTRA-CUT 100 XT/200 XT/300 XT/400 XT
6.15 TSC-3000 Touch Screen Control Remote and Internal Replacement Parts
Item # Qty Description
1 1
2 1
3
4
1
1
Assy, TSC-3000, Remote , Demo
Touch Panel Computer
Switch, Rocker SPST
Ribbon Cable HMI to Interface PCB
5
6
1
1
PCB
4
USB Panel Mount Extension
3 2 1
Catalog #
9-9490D
9-7543
9-1042
N/A
9-7547
9-7545
5
6
0-5578 PARTS LISTS 6-15
ULTRA-CUT 100 XT/200 XT/300 XT/400 XT
6.16 Remote Arc Starter (RAS-1000 XT) Replacement Parts
Item # Qty
1
2
3
1
1
1
Description
Complete RAS 1000 XT Assembly
Pilot Cap Assembly
Electronic Ignition Module
1
2
3
4
Art # A-12066
Catalog #
3-9130E
9-9423
9-7342
9-7343
6-16 PARTS LISTS 0-5578
ULTRA-CUT 100 XT/200 XT/300 XT/400 XT
6.17 HE400XT Heat Exchanger - Replacement Parts
Item # Qty Description
1 1 Assembly, HE400XT Heat Exchanger
2 1 Fan
3 1 Radiator
4 1 Capacitor
Catalog #
9-9416
9-7348
9-7349
9-1059
9-1448
1
2
4 3
5
Art # A-12672
0-5578 PARTS LISTS 6-17
ULTRA-CUT 100 XT/200 XT/300 XT/400 XT
This Page Intentionally Blank
6-18 PARTS LISTS 0-5578
ULTRA-CUT 130 XT/200 XT/300 XT/400 XT
SECTION 7: TORCH MAINTENANCE
7.01 Consumable Removal
1. Use the removal tool to hold the Shield Cup & Cartridge Assembly stationary. Turn the Shield Cup to remove it from the Cartridge Assembly.
Cartridge Tool
Assembled Cartridge
Art # A-04344_AB
Shield Cup
2. Take the Removal Tool off the back of the Cartridge Assembly Use the removal tool to push the consumable parts out of the Cartridge.
Cartridge Tool Cartridge Assembly
Art # A-04345_AB
0-5578 TORCH INFORMATION 7-1
ULTRA-CUT 130 XT/200 XT/300 XT/400 XT
7.02 O-Ring Lubrication
Lubricate all three O-Rings on the Cartridge Assembly and all three O-Rings on the Torch Head periodically with O-Ring
Lubricant supplied. Remove the snap ring on the cartridge assembly and slide the locking ring downward for access to the O-Ring under the locking ring.
Inner O-Ring (Cat. No. 9-3030)
Location (Under Locking Ring)
O-Rings Torch Head
Cat. No. 9-9041
O-Ring, Cat. No. 9-3029
O-Ring, Cat. No. 9-3028
Snap Ring
Cartridge Assembly
Cat. No. 8-0524
Cat. No. 9-3026
Cat. No. 9-3025
Art # A-04071_AC
Cat. No. 9-9429
Inner O-Ring (Cat. No. 9-3030)
Location (Under Speed Lock Ring)
O-Ring, Cat. No. 9-3029
O-Ring, Cat. No. 9-3028
Cartridge Assembly
Speed Lock Ring and
Threaded Ring removed for clarity
Art # A-09684_AD
O-Ring, Cat. No. 8-0547
O-Ring,
Cat. No. 8-0561
O-Ring,
Cat. No.
9-3029
Outer Cartridge
Art # A-04066_AE
!!
CAUTION
Use only Thermal Dynamics No. 9-4893 O-Ring Lubricant (Christo Lube MCG-129) with this torch part.
Use of other lubricants may cause irreparable damage to the torch.
7-2 TORCH INFORMATION 0-5578
7.03 Parts Wear
ULTRA-CUT 130 XT/200 XT/300 XT/400 XT
Replace the Gas Distributor if it is charred or cracked.
Replace the Gas Distributor if the flange is damaged in any way.
Replace the tip and/or electrode if they are worn.
Good Tip Worn Tip Good Electrode Worn Electrode
Art # A-04745_AB
0-5578 TORCH INFORMATION 7-3
ULTRA-CUT 130 XT/200 XT/300 XT/400 XT
7.04 Torch Consumables Installation
WARNINGS
Do not install consumables into the Cartridge while the Cartridge is attached to the Torch Head.
Keep foreign materials out of the consumables and Cartridge.
Handle all parts carefully to avoid damage, which may affect torch performance.
Art # A-03887
1. Install the consumables as follows: 30-100 amp shown as an example.
1: Stack Parts 2: Press Cartridge onto Stacked Parts
Electrode
Plasma Gas
Distributor
Tip
Upper O-Ring on Tip
No Gaps
Between Parts
Shield Gas
Distributor
Shield Cap
3: Thread Shield Cup onto Cartridge 4: Check Shield Cap Protrusion
Cartridge Covers
Upper O-Ring on Torch Tip
Shield Cup
Shield Cap
Shield Cap Protrudes
0.063-0.083" (1.6 - 2.1 mm)
Art # A-04716_AB
7-4
2, Remove the Removal Tool from the Cartridge and install the assembled Cartridge onto the Torch Head.
TORCH INFORMATION 0-5578
!
!
ULTRA-CUT 130 XT/200 XT/300 XT/400 XT
CAUTION
The cartridge assembly must cover the O-Ring on the torch head.
Do not force the cartridge if it will not tighten fully. Remove the cartridge assembly and gently clean the threads on the torch head with a wire brush. Apply oxygen-compatible lubricant (supplied with the torch) to the threads.
Torch Head
Torch Head O-Ring
0.063 - 0.083"
(1.6 - 2.1 mm)
Protrusion
Art # A-07202_AB
Installing Assembled Cartridge Onto Torch Head
3. Slide the ohmic clip over the shield cup if using ohmic torch height control sensing.
NOTE!
Ohmic height sensing is not recommended with water shield. Water on the plate interferes electrically with the ohmic sensing circuit.
Ohmic Clip
Art # A-03393_AB
4. Connect the wire lead from the height finder to the ohmic clip.
0-5578 TORCH INFORMATION 7-5
ULTRA-CUT 130 XT/200 XT/300 XT/400 XT
7.05 Coolant Leak Trouble-Shooting
Never operate the system if coolant leaks from the torch. A steady drip indicates that torch parts are damaged 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
Yes
Are Parts New or Used?
New
Used
Leaking from
Coolant Supply or
Coolant Return?
Return
Supply
Order Coolant
Check Valve
Kit 9-4846
Order Coolant
Tube Replacement Kit
The parts probably are worn out.
See chart for approximate life expectancy.
The torch may be damaged. See page to determine if head damage has occurred.
Are Parts fully assembled into the Torch?
Yes Is the Torch Damaged?
No
Remove and Lubricate all O-rings on Torch Head,
Consumables Cartridge, and Consumables.
Re-assemble Torch.
Still leaks?
Yes
Unsure?
Disassembly fully and re-assemble the Torch Properly.
See Installation Manual.
Yes
Replace Torch Head Yes
Replace Consumable
Cartridge and Shield Cup.
Torch still leaks?
Art # A-09638
7-6 TORCH INFORMATION 0-5578
ULTRA-CUT 130 XT/200 XT/300 XT/400 XT
0-5578
Torch
Electrodes
Amperage
30
50
70
85
100
130
150
200
250
300
400
Art # A-09653
Plasma Gas
0.08
0.08
0.06
0.08
0.04
0.08
0.08
0.06
0.08
0.06
0.08
0.08
0.06
0.06
0.08
0.08
0.08
0.08
0.08
0.08
Recommended Wear
Depth for Electrode
Replacement
Inch
0.04
mm
1
0.04
0.04
0.04
0.08
1
1
1
2
0.04
0.04
0.08
0.04
0.08
2
1
2
1
1
2
2
2
1.5
2
2
2
2
2
1.5
2
1
2
2
1.5
2
1.5
2
2
1.5
TORCH INFORMATION
N2
O2
H35
N2
O2
H35
N2
O2
H35
O2
H35
N2
O2
H17
H35
N2
Air
N2
Air
O2
H35
N2
O2
O2
Air
N2
O2
Air
N2
O2
7-7
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This Page Intentionally Blank
7-8 TORCH INFORMATION 0-5578
ULTRA-CUT 130 XT/200 XT/300 XT/400 XT
APPENDIX 1: CNC - Control Module PCB Connections
Art # A-11512_AD
0-5578 APPENDIX A-1
ULTRA-CUT 130 XT/200 XT/300 XT/400 XT
APPENDIX 2: SERIAL COMMUNICATIONS
A2.01 Cables and Switch Settings for 2 and 4 Wire
The CCM communicates with the CNC controller over a serial interface using the CCM default setting of 4 wire RS422 (half duplex). Or with the TSC 3000 (touch screen HMI panel) over 2 wire RS 485 (half duplex). For communication with the TSC
3000 the jumper on J14 in the CCM needs to be moved to the 2W (2 wire) position as shown. RS 422 is normally full duplex but the CCM only supports half duplex. RS 232 is not directly supported. Converters are available from various sources to convert RS 232 to RS 422 or RS 485. The serial communications port of the CCM is provided with 3KV isolation from the rest of the plasma supply circuitry.
RS 485 wiring (2 wire, half duplex)
CCM Module
JUMPER for 2 WIRE
(RS485 only) use Data +,
Data -, Gnd.
J14
Data-
SW14 - LINE
TERMINATION normally on
(refer to manual)
SW14
J54
9
10
11
12
13
14
7
8
5
6
3
4
1
2
REMOTE TSC to CCM CABLE (V):
(W)
(R)
(BK)
(OR)
(GN)
(OR / W)
(W / BL)
(W / OR)
(GN / W)
(BL / W)
(W / GN)
The multicolor wires are twisted pairs.
OR / W = Orange wire with White stripe
CCM to TSC 3000 is RS 485 - 2 wire.
J61
13
14
15
16
9
10
11
12
7
8
5
6
3
4
1
2
TSC 3000
PLASMA ENABLE
Art # A-09481
RS 422 wiring (4 wire, half duplex) (also called RS 485 4 wire)
CCM Module
JUMPER for 4 WIRE use TX+, TX-,
RX+, RX-
J14
SW14
SW14 - LINE norm ally on
KEY PLUG
Tx+
TERMINATION
(refer to m anual)
Tx-
Rx+
Rx-
COMMUNICATIONS & Norm ally open (NO) PLASMA ENABLE (close to enable)
CONTROL CABLE (W) jum per #1 to #3, connect SW to #5 & #6.
CNC to CCM
J54
Norm ally closed (NC) PLASMA ENABLE (open to enable) connect SW to #1 & #3 in place of the jumper.
(W)
(R)
(BK)
(OR / W)
(W / BL)
(BL / W)
#1
#2
#3
No jum per required.
#1
9
10
11
12
13
14
7
8
5
6
3
4
1
2
(OR)
(GN)
(W / OR)
GN / W)
(W / GN)
OR / W = Orange wire
#3
PLASMA ENABLE NC
(open SW to enable)
#5
#6
PLASMA ENABLE NO
(used with jumper)
#8
#9
#10
#12
#13
#14 to CNC Tx-
SHIELD 2
SHIELD 1 to CNC Rx+
Signal Gnd to CNC Rxto CNC Tx+
The multicolor wires are twisted pairs.
Connect both shields to earth ground at the CNC end of cable.
with White stripe.
Recommend using the 4 wire when possible as it is easier to troubleshoot if there is a problem. Note that CCM Tx+ connects to CNC Rx+ and CCM TX- connects to CNC RX- for 4 wire half duplex. If using 2 wire RS 485 connect CCM Tx+ (also called
D+ or Data +) to CNC Tx+ and CCM Tx- (also called D- or Data- ) to CNC Tx-. The Rx wires are not used for 2 wire.
A-2 APPENDIX 0-5578
Line termination:
ULTRA-CUT 130 XT/200 XT/300 XT/400 XT
RS 485 and RS 422 are both “multi-drop protocols, that is there can be multiple devices on the same line. We do not currently support more than one CCM. Until we do line termination should always be ON.
For RS 485 it is recommended that the communication lines be terminated at each end with the line’s characteristic impedance. For RS 422 it is recommended the line be terminated at the receiver end.
The CCM has a line termination switch SW14 whose default position is ON. For CCMs that are not at the end of the line
(like CCM #1 & #2 below) switch off SW14.
RS 485 with multiple CCMs:
TSC 3000 (HMI) or CNC using
2 wire RS 485
Data+
120
Data-
Signal GND also required but not shown.
SW14 OFF
CCM #1
Art # A-09483
RS 422 4 wire half duplex:
CNC using
RS 422 half duplex
Tx+
Tx-
120
Rx+
Rx-
Signal GND also required but not shown.
SW14 OFF
CCM #2
120
SW14 ON
CCM # (last in line)
Rx Tx
SW14 OFF
CCM #1
Rx Tx
SW14 OFF
CCM #2
Rx
120
Tx
SW14 ON
CCM # (last in line)
Art # A-09484_AB
CCM Address:
When more than one device is used in parallel on a serial communication line each has to have a unique address. The
CCM has a switch SW10 to set the address of each CCM. The “0” factory setting is correct for system with one plasma (one
CCM). We do not currently support CCMs in parallel. When that becomes available details for setting other addresses will be included in an updated manual explaining installation and set up of parallel systems.
0-5578 APPENDIX A-3
ULTRA-CUT 130 XT/200 XT/300 XT/400 XT
APPENDIX 3: 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)
Start/Stop
Ok to Move (contacts or voltage 1)
Divided Arc volts (selectable ratio
50:1; 40:1; 30:1; 16.6:1, 25:1)
PreFlow ON
Corner Current Reduction
Isolated Circuit Comm (for SC-11) 8
1
3 (+); 4 (-)
12(-); 14 (+)
5 (-); 6 (+)
7 (+); 9 (-)
10 (+); 11 (-)
Hold Start
Plasma Mark
Cut Expanded Metal
CNC Plasma Enable 2
Remote Analog Current Control 3
Stop (Latched) SW4
Pilot is ON (contacts)
16(+); 17 (-)
21 (+); 22 (-)
23 (+); 24 (-)
25 (+); 26 (-)
29 (+); 30 (signal); 31 (-)
32 (+); 33 (-)(comm.)
34; 35
A-4 APPENDIX 0-5578
ULTRA-CUT 130 XT/200 XT/300 XT/400 XT
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
CNC Enable/Disable
OK to Move 2
Stop Latched (NC) 4
Start/Stop or Start Latched 4
Divided Arc Voltage
Remote Analog Current Control
TB2
TB1-2 (+), TB1-1(-)(comm.)
TB1-3 &TB1-12 Contacts only, rated 1A @ 28 VAC/DC
TB1-4 (+) & TB1-5 (-) (comm.) used with Start Latched
TB1-6 (+), TB1-5 (-) (comm.)
TB1-8 (+), TB1-7 (-) comm.
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)
Hold Start
Preflow ON
TB2-2 (+),TB2-1 (-) (comm. )
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
Plasma Marking TB3-2(+), TB3-1(-) (comm.)
Spare NC Contact
Spare NO Contact
TB3-9, TB3-10
TB3-11, TB3-12
1 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
2 Remove factory installed jumper from TB1-1 & 2 if using CNC Plasma Enable in J15.
3-5 See below.
0-5578 APPENDIX A-5
ULTRA-CUT 130 XT/200 XT/300 XT/400 XT
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 removed when connecting user supplied E-Stop circuit.
4 Start/Stop input —Switch (momentary or sustained) rating 35ma. @ 20 VDC
Start / Stop circuit configurations. Momentary Start / Stop (Latched) is only available at TB1.
MOMENTARY START / STOP
SUSTAINED START / STOP
STOP
TB1-4
TB1-5
START / STOP
TB1-5
TB1-6 START
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.
3 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).
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-6 APPENDIX 0-5578
ULTRA-CUT 130 XT/200 XT/300 XT/400 XT
5 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.
Ext. +10V TB1
11
10
9
+10V
WIPER
Art # A-09246
5 Plasma Marking Select (Remote) – Plasma Marking, available only with DFC 3000, 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 Ultracut power supplies It is OK to leave
SW8-4 on whether you are marking or not.
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.
0-5578 APPENDIX A-7
ULTRA-CUT 130 XT/200 XT/300 XT/400 XT
Simplified CNC Circuit
Ultracut XT Simplified CNC
OK TO MOVE SELECT
18 VDC or Contacts
SW6A
DC VOLTS
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 (-)
TB1
12
11
10
9
8
7
6
5
4
3
2
1
OK2
+18VDC
CONTACTS
SW6B
B
3
+
4
OK to MOVE (+)
OK to MOVE (-)
PILOT is ON
PILOT is ON
Preflow ON (+)
Preflow ON (-)
Hold Start (+)
Hold Start (-)
TB2
12
11
10
9
6
5
4
8
7
3
2
1
-
VOLTAGE DIVIDER
5
OK
+10V
GND
ALL SW OFF for 50:1 (default)
SW12A (1) ON = 16.7:1 (SC-11)
SW12B (2) ON = 30:1
SW12C (3) ON = 40:1
SW12D (4) ON = 25:1
Spare Input (-)
Spare Input (+)
/ SLAVE UNIT
*Plasma Ready (b)
Spare Input (-)
Spare Input (+)
Spare Input (-)
Spare Input (+)
/ Plasma Marking (-)
/ Plasma Marking (+)
TB2
8
7
6
5
4
3
2
1
12
11
10
9
PSR
* CCM Cdoe 2.5 or later
Art # A-11579_AB
A-8 APPENDIX 0-5578
7
8
9
4
5
6
10
11
1
2
3
12
13
14
15
16
17
18
J21
GND
* Plasma Ready (a)
9
10
11
7
8
5
6
12
1
2
3
4
13
14
15
16
17
18
19
20
J22
* CCM Cdoe 2.5 or later
(133)
(134)
(137)
(139)
(138)
(143)
(140)
(141)
(136)
(135)
(132)
(153)
(142)
(144)
(145)
(146)
(147)
(148)
(149)
(150)
(151)
Preflow ON
(152)
Rem POT Low
(154)
(155)
(156)
(157)
(158)
(159)
Harness to Relay PCB
Harness to CPU PCB
J15-1 to chassis used for
SC-11 cable shield
The COMM Ref at pin
8 is also for the SC-11
(115)
(116)
(117)
(118)
(119)
(120)
J54 - Remote HMI & CNC COMM
(100)
(101)
(102)
1
2
3
1 - 24 VAC
3- Jumper to 24 VAC
4
(109)
(108)
5
6
7
8
9
10
7 - Key Plug
8 - Tx+
9 - GND
10 - GND
11
12
13
RS 485
/ 422
Comm
14
12 - Tx-
14 - Rx-
J15-CNC
Chassis
(133)
(134)
(135)
(136)
(137)
(138)
(139)
(140)
(141)
(142)
(143)
(144)
(145)
(146)
(147)
(148)
(149)
(150)
(151)
J15-13 connects SC-11 chassis to PS chassis.
(132)
(152)
(153)
(154)
(155)
(156)
(157)
(158)
(159)
24
25
26
27
28
29
16
17
18
19
20
21
22
23
30
31
32
33
34
35
36
37
8
9
10
11
12
13
14
15
3
4
5
1
2
6
7
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 (-)
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- 37 Plasma is Ready (a)
Normally Open Contact
* Used with Momentary CNC Start SW
Art # A-11579_AB
Ultracut XT Simplified CNC
OK TO MOVE SELECT
18 VDC or Contacts
SW6A
DC VOLTS
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 (-)
TB1
12
11
10
9
8
7
6
5
4
3
2
1
OK2
+18VDC
CONTACTS
SW6B
B
3
+
4
OK to MOVE (+)
OK to MOVE (-)
PILOT is ON
PILOT is ON
Preflow ON (+)
Preflow ON (-)
Hold Start (+)
Hold Start (-)
TB2
12
11
10
9
6
5
4
8
7
3
2
1
-
VOLTAGE DIVIDER
5
OK
+10V
GND
ALL SW OFF for 50:1 (default)
SW12A (1) ON = 16.7:1 (SC-11)
SW12B (2) ON = 30:1
SW12C (3) ON = 40:1
SW12D (4) ON = 25:1
Spare Input (-)
Spare Input (+)
/ SLAVE UNIT
*Plasma Ready (b)
Spare Input (-)
Spare Input (+)
Spare Input (-)
Spare Input (+)
/ Plasma Marking (-)
/ Plasma Marking (+)
TB2
8
7
6
5
4
3
2
1
12
11
10
9
PSR
* CCM Cdoe 2.5 or later
Art # A-11579_AB
ULTRA-CUT 130 XT/200 XT/300 XT/400 XT
7
8
9
4
5
6
10
11
1
2
3
12
13
14
15
16
17
18
J21
GND
* Plasma Ready (a)
9
10
11
7
8
5
6
12
1
2
3
4
13
14
15
16
17
18
19
20
J22
* CCM Cdoe 2.5 or later
(133)
(134)
(137)
(139)
(138)
(143)
(140)
(141)
(136)
(135)
(132)
(153)
(142)
(144)
(145)
(146)
(147)
(148)
(149)
(150)
(151)
Preflow ON
(152)
Rem POT Low
(154)
(155)
(156)
(157)
(158)
(159)
Harness to Relay PCB
Harness to CPU PCB
J15-1 to chassis used for
SC-11 cable shield
The COMM Ref at pin
8 is also for the SC-11
(115)
(116)
(117)
(118)
(119)
(120)
J54 - Remote HMI & CNC COMM
(100)
(101)
(102)
1
2
3
1 - 24 VAC
3- Jumper to 24 VAC
4
(109)
(108)
5
6
7
8
9
10
7 - Key Plug
8 - Tx+
9 - GND
10 - GND
11
12
13
RS 485
/ 422
Comm
14
12 - Tx-
14 - Rx-
J15-CNC
Chassis
(133)
(134)
(135)
(136)
(137)
(138)
(139)
(140)
(141)
(142)
(143)
(144)
(145)
(146)
(147)
(148)
(149)
(150)
(151)
J15-13 connects SC-11 chassis to PS chassis.
(132)
(152)
(153)
(154)
(155)
(156)
(157)
(158)
(159)
24
25
26
27
28
29
16
17
18
19
20
21
22
23
30
31
32
33
34
35
36
37
8
9
10
11
12
13
14
15
3
4
5
1
2
6
7
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 (-)
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- 37 Plasma is Ready (a)
Normally Open Contact
* Used with Momentary CNC Start SW
Art # A-11579_AB
0-5578 APPENDIX A-9
ULTRA-CUT 130 XT/200 XT/300 XT/400 XT
CNC Connections
Cutting Machine CNC Cable
START/STOP
Start Motion
(OK-To-Move)
10 K
{
*
(1)
(16)
(17)
(29)
(30)
(31)
(32)
(33)
(34)
(35)
(36)
(37)
(21)
(22)
(23)
(24)
(25)
(26)
( )
( )
5
( )
( )
Power Supply
J15
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
10
11
7
8
9
5
6
3
4
12
13
1
2
*
NC
..........
Source, 16 VDC, 10 ma.
..........
..........
... Divided Arc V (-)
Divided Arc V (+)
Pre Flow ON (+)
*
..........
..........
...
..........
..........
Pre Flow ON (-)
Corner Current Reduction (+)
Corner Current Reduction (-)
SW6
(+)
DC
/Hold Start(+)
/Hold Start(-)
OK-To-Move
Relay DCV (-)
Contact or
(1A @ DCV (+)
120 VAC ( 15 - 18 VDC @ or 28 VDC) up to 100 ma.)
..........
..........
..........
..........
..........
..........
..........
..........
..........
..........
..........
..........
..........
..........
..........
/Plasma Mark (+)
/Plasma Mark (-)
/Cut Expanded Metal (+)
/Cut Expanded Metal (-)
/CNC Plasma Enable (+)
/CNC Plasma Enable (-)
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)
Pilot is ON (b)
Spare OUT #1 (a)
Spare OUT #1 (b)
Relay contact 1A @
120 VAC or 28
Shield
**
Represents switch, relay, open collector transistor, etc.
* 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.
Art # A-11901
A-10 APPENDIX 0-5578
CNC Cable Color Code
ULTRA-CUT 130 XT/200 XT/300 XT/400 XT
PIN
LOCATION
3
4
5
26
29
30
23
24
25
16
17
21
22
9
10
11
12
14
6
7
8
34
35
36
37
31
32
33
TABLE 1: CABLE ITEM#4 COLOR CODE TABLE
COLOR
WHITE/BLUE
WHITE/VIOLET
WHITE/BROWN/VIOLET
WHITE/BROWN
YELLOW
GREEN
WHITE/BLACK/BROWN
WHITE/BROWN/BLUE
WHITE/BLACK
BLACK
BLUE
WHITE/BROWN/YELLOW
WHITE/BROWN/GREEN
WHITE/BLACK/ORANGE
WHITE/BLACK/RED
WHITE/BROWN/ORANGE
ORANGE
RED
BROWN
WHITE/BROWN RED
WHITE
GRAY
VIOLET
WHITE/BLACK/YELLOW
WHITE/BLACK/GRAY
WHITE/BLACK/VIOLET
WHITE/BLACK/BLUE
WHITE/BLACK/GREEN
SIGNAL DESCRIPTION
START CNC (+)
START CNC (-)
DIV ARC (-)
DIV ARC(+)
PREFLOW ON (+)
COMM 1K
PREFLOW ON (-)
CORNER CR (+)
CORNER CR (-)
OK TO MOVE (-)
OK TO MOVE (+)
/HOLD START (+)
/HOLD START (-)
/PLASMA MARK (+)
/PLASMA MARK (-)
/CUT EXPANDED METAL (+)
/CUT EXPANDED METAL (-)
/CNC PLASMA ENABLE (+)
/CNC PLASMA ENABLE (-)
REMOTE CC POT HIGH
REMOTE CC (ANALOG)
REMOTE CC POT LOW
STOP SW (MOMENTARY)
STOP SW RETURN
PILOT IS ON (A)
PILOT IS ON (B)
SPARE OUT #1 (A)
SPARE OUT #1 (B)
PIN 1
Art # A-12757
0-5578 APPENDIX A-11
ULTRA-CUT 130 XT/200 XT/300 XT/400 XT
APPENDIX 4: DMC-3000 Control PCB Layout
TP5
J6
TP4
SW2
SW1
TP3 J5
TP6 TP2
TP7
TP1
J8
LED
D1
D-17
LED
D_E1
D_E15
J1
J2
J3
D21
D22
J4
Art # A-09188_AC
J9
A-12 APPENDIX 0-5578
ULTRA-CUT 130 XT/200 XT/300 XT/400 XT
APPENDIX 5: DPC-3000 Control PCB Layout
J9
D7
J6
D12
J5
SW2
J4
J3
J2
SW1
J1
TP5
Art # A-09189_AB
TP3
D11
TP7
D10
TP1
D6
TP6
D5
D4
D3
TP4
J8
D2
D9
D8
TP8
D1
TP11
TP2
TP10
TP9
J10
0-5578 APPENDIX A-13
ULTRA-CUT 130 XT/200 XT/300 XT/400 XT
APPENDIX 6: DMC-3000 / DPC-3000 Power Supply PCB Layout
J2
D9 D7
D6
TP6
TP1
D5
F2
TP7
TP8
D16
J1 F1
Art # A-09597_AB
TP3
TP2
TP5
TP4
A-14 APPENDIX 0-5578
J1
D1
ULTRA-CUT 130 XT/200 XT/300 XT/400 XT
APPENDIX 7: TSC-3000 PCB Layout
TP4 D11 TP3
D13
TP1
D14 D15
J2 TP2 J3 J4
Art # A-09190_AB
J5
0-5578 APPENDIX A-15
ULTRA-CUT 130 XT/200 XT/300 XT/400 XT
APPENDIX 8: CCM CPU PCB Layout
= Test Point
A-16 APPENDIX
Art # A-11675_AC
0-5578
CCM CPU PCB
Test Points
TP1
TP2
TP3
TP4
TP5
TP6
TP7
GND
ISO +5.0V
+24V
+3.3V
ISO GND
+5.0V
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
LED Reference
D2 Red RXD
D3
D4
D7
D11
D17
Red TXD
Red Fiber Out 2
Red Fiber Out 1
Green Future Use
Green Future Use
ULTRA-CUT 130 XT/200 XT/300 XT/400 XT
0-5578 APPENDIX A-17
ULTRA-CUT 130 XT/200 XT/300 XT/400 XT
APPENDIX 9: CCM I/O PCB Layout
= Test Point
A-18 APPENDIX 0-5578
CCM I/O PCB
Test Points
TP1
TP2
TP3
TP4
TP5
TP6
TP7
TP8
TP9
TP10
TP11
GND
/COOLANT FANS ON
/TORCH PUMP ON
LOW COOLANT FLOW (SW)
COOLANT FLOW SIGNAL (PULSE)
+15V ISOLATED
-15V ISOLATED
+18V ISOLATED
ANALOG CURRENT CONTROL 0-3.3V
GND ISOLATED
/PILOT ENABLE
TP12 +5VDC
TP13 -15VDC
TP14 +15VDC
ULTRA-CUT 130 XT/200 XT/300 XT/400 XT
J Connectors
J21 BASIC CNC
J22 EXTENDED CNC
J23 RELAY - INTERFACE BOARD
J24 ARC / TIP VOLTS
J25 TEST
J26 GAS BOX
J28 TO CPU
J29 TO CPU
D33
D37
D41
D43
D12
D13
D18
D20
D25
TP15 24VDC
TP18 +5V ISOLATED
WORK CURRENT TP19
LED Reference
D2
D3
Green PLASMA ENABLE
Green E-STOP_PS
D4
D6
D8
Green GAS ON
Green CNC START
Green HOLD START
Green PREFLOW ON
Green CSD
Green MARK
Green SPARE1
Green EXP METAL
Green OK TO MOVE
Green PSR
Green SPARE FIELD OUT 2
Green SPARE FIELD OUT 1
0-5578 APPENDIX A-19
ULTRA-CUT 130 XT/200 XT/300 XT/400 XT
APPENDIX 10: Pilot PCB Layout
= Test Point
A-20 APPENDIX
Art # A-11677_AB
0-5578
Pilot PCB Test Points
TP1 GND
TP2
TP3
TP4
LED Reference
D2
D11
PILOT GATE
+5V
TIP
Green PILOT ENABLE
Green +5V
ULTRA-CUT 130 XT/200 XT/300 XT/400 XT
0-5578 APPENDIX A-21
ULTRA-CUT 130 XT/200 XT/300 XT/400 XT
APPENDIX 11: Relay and Interface PCB Layout
= Test Point
A-22 APPENDIX
Art # A-11678_AB
0-5578
Relay and Interface PCB Test Points
TP1 GND
D11
D12
D22
D23
D24
D25
D26
D27
TP2
TP3
TP4
TP5
TP6
TP7
LED Reference
D2
D7
-15V
+5VDC
+12V
+24V
+15V
+5VDC
Green 1 TORCH GAS ON
Green PILOT ENABLE
Green PILOT CURRENT DETECTED
Green WORK CURRENT DETECTED
Green CONTACTORS ON
Green RF ON
Green FANS ON
Green PLASMA ENABLED
Green 1 TORCH ON
Green TORCH COOLANT ON
ULTRA-CUT 130 XT/200 XT/300 XT/400 XT
0-5578 APPENDIX A-23
ULTRA-CUT 130 XT/200 XT/300 XT/400 XT
APPENDIX 12: Display PCB Layout
= Test Point
A-24 APPENDIX
Art # A-11679
0-5578
Display PCB Test Points
TP1 GND
TP2
TP3
+5VDC
+24VDC
ULTRA-CUT 130 XT/200 XT/300 XT/400 XT
0-5578 APPENDIX A-25
ULTRA-CUT 130 XT/200 XT/300 XT/400 XT
APPENDIX 13: System Bias PCB Layout
= Test Point
A-26
Art # A-11680_AB
APPENDIX 0-5578
TP2
TP3
TP4
TP5
TP6
TP7
TP8
TP9
TP10
LED Reference
D3
D4
D14
D15
D26
D27
D30
D44
System Bias PCB Test Points
TP1 GND
24VDC
DC INPUT POSITIVE
Vcc1
Vcc2
GATE
PRIMARY GND
+12V PRIMARY
P_ISOL_GND
DC SENSE POSITIVE
Red MISSING PHASE
Red AC V HIGH
Red AC V LOW
Green VAC_IDA
Green +12V PRIMARY
Green VAC_IDB
Green 24VDC
Green TRANSFORMER ON
ULTRA-CUT 130 XT/200 XT/300 XT/400 XT
0-5578 APPENDIX A-27
ULTRA-CUT 130 XT/200 XT/300 XT/400 XT
APPENDIX 14: Main Inverter Bottom PCB Layout
= Test Point
A-28 APPENDIX 0-5578
Main Inverter Bottom PCB Test Points
TP1 GND
TP2
TP3
TP4
TP5
TP6
GATE 2A
GATE 1A
GATE 3A
GATE 4A
GATE 2B
TP7
TP8
GATE 1B
GATE 4B
TP9 GATE 3B
TP10 +12VP
TP11 +12VDC
TP12 THERMISTOR SIDE A
TP13 THERMISTOR SIDE B
TP14 +5VDC
TP15 PGND
LED Reference
D3 Red CAP IMBALANCE
D4 Green READY
ULTRA-CUT 130 XT/200 XT/300 XT/400 XT
0-5578 APPENDIX A-29
ULTRA-CUT 130 XT/200 XT/300 XT/400 XT
APPENDIX 15: Main Inverter Top PCB Layout
= Test Point
A-30 APPENDIX 0-5578
Main Inverter Top PCB Test Points
TP1 GND
TP2
TP3
TP4
TP5
TP6
GATE 2A
GATE 1A
GATE 3A
GATE 4A
GATE 2B
TP7
TP8
GATE 1B
GATE 4B
TP9 GATE 3B
TP10 +12VP
TP11 +12VDC
TP12 THERMISTOR SIDE A
TP13 THERMISTOR SIDE B
TP14 +5VDC
TP15 PGND
LED Reference
D3 Red CAP IMBALANCE
D4 Green READY
ULTRA-CUT 130 XT/200 XT/300 XT/400 XT
0-5578 APPENDIX A-31
ULTRA-CUT 130 XT/200 XT/300 XT/400 XT
APPENDIX 16: Control and Fault PCB Layout
= Test Point
Art # A-11683_AC
A-32 APPENDIX 0-5578
Control and Fault PCB Test Points
TP1 GND
TP22 +12VDC
TP23 +5VDC
TP24 GATE 1+
TP25 A_OUT1
TP26 B_OUT1
TP27 GATE 1-
TP28 I_SNS1
TP29
TP30
GATE 2+
I_DMD1 0.5V-6.7V
TP31 GATE 2-
TP32 -12VDC
TP33 START 2
TP34 SHDN
TP35 ENABLE
TP36
TP37
LED Reference
D1
READY IN
READY OUT
Red INV FLT
D14
D24
D32
Red OVER TEMP
Green PWM ON
Red PRI OC
ULTRA-CUT 130 XT/200 XT/300 XT/400 XT
0-5578 APPENDIX A-33
ULTRA-CUT 130 XT/200 XT/300 XT/400 XT
APPENDIX 17: Cap Bias Bottom PCB Layout
A-34 APPENDIX
Art # A-11685_AC
0-5578
ULTRA-CUT 130 XT/200 XT/300 XT/400 XT
APPENDIX 18: Cap Bias Top PCB Layout
0-5578 APPENDIX
Art # A-11686_AC
A-35
ULTRA-CUT 130 XT/200 XT/300 XT/400 XT
APPENDIX 19: Suppression PCB Layout
A-36 APPENDIX
Art # A-11684_AC
0-5578
ULTRA-CUT 130 XT/200 XT/300 XT/400 XT
APPENDIX 20: COOLING DIAGRAM
0-5578 APPENDIX A-37
ULTRA-CUT 130 XT/200 XT/300 XT/400 XT
APPENDIX 21: Remote Arc Starter Schematic
1 2 3 4 5 6
A
B
Jumper in cable to ID Arc Starter is connected.
PLASMA
POWER
SUPPLY
GND
J59-RAS
8
9
10
11
12
13
14
3
4
5
1
2
6
7
Chassis gnd
120 VAC
120 VAC RET
J58
8
9
10
11
12
13
14
15
16
3
4
5
1
2
6
7
RAS
1000 XT
GND
(99)
(98)
NEG
NEG
PILOT
IGNITION UNIT SIG 4.5
115 Vac
115 Vac RET
Ho
(49)
NEG RAS Capacitor PCB
GND
CGND
0.047 uf
100K
0.047 uf
PLT
0.1 uf
Neon
PU
Hb
(52)
PILOT
L1
C
WORK
Torch Shield
GND
(-)
TORCH
(+)
Tip
Work
(+)
C
B
A
D
Rev
AA ECO B2487
Revision
Art # A-12071_AC
2
By Date
RWH 07/30/2013
The information contained herein is proprietary to Victor Technologies.
Not for release, reproduction or distribution without written consent.
Title SCHEMATIC
RAS 1000 XT Arc Starter
Victor Technologies Headquarters
16052 Swingley Ridge Road, Suite 300
St Louis, Missouri 63017 USA
Date Printed
7/30/2013
Drawn
DAT
Size
A
Drawing Number
Date Revised
7/30/2013
Date
03/13/2013
Sheet
1 of 1
042X1361
D
3 4 5 6 1
A-38 APPENDIX 0-5578
ULTRA-CUT 130 XT/200 XT/300 XT/400 XT
This Page Intentionally Blank
0-5578 APPENDIX A-39
ULTRA-CUT 130 XT/200 XT/300 XT/400 XT
APPENDIX 22: Schematic, DFC-3000 Auto Gas Box System
D
1 2 3
DMC3000 - MANIFOLD CONTROLLER ASSEMBLY
19X2367
A
ULTRACUT POWER SUPPLY
PLASMA ENABLE +
PLASMA ENABLE -
UNIT E-STOP
24 VAC
CHASSIS GND
+15 VDC
15 VDC RET
24 VAC RET
SHIELD
120 VAC ULTRACUT
120 VAC ULTRACUT RET
27
28
29
30
31
32
33
34
35
36
37
22
23
24
25
26
17
18
19
20
21
12
13
14
15
16
8
9
10
11
3
4
1
2
5
6
7
CCM
CPU PCB
1
2
27
28
29
30
31
32
33
34
35
36
37
22
23
24
25
26
17
18
19
20
21
12
13
14
15
16
10
11
8
9
3
4
1
2
5
6
7
755x000
CONTROL
CABLE
27
28
29
30
31
32
33
34
35
36
37
22
23
24
25
26
17
18
19
20
21
12
13
14
15
16
8
9
10
11
3
4
1
2
5
6
7
27
28
29
30
31
32
33
34
35
36
37
22
23
24
25
26
17
18
19
20
21
5
6
7
8
9
3
4
1
2
10
11
12
13
14
15
16
1
2
B
I/O PCB
PLASMA ENABLE
BYPASS RELAY 24 VAC
24 VAC RET
PLASMA ENABLE
CPU PCB
KEY PLUG
Tx+ (A)
I
SERIAL
Tx- (B)
COMMUNICATION
(Isolated)
Rx+
Rx-
6
7
8
9
10
1
2
3
4
5
11
12
13
14
9
10
6
7
8
1
2
3
4
5
11
12
13
14
C
J14
JUMPER for 4 WIRE uses
TX+, TX-
RX+, RX-
JUMPER for 2 WIRE
(RS485 only) wire to A & B
J14
SW14 - LINE
TERMINATION
SW14 normally on
(refer to manual)
SW10-ADDRESS normally 0
(refer to manual)
+5 VDC
Data +
Data -
COM
Shield
8
76
9
0
1
2
5
4
3
CPU LEDS
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
5
6
7
8
9
3
4
1
2
10
11
12
13
14
3
4
1
2
5
6
(JMP)
(
(
5 )
6 )
(3)
(2c)
(1)
(3)
(2b)
(
( 5
6
)
)
(8)
(9)
FERRITE
CORE
BLK
6
7
4
5
8
1
2
3
Power Supply PCB (19X2384) LEDS
See list by DPC 3000 Power Supply
19X2384 SMPS +24; +/-12; +5
120 VAC
F1 1.6A SB
120 VAC RET
+24 VDC
3
4
5
1
2
6
7
8
-12V
GND
+5V
+12V
+24V SW
+24V FUSED
GND
PANEL INDICATORS
WHT
GRN
RED
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)
D9 - SOL_V9 (H2O SHIELD)
D10 - SOL_V10 (O2 PREFLOW)
D11 - SOL_V11 (AIR PREFLOW)
D12 - SOL_V12 (N2 PREFLOW)
D13 - SOL_V13 (ARGON MARKING)
1
2
3
D14 - SOL_V14 (AIR MARKING)
D15 - SOL_V15 (N2 MARKING)
D16 - (SPARE)
D17 - +5VDC
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)
TSC 3000 19X2200
1
2
3
FERRITE
CORE
4
3
2
1
DMC3000 CONTROL PCB
19X2385
OPTION SWITCHES
1
2
7
8
9
5
6
10
11
3
4
1
2
12
13
14
DMC FiberOptic Ports
CCM CANBUS
ACTIVE
DPC CANBUS
ACTIVE
Tx Gray;
Rx Black
5
6
7
8
9
3
4
1
2
+5 VDC
TPC- 660E TOUCH SCREEN PANEL
20
19
18
17
16
15
14
13
12
11
10
9
8
7
6
5
4
3
2
1
5
6
7
8
9
3
4
1
2
10
11
12
13
14
15
16
17
18
120VAC DMC
120VAC DMC RET
E_STOP NO
E_STOP COM
(1)
(2a)
KEY PLUG
(8)
(9)
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.
SHIELD
CHASSIS GND
3
4
5
1
2
8
9
10
11
12
13
14
6
7
3
4
5
1
2
6
7
8
9
10
11
12
13
14
MANIFOLD
(S1-T)
H35_PLASMA
(S1-B)
SOL3
(S3-T)
(S3-B)
(S2-T)
SOL2
(S2-B)
AIR_PLASMA
O2_PLASMA
(S4-T)
SOL4
(S4-B)
N2_PLASMA
(S5-T)
SOL5
(S5-B)
FUEL_PLASMA
(S7-T)
(S7-B)
SOL7
(S6-T)
SOL6
(S6-B)
AIR_SHIELD
O2_SHIELD
N2_SHIELD
(S8-T)
(S8-B)
(S9-T)
SOL9
(S9-B)
H20_SHIELD
O2_PREFLOW
(S10T)
(S10B)
SOL11
(S11T)
(S11B)
AIR_PREFLOW
(S12T)
SOL12
(S12B)
N2_PREFLOW
(S13T)
SOL13 ARGON_MARKING
(S13B)
AIR_MARKING
(S14T)
(S14B)
N2_MARKING
(S15T)
(S14B)
TEST POINTS - CONTROL PCB
TP1 - GND
TP2 - Processor TEMP
TP3 - +VREF
TP4 - Processor CLKO
TP5 - +3.3V
TP6 - AGND
TP7 - +5V
GROUNDING SCREW
PLASMA ENABLE
(6)
Configured for RS485
(5)
24 VAC
24 VAC RET
HMI PRESENT
PLASMA ENABLE
COM
KEY
Tx+ (A)
SIG COM
SIG COM
Tx- (B)
Rx+
Rx-
SHIELD
SHIELD
HMI CONTROL &
COMMUNICATIONS
7
8
9
10
11
12
13
14
15
16
1
2
3
4
5
6
10
11
12
13
14
15
16
7
8
9
1
2
3
4
5
6
(
(1)
(2)
3 )
(5)
(6)
(8)
(
(
1
9 )
0 )
(12)
GROUNDING SCREW
Tx+ (A)
Tx- (B)
(
(
1
9 )
0 )
(8)
(12)
(0V)
(20V)
( 3 )
(2)
(1)
P3
POWER
HMI INTERFACE PCB
19X2407
3
4
5
1
2
6
POWER SUPPLY
24 VAC to 20 VDC
4
5
6
1
2
3
RS232
ISOLATED
3
4
1
2
5
6
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
1
2
3
4
7
8
5
6
9
J63 HARNESS NOT INSTALLED
(for future use with Height Control)
Art # A-09197_AD
1 2 3
A-40 APPENDIX 0-5578
KEY PLUG
1
2
3
6
7
8
4
5
9
10
11
12
13
14
15
16
9
10
6
7
8
4
5
1
2
3
11
12
13
14
15
16
4
DPC3000 - PRESSURE CONTROL ASSEMBLY 19X2383
5
PANEL INDICATORS
Power Supply PCB (19X2384) LEDS
D5 = +VDC Fused (24VDC )
D6 = +12VDC
D7 = +24VDC SW (24VDC to Valves
& Solenoids through E-Stop Relay
D9 = +5VDC
D16 = -12VDC
(2a)
(8)
(9)
( 1 ) 120 VAC
FERRITE
CORE
( 1 )
120 VAC RET
E_STOP NO
E_STOP COM
(2a)
(8)
(9)
19X2384 SMPS +24; +/-12; +5
120 VAC
5
6
7
8
3
4
1
2
120 VAC RET
+24 VDC
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.
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.
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
(WHT)
(BLK)
(WHT)
MANIFOLD (partial)
PLASMA_CUTTING
(S3-T)
(S3-B)
PLASMA_VENT
(S2-B)
(S2-B)
1
2
3
Plasma_Cut_Hi 1
2
3
(V5-1)
(V5-2)
(V1-1)
(V1-2)
1
2
3
(V2-1)
(V2-2)
1
2
3
(V3-1)
(V3-2)
1
2
3
PLASMA_MARK
(S1-T)
(S1-B)
(V4-1)
(V4-B)
3
4
5
1
2
6
7
8
FERRITE
CORE
(PW1)
(PW2)
(PW3)
(PW4)
-12VDC
GND
+5VDC
+12VDC
(PW5)
(PW6)
(PW7)
(PW8)
+24VDC SW
+24 VDC_FUSED
GND
E-STOP
3
4
5
1
2
6
7
8
4
3
2
1
DPC3000 CONTROL PCB
19X2382
OPTION SWITCHES
3
2
1
LEDs Listed Below
+12V
1
2
3
4
5
6
7
8
9
10
8
9
11
12
13
14
3
4
5
1
2
6
7
15
16
17
18
9
8
7
6
5
11
10
4
3
2
1
16
15
14
13
12 7
8
9
5
6
10
11
3
4
1
2
12
13
14
1
2
DPC FiberOptic Port
+5V
1
2
Tx Gray;
Rx Black DPC CANBUS
ACTIVE
GROUNDING SCREW
1
2
3
6
MANIFOLD (partial)
1
2
3
MANAFOLD ID
BLK
PURPLE
ORANGE
1
2
3
BLK
PURPLE
ORANGE
1
2
3
BLK
PURPLE
ORANGE
1
2
3
BLK
PURPLE
ORANGE
1
2
3
BLK
PURPLE
ORANGE
1
2
3
BLK
PURPLE
ORANGE
1
2
3
BLACK/SHIELD
WHITE
RED
1
2
3
DPC3000 Control PCB LEDs
D1 - PLASMA_PWM
D2 - PLASMA_VENT_PWM
D3 - SHIELD_H20_PWM
D4 - SHIELD_GAS_PWM
D5 - MARKING_PWM
D6 - PLASMA_PILOT_PWM
D7 - +5VDC
D8 - DPC STATUS
D9 - SHIELD_H20_FLOW
D10 - PLASMA_CUT_PWM
D11 - PLASMA_LOW_PWM
D12 - CANBUS COMMUNICATION
C
GROUNDING SCREW
H35 >
O2 >
AUX >
DMC MANIFOLD
SOL#
INLET PASSAGES
OUTLET PASSAGES
HOSE
1 2 3 4
5 6 7 8
SOL# = ON/OFF CONTROL VALVE
V# = PROPORTIONAL VALVE
PS# = PRESSURE SENSOR
FS# = FLOW SENSOR (LIQUID)
> GAS SHIELD
H2O > 9 > H2O SHIELD
10 11 12 > PREFLOW
AIR >
ARGON >
N2 >
4
13 14 15 > MARKING
> 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.
5
PLASMA >
PRE-FLOW >
SOL3
H2O SHIELD >
GAS SHIELD >
Rev
AA
AB
Revisions
ECO-B1391
ECO-B1507 - added text
MARKING >
DPC MANIFOLD
SOL1
Last Modified: Monday, April 19, 2010
14:00:59
V1
V4
V3
V2
PLASMA OUT
SOL2
VENT
SHIELD OUT
By Date
DAT
4-24-2009
DAT
4-19-2010
Art # A-09197_AD
Thermal Dynamics Corporation
2800 Airport Rd.
Denton, Texas 76207 USA
PCB No:
Assy No:
References
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:
DFC 3000 SYSTEM SCHEMATIC
Scale
N/A
Supersedes
Friday, December 08, 2006
Drawn:
DAT
Chk: App:
Date:
4/24/2009
Sheet
1 of 1
Size DWG No:
6
D
A
B
D
1 2 3
DMC3000 - MANIFOLD CONTROLLER ASSEMBLY
19X2367
A
ULTRACUT POWER SUPPLY
PLASMA ENABLE +
PLASMA ENABLE -
UNIT E-STOP
24 VAC
CHASSIS GND
+15 VDC
15 VDC RET
24 VAC RET
SHIELD
120 VAC ULTRACUT
120 VAC ULTRACUT RET
27
28
29
30
31
32
33
34
35
36
37
22
23
24
25
26
17
18
19
20
21
12
13
14
15
16
8
9
10
11
3
4
1
2
5
6
7
CCM
CPU PCB
1
2
27
28
29
30
31
32
33
34
35
36
37
22
23
24
25
26
17
18
19
20
21
12
13
14
15
16
10
11
8
9
3
4
1
2
5
6
7
755x000
CONTROL
CABLE
27
28
29
30
31
32
33
34
35
36
37
22
23
24
25
26
17
18
19
20
21
12
13
14
15
16
8
9
10
11
3
4
1
2
5
6
7
27
28
29
30
31
32
33
34
35
36
37
22
23
24
25
26
17
18
19
20
21
5
6
7
8
9
3
4
1
2
10
11
12
13
14
15
16
1
2
B
I/O PCB
PLASMA ENABLE
BYPASS RELAY 24 VAC
24 VAC RET
PLASMA ENABLE
CPU PCB
KEY PLUG
Tx+ (A)
I
SERIAL
Tx- (B)
COMMUNICATION
(Isolated)
Rx+
Rx-
6
7
8
9
10
1
2
3
4
5
11
12
13
14
9
10
6
7
8
1
2
3
4
5
11
12
13
14
C
J14
JUMPER for 4 WIRE uses
TX+, TX-
RX+, RX-
JUMPER for 2 WIRE
(RS485 only) wire to A & B
J14
SW14 - LINE
TERMINATION
SW14 normally on
(refer to manual)
SW10-ADDRESS normally 0
(refer to manual)
+5 VDC
Data +
Data -
COM
Shield
8
76
9
0
1
2
5
4
3
CPU LEDS
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
5
6
7
8
9
3
4
1
2
10
11
12
13
14
3
4
1
2
5
6
(JMP)
(
(
5 )
6 )
(3)
(2c)
(1)
(3)
(2b)
(
( 5
6
)
)
(8)
(9)
FERRITE
CORE
BLK
6
7
4
5
8
1
2
3
Power Supply PCB (19X2384) LEDS
See list by DPC 3000 Power Supply
19X2384 SMPS +24; +/-12; +5
120 VAC
F1 1.6A SB
120 VAC RET
+24 VDC
3
4
5
1
2
6
7
8
-12V
GND
+5V
+12V
+24V SW
+24V FUSED
GND
PANEL INDICATORS
WHT
GRN
RED
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)
D9 - SOL_V9 (H2O SHIELD)
D10 - SOL_V10 (O2 PREFLOW)
D11 - SOL_V11 (AIR PREFLOW)
D12 - SOL_V12 (N2 PREFLOW)
D13 - SOL_V13 (ARGON MARKING)
1
2
3
D14 - SOL_V14 (AIR MARKING)
D15 - SOL_V15 (N2 MARKING)
D16 - (SPARE)
D17 - +5VDC
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)
TSC 3000 19X2200
1
2
3
FERRITE
CORE
4
3
2
1
DMC3000 CONTROL PCB
19X2385
OPTION SWITCHES
1
2
7
8
9
5
6
10
11
3
4
1
2
12
13
14
DMC FiberOptic Ports
CCM CANBUS
ACTIVE
DPC CANBUS
ACTIVE
Tx Gray;
Rx Black
5
6
7
8
9
3
4
1
2
+5 VDC
TPC- 660E TOUCH SCREEN PANEL
20
19
18
17
16
15
14
13
12
11
10
9
8
7
6
5
4
3
2
1
5
6
7
8
9
3
4
1
2
10
11
12
13
14
15
16
17
18
120VAC DMC
120VAC DMC RET
E_STOP NO
E_STOP COM
(1)
(2a)
KEY PLUG
(8)
(9)
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.
SHIELD
CHASSIS GND
3
4
5
1
2
8
9
10
11
12
13
14
6
7
3
4
5
1
2
6
7
8
9
10
11
12
13
14
MANIFOLD
(S1-T)
H35_PLASMA
(S1-B)
SOL3
(S3-T)
(S3-B)
(S2-T)
SOL2
(S2-B)
AIR_PLASMA
O2_PLASMA
(S4-T)
SOL4
(S4-B)
N2_PLASMA
(S5-T)
SOL5
(S5-B)
FUEL_PLASMA
(S7-T)
(S7-B)
SOL7
(S6-T)
SOL6
(S6-B)
AIR_SHIELD
O2_SHIELD
N2_SHIELD
(S8-T)
(S8-B)
(S9-T)
SOL9
(S9-B)
H20_SHIELD
O2_PREFLOW
(S10T)
(S10B)
SOL11
(S11T)
(S11B)
AIR_PREFLOW
(S12T)
SOL12
(S12B)
N2_PREFLOW
(S13T)
SOL13 ARGON_MARKING
(S13B)
AIR_MARKING
(S14T)
(S14B)
N2_MARKING
(S15T)
(S14B)
TEST POINTS - CONTROL PCB
TP1 - GND
TP2 - Processor TEMP
TP3 - +VREF
TP4 - Processor CLKO
TP5 - +3.3V
TP6 - AGND
TP7 - +5V
GROUNDING SCREW
PLASMA ENABLE
(6)
Configured for RS485
(5)
24 VAC
24 VAC RET
HMI PRESENT
PLASMA ENABLE
COM
KEY
Tx+ (A)
SIG COM
SIG COM
Tx- (B)
Rx+
Rx-
SHIELD
SHIELD
HMI CONTROL &
COMMUNICATIONS
7
8
9
10
11
12
13
14
15
16
1
2
3
4
5
6
10
11
12
13
14
15
16
7
8
9
1
2
3
4
5
6
(
(1)
(2)
3 )
(5)
(6)
(8)
(
(
1
9 )
0 )
(12)
GROUNDING SCREW
Tx+ (A)
Tx- (B)
(
(
1
9 )
0 )
(8)
(12)
(0V)
(20V)
( 3 )
(2)
(1)
P3
POWER
HMI INTERFACE PCB
19X2407
3
4
5
1
2
6
POWER SUPPLY
24 VAC to 20 VDC
4
5
6
1
2
3
RS232
ISOLATED
3
4
1
2
5
6
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
1
2
3
4
7
8
5
6
9
J63 HARNESS NOT INSTALLED
(for future use with Height Control)
Art # A-09197_AD
1 2 3
ULTRA-CUT 130 XT/200 XT/300 XT/400 XT
0-5578
KEY PLUG
1
2
3
6
7
8
4
5
9
10
11
12
13
14
15
16
9
10
6
7
8
4
5
1
2
3
11
12
13
14
15
16
4
DPC3000 - PRESSURE CONTROL ASSEMBLY 19X2383
5
PANEL INDICATORS
Power Supply PCB (19X2384) LEDS
D5 = +VDC Fused (24VDC )
D6 = +12VDC
D7 = +24VDC SW (24VDC to Valves
& Solenoids through E-Stop Relay
D9 = +5VDC
D16 = -12VDC
(2a)
(8)
(9)
( 1 ) 120 VAC
FERRITE
CORE
( 1 )
120 VAC RET
E_STOP NO
E_STOP COM
(2a)
(8)
(9)
19X2384 SMPS +24; +/-12; +5
120 VAC
5
6
7
8
3
4
1
2
120 VAC RET
+24 VDC
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.
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.
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
(WHT)
(BLK)
(WHT)
MANIFOLD (partial)
PLASMA_CUTTING
(S3-T)
(S3-B)
PLASMA_VENT
(S2-B)
(S2-B)
1
2
3
Plasma_Cut_Hi 1
2
3
(V5-1)
(V5-2)
(V1-1)
(V1-2)
1
2
3
(V2-1)
(V2-2)
1
2
3
(V3-1)
(V3-2)
1
2
3
PLASMA_MARK
(S1-T)
(S1-B)
(V4-1)
(V4-B)
3
4
5
1
2
6
7
8
FERRITE
CORE
(PW1)
(PW2)
(PW3)
(PW4)
-12VDC
GND
+5VDC
+12VDC
(PW5)
(PW6)
(PW7)
(PW8)
+24VDC SW
+24 VDC_FUSED
GND
E-STOP
3
4
5
1
2
6
7
8
4
3
2
1
DPC3000 CONTROL PCB
19X2382
OPTION SWITCHES
3
2
1
LEDs Listed Below
+12V
1
2
3
4
5
6
7
8
9
10
8
9
11
12
13
14
3
4
5
1
2
6
7
15
16
17
18
9
8
7
6
5
11
10
4
3
2
1
16
15
14
13
12 7
8
9
5
6
10
11
3
4
1
2
12
13
14
1
2
DPC FiberOptic Port
+5V
1
2
Tx Gray;
Rx Black DPC CANBUS
ACTIVE
GROUNDING SCREW
1
2
3
6
MANIFOLD (partial)
1
2
3
MANAFOLD ID
BLK
PURPLE
ORANGE
1
2
3
BLK
PURPLE
ORANGE
1
2
3
BLK
PURPLE
ORANGE
1
2
3
BLK
PURPLE
ORANGE
1
2
3
BLK
PURPLE
ORANGE
1
2
3
BLK
PURPLE
ORANGE
1
2
3
BLACK/SHIELD
WHITE
RED
1
2
3
DPC3000 Control PCB LEDs
D1 - PLASMA_PWM
D2 - PLASMA_VENT_PWM
D3 - SHIELD_H20_PWM
D4 - SHIELD_GAS_PWM
D5 - MARKING_PWM
D6 - PLASMA_PILOT_PWM
D7 - +5VDC
D8 - DPC STATUS
D9 - SHIELD_H20_FLOW
D10 - PLASMA_CUT_PWM
D11 - PLASMA_LOW_PWM
D12 - CANBUS COMMUNICATION
C
GROUNDING SCREW
H35 >
O2 >
AUX >
DMC MANIFOLD
SOL#
INLET PASSAGES
OUTLET PASSAGES
HOSE
1 2 3 4
5 6 7 8
SOL# = ON/OFF CONTROL VALVE
V# = PROPORTIONAL VALVE
PS# = PRESSURE SENSOR
FS# = FLOW SENSOR (LIQUID)
> GAS SHIELD
H2O > 9 > H2O SHIELD
10 11 12 > PREFLOW
AIR >
ARGON >
N2 >
4
13 14 15 > MARKING
> 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.
5
PLASMA >
PRE-FLOW >
SOL3
H2O SHIELD >
GAS SHIELD >
Rev
AA
AB
Revisions
ECO-B1391
ECO-B1507 - added text
MARKING >
DPC MANIFOLD
SOL1
Last Modified: Monday, April 19, 2010
14:00:59
V1
V4
V3
V2
PLASMA OUT
SOL2
VENT
SHIELD OUT
By Date
DAT
4-24-2009
DAT
4-19-2010
Art # A-09197_AD
Thermal Dynamics Corporation
2800 Airport Rd.
Denton, Texas 76207 USA
PCB No:
Assy No:
References
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:
DFC 3000 SYSTEM SCHEMATIC
Scale
N/A
Supersedes
Friday, December 08, 2006
Drawn:
DAT
Chk: App:
Date:
4/24/2009
Sheet
1 of 1
Size DWG No:
6
D
A
B
APPENDIX A-41
ULTRA-CUT 130 XT/200 XT/300 XT/400 XT
APPENDIX 23: System Schematic 130A, 380-415V PG 1
1 2 3 4 5
A
A-42
B
380-415
VAC
INPUT
(Customer supplied power cord must pass through ferrite core assembly.)
L1
L2
L3
1
(1)
1
(2)
1
(3)
Earth 1
1
2
IN1
EMI
FIL-
TER
PCB
OUT1
2
1
1
2
1
2
IN2
GND2B
IN3
OUT2
OUT3
2
1
2
1
CHASSIS GND
(20)
(21)
(22)
W1A
W1B
W1C
(7)
(8)
(9)
L5
Toriod Core
J105B
1
2
J104B
1
2
J103B
1
2
(7)
(8)
(9)
L4
Toriod Core
J105A
1
2
J104A
1
2
J103A
1
2
AC INPUT
AC INPUT
019x502700
INVERTER MODULE (IM) #`1 (bottom)
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
IM #1 Section A (lower)
WORK (+)
019x502000
C
CHASSIS GND
E
F
D
18 AWG wire both in and out of
CB1
CB1
ON / OFF
16 A
(1)
(2)
(3)
9
10
11
12
13
14
7
8
5
6
3
4
1
2
AC LINE
J50
AC
SUPPRESSION
PCB
J51
019X504000
3
4
1
2
GND
J52
3
4
1
2
(10)
(11)
(12)
(13)
INTERNAL AC INDICATOR
CHASSIS GND
LT1
LT2
LT1 & LT2
INPUT POWER
NEON INDICATORS
Rear Panel & Internal
F1
8A, 500V, SB
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
Art # A-11959_AE
F2
8A, 500V, SB
(86A)
(27A)
(85A)
(86B)
(27B)
(85B)
AC INPUT
13
14
15
16
9
10
11
12
17
18
7
8
5
6
3
4
1
2
J60
J63
J62
10
11
7
8
9
4
5
6
12
13
14
1
2
3
To J27 on CCM I/O PCB
(Sht 2, E3)
SYSTEM BIAS SUPPLY PCB
019X501900
+24VDC
(43A)
1 2 3 4 5 6 7 8 9 10 11 12
TO AUX TRANSFORMER
(44A)
TO J12
T1 PRIMARY
(Sht 2, A1)
+ V
GND
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
230V 400V 480V ERR
/VAC_IDAb 0 1 0 1
/VAC_IDBb 0 0 1 1
(29)
(30)
(31)
(32)
(33)
(34)
(35)
(36)
(37)
(38)
(39)
(40)
(41)
(42)
Measure relative to TP1 (24VDC_RET)
"0" = 10-12V "1" = 24V
J61
VOLTAGE SELECTION
(48)
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
Component Locations (not including PCB components)
C4 Capacitor, fan starting, 8uf 440VAC (Sht 2, E1)
CB1 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
HCT1
Flow SW, 0.5 GPM (3.8 lpm), N.O. (Sht 2, A2)
Current Sensor, Hall Effect 200A, Work Lead
(Sht 1, C8)
K1 Relay, 24VAC, Inrush Control, (Sht2, B9)
L1 Inductor, (Sht 1, B7)
L3-5 Toriod Core Common Mode Ind (Sht1 B8, B&C3)
LS1 Level Switch, Coolant Tank (Sht 2, A3)
LT1, LT2 Indicator, Neon, 250V, AC Volts Present
(Sht 1, B2 & C2)
M1 Motor, Pump, ½ hp 230VAC, 50/60 Hz, 1Ph
(Sht 2, C2)
MC1 Relay, 120VAC, Inrush, coil (Sht2, B9)
contact (Sht2, A1)
MC2 Relay, 120 VAC, Fan Control, coil
(Coil at Sht 2, A7)(Contacts at Sht 2, D1)
MC3 Relay, 120 VAC, Pump Motor Control, coil
(Coil at Sht 2, A7)(Contacts at Sht 2, C1)
R2 Inrush, 4.7 Ohm, 30W (Sht2, A1)
R3,4 Ext RC, 100 ohm 55W (Sht1, A7)
SA1-3 Snubber, Contactor & Relay coils
(Sht 2, A8 & A9)
T1
TB4
Aux Transformer (Sht 2, B2)
Terminal Block (Sht 1, C9)
TS1 Temperature Sensor, NTC, Coolant Return
(Sht 2, A5)
TS2 Temperature Sensor, NTC, Ambient (Sht 2, A5)
W1 Contactor , Input (Coil Sht 2, A8), (Contacts C2)
1 2 3 4
APPENDIX 0-5578
5
6 7 8 9 10
TORCH
To TB4-7
L3
(49)
TORCH
1
PILOT BOARD
LED'S
D2 PILOT ENABLE
D11 +5V
TEST POINTS
TP1 GND
TP2 PILOT GATE
TP3 +5V
J43
ELECTRODE
(49)
J58A PILOT PCB J44
1
R3 & R4
J100 -- 30 CKT RIBBON
ELECTRODE (-)
WORK (+)
OUTPUT
TO CCM
CPU PCB
J32
(Sht 2, C3)
5
4
3
2
1
J102B
(49B)
TO CCM
CPU PCB
J31
(Sht 2, C3)
(51B)
(50)
CHASSIS GND
J58C
5
4
3
2
1
J40
INVERTER
L1
J42
019X501600
1 2 3 4 5 6 7 8 9 10
10 ckt Ribbon
TO J3 on RELAY PCB
(Sht 2, A5)
TIP VOLTS
1 2 3 4 5 6 7 8
(53)
To J24 on I-O PCB
(Sht 2, D3)
WORK
ARC VOLTS
(51)
(55)
J41
1
2
TIP
J45
(52)
J100 -- 30 CKT RIBBON
ELECTRODE (-)
WORK (+)
OUTPUT
5
4
3
2
1
J102A
(49A)
(50)
(51) (51)
HCT1
Hall Effect Sensor
(51)
J16
TO J1 on RELAY PCB
(Sht 2, B9)
(56)
(57)
(58)
(59) g w o b
To TB4-6 TIP
J41 (J87)
(52)
To / From Optional
1 Torch Module
(Refer to 1 Torch section for details.)
(51)
PILOT
1
CHASSIS GND
WORK
1
TORCH
(Sht 1, A9)
TIP
(Sht 1, A9)
AC 120V- TB4-4
AC 120V- Ret- TB4-3
AC 24V-TB4-2
AC 24V- Ret -TB4-1
(J10 Sht 2, B8)
(49)
(52)
(51)
(60)
(61)
(62)
(63)
TB4
7
6
5
4
3
2
1
ARC VOLTS (TORCH)
TIP VOLTS (PILOT)
WORK
120 VAC @ 100 ma.
24 VAC @ 1A
RAS
(-)
SHIELD
(+)
Tip
Work (+)
B
A
C
RIBBON CABLE 30 ckt.
CCM (J31& 32) - INVERTER (J100)
1 READY +
2 READY -
3 INVERTER_FLT +
4 INVERTER_FLT -
5 OVERTEMP_FLT +
6 OVERTEMP_FLT -
7 PWR_PRESENT +
8 PWR_PRESENT -
9 OUT_COM (+3 to 5VDC)
10 VAC_SELA
11 VAC_SELB
12 IS_IDA
13 IS_IDB
14 IS_IDC
15 ENABLE +
16 ENABLE -
17 START2 +
18 START2 -
19 SPARE
20 SYNC_IN +
21 SYNC_IN -
22 NC
23 NC
24 47 OHM to COMM
25 DEMAND +
26 DEMAND -
27 47 OHM to COMM
28 CURRENT +
29 CURRENT -
30 47 OHM to COMM
RIBBON CABLE 40 ckt CCM (J23) - RELAY PCB (J4)
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 SIG-
24 NC
25 PILOT CURRENT SIG+
26 COMMON
27 WORK CURRENT SIG-
28 WORK CURRENT SIG+
29 NC
30 AMBIENT TEMP
31 COOLANT TEMP
* Used with 1 Torch O ption
32 COMMON
33 -15 VDC
34 COMMON
35 24 VDC
36 COMMON
37 24 VDC
38 COMMON
39 24 VDC
40 COMMON
RIBBON CABLE 16 ckt
CCM ( J37) - DISPLAY
PCB (J17)
1,3,5,7
2,4,6,8
9,10 NC
11-16
RIBBON CABLE 10 ckt
RELAY PCB (J3) – PILOT PCB (J42)
1,2
24 VDC
COMMON
SERIAL DATA
24 VDC
3,4,7,10 COMMON
5 PILOT ENABLE +
6 PILOT ENABLE –
8 PILOT CURRENT SIG –
9 PILOT CURRENT SIG +
D
E
Rev
00
A A
Revision
Initial Design
AB ECO-B2687
6
By Date
DAT 10/03/2012
D A T 9 / 1 6 / 2 0 1 4
DAT 10/17/2014
Rev
7
Revision By Date
8
The information contained herein is proprietary to Thermal Dynamics.
Not for release, reproduction or distribution without written consent.
Title SCHEMATIC
Ultra-Cut XT 130A CE 380-415 VAC
10 9
Art # A-11959_AE
Thermal Dynamics Corporation
2800 Airport Rd.
Denton, Texas 76207 USA
Date Printed
12/16/2014
Drawn
DAT
Size
C
Drawing Number
Date Revised
11/20/2014
Date
10/03/2012
Sheet
1 of 2
042X1354
F
1 2 3 4 5
A
B
380-415
VAC
INPUT
(Customer supplied power cord must pass through ferrite core assembly.)
L1
L2
L3
1
(1)
1
(2)
1
(3)
Earth 1
1
2
IN1
EMI
FIL-
TER
PCB
OUT1
2
1
1
2
1
2
IN2
GND2B
IN3
OUT2
OUT3
2
1
2
1
CHASSIS GND
(20)
(21)
(22)
W1A
W1B
W1C
(7)
(8)
(9)
L5
Toriod Core
J105B
1
2
J104B
1
2
J103B
1
2
(7)
(8)
(9)
L4
Toriod Core
J105A
1
2
J104A
1
2
J103A
1
2
AC INPUT
AC INPUT
019x502700
INVERTER MODULE (IM) #`1 (bottom)
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
IM #1 Section A (lower)
WORK (+)
019x502000
C
CHASSIS GND
E
F
D
18 AWG wire both in and out of
CB1
CB1
ON / OFF
16 A
(1)
(2)
(3)
9
10
11
12
13
14
7
8
5
6
3
4
1
2
AC LINE
J50
AC
SUPPRESSION
PCB
J51
019X504000
3
4
1
2
GND
J52
3
4
1
2
(10)
(11)
(12)
(13)
INTERNAL AC INDICATOR
CHASSIS GND
LT1
LT2
LT1 & LT2
INPUT POWER
NEON INDICATORS
Rear Panel & Internal
F1
8A, 500V, SB
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
Art # A-11959_AE
F2
8A, 500V, SB
(86A)
(27A)
(85A)
(86B)
(27B)
(85B)
AC INPUT
13
14
15
16
9
10
11
12
17
18
7
8
5
6
3
4
1
2
J60
J63
J62
10
11
7
8
9
4
5
6
12
13
14
1
2
3
To J27 on CCM I/O PCB
(Sht 2, E3)
SYSTEM BIAS SUPPLY PCB
019X501900
+24VDC
(43A)
1 2 3 4 5 6 7 8 9 10 11 12
TO AUX TRANSFORMER
(44A)
TO J12
T1 PRIMARY
(Sht 2, A1)
+ V
GND
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
230V 400V 480V ERR
/VAC_IDAb 0 1 0 1
/VAC_IDBb 0 0 1 1
(29)
(30)
(31)
(32)
(33)
(34)
(35)
(36)
(37)
(38)
(39)
(40)
(41)
(42)
Measure relative to TP1 (24VDC_RET)
"0" = 10-12V "1" = 24V
J61
VOLTAGE SELECTION
(48)
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
Component Locations (not including PCB components)
C4 Capacitor, fan starting, 8uf 440VAC (Sht 2, E1)
CB1 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
HCT1
Flow SW, 0.5 GPM (3.8 lpm), N.O. (Sht 2, A2)
Current Sensor, Hall Effect 200A, Work Lead
(Sht 1, C8)
K1 Relay, 24VAC, Inrush Control, (Sht2, B9)
L1 Inductor, (Sht 1, B7)
L3-5 Toriod Core Common Mode Ind (Sht1 B8, B&C3)
LS1 Level Switch, Coolant Tank (Sht 2, A3)
LT1, LT2 Indicator, Neon, 250V, AC Volts Present
(Sht 1, B2 & C2)
M1 Motor, Pump, ½ hp 230VAC, 50/60 Hz, 1Ph
(Sht 2, C2)
MC1 Relay, 120VAC, Inrush, coil (Sht2, B9)
contact (Sht2, A1)
MC2 Relay, 120 VAC, Fan Control, coil
(Coil at Sht 2, A7)(Contacts at Sht 2, D1)
MC3 Relay, 120 VAC, Pump Motor Control, coil
(Coil at Sht 2, A7)(Contacts at Sht 2, C1)
R2 Inrush, 4.7 Ohm, 30W (Sht2, A1)
R3,4 Ext RC, 100 ohm 55W (Sht1, A7)
SA1-3 Snubber, Contactor & Relay coils
(Sht 2, A8 & A9)
T1
TB4
Aux Transformer (Sht 2, B2)
Terminal Block (Sht 1, C9)
TS1 Temperature Sensor, NTC, Coolant Return
(Sht 2, A5)
TS2 Temperature Sensor, NTC, Ambient (Sht 2, A5)
W1 Contactor , Input (Coil Sht 2, A8), (Contacts C2)
1 2 3 4
ULTRA-CUT 130 XT/200 XT/300 XT/400 XT
5
6 7 8 9 10
TORCH
To TB4-7
L3
(49)
TORCH
1
PILOT BOARD
LED'S
D2 PILOT ENABLE
D11 +5V
TEST POINTS
TP1 GND
TP2 PILOT GATE
TP3 +5V
J43
ELECTRODE
(49)
J58A PILOT PCB J44
1
R3 & R4
J100 -- 30 CKT RIBBON
ELECTRODE (-)
WORK (+)
OUTPUT
TO CCM
CPU PCB
J32
(Sht 2, C3)
5
4
3
2
1
J102B
(49B)
TO CCM
CPU PCB
J31
(Sht 2, C3)
(51B)
(50)
CHASSIS GND
J58C
5
4
3
2
1
J40
INVERTER
L1
J42
019X501600
1 2 3 4 5 6 7 8 9 10
10 ckt Ribbon
TO J3 on RELAY PCB
(Sht 2, A5)
TIP VOLTS
1 2 3 4 5 6 7 8
(53)
To J24 on I-O PCB
(Sht 2, D3)
WORK
ARC VOLTS
(51)
(55)
J41
1
2
TIP
J45
(52)
J100 -- 30 CKT RIBBON
ELECTRODE (-)
WORK (+)
OUTPUT
5
4
3
2
1
J102A
(49A)
(50)
(51) (51)
HCT1
Hall Effect Sensor
(51)
J16
TO J1 on RELAY PCB
(Sht 2, B9)
(56)
(57)
(58)
(59) g w o b
To TB4-6 TIP
J41 (J87)
(52)
To / From Optional
1 Torch Module
(Refer to 1 Torch section for details.)
(51)
PILOT
1
CHASSIS GND
WORK
1
TORCH
(Sht 1, A9)
TIP
(Sht 1, A9)
AC 120V- TB4-4
AC 120V- Ret- TB4-3
AC 24V-TB4-2
AC 24V- Ret -TB4-1
(J10 Sht 2, B8)
(49)
(52)
(51)
(60)
(61)
(62)
(63)
TB4
7
6
5
4
3
2
1
ARC VOLTS (TORCH)
TIP VOLTS (PILOT)
WORK
120 VAC @ 100 ma.
24 VAC @ 1A
RAS
(-)
SHIELD
(+)
Tip
Work (+)
B
A
C
RIBBON CABLE 30 ckt.
CCM (J31& 32) - INVERTER (J100)
1 READY +
2 READY -
3 INVERTER_FLT +
4 INVERTER_FLT -
5 OVERTEMP_FLT +
6 OVERTEMP_FLT -
7 PWR_PRESENT +
8 PWR_PRESENT -
9 OUT_COM (+3 to 5VDC)
10 VAC_SELA
11 VAC_SELB
12 IS_IDA
13 IS_IDB
14 IS_IDC
15 ENABLE +
16 ENABLE -
17 START2 +
18 START2 -
19 SPARE
20 SYNC_IN +
21 SYNC_IN -
22 NC
23 NC
24 47 OHM to COMM
25 DEMAND +
26 DEMAND -
27 47 OHM to COMM
28 CURRENT +
29 CURRENT -
30 47 OHM to COMM
RIBBON CABLE 40 ckt CCM (J23) - RELAY PCB (J4)
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 SIG-
24 NC
25 PILOT CURRENT SIG+
26 COMMON
27 WORK CURRENT SIG-
28 WORK CURRENT SIG+
29 NC
30 AMBIENT TEMP
31 COOLANT TEMP
* Used with 1 Torch O ption
32 COMMON
33 -15 VDC
34 COMMON
35 24 VDC
36 COMMON
37 24 VDC
38 COMMON
39 24 VDC
40 COMMON
RIBBON CABLE 16 ckt
CCM ( J37) - DISPLAY
PCB (J17)
1,3,5,7
2,4,6,8
9,10 NC
11-16
RIBBON CABLE 10 ckt
RELAY PCB (J3) – PILOT PCB (J42)
1,2
24 VDC
COMMON
SERIAL DATA
24 VDC
3,4,7,10 COMMON
5 PILOT ENABLE +
6 PILOT ENABLE –
8 PILOT CURRENT SIG –
9 PILOT CURRENT SIG +
D
E
Rev
00
A A
Revision
Initial Design
AB ECO-B2687
6
By Date
DAT 10/03/2012
D A T 9 / 1 6 / 2 0 1 4
DAT 10/17/2014
Rev
7
Revision By Date
8
The information contained herein is proprietary to Thermal Dynamics.
Not for release, reproduction or distribution without written consent.
Title SCHEMATIC
Ultra-Cut XT 130A CE 380-415 VAC
10 9
Art # A-11959_AE
Thermal Dynamics Corporation
2800 Airport Rd.
Denton, Texas 76207 USA
Date Printed
12/16/2014
Drawn
DAT
Size
C
Drawing Number
Date Revised
11/20/2014
Date
10/03/2012
Sheet
1 of 2
042X1354
F
0-5578 APPENDIX A-43
ULTRA-CUT 130 XT/200 XT/300 XT/400 XT
APPENDIX 24: System Schematic 130A, 380-415V PG 2
E
A
B
C
D
1 2 3 4 5
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
From Sys Bias J63
(Sht 1, F2)
LS1
COOLANT LEVEL
1
4
J71
2
3
(90)
(89)
AMBIENT
TS2
COOLANT
TS1
(43A) (44A)
MC1A
FS1
COOLANT
0.7 GPM
J74
1
2
(84)
(83)
(92) (93)
(94)
(95)
Mini-Fit Jr
J12
1 2 3 4
5 6 7 8
(87)
460V
400V
220V
T1
FL1
24V RET
24V
120V_2 RET
120V_2
120V-1 RET
120V_1
1
2
3
BLUE
RED
YELLOW
BLUE
RED
YELLOW r b g
6
5
4
3
2
1
J14
3
4
1
2
J49
(80)
(81)
(82)
(79)
(77)
CB2 5 A
(74)
CB3 5 A
(78)
(76)
(75)
(73)
(71)
CB4 5 A
(72)
To J100 of IM #1B
To J100 of IM #1A
(Sht 1, B&C- 5&6)
J6
3
4
1
2
8
7
6
5
4
3
2
1
12
11
10
9
J9
J5 J7 J1
COOLANT FLOW SW
+5VDC
SIGNAL (pulse)
TORCH FLOW SENSOR
120VAC_2
24VAC
LEVEL SENSORS WORK CURRENT SENSOR
RELAY & INTERFACE PCB
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
J2
120VAC_1
BIAS TRANSFORMER 019X501700
TEMP SENSOR
Test Points
TP1, GND
TP2, -15V
TP3, +5VDC
TP4, +12V
TP5, +24V
TP6, +15V
TP7, +5VDC
1 TORCH INTERFACE
Refer to 1 Torch Module Schematic for Details
J11 J84
0 V
Mini-Fit
J13
MC3A
(66)
J16
1
2
3
M1
J13 to CB5 and to MC2
& MC3, also
J14, J16
all 18 AWG
(65A)
(64A)
MC3B
(64B)
MC2A
MC2B
CHASSIS GND
(67)
(69)
(70)
(69)
(70)
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.
BK
J72
1
2
3
R
C4
BN
FAN1
BL
R
Torch Coolant Pump
(69)
J72
1
2
3
230 VAC _ SW _ RET
(A9)
FAN1
Harness from Pilot PCB J45
(Sht 1, B8)
J73
1
2
3
(70)
230 VAC _ SW
(A9)
FAN2
230 VAC_SW goes to J70
for HE 400
(55)
(51)
(53)
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
13
14
J27
6
7
4
5
1
2
3
8
9
10
11
12
(37)
(38)
(39)
(40)
(41)
(42)
(29)
(30)
(31)
(32)
(33)
(34)
(35)
(36)
. 230V 400V 480V ERR
J62-12 (/VAC_IDAb) 0 1 0 1
J62-14 (/VAC_IDBb) 0 0 1 1
Measure relative to TP1 (24VDC_RET)
"0" = 10-12V "1" = 24V
7
8
5
6
3
4
1
2
J24
J31 - 30 CKT RIBBON
N/C
J33 - 30 CKT RIBBON
N/C
J35 - 30 CKT RIBBON
J32 - 30 CKT RIBBON
N/C
J34 - 30 CKT RIBBON
N/C
J36 - 30 CKT RIBBON
CPU PCB (CCM )
J28 30 CKT RECEPTACLE - BOTTOM ENTRY
19X501100
I-O PCB (CCM)
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
J28 30 CKT PIN HEADER
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
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)
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)
J85
F
Art # A-11960_AE
1 2 3 4
A-44 APPENDIX 0-5578
5
6 7 8 9 10
TO PILOT PCB
(Sht 1, B8)
SA3
MC2 Fan Control
(96)
230 VAC _ SW
(D2)
230 VAC _ SW _ RET
(D2)
(70)
( 6 9 )
230 VAC to HE 400
230 VAC Ret
(70)
( 6 9 )
J70 - HE
5
6
7
3
4
1
2
ARC_SUPPRESSOR MC3 Pump Motor Control W1
J3
PILOT PCB
GND
J38
24 VDC
J4 -- 40 CKT RIBBON CABLE
1 2 3 4 5 6 7 8 9
RS 232 D-SUB
SERIAL PROG
PORT
3
4
1
2
5
6
J18
PROG
USB IC
J29 30 CKT RECEPTACLE - BOTTOM ENTRY
J29 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)
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
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.)
J8
ARC_SUPPRESSOR
CONTROL OUTPUTS
7
8
5
6
3
4
1
2
9
10
11
12
J19
SA4
24 VAC
(96)
(98)
(99)
(97)
SA1
ARC_SUPPRESSOR
(97)
120 VAC_1
120 VAC_2
HMI/GCM
J39
USB
PORT
18
17
16
15
14
13
12
11
10
9
8
7
6
5
4
3
2
1
J10
(100)
(101)
(102)
(103)
(104)
(106)
(108)
(109)
(110)
(111)
(113)
(61)
AC 24V GCM2
AC 120V - GCM
AC 24V - RET - GCM2
AC 120V- Ret- GCM
AC 120V- Ret- TB4-3
7
8
5
6
3
4
1
2
9
10
11
12
J20
USB Cable to Front Panel
1 2 3 4
GND
GND
Rx-
Tx+
Rx+
Tx-
3
4
1
2
5
6
J30
3
4
1
2
J47
(116)
(117)
(120)
(115)
(119)
(118)
J37
(62)
1
K1
(63)
5
Harness
(62)
(60)
(63)
16 CKT RIBBON
120VAC
AC 24V GCM1
AC 24V-TB4-2
AC 120V- TB4-4
AC 24V Ret- GCM1
AC 24V- Ret -TB4-1
2
4
3
INRUSH CONTROL
(107)
(61)
(107)
CHASSIS GND
120 VAC to RAS
120 VAC Ret
Harness
(99)
(98)
J59 - RAS
9
10
11
12
13
14
7
8
5
6
3
4
1
2
3 - Key Plug
A
J54 - Remote HMI & CNC COMM
(100)
(101)
(102)
(109)
(108)
(115)
(116)
(117)
(118)
(119)
(120)
9
10
11
12
13
14
7
8
5
6
3
4
1
2
1 - 24 VAC
2 - 24 VAC Ret
3- Jumper to 24 VAC
5-HMI Plasma Enable SW
6-HMI Plasma Enable SW
7 - Key Plug
8 - Tx+
9 - GND
10 - GND
RS 485
/ 422
Comm
12 - Tx-
13 - Rx+
14 - Rx-
(61)
B
J17
Display PCB
019X501800
(121)
(122)
(123)
(124)
(125)
(126)
(127)
(128)
(129)
(130)
(131)
C
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 (-)
TB1
8
7
6
5
4
3
2
1
12
11
10
9
OK to MOVE (+)
OK to MOVE (-)
PILOT is ON
PILOT is ON
Preflow ON (+)
Preflow ON (-)
Hold Start (+)
Hold Start (-)
Spare
Digital
Inputs
Spare #1b NO
Spare
Digital
Inputs
/ Plasma Marking (-)
/ Plasma Marking (+)
TB3
8
7
6
5
4
3
2
1
12
11
10
9
TB2
8
7
6
5
4
3
2
1
12
11
10
9
OK
ENABLE
PLAS_ENABLE SW
PLAS_ EN_SW_RET
/ GAS PRESS OK
/ BASIC ID
+10V
GND
PSR
GAS ON
SPARE #1a
GND
GND
13
14
15
16
9
10
11
12
7
8
5
6
3
4
1
2
J26
13
14
15
16
9
10
11
12
17
18
7
8
5
6
3
4
1
2
J21
13
14
15
16
9
10
11
12
17
18
19
20
7
8
5
6
3
4
1
2
J22
(130)
(131)
(112)
(114)
(121)
(122)
(124)
(129)
(128)
(123)
(125)
(126)
(127)
(142)
(140)
(141)
(136)
(135)
(132)
(153)
(144)
(145)
(146)
(147)
(148)
(149)
(150)
(151)
(133)
(134)
(137)
(139)
(138)
(143)
(152)
(154)
(155)
(156)
(157)
(158)
(159)
(60)
MC1
AC 24V-GCM1
AC 24V Ret - GCM1
AC 24V-GCM2
AC 24V Ret-GCM2
J69
2
1
AC 120V - GCM
AC 120V- Ret- GCM
(104)
(111)
(166)
(167)
(106)
(113)
CHASSIS GND
(133)
(134)
(135)
(136)
(137)
(138)
(139)
(140)
(141)
(142)
(143)
(144)
(145)
(132)
(152)
(153)
(154)
(155)
(156)
(157)
(158)
(159)
(146)
(147)
(148)
(149)
(150)
(151)
(112)
(114)
(103)
(110)
29
30
31
32
25
26
27
28
33
34
35
36
37
21
22
23
24
17
18
19
20
13
14
15
16
9
10
11
12
7
8
5
6
3
4
1
2
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 **
10-
11-
GCM 1000 XT
Jumper
14-
15- 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
J15-1 to chassis used for
SC-11 cable shield
J15-13 connects SC-11 chassis to PS chassis.
J15-CNC
29
30
31
32
25
26
27
28
33
34
35
36
37
21
22
23
24
17
18
19
20
13
14
15
16
9
10
11
12
7
8
5
6
3
4
1
2
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 (-)
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)
D
E
Art # A-11960_AE
* Used with Momentary CNC Start SW
Rev
00
A A
AB ECO-B2687
Revision
Initial Design
6
By Date
DAT 10/03/2012
D A T 9 / 1 6 / 2 0 1 4
DAT 10/17/2014
Rev
7
Revision By Date
8
The information contained herein is proprietary to Thermal Dynamics.
Not for release, reproduction or distribution without written consent.
Title SCHEMATIC
Ultra-Cut XT 130A CE 380-415 VAC
9
Thermal Dynamics Corporation
2800 Airport Rd.
Denton, Texas 76207 USA
Date Printed
12/16/2014
Drawn
DAT
Size
C
Drawing Number
Date Revised
11/20/2014
Date
10/3/2012
Sheet
2 of 2
042X1354
10
F
F
E
A
B
C
D
1 2 3 4 5
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
From Sys Bias J63
(Sht 1, F2)
LS1
COOLANT LEVEL
1
4
J71
2
3
(90)
(89)
AMBIENT
TS2
COOLANT
TS1
(43A) (44A)
MC1A
FS1
COOLANT
0.7 GPM
J74
1
2
(84)
(83)
(92) (93)
(94)
(95)
Mini-Fit Jr
J12
1 2 3 4
5 6 7 8
(87)
460V
400V
220V
T1
FL1
24V RET
24V
120V_2 RET
120V_2
120V-1 RET
120V_1
1
2
3
BLUE
RED
YELLOW
BLUE
RED
YELLOW r b g
6
5
4
3
2
1
J14
3
4
1
2
J49
(80)
(81)
(82)
(79)
(77)
CB2 5 A
(74)
CB3 5 A
(78)
(76)
(75)
(73)
(71)
CB4 5 A
(72)
To J100 of IM #1B
To J100 of IM #1A
(Sht 1, B&C- 5&6)
J6
3
4
1
2
8
7
6
5
4
3
2
1
12
11
10
9
J9
J5 J7 J1
COOLANT FLOW SW
+5VDC
SIGNAL (pulse)
TORCH FLOW SENSOR
120VAC_2
24VAC
LEVEL SENSORS WORK CURRENT SENSOR
RELAY & INTERFACE PCB
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
J2
120VAC_1
BIAS TRANSFORMER 019X501700
TEMP SENSOR
Test Points
TP1, GND
TP2, -15V
TP3, +5VDC
TP4, +12V
TP5, +24V
TP6, +15V
TP7, +5VDC
1 TORCH INTERFACE
Refer to 1 Torch Module Schematic for Details
J11 J84
0 V
Mini-Fit
J13
MC3A
(66)
J16
1
2
3
M1
J13 to CB5 and to MC2
& MC3, also
J14, J16
all 18 AWG
(65A)
(64A)
MC3B
(64B)
MC2A
MC2B
CHASSIS GND
(67)
(69)
(70)
(69)
(70)
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.
BK
J72
1
2
3
R
C4
BN
FAN1
BL
R
Torch Coolant Pump
(69)
J72
1
2
3
230 VAC _ SW _ RET
(A9)
FAN1
Harness from Pilot PCB J45
(Sht 1, B8)
J73
1
2
3
(70)
230 VAC _ SW
(A9)
FAN2
230 VAC_SW goes to J70
for HE 400
(55)
(51)
(53)
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
13
14
J27
6
7
4
5
1
2
3
8
9
10
11
12
(37)
(38)
(39)
(40)
(41)
(42)
(29)
(30)
(31)
(32)
(33)
(34)
(35)
(36)
. 230V 400V 480V ERR
J62-12 (/VAC_IDAb) 0 1 0 1
J62-14 (/VAC_IDBb) 0 0 1 1
Measure relative to TP1 (24VDC_RET)
"0" = 10-12V "1" = 24V
7
8
5
6
3
4
1
2
J24
J31 - 30 CKT RIBBON
N/C
J33 - 30 CKT RIBBON
N/C
J35 - 30 CKT RIBBON
J32 - 30 CKT RIBBON
N/C
J34 - 30 CKT RIBBON
N/C
J36 - 30 CKT RIBBON
CPU PCB (CCM )
J28 30 CKT RECEPTACLE - BOTTOM ENTRY
19X501100
I-O PCB (CCM)
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
J28 30 CKT PIN HEADER
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
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)
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)
J85
Art # A-11960_AE
1 2 3 4
ULTRA-CUT 130 XT/200 XT/300 XT/400 XT
5
0-5578
6 7 8 9 10
TO PILOT PCB
(Sht 1, B8)
SA3
MC2 Fan Control
(96)
230 VAC _ SW
(D2)
230 VAC _ SW _ RET
(D2)
(70)
( 6 9 )
230 VAC to HE 400
230 VAC Ret
(70)
( 6 9 )
J70 - HE
5
6
7
3
4
1
2
ARC_SUPPRESSOR MC3 Pump Motor Control W1
J3
PILOT PCB
GND
J38
24 VDC
J4 -- 40 CKT RIBBON CABLE
1 2 3 4 5 6 7 8 9
RS 232 D-SUB
SERIAL PROG
PORT
3
4
1
2
5
6
J18
PROG
USB IC
J29 30 CKT RECEPTACLE - BOTTOM ENTRY
J29 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)
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
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.)
J8
ARC_SUPPRESSOR
CONTROL OUTPUTS
7
8
5
6
3
4
1
2
9
10
11
12
J19
SA4
24 VAC 120 VAC_1
120 VAC_2
HMI/GCM
J39
USB
PORT
18
17
16
15
14
13
12
11
10
9
8
7
6
5
4
3
2
1
J10
(100)
(101)
(102)
(103)
(104)
(106)
(108)
(109)
(110)
(111)
(113)
(61)
AC 24V GCM2
AC 120V - GCM
AC 24V - RET - GCM2
AC 120V- Ret- GCM
AC 120V- Ret- TB4-3
7
8
5
6
3
4
1
2
9
10
11
12
J20
USB Cable to Front Panel
1 2 3 4
GND
GND
Rx-
Tx+
Rx+
Tx-
3
4
1
2
5
6
J30
3
4
1
2
J47
(116)
(117)
(120)
(115)
(119)
(118)
J37
(62)
1
K1
(63)
5
Harness
(62)
(60)
(63)
16 CKT RIBBON
120VAC
AC 24V GCM1
AC 24V-TB4-2
AC 120V- TB4-4
AC 24V Ret- GCM1
AC 24V- Ret -TB4-1
2
4
3
INRUSH CONTROL
(107)
(61)
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 (-)
TB1
8
7
6
5
4
3
2
1
12
11
10
9
OK to MOVE (+)
OK to MOVE (-)
PILOT is ON
PILOT is ON
Preflow ON (+)
Preflow ON (-)
Hold Start (+)
Hold Start (-)
Spare
Digital
Inputs
Spare #1b NO
Spare
Digital
Inputs
/ Plasma Marking (-)
/ Plasma Marking (+)
TB3
8
7
6
5
4
3
2
1
12
11
10
9
TB2
8
7
6
5
4
3
2
1
12
11
10
9
OK
(96)
(98)
(99)
(97)
SA1
ARC_SUPPRESSOR
ENABLE
PLAS_ENABLE SW
PLAS_ EN_SW_RET
/ GAS PRESS OK
/ BASIC ID
+10V
GND
PSR
GAS ON
SPARE #1a
GND
GND
13
14
15
16
9
10
11
12
7
8
5
6
3
4
1
2
J26
13
14
15
16
9
10
11
12
17
18
7
8
5
6
3
4
1
2
J21
13
14
15
16
9
10
11
12
17
18
19
20
7
8
5
6
3
4
1
2
J22
(97)
(130)
(131)
(112)
(114)
(121)
(122)
(124)
(129)
(128)
(123)
(125)
(126)
(127)
(142)
(140)
(141)
(136)
(135)
(132)
(153)
(144)
(145)
(146)
(147)
(148)
(149)
(150)
(151)
(133)
(134)
(137)
(139)
(138)
(143)
(152)
(154)
(155)
(156)
(157)
(158)
(159)
(60)
MC1
(107)
CHASSIS GND
120 VAC to RAS
120 VAC Ret
Harness
(99)
(98)
J59 - RAS
9
10
11
12
13
14
7
8
5
6
3
4
1
2
3 - Key Plug
A
J54 - Remote HMI & CNC COMM
(100)
(101)
(102)
(109)
(108)
(115)
(116)
(117)
(118)
(119)
(120)
9
10
11
12
13
14
7
8
5
6
3
4
1
2
1 - 24 VAC
2 - 24 VAC Ret
3- Jumper to 24 VAC
5-HMI Plasma Enable SW
6-HMI Plasma Enable SW
7 - Key Plug
8 - Tx+
9 - GND
10 - GND
RS 485
/ 422
Comm
12 - Tx-
13 - Rx+
14 - Rx-
(61)
B
AC 24V-GCM1
AC 24V Ret - GCM1
AC 24V-GCM2
AC 24V Ret-GCM2
J69
2
1
AC 120V - GCM
AC 120V- Ret- GCM
J17
(104)
(111)
(166)
(167)
(106)
(113)
CHASSIS GND
019X501800
(133)
(134)
(135)
(136)
(137)
(138)
(139)
(140)
(141)
(142)
(143)
(144)
(145)
(132)
(152)
(153)
(154)
(155)
(156)
(157)
(158)
(159)
(146)
(147)
(148)
(149)
(150)
(151)
Display PCB
(121)
(122)
(123)
(124)
(125)
(126)
(127)
(128)
(129)
(130)
(131)
(112)
(114)
(103)
(110)
29
30
31
32
25
26
27
28
33
34
35
36
37
21
22
23
24
17
18
19
20
13
14
15
16
9
10
11
12
7
8
5
6
3
4
1
2
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 **
10-
11-
GCM 1000 XT
Jumper
14-
15- 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
J15-1 to chassis used for
SC-11 cable shield
J15-13 connects SC-11 chassis to PS chassis.
J15-CNC
29
30
31
32
25
26
27
28
33
34
35
36
37
21
22
23
24
17
18
19
20
13
14
15
16
9
10
11
12
7
8
5
6
3
4
1
2
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 (-)
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)
C
D
E
Art # A-11960_AE
* Used with Momentary CNC Start SW
Rev
00
A A
AB ECO-B2687
Revision
Initial Design
6
By Date
DAT 10/03/2012
D A T 9 / 1 6 / 2 0 1 4
DAT 10/17/2014
Rev
7
Revision By Date
8
The information contained herein is proprietary to Thermal Dynamics.
Not for release, reproduction or distribution without written consent.
Title SCHEMATIC
Ultra-Cut XT 130A CE 380-415 VAC
9
Thermal Dynamics Corporation
2800 Airport Rd.
Denton, Texas 76207 USA
Date Printed
12/16/2014
Drawn
DAT
Size
C
Drawing Number
Date Revised
11/20/2014
Date
10/3/2012
Sheet
2 of 2
042X1354
10
F
APPENDIX A-45
ULTRA-CUT 130 XT/200 XT/300 XT/400 XT
APPENDIX 25: 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
FIL-
TER
PCB
OUT1
2
1
1
2
1
2
IN2
OUT2
IN3
GND2B
OUT3
2
1
2
1
CHASSIS GND
(20)
(21)
(22)
(7)
(8)
L6
(9)
Toriod Core
J105A
1
2
J104A
1
2
J103A
1
2
AC INPUT
019x502000
IM #2 Section A (lower)
B
E
C
D
F
CB1
ON / OFF
16 A
(7) L5
(7)
L4
INVERTER MODULE (IM) #`1 (bottom)
Art # A-11961_AD
1
2
IN1
EMI
FIL-
TER
PCB
OUT1
2
1
1
2
1
2
IN2
GND2B
OUT2
IN3 OUT3
2
1
2
1
(20)
(21)
(22)
W1A
W1B
W1C
(8)
(9)
Toriod Core
J105B
1
2
J104B
1
2
J103B
1
2
AC INPUT
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
L1
L2
L3
Earth
1
1
1
1
CHASSIS GND
(1)
(2)
(3)
380-415
VAC
INPUT
(Customer supplied power cord must pass through ferrite core assembly.)
F1
8A, 500V, SB
(86A)
(27A)
(27B)
(85B)
CHASSIS GND
(1)
(2)
(3)
18 AWG wire both in and out of
CB1
(FRONT PANEL)
F2
8A, 500V, SB
(85A)
(86B)
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
AC INPUT
11
12
13
14
7
8
9
10
15
16
17
18
5
6
3
4
1
2
J60
J63
SYSTEM BIAS SUPPLY PCB
019X501900
+24VDC
(43A)
(8)
J105A
1
2
J104A
1
2
J103A
1
2
AC INPUT IM #1 Section A (lower)
J50
10
11
12
13
8
9
6
7
14
1
4
5
2
3
AC LINE
AC
SUPPRESSION
PCB
019X504000
GND
(10)
J51
1
2
3
4
(11)
PANEL AC INDICATOR
(12)
J52
1
2
3
4
(13)
INTERNAL AC INDICATOR
CHASSIS GND
K1A
TO AUX TRANSFORMER
TO J12
T1 PRIMARY
(Sht 2, A1)
K1B
(44A)
+ V
GND
J62
6
7
4
5
1
2
3
8
9
10
11
12
13
14
LT1
(9)
Toriod Core
LT1 & LT2
INPUT POWER
NEON INDICATORS
LT2 Rear Panel & Internal
To J27 on CCM I/O PCB
(Sht 2, 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
230V 400V 480V ERR
/VAC_IDAb 0 1 0 1
/VAC_IDBb 0 0 1 1
J61
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
(37)
(38)
(39)
(40)
(41)
(42)
(29)
(30)
(31)
(32)
(33)
(34)
(35)
(36)
019x502000
Component Locations (not including PCB components)
WORK (+)
C4 Capacitor, fan starting, 8uf 440VAC (Sht 2, E1)
CB1 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)
K1 Relay, 24VAC, Inrush Control, (Sht2, B9)
L1 Inductor, (Sht 1, B7)
L3-5 Toriod Core Common Mode Ind (Sht1 B8, B&C3)
LS1 Level Switch, Coolant Tank (Sht 2, A3)
LT1, LT2 Indicator, Neon, 250V, AC Volts Present
(Sht 1, B2 & C2)
M1 Motor, Pump, ½ hp 230VAC, 50/60 Hz, 1Ph
(Sht 2, C2)
MC1 Relay, 120VAC, Inrush, coil (Sht2, B9)
contact (Sht2, A1)
MC2 Relay, 120 VAC, Fan Control, coil
(Coil at Sht 2, A7)(Contacts at Sht 2, D1)
MC3 Relay, 120 VAC, Pump Motor Control, coil
(Coil at Sht 2, A7)(Contacts at Sht 2, C1)
R2 Inrush, 4.7 Ohm, 30W (Sht2, A1)
R3,4 Ext RC, 100 ohm 55W (Sht1, A7)
SA1-3 Snubber, Contactor & Relay coils
(Sht 2, A8 & A9)
T1 Aux Transformer (Sht 2, B2)
TB4
TS1
Terminal Block (Sht 1, C9)
Temperature Sensor, NTC, Coolant Return
(Sht 2, A5)
TS2 Temperature Sensor, NTC, Ambient (Sht 2, A5)
W1 Contactor , Input (Coil Sht 2, A8), (Contacts C2)
1 2 3 4
A-46 APPENDIX 0-5578
5
6 7 8 9 10
J100 -- 30 CKT RIBBON
ELECTRODE (-)
WORK (+)
OUTPUT
TO CCM
CPU PCB
J33
(Sht 2, C3)
5
4
3
2
1
J102A
(49C)
(51C)
J100 -- 30 CKT RIBBON
ELECTRODE (-)
WORK (+)
OUTPUT
TO CCM
CPU PCB
J32
(Sht 2, C3)
5
4
3
2
1
J102B
(49B)
TO CCM
CPU PCB
J31
(Sht 2, C3)
J100 -- 30 CKT RIBBON
ELECTRODE (-)
WORK (+)
OUTPUT
4
3
2
1
J102A
(49A)
5
(51)
(50)
PILOT BOARD LED'S
D2 PILOT ENABLE
D11 +5V
(49)
TEST POINTS
TP1 GND
TP2 PILOT GATE
TP3 +5V
J58A
(49)
J43
ELECTRODE
PILOT PCB
J44
1
R3 & R4
(50)
J58C
(51F)
J40
INVERTER
5
4
3
2
1
J42
019X501600
TO J3 on RELAY PCB
(Sht 2, A5)
10 ckt Ribbon
(53)
TIP VOLTS
To J24 on I-O PCB
(Sht 2, D3)
WORK
ARC VOLTS
(51)
L1
(51)
HCT1
Hall Effect Sensor
(55)
CHASSIS GND
J41
1
2
TIP
J45
J16
TO J1 on RELAY PCB
(Sht 2, B9)
(56)
(57)
(58)
(59) o b g w
TORCH
To TB4-7
To TB4-6 TIP
J41 (J87)
L3
(49)
(52)
To / From Optional
1 Torch Module
(Refer to 1 Torch section for details.)
TORCH
1
PILOT
1
RAS
CHASSIS GND
WORK
1
TORCH
(Sht 1, A9)
TIP
(Sht 1, A9)
AC 120V- TB4-4
AC 120V- Ret- TB4-3
AC 24V-TB4-2
AC 24V- Ret -TB4-1
(J10 Sht 2, B8)
(49)
(52)
(51)
(60)
(61)
(62)
(63)
TB4
7
6
5
4
3
2
1
ARC VOLTS (TORCH)
TIP VOLTS (PILOT)
WORK
120 VAC @ 100 ma.
24 VAC @ 1A
(-)
SHIELD
(+)
Tip
SHIELD
Work
(+)
B
A
C
RIBBON CABLE 30 ckt.
CCM (J31-36) - INVERTER (J100)
1 READY +
2 READY -
3 INVERTER_FLT +
4 INVERTER_FLT -
5 OVERTEMP_FLT +
6 OVERTEMP_FLT -
7 PWR_PRESENT +
8 PWR_PRESENT -
9 OUT_COM (+3 to 5VDC)
10 VAC_SELA
11 VAC_SELB
12 IS_IDA
13 IS_IDB
14 IS_IDC
15 ENABLE +
16 ENABLE -
17 START2 +
18 START2 -
19 SPARE
20 SYNC_IN +
21 SYNC_IN -
22 NC
23 NC
24 47 OHM to COMM
25 DEMAND +
26 DEMAND -
27 47 OHM to COMM
28 CURRENT +
29 CURRENT -
30 47 OHM to COMM
Rev
00
Revision
Initial Design
A A
AB ECO-B2687
6
By Date
DAT 10/03/2012
D A T 9 / 1 6 / 2 0 1 4
DAT 10/17/2014
Rev
7
RIBBON CABLE 40 ckt CCM (J23) - RELAY PCB (J4)
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 SIG-
24 NC
25 PILOT CURRENT SIG+
26 COMMON
27 WORK CURRENT SIG-
28 WORK CURRENT SIG+
29 NC
30 AMBIENT TEMP
31 COOLANT TEMP
* Used with 1 Torch Option
32 COMMON
33 -15 VDC
34 COMMON
35 24 VDC
36 COMMON
37 24 VDC
38 COMMON
39 24 VDC
40 COMMON
RIBBON CABLE 16 ckt
CCM ( J37) - DISPLAY PCB (J17)
1,3,5,7
2,4,6,8
24 VDC
COMMON
9,10 NC
11-16 SERIAL DATA
RIBBON CABLE 10 ckt
RELAY PCB (J3) – PILOT PCB (J42)
1,2 24 VDC
3,4,7,10 COMMON
5 PILOT ENABLE +
6 PILOT ENABLE –
8 PILOT CURRENT SIG –
9 PILOT CURRENT SIG +
Art # A-11961_AD
Revision By Date
8
The information contained herein is proprietary to Thermal Dynamics.
Not for release, reproduction or distribution without written consent.
Title SCHEMATIC
Ultra-Cut XT 200A CE 380-415 VAC
9
Thermal Dynamics Corporation
2800 Airport Rd.
Denton, Texas 76207 USA
F
Date Printed
12/16/2014
Drawn
DAT
Size
C
Drawing Number
Date Revised
11/20/2014
Date
10/04/2012
Sheet
1 of
2
042X1353
10
D
E
1 2 3 4 5
A
INVERTER 1/2 MODULE (IM) #2 (top)
(1)
(2)
(3)
1
2
IN1
EMI
FIL-
TER
PCB
OUT1
2
1
1
2
1
2
IN2
OUT2
IN3
GND2B
OUT3
2
1
2
1
CHASSIS GND
(20)
(21)
(22)
(7)
(8)
L6
(9)
Toriod Core
J105A
1
2
J104A
1
2
J103A
1
2
AC INPUT
019x502000
IM #2 Section A (lower)
B
E
C
D
F
CB1
ON / OFF
16 A
(7) L5
(7)
L4
INVERTER MODULE (IM) #`1 (bottom)
Art # A-11961_AD
1
2
IN1
EMI
FIL-
TER
PCB
OUT1
2
1
1
2
1
2
IN2
GND2B
OUT2
IN3 OUT3
2
1
2
1
(20)
(21)
(22)
W1A
W1B
W1C
(8)
(9)
Toriod Core
J105B
1
2
J104B
1
2
J103B
1
2
AC INPUT
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
L1
L2
L3
Earth
1
1
1
1
CHASSIS GND
(1)
(2)
(3)
380-415
VAC
INPUT
(Customer supplied power cord must pass through ferrite core assembly.)
F1
8A, 500V, SB
(86A)
(27A)
(27B)
(85B)
CHASSIS GND
(1)
(2)
(3)
18 AWG wire both in and out of
CB1
(FRONT PANEL)
F2
8A, 500V, SB
(85A)
(86B)
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
AC INPUT
11
12
13
14
7
8
9
10
15
16
17
18
5
6
3
4
1
2
J60
J63
SYSTEM BIAS SUPPLY PCB
019X501900
+24VDC
(43A)
(8)
J105A
1
2
J104A
1
2
J103A
1
2
AC INPUT IM #1 Section A (lower)
J50
10
11
12
13
8
9
6
7
14
1
4
5
2
3
AC LINE
AC
SUPPRESSION
PCB
019X504000
GND
(10)
J51
1
2
3
4
(11)
PANEL AC INDICATOR
(12)
J52
1
2
3
4
(13)
INTERNAL AC INDICATOR
CHASSIS GND
K1A
TO AUX TRANSFORMER
TO J12
T1 PRIMARY
(Sht 2, A1)
K1B
(44A)
+ V
GND
J62
6
7
4
5
1
2
3
8
9
10
11
12
13
14
LT1
(9)
Toriod Core
LT1 & LT2
INPUT POWER
NEON INDICATORS
LT2 Rear Panel & Internal
To J27 on CCM I/O PCB
(Sht 2, 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
230V 400V 480V ERR
/VAC_IDAb 0 1 0 1
/VAC_IDBb 0 0 1 1
J61
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
(37)
(38)
(39)
(40)
(41)
(42)
(29)
(30)
(31)
(32)
(33)
(34)
(35)
(36)
019x502000
Component Locations (not including PCB components)
WORK (+)
C4 Capacitor, fan starting, 8uf 440VAC (Sht 2, E1)
CB1 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)
K1 Relay, 24VAC, Inrush Control, (Sht2, B9)
L1 Inductor, (Sht 1, B7)
L3-5 Toriod Core Common Mode Ind (Sht1 B8, B&C3)
LS1 Level Switch, Coolant Tank (Sht 2, A3)
LT1, LT2 Indicator, Neon, 250V, AC Volts Present
(Sht 1, B2 & C2)
M1 Motor, Pump, ½ hp 230VAC, 50/60 Hz, 1Ph
(Sht 2, C2)
MC1 Relay, 120VAC, Inrush, coil (Sht2, B9)
contact (Sht2, A1)
MC2 Relay, 120 VAC, Fan Control, coil
(Coil at Sht 2, A7)(Contacts at Sht 2, D1)
MC3 Relay, 120 VAC, Pump Motor Control, coil
(Coil at Sht 2, A7)(Contacts at Sht 2, C1)
R2 Inrush, 4.7 Ohm, 30W (Sht2, A1)
R3,4 Ext RC, 100 ohm 55W (Sht1, A7)
SA1-3 Snubber, Contactor & Relay coils
(Sht 2, A8 & A9)
T1 Aux Transformer (Sht 2, B2)
TB4
TS1
Terminal Block (Sht 1, C9)
Temperature Sensor, NTC, Coolant Return
(Sht 2, A5)
TS2 Temperature Sensor, NTC, Ambient (Sht 2, A5)
W1 Contactor , Input (Coil Sht 2, A8), (Contacts C2)
1 2 3 4
ULTRA-CUT 130 XT/200 XT/300 XT/400 XT
5
6 7 8 9 10
J100 -- 30 CKT RIBBON
ELECTRODE (-)
WORK (+)
OUTPUT
TO CCM
CPU PCB
J33
(Sht 2, C3)
5
4
3
2
1
J102A
(49C)
(51C)
J100 -- 30 CKT RIBBON
ELECTRODE (-)
WORK (+)
OUTPUT
TO CCM
CPU PCB
J32
(Sht 2, C3)
5
4
3
2
1
J102B
(49B)
TO CCM
CPU PCB
J31
(Sht 2, C3)
J100 -- 30 CKT RIBBON
ELECTRODE (-)
WORK (+)
OUTPUT
4
3
2
1
J102A
(49A)
5
(51)
(50)
PILOT BOARD LED'S
D2 PILOT ENABLE
D11 +5V
(49)
TEST POINTS
TP1 GND
TP2 PILOT GATE
TP3 +5V
J58A
(49)
J43
ELECTRODE
PILOT PCB
J44
1
R3 & R4
(50)
J58C
(51F)
J40
INVERTER
5
4
3
2
1
J42
019X501600
TO J3 on RELAY PCB
(Sht 2, A5)
10 ckt Ribbon
(53)
TIP VOLTS
To J24 on I-O PCB
(Sht 2, D3)
WORK
ARC VOLTS
(51)
L1
(51)
HCT1
Hall Effect Sensor
(55)
CHASSIS GND
J41
1
2
TIP
J45
J16
TO J1 on RELAY PCB
(Sht 2, B9)
(56)
(57)
(58)
(59) o b g w
TORCH
To TB4-7
To TB4-6 TIP
J41 (J87)
L3
(49)
(52)
To / From Optional
1 Torch Module
(Refer to 1 Torch section for details.)
TORCH
1
PILOT
1
RAS
CHASSIS GND
WORK
1
TORCH
(Sht 1, A9)
TIP
(Sht 1, A9)
AC 120V- TB4-4
AC 120V- Ret- TB4-3
AC 24V-TB4-2
AC 24V- Ret -TB4-1
(J10 Sht 2, B8)
(49)
(52)
(51)
(60)
(61)
(62)
(63)
TB4
7
6
5
4
3
2
1
ARC VOLTS (TORCH)
TIP VOLTS (PILOT)
WORK
120 VAC @ 100 ma.
24 VAC @ 1A
(-)
SHIELD
(+)
Tip
SHIELD
Work
(+)
B
A
C
RIBBON CABLE 30 ckt.
CCM (J31-36) - INVERTER (J100)
1 READY +
2 READY -
3 INVERTER_FLT +
4 INVERTER_FLT -
5 OVERTEMP_FLT +
6 OVERTEMP_FLT -
7 PWR_PRESENT +
8 PWR_PRESENT -
9 OUT_COM (+3 to 5VDC)
10 VAC_SELA
11 VAC_SELB
12 IS_IDA
13 IS_IDB
14 IS_IDC
15 ENABLE +
16 ENABLE -
17 START2 +
18 START2 -
19 SPARE
20 SYNC_IN +
21 SYNC_IN -
22 NC
23 NC
24 47 OHM to COMM
25 DEMAND +
26 DEMAND -
27 47 OHM to COMM
28 CURRENT +
29 CURRENT -
30 47 OHM to COMM
Rev
00
Revision
Initial Design
A A
AB ECO-B2687
6
By Date
DAT 10/03/2012
D A T 9 / 1 6 / 2 0 1 4
DAT 10/17/2014
Rev
7
RIBBON CABLE 40 ckt CCM (J23) - RELAY PCB (J4)
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 SIG-
24 NC
25 PILOT CURRENT SIG+
26 COMMON
27 WORK CURRENT SIG-
28 WORK CURRENT SIG+
29 NC
30 AMBIENT TEMP
31 COOLANT TEMP
* Used with 1 Torch Option
32 COMMON
33 -15 VDC
34 COMMON
35 24 VDC
36 COMMON
37 24 VDC
38 COMMON
39 24 VDC
40 COMMON
RIBBON CABLE 16 ckt
CCM ( J37) - DISPLAY PCB (J17)
1,3,5,7
2,4,6,8
24 VDC
COMMON
9,10 NC
11-16 SERIAL DATA
RIBBON CABLE 10 ckt
RELAY PCB (J3) – PILOT PCB (J42)
1,2 24 VDC
3,4,7,10 COMMON
5 PILOT ENABLE +
6 PILOT ENABLE –
8 PILOT CURRENT SIG –
9 PILOT CURRENT SIG +
Art # A-11961_AD
Revision By Date
8
The information contained herein is proprietary to Thermal Dynamics.
Not for release, reproduction or distribution without written consent.
Title SCHEMATIC
Ultra-Cut XT 200A CE 380-415 VAC
9
Thermal Dynamics Corporation
2800 Airport Rd.
Denton, Texas 76207 USA
F
Date Printed
12/16/2014
Drawn
DAT
Size
C
Drawing Number
Date Revised
11/20/2014
Date
10/04/2012
Sheet
1 of
2
042X1353
10
D
E
0-5578 APPENDIX A-47
ULTRA-CUT 130 XT/200 XT/300 XT/400 XT
APPENDIX 26: System Schematic 200A, 380-415V PG 2
F
E
A
B
C
D
1 2 3 4 5
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
From Sys Bias J63
(Sht 1, F2)
(44A)
(43A)
MC1A
LS1
COOLANT LEVEL
4
J71
1
2
3
(90)
(89)
AMBIENT
TS2
COOLANT
TS1
FS1
COOLANT
0.7 GPM
J74
1
2
(84)
(83)
(92) (93)
(94)
(95)
J12
1 2 3 4
5 6 7 8
R2
4.7 30W
(87)
460V
400V
220V
T1
FL1
24V RET
24V
120V_2 RET
120V_2
120V-1 RET
120V_1
1
2
3
BLUE
RED
YELLOW
BLUE
RED
YELLOW r b g
2
1
4
3
6
5
J14
3
4
1
2
J49
(80)
(81)
(82)
(79)
(77)
CB2 5 A
(78)
(76)
(74)
CB3 5 A
(71)
CB4 5 A
(75)
(73)
(72)
To J100 of IM #1B
(Sht 1, C,D6)
3
4
1
2
J6
8
7
6
5
4
3
2
1
12
11
10
9
J9
J5 J7 J1 J2
COOLANT FLOW SW
+5VDC
SIGNAL (pulse)
TORCH FLOW SENSOR
120VAC_2
24VAC
LEVEL SENSORS WORK CURRENT SENSOR
RELAY & INTERFACE PCB
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
BIAS TRANSFORMER
019X501700
TEMP SENSORS
Test Points
TP1, GND
TP2, -15V
TP3, +5VDC
TP4, +12V
TP5, +24V
TP6, +15V
TP7, +5VDC
1 TORCH INTERFACE
Refer to 1 Torch Module Schematic for Details
J11 J84
0 V
J31 - 30 CKT RIBBON J32 - 30 CKT RIBBON CPU PCB (CPU)
To J100 of IM #2A
(Sht 1, B,C6)
J33 - 30 CKT RIBBON J34 - 30 CKT RIBBON
J13
J13 to CB5 and to MC2
& MC3, also
J14, J16
all 18 AWG
(65A)
(64A)
MC3A
MC3B
(64B)
MC2A
MC2B
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.
BK R
1
2
3
J72 C4
BN
R
FAN1
BL
(66)
(67)
(69)
(70)
(69)
J72
1
2
3
230 VAC _ SW _ RET
(A9)
FAN1
(69)
(70)
CHASSIS GND
J73
1
2
3
FAN2
(70)
230 VAC _ SW
(A9)
230 VAC_SW goes to J70
for HE 400
J35 - 30 CKT RIBBON J36 - 30 CKT RIBBON
J16
1
2
3
M1
Torch Coolant Pump Harness from Pilot PCB J45
(Sht 1, B8)
(55)
(51)
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
. 230V 400V 480V ERR
J62-12 (/VAC_IDAb) 0 1 0 1
J62-14 (/VAC_IDBb) 0 0 1 1
Measure relative to TP1 (24VDC_RET)
"0" = 10-12V "1" = 24V
(53)
10
11
12
13
14
J27
7
8
5
6
9
3
4
1
2
(29)
(30)
(31)
(32)
(33)
(34)
(35)
(36)
(37)
(38)
(39)
(40)
(41)
(42)
7
8
5
6
3
4
1
2
J24
J28 30 CKT RECEPTACLE - BOTTOM ENTRY
19X501100
I-O PCB (CCM)
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
J28 30 CKT PIN HEADER
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
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)
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)
J85
Art # A-11962_AD
1 2 3 4
A-48 APPENDIX 0-5578
5
6 7 8 9 10
SA3
MC2 Fan Control
SA1
230 VAC _ SW
(D2)
230 VAC _ SW _ RET
(D2)
(70)
( 6 9 )
230 VAC to HE 400
230 VAC Ret
(70)
( 6 9 )
J70 - HE
5
6
7
3
4
1
2
J3
J29 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)
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
J8
ARC_SUPPRESSOR
SA4
ARC_SUPPRESSOR
MC3 Pump Motor Control
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 (-)
TB1
9
8
7
6
5
4
3
2
1
12
11
10
OK to MOVE (+)
OK to MOVE (-)
PILOT is ON
PILOT is ON
Preflow ON (+)
Preflow ON (-)
Hold Start (+)
Hold Start (-)
(96)
(98)
(99)
(97)
ARC_SUPPRESSOR
ENABLE
PLAS_ENABLE SW
PLAS_ EN_SW_RET
/ GAS PRESS OK
/ BASIC ID
W1
(133)
(134)
(137)
(139)
(138)
(143)
(140)
(141)
(136)
(135)
(132)
(153)
(130)
(131)
(112)
(114)
(121)
(122)
(124)
(129)
(128)
(123)
(125)
(126)
(127)
(152)
(154)
(155)
(60)
MC1
CHASSIS GND
120 VAC to RAS
120 VAC Ret
(99)
(98)
J59 - RAS
9
10
11
12
13
14
7
8
5
6
3
4
1
2
3 - Key Plug
PILOT PCB
GND
J38
3
4
1
2
5
6
J18
24 VDC
RS 232 D-SUB
SERIAL PROG
PORT
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.)
CONTROL OUTPUTS
24 VAC
J4 -- 40 CKT RIBBON CABLE
1 2 3 4 5 6 7 8 9
PROG
USB IC
J29 30 CKT RECEPTACLE - BOTTOM ENTRY
7
8
5
6
3
4
1
2
9
10
11
12
J19
J23- 40 ckt ribbon cable
Spare
Digital
Inputs
Spare #1b NO
Spare
Digital
Inputs
/ Plasma Marking (-)
/ Plasma Marking (+)
TB3
8
7
6
5
4
3
2
1
12
11
10
9
TB2
7
6
5
4
3
2
1
12
11
10
9
8
120 VAC_1
120 VAC_2
HMI/GCM
J39
USB
PORT
18
17
16
15
14
13
12
11
10
9
8
7
6
5
4
3
2
1
J10
(100)
(101)
(102)
(104)
(106)
(108)
(109)
(110)
(111)
(113)
(61)
AC 24V GCM2
AC 120V - GCM
AC 24V - RET - GCM2
AC 120V- Ret- GCM
AC 120V- Ret- TB4-3
7
8
5
6
3
4
1
2
9
10
11
12
J20
USB Cable to Front Panel
1 2 3 4
GND
GND
Rx-
Tx+
Rx+
Tx-
3
4
1
2
5
6
J30
3
4
1
2
J47
(116)
(117)
(120)
(115)
(119)
(118)
J37
(62)
(60)
120VAC
AC 24V GCM1
AC 24V-TB4-2
AC 120V- TB4-4
(63)
AC 24V Ret- GCM1
AC 24V- Ret -TB4-1
(62) 1
K1
(63) 5
INRUSH CONTROL
2
4
3
Harness
16 CKT RIBBON
OK
+10V
GND
PSR
GAS ON
SPARE #1a
GND
GND
13
14
15
16
9
10
11
12
7
8
5
6
3
4
1
2
J26
13
14
15
16
9
10
11
12
17
18
7
8
5
6
3
4
1
2
J21
13
14
15
16
9
10
11
12
17
18
19
20
7
8
5
6
3
4
1
2
J22
(142)
(144)
(145)
(146)
(147)
(148)
(149)
(150)
(151)
(156)
(157)
(158)
(159)
Harness
J17
J54 - Remote HMI & CNC COMM
(100)
(101)
(102)
(109)
(108)
(115)
(116)
(117)
(118)
(119)
(120)
9
10
11
12
13
14
7
8
5
6
3
4
1
2
1 - 24 VAC
2 - 24 VAC Ret
3- Jumper to 24 VAC
5-HMI Plasma Enable SW
6-HMI Plasma Enable SW
7 - Key Plug
8 - Tx+
9 - GND
10 - GND
RS 485
/ 422
Comm
12 - Tx-
13 - Rx+
14 - Rx-
Display PCB
019X501800
AC 24V-GCM1
AC 24V Ret - GCM1
AC 24V-GCM2
AC 24V Ret-GCM2
J69
2
1
AC 120V - GCM
AC 120V- Ret- GCM
Art # A-11962_AD
(104)
(111)
(166)
(167)
(106)
(113)
CHASSIS GND
(133)
(134)
(135)
(136)
(137)
(138)
(139)
(140)
(141)
(142)
(143)
(144)
(145)
(146)
(147)
(148)
(149)
(150)
(151)
(132)
(152)
(153)
(154)
(155)
(156)
(157)
(158)
(159)
(121)
(122)
(123)
(124)
(125)
(126)
(127)
(128)
(129)
(130)
(131)
(112)
(114)
(103)
(110)
J55 - GCM
29
30
31
32
25
26
27
28
33
34
35
36
37
21
22
23
24
17
18
19
20
13
14
15
16
9
10
11
12
7
8
5
6
3
4
1
2
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 **
10-
11-
GCM 1000 XT
Jumper
14-
15- 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
J15-1 to chassis used for
SC-11 cable shield
J15-13 connects SC-11 chassis to PS chassis.
J15-CNC
29
30
31
32
25
26
27
28
33
34
35
36
37
21
22
23
24
17
18
19
20
13
14
15
16
9
10
11
12
7
8
5
6
3
4
1
2
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 (-)
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
Rev
00
Revision
Initial Design
A A
AB ECO-B2687
6
By Date
DAT 10/03/2012
D A T 9 / 1 6 / 2 0 1 4
DAT 10/17/2014
Rev
7
Revision By Date
8
The information contained herein is proprietary to Thermal Dynamics.
Not for release, reproduction or distribution without written consent.
Title SCHEMATIC
Ultra-Cut XT 200A CE 380-415 VAC
9
Thermal Dynamics Corporation
2800 Airport Rd.
Denton, Texas 76207 USA
Date Printed
12/16/2014
Drawn
DAT
Size
C
Drawing Number
Date Revised
11/20/2014
Date
10/4/2012
Sheet
2 of 2
042X1353
10
A
C
D
E
B
F
F
E
A
B
C
D
1 2 3 4 5
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
From Sys Bias J63
(Sht 1, F2)
(44A)
(43A)
MC1A
LS1
COOLANT LEVEL
4
J71
1
2
3
(90)
(89)
AMBIENT
TS2
COOLANT
TS1
FS1
COOLANT
0.7 GPM
J74
1
2
(84)
(83)
(92) (93)
(94)
(95)
J12
1 2 3 4
5 6 7 8
R2
4.7 30W
(87)
460V
400V
220V
T1
FL1
24V RET
24V
120V_2 RET
120V_2
120V-1 RET
120V_1
1
2
3
BLUE
RED
YELLOW
BLUE
RED
YELLOW r b g
2
1
4
3
6
5
J14
3
4
1
2
J49
(80)
(81)
(82)
(79)
(77)
CB2 5 A
(78)
(76)
(74)
CB3 5 A
(71)
CB4 5 A
(75)
(73)
(72)
To J100 of IM #1B
(Sht 1, C,D6)
3
4
1
2
J6
8
7
6
5
4
3
2
1
12
11
10
9
J9
J5 J7 J1 J2
COOLANT FLOW SW
+5VDC
SIGNAL (pulse)
TORCH FLOW SENSOR
120VAC_2
24VAC
LEVEL SENSORS WORK CURRENT SENSOR
RELAY & INTERFACE PCB
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
BIAS TRANSFORMER
019X501700
TEMP SENSORS
Test Points
TP1, GND
TP2, -15V
TP3, +5VDC
TP4, +12V
TP5, +24V
TP6, +15V
TP7, +5VDC
1 TORCH INTERFACE
Refer to 1 Torch Module Schematic for Details
J11 J84
0 V
J31 - 30 CKT RIBBON J32 - 30 CKT RIBBON CPU PCB (CPU)
To J100 of IM #2A
(Sht 1, B,C6)
J33 - 30 CKT RIBBON J34 - 30 CKT RIBBON
J13
J13 to CB5 and to MC2
& MC3, also
J14, J16
all 18 AWG
(65A)
(64A)
MC3A
MC3B
(64B)
MC2A
MC2B
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.
BK R
1
2
3
J72 C4
BN
R
FAN1
BL
(66)
(67)
(69)
(70)
(69)
J72
1
2
3
230 VAC _ SW _ RET
(A9)
FAN1
(69)
(70)
CHASSIS GND
J73
1
2
3
FAN2
(70)
230 VAC _ SW
(A9)
230 VAC_SW goes to J70
for HE 400
J35 - 30 CKT RIBBON J36 - 30 CKT RIBBON
J16
1
2
3
M1
Torch Coolant Pump Harness from Pilot PCB J45
(Sht 1, B8)
(55)
(51)
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
. 230V 400V 480V ERR
J62-12 (/VAC_IDAb) 0 1 0 1
J62-14 (/VAC_IDBb) 0 0 1 1
Measure relative to TP1 (24VDC_RET)
"0" = 10-12V "1" = 24V
(53)
10
11
12
13
14
J27
7
8
5
6
9
3
4
1
2
(29)
(30)
(31)
(32)
(33)
(34)
(35)
(36)
(37)
(38)
(39)
(40)
(41)
(42)
7
8
5
6
3
4
1
2
J24
J28 30 CKT RECEPTACLE - BOTTOM ENTRY
19X501100
I-O PCB (CCM)
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
J28 30 CKT PIN HEADER
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
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)
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)
J85
Art # A-11962_AD
1 2 3 4 5
ULTRA-CUT 130 XT/200 XT/300 XT/400 XT
0-5578
6 7 8 9 10
SA3
MC2 Fan Control
SA1
230 VAC _ SW
(D2)
230 VAC _ SW _ RET
(D2)
(70)
( 6 9 )
230 VAC to HE 400
230 VAC Ret
(70)
( 6 9 )
J70 - HE
5
6
7
3
4
1
2
J3
J29 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)
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
J8
ARC_SUPPRESSOR
SA4
ARC_SUPPRESSOR
MC3 Pump Motor Control
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 (-)
TB1
9
8
7
6
5
4
3
2
1
12
11
10
OK to MOVE (+)
OK to MOVE (-)
PILOT is ON
PILOT is ON
Preflow ON (+)
Preflow ON (-)
Hold Start (+)
Hold Start (-)
(96)
(98)
(99)
(97)
ARC_SUPPRESSOR
ENABLE
PLAS_ENABLE SW
PLAS_ EN_SW_RET
/ GAS PRESS OK
/ BASIC ID
W1
(133)
(134)
(137)
(139)
(138)
(143)
(140)
(141)
(136)
(135)
(132)
(153)
(130)
(131)
(112)
(114)
(121)
(122)
(124)
(129)
(128)
(123)
(125)
(126)
(127)
(152)
(154)
(155)
(60)
MC1
CHASSIS GND
120 VAC to RAS
120 VAC Ret
(99)
(98)
J59 - RAS
9
10
11
12
13
14
7
8
5
6
3
4
1
2
3 - Key Plug
PILOT PCB
GND
J38
3
4
1
2
5
6
J18
24 VDC
RS 232 D-SUB
SERIAL PROG
PORT
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.)
CONTROL OUTPUTS
24 VAC
J4 -- 40 CKT RIBBON CABLE
1 2 3 4 5 6 7 8 9
PROG
USB IC
J29 30 CKT RECEPTACLE - BOTTOM ENTRY
7
8
5
6
3
4
1
2
9
10
11
12
J19
J23- 40 ckt ribbon cable
Spare
Digital
Inputs
Spare #1b NO
Spare
Digital
Inputs
/ Plasma Marking (-)
/ Plasma Marking (+)
TB3
8
7
6
5
4
3
2
1
12
11
10
9
TB2
7
6
5
4
3
2
1
12
11
10
9
8
120 VAC_1
120 VAC_2
HMI/GCM
J39
USB
PORT
18
17
16
15
14
13
12
11
10
9
8
7
6
5
4
3
2
1
J10
(100)
(101)
(102)
(104)
(106)
(108)
(109)
(110)
(111)
(113)
(61)
AC 24V GCM2
AC 120V - GCM
AC 24V - RET - GCM2
AC 120V- Ret- GCM
AC 120V- Ret- TB4-3
7
8
5
6
3
4
1
2
9
10
11
12
J20
USB Cable to Front Panel
1 2 3 4
GND
GND
Rx-
Tx+
Rx+
Tx-
3
4
1
2
5
6
J30
3
4
1
2
J47
(116)
(117)
(120)
(115)
(119)
(118)
J37
(62)
(60)
120VAC
AC 24V GCM1
AC 24V-TB4-2
AC 120V- TB4-4
(63)
AC 24V Ret- GCM1
AC 24V- Ret -TB4-1
(62) 1
K1
(63) 5
INRUSH CONTROL
2
4
3
Harness
16 CKT RIBBON
OK
+10V
GND
PSR
GAS ON
SPARE #1a
GND
GND
13
14
15
16
9
10
11
12
7
8
5
6
3
4
1
2
J26
13
14
15
16
9
10
11
12
17
18
7
8
5
6
3
4
1
2
J21
13
14
15
16
9
10
11
12
17
18
19
20
7
8
5
6
3
4
1
2
J22
(142)
(144)
(145)
(146)
(147)
(148)
(149)
(150)
(151)
(156)
(157)
(158)
(159)
Harness
J17
J54 - Remote HMI & CNC COMM
(100)
(101)
(102)
(109)
(108)
(115)
(116)
(117)
(118)
(119)
(120)
9
10
11
12
13
14
7
8
5
6
3
4
1
2
1 - 24 VAC
2 - 24 VAC Ret
3- Jumper to 24 VAC
5-HMI Plasma Enable SW
6-HMI Plasma Enable SW
7 - Key Plug
8 - Tx+
9 - GND
10 - GND
RS 485
/ 422
Comm
12 - Tx-
13 - Rx+
14 - Rx-
Display PCB
019X501800
AC 24V-GCM1
AC 24V Ret - GCM1
AC 24V-GCM2
AC 24V Ret-GCM2
J69
2
1
AC 120V - GCM
AC 120V- Ret- GCM
Art # A-11962_AD
(104)
(111)
(166)
(167)
(106)
(113)
CHASSIS GND
(133)
(134)
(135)
(136)
(137)
(138)
(139)
(140)
(141)
(142)
(143)
(144)
(145)
(146)
(147)
(148)
(149)
(150)
(151)
(132)
(152)
(153)
(154)
(155)
(156)
(157)
(158)
(159)
(121)
(122)
(123)
(124)
(125)
(126)
(127)
(128)
(129)
(130)
(131)
(112)
(114)
(103)
(110)
J55 - GCM
29
30
31
32
25
26
27
28
33
34
35
36
37
21
22
23
24
17
18
19
20
13
14
15
16
9
10
11
12
7
8
5
6
3
4
1
2
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 **
10-
11-
GCM 1000 XT
Jumper
14-
15- 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
J15-1 to chassis used for
SC-11 cable shield
J15-13 connects SC-11 chassis to PS chassis.
J15-CNC
29
30
31
32
25
26
27
28
33
34
35
36
37
21
22
23
24
17
18
19
20
13
14
15
16
9
10
11
12
7
8
5
6
3
4
1
2
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 (-)
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
Rev
00
Revision
Initial Design
A A
AB ECO-B2687
6
By Date
DAT 10/03/2012
D A T 9 / 1 6 / 2 0 1 4
DAT 10/17/2014
Rev
7
Revision By Date
8
The information contained herein is proprietary to Thermal Dynamics.
Not for release, reproduction or distribution without written consent.
Title SCHEMATIC
Ultra-Cut XT 200A CE 380-415 VAC
9
Thermal Dynamics Corporation
2800 Airport Rd.
Denton, Texas 76207 USA
Date Printed
12/16/2014
Drawn
DAT
Size
C
Drawing Number
Date Revised
11/20/2014
Date
10/4/2012
Sheet
2 of 2
042X1353
10
A
C
D
E
B
F
APPENDIX A-49
ULTRA-CUT 130 XT/200 XT/300 XT/400 XT
APPENDIX 27: System Schematic 300A, 380-415V PG 1
A-50
1 2 3 4 5
E
F
A
B
C
D
(1)
(2)
(3)
1
2
IN1
EMI
FIL-
TER
PCB
OUT1
2
1
1
2
1
2
IN2
GND2B
IN3
OUT2
OUT3
2
1
2
1
(4)
(5)
(6)
(7)
(8)
(9)
L9
J105B
1
2
J104B
1
2
J103B
1
2
AC INPUT
INVERTER MODULE (IM) #3 (top)
IM #3 Section B
CHASSIS GND
Toriod Core
019X502700
(4)
W2A
380-415
VAC
INPUT
(Customer supplied power cord must pass through ferrite core assembly.)
L1
L2
L3
Earth
1
1
1
1
CHASSIS GND
(1)
(2)
(3)
(1)
(2)
(3)
1
2
IN1
EMI
FIL-
TER
PCB
OUT1
2
1
1
2
1
2
IN2
GND2B
IN3
OUT2
OUT3
2
1
2
1
CHASSIS GND
(5)
(6)
W2B
W2C
9
10
11
12
13
14
7
8
5
6
3
4
1
2
AC SUPPRESSION
J50
019X504000
J51
GND
J52
3
4
1
2
AC LINE
3
4
1
2
(10)
(11)
(12)
(13)
INTERNAL AC INDICATOR
CHASSIS GND
LT1
LT2
LT1 & LT2
INPUT POWER
NEON INDICATORS
Rear Panel & Internal
(7)
(8)
(9)
(7)
(8)
(9)
(23)
(24)
L8
Toriod Core
L6
(25)
Toriod Core
J105A
1
2
J104A
1
2
J103A
1
2
J105A
1
2
J104A
1
2
J103A
1
2
AC INPUT
019X502000
AC INPUT
019x502000
IM #3 Section A
INVERTER MODULE (IM) #2 (middle)
IM #2 Section A (lower)
(1)
(2)
(3)
1
2
1
2
1
2
IN1
EMI
FIL-
TER
PCB
IN2
GND2B
OUT1
OUT2
2
1
2
1
2
1
(20)
(21)
(22)
W1A
W1B
W1C
(23)
(24)
(25)
(23)
L5
(24)
(25)
Toriod Core
J105B
1
2
J104B
J103B
1
2
1
2
AC INPUT
019x502700
INVERTER MODULE (IM) #`1 (bottom)
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
IN3 OUT3
CB1
ON / OFF
CHASSIS GND (23)
L4
J105A
AC INPUT IM #1 Section A (lower)
(1)
1
2
IN1
EMI
FIL-
TER
PCB
OUT1
2
1
(24)
(25)
J104A
1
2
1
2
J103A
1
2
F1
8A, 500V, SB
(1-20)
(2-21)
(3-22)
(2)
F2
8A, 500V, SB
(85A)
(86B)
1
2
2
1
SYSTEM BIAS
SUPPLY PCB
019X501900
TO AUX TRANSFORMER
TO J12
T1 PRIMARY
(Sht 2, A1)
(44A)
Toriod Core
WORK (+)
16 A
(FRONT PANEL)
Art # A-11963_AD
(86A)
(27A)
(27B)
(85B)
(3)
AC INPUT
13
14
15
16
9
10
11
12
17
18
7
8
5
6
3
4
1
2
1
2
IN2
(43A)
GND2B
IN3
CHASSIS GND
J60
J63
OUT2
OUT3
2
1
K1A K1B
1 2 3 4 5 6 7 8 9 10 11 12
019x502000
+ V
GND
+24VDC
System Bias LEDs & Test Points
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
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
(48)
J62
1
10
11
12
13
14
8
9
6
7
4
5
2
3
To J27 on CCM I/O PCB
(Sht 2, 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
J61
Measure relative to TP1 (24VDC_RET)
"0" = 10-12V "1" = 24V
VOLTAGE SELECTION
Wire #48 from J61-1 to:
J61-2 for 208-230 VAC
J61-3 for 400 VAC
J61-4 for 480 VAC
(37)
(38)
(39)
(40)
(41)
(42)
(29)
(30)
(31)
(32)
(33)
(34)
(35)
(36)
230V 400V 480V ERR
/VAC_IDAb 0 1 0 1
/VAC_IDBb 0 0 1 1
Component Locations (not including PCB components)
C4 Capacitor, fan starting, 8uf 440VAC (Sht 2, D2)
CB1 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
HCT1
Flow SW, 0.5 GPM (3.8 lpm), N.O. (Sht 2, A2)
Current Sensor, Hall Effect 200A, Work Lead
(Sht 1, C8)
K1 Relay, 24VAC, Inrush Control, (Sht2, B9)
L1 Inductor, (Sht 1, B7)
L3-9 Toriod Core Common Mode Ind (Sht1 B8, A-D3)
LS1 Level Switch, Coolant Tank (Sht 2, A3)
LT1, LT2 Indicator, Neon, 250V, AC Volts Present
(Sht 1, B2 & C2)
M1 Motor, Pump, ½ hp 230VAC, 50/60 Hz, 1Ph
(Sht 2, C2)
MC1 Relay, 120VAC, Inrush, coil (Sht2, B9)
contact (Sht2, A1)
MC2 Relay, 120 VAC, Fan Control, coil
(Coil at Sht 2, A7)(Contacts at Sht 2, D1)
MC3 Relay, 120 VAC, Pump Motor Control, coil
(Coil at Sht 2, A7)(Contacts at Sht 2, C1)
R2 Inrush, 4.7 Ohm, 30W (Sht2, A1)
R3,4 Ext RC, 100 ohm 55W (Sht1, A7)
SA1-4 Snubber, Contactor & Relay coils
(Sht 2, A8 & A9)
T1
TB4
Aux Transformer (Sht 2, B2)
Terminal Block (Sht 1, C9)
TS1 Temperature Sensor, NTC, Coolant Return
(Sht 2, A5)
TS2 Temperature Sensor, NTC, Ambient (Sht 2, A5)
W1 Contactor , Input (Coil Sht 2, A8), (Contacts C2)
W2 Contactor , Input (Coil Sht 2, A8), (Contacts A2)
1 2 3 4 5
APPENDIX 0-5578
6 7 8 9 10
TO CCM
CPU PCB J36
(Sht 2, C3)
J100 -- 30 CKT RIBBON
ELECTRODE (-)
WORK (+)
OUTPUT
J100 -- 30 CKT RIBBON
ELECTRODE (-)
WORK (+)
OUTPUT
J100 -- 30 CKT RIBBON
ELECTRODE (-)
WORK (+)
OUTPUT
(49F)
5
4
3
2
1
J102B
TO CCM
CPU PCB
J35
(Sht 2, C3)
(51F) PILOT BOARD LED'S
D2 PILOT ENABLE
D11 +5V
R3 & R4
(49E)
5
4
3
2
1
J102A
(50)
TEST POINTS
TP1 GND
TP2 PILOT GATE
TP3 +5V
J58A
(49)
(51F)
J58C
5
4
3
2
1
J40
INVERTER
J42
019X501600
1 2 3 4 5 6 7 8 9 10
(49)
J43
ELECTRODE
PILOT PCB
1 2 3 4 5 6 7 8
J44
1
CHASSIS GND
J41
1
2
TIP
J45
TO CCM
CPU PCB
J33
(Sht 2, C3)
5
4
3
2
1
J102A
(49C)
TO J3 on RELAY PCB
(Sht 2, A5)
10 ckt Ribbon
TIP VOLTS
(53)
To J24 on I-O PCB
(Sht 2, D3)
WORK
ARC VOLTS
(51)
L1
(55)
(51) (51)
HCT1
Hall Effect Sensor
J16
J100 -- 30 CKT RIBBON
ELECTRODE (-)
WORK (+)
OUTPUT
TO CCM
CPU PCB
J32
(Sht 2, C3)
J102B
(49B)
5
4
3
2
1
TO CCM
CPU PCB
J31
(Sht 2, C3)
J100 -- 30 CKT RIBBON
ELECTRODE (-)
WORK (+)
OUTPUT
5
4
3
2
1
(50)
J46-M
J46-F
TO J1 on RELAY PCB
(Sht 2, B9)
(56)
(57)
(58)
(59) g w o b
RIBBON CABLE 30 ckt.
CCM (J31-36) - INVERTER (J100)
1 READY +
2 READY -
3 INVERTER_FLT +
4 INVERTER_FLT -
5 OVERTEMP_FLT +
6 OVERTEMP_FLT -
7 PWR_PRESENT +
8 PWR_PRESENT -
9 OUT_COM (+3 to 5VDC)
10 VAC_SELA
11 VAC_SELB
12 IS_IDA
13 IS_IDB
14 IS_IDC
15 ENABLE +
16 ENABLE -
17 START2 +
18 START2 -
19 SPARE
20 SYNC_IN +
21 SYNC_IN -
22 NC
23 NC
24 47 OHM to COMM
25 DEMAND +
26 DEMAND -
27 47 OHM to COMM
28 CURRENT +
29 CURRENT -
30 47 OHM to COMM
TORCH
To TB4-7
To TB4-6 TIP
J41 (J87)
L3
(49)
(52)
To / From Optional
1 Torch Module
(Refer to 1 Torch section for details.)
TORCH
1
PILOT
1
RAS
CHASSIS GND
WORK
1
TORCH
(Sht 1, A9)
TIP
(Sht 1, A9)
AC 120V- TB4-4
AC 120V- Ret- TB4-3
AC 24V-TB4-2
AC 24V- Ret -TB4-1
(J10 Sht 2, B8)
(49)
(52)
(51)
(60)
(61)
(62)
(63)
TB4
7
6
5
4
3
2
1
ARC VOLTS (TORCH)
TIP VOLTS (PILOT)
WORK
120 VAC @ 100 ma.
24 VAC @ 1A
(+)
(-)
Tip
Work
RIBBON CABLE 40 ckt CCM (J23) - RELAY PCB (J4)
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 SIG-
24 NC
25 PILOT CURRENT SIG+
26 COMMON
27 WORK CURRENT SIG-
28 WORK CURRENT SIG+
29 NC
30 AMBIENT TEMP
31 COOLANT TEMP
* Used with 1 Torch Option
32 COMMON
33 -15 VDC
34 COMMON
35 24 VDC
36 COMMON
37 24 VDC
38 COMMON
39 24 VDC
40 COMMON
RIBBON CABLE 16 ckt
CCM ( J37) - DISPLAY
PCB (J17)
1,3,5,7
2,4,6,8
9,10 NC
11-16
RIBBON CABLE 10 ckt
RELAY PCB (J3) – PILOT PCB (J42)
1,2
24 VDC
COMMON
SERIAL DATA
24 VDC
3,4,7,10 COMMON
5 PILOT ENABLE +
6 PILOT ENABLE –
8 PILOT CURRENT SIG –
9 PILOT CURRENT SIG +
SHIELD
(+)
A
B
C
D
E
Rev Revision
00 Initial Design
A A
AB ECO 1 Torch Option
6
By Date
DAT 10/03/2012
D A T 9 / 1 6 / 2 0 1 4
DAT 10/17/2014
Rev
7
Revision By Date
8
The information contained herein is proprietary to Thermal Dynamics.
Not for release, reproduction or distribution without written consent.
Title SCHEMATIC
Ultra-Cut XT 300A CE 380-415 VAC
9
Art # A-11963_AD
Thermal Dynamics Corporation
2800 Airport Rd.
Denton, Texas 76207 USA
Date Printed
12/16/2014
Drawn
DAT
Size
C
Drawing Number
Date Revised
10/20/2014
Date
10/04/2012
Sheet
1 of 2
042X1352
10
F
1 2 3 4 5
E
F
A
B
C
D
(1)
(2)
(3)
1
2
IN1
EMI
FIL-
TER
PCB
OUT1
2
1
1
2
1
2
IN2
GND2B
IN3
OUT2
OUT3
2
1
2
1
(4)
(5)
(6)
(7)
(8)
(9)
L9
J105B
1
2
J104B
1
2
J103B
1
2
AC INPUT
INVERTER MODULE (IM) #3 (top)
IM #3 Section B
CHASSIS GND
Toriod Core
019X502700
(4)
W2A
380-415
VAC
INPUT
(Customer supplied power cord must pass through ferrite core assembly.)
L1
L2
L3
Earth
1
1
1
1
CHASSIS GND
(1)
(2)
(3)
(1)
(2)
(3)
1
2
IN1
EMI
FIL-
TER
PCB
OUT1
2
1
1
2
1
2
IN2
GND2B
IN3
OUT2
OUT3
2
1
2
1
CHASSIS GND
(5)
(6)
W2B
W2C
9
10
11
12
13
14
7
8
5
6
3
4
1
2
AC SUPPRESSION
J50
019X504000
J51
GND
J52
3
4
1
2
AC LINE
3
4
1
2
(10)
(11)
(12)
(13)
INTERNAL AC INDICATOR
CHASSIS GND
LT1
LT2
LT1 & LT2
INPUT POWER
NEON INDICATORS
Rear Panel & Internal
(7)
(8)
(9)
(7)
(8)
(9)
(23)
(24)
L8
Toriod Core
L6
(25)
Toriod Core
J105A
1
2
J104A
1
2
J103A
1
2
J105A
1
2
J104A
1
2
J103A
1
2
AC INPUT
019X502000
AC INPUT
019x502000
IM #3 Section A
INVERTER MODULE (IM) #2 (middle)
IM #2 Section A (lower)
(1)
(2)
(3)
1
2
1
2
1
2
IN1
EMI
FIL-
TER
PCB
IN2
GND2B
OUT1
OUT2
2
1
2
1
2
1
(20)
(21)
(22)
W1A
W1B
W1C
(23)
(24)
(25)
(23)
L5
(24)
(25)
Toriod Core
J105B
1
2
J104B
J103B
1
2
1
2
AC INPUT
019x502700
INVERTER MODULE (IM) #`1 (bottom)
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
IN3 OUT3
CB1
ON / OFF
CHASSIS GND (23)
L4
J105A
AC INPUT IM #1 Section A (lower)
(1)
1
2
IN1
EMI
FIL-
TER
PCB
OUT1
2
1
(24)
(25)
J104A
1
2
1
2
J103A
1
2
F1
8A, 500V, SB
(1-20)
(2-21)
(3-22)
(2)
F2
8A, 500V, SB
(85A)
(86B)
1
2
2
1
SYSTEM BIAS
SUPPLY PCB
019X501900
TO AUX TRANSFORMER
TO J12
T1 PRIMARY
(Sht 2, A1)
(44A)
Toriod Core
WORK (+)
16 A
(FRONT PANEL)
Art # A-11963_AD
(86A)
(27A)
(27B)
(85B)
(3)
AC INPUT
13
14
15
16
9
10
11
12
17
18
7
8
5
6
3
4
1
2
1
2
IN2
(43A)
GND2B
IN3
CHASSIS GND
J60
J63
OUT2
OUT3
2
1
K1A K1B
1 2 3 4 5 6 7 8 9 10 11 12
019x502000
+ V
GND
+24VDC
System Bias LEDs & Test Points
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
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
(48)
J62
1
10
11
12
13
14
8
9
6
7
4
5
2
3
To J27 on CCM I/O PCB
(Sht 2, 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
J61
Measure relative to TP1 (24VDC_RET)
"0" = 10-12V "1" = 24V
VOLTAGE SELECTION
Wire #48 from J61-1 to:
J61-2 for 208-230 VAC
J61-3 for 400 VAC
J61-4 for 480 VAC
(37)
(38)
(39)
(40)
(41)
(42)
(29)
(30)
(31)
(32)
(33)
(34)
(35)
(36)
230V 400V 480V ERR
/VAC_IDAb 0 1 0 1
/VAC_IDBb 0 0 1 1
Component Locations (not including PCB components)
C4 Capacitor, fan starting, 8uf 440VAC (Sht 2, D2)
CB1 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
HCT1
Flow SW, 0.5 GPM (3.8 lpm), N.O. (Sht 2, A2)
Current Sensor, Hall Effect 200A, Work Lead
(Sht 1, C8)
K1 Relay, 24VAC, Inrush Control, (Sht2, B9)
L1 Inductor, (Sht 1, B7)
L3-9 Toriod Core Common Mode Ind (Sht1 B8, A-D3)
LS1 Level Switch, Coolant Tank (Sht 2, A3)
LT1, LT2 Indicator, Neon, 250V, AC Volts Present
(Sht 1, B2 & C2)
M1 Motor, Pump, ½ hp 230VAC, 50/60 Hz, 1Ph
(Sht 2, C2)
MC1 Relay, 120VAC, Inrush, coil (Sht2, B9)
contact (Sht2, A1)
MC2 Relay, 120 VAC, Fan Control, coil
(Coil at Sht 2, A7)(Contacts at Sht 2, D1)
MC3 Relay, 120 VAC, Pump Motor Control, coil
(Coil at Sht 2, A7)(Contacts at Sht 2, C1)
R2 Inrush, 4.7 Ohm, 30W (Sht2, A1)
R3,4 Ext RC, 100 ohm 55W (Sht1, A7)
SA1-4 Snubber, Contactor & Relay coils
(Sht 2, A8 & A9)
T1
TB4
Aux Transformer (Sht 2, B2)
Terminal Block (Sht 1, C9)
TS1 Temperature Sensor, NTC, Coolant Return
(Sht 2, A5)
TS2 Temperature Sensor, NTC, Ambient (Sht 2, A5)
W1 Contactor , Input (Coil Sht 2, A8), (Contacts C2)
W2 Contactor , Input (Coil Sht 2, A8), (Contacts A2)
1 2 3 4 5
ULTRA-CUT 130 XT/200 XT/300 XT/400 XT
6 7 8 9 10
TO CCM
CPU PCB J36
(Sht 2, C3)
J100 -- 30 CKT RIBBON
ELECTRODE (-)
WORK (+)
OUTPUT
J100 -- 30 CKT RIBBON
ELECTRODE (-)
WORK (+)
OUTPUT
J100 -- 30 CKT RIBBON
ELECTRODE (-)
WORK (+)
OUTPUT
(49F)
5
4
3
2
1
J102B
TO CCM
CPU PCB
J35
(Sht 2, C3)
(51F) PILOT BOARD LED'S
D2 PILOT ENABLE
D11 +5V
R3 & R4
(49E)
5
4
3
2
1
J102A
(50)
TEST POINTS
TP1 GND
TP2 PILOT GATE
TP3 +5V
J58A
(49)
(51F)
J58C
5
4
3
2
1
J40
INVERTER
J42
019X501600
1 2 3 4 5 6 7 8 9 10
(49)
J43
ELECTRODE
PILOT PCB
1 2 3 4 5 6 7 8
J44
1
CHASSIS GND
J41
1
2
TIP
J45
TO CCM
CPU PCB
J33
(Sht 2, C3)
5
4
3
2
1
J102A
(49C)
TO J3 on RELAY PCB
(Sht 2, A5)
10 ckt Ribbon
TIP VOLTS
(53)
To J24 on I-O PCB
(Sht 2, D3)
WORK
ARC VOLTS
(51)
L1
(55)
(51) (51)
HCT1
Hall Effect Sensor
J16
J100 -- 30 CKT RIBBON
ELECTRODE (-)
WORK (+)
OUTPUT
TO CCM
CPU PCB
J32
(Sht 2, C3)
J102B
(49B)
5
4
3
2
1
TO CCM
CPU PCB
J31
(Sht 2, C3)
J100 -- 30 CKT RIBBON
ELECTRODE (-)
WORK (+)
OUTPUT
5
4
3
2
1
(50)
J46-M
J46-F
TO J1 on RELAY PCB
(Sht 2, B9)
(56)
(57)
(58)
(59) g w o b
RIBBON CABLE 30 ckt.
CCM (J31-36) - INVERTER (J100)
1 READY +
2 READY -
3 INVERTER_FLT +
4 INVERTER_FLT -
5 OVERTEMP_FLT +
6 OVERTEMP_FLT -
7 PWR_PRESENT +
8 PWR_PRESENT -
9 OUT_COM (+3 to 5VDC)
10 VAC_SELA
11 VAC_SELB
12 IS_IDA
13 IS_IDB
14 IS_IDC
15 ENABLE +
16 ENABLE -
17 START2 +
18 START2 -
19 SPARE
20 SYNC_IN +
21 SYNC_IN -
22 NC
23 NC
24 47 OHM to COMM
25 DEMAND +
26 DEMAND -
27 47 OHM to COMM
28 CURRENT +
29 CURRENT -
30 47 OHM to COMM
TORCH
To TB4-7
To TB4-6 TIP
J41 (J87)
L3
(49)
(52)
To / From Optional
1 Torch Module
(Refer to 1 Torch section for details.)
TORCH
1
PILOT
1
RAS
CHASSIS GND
WORK
1
TORCH
(Sht 1, A9)
TIP
(Sht 1, A9)
AC 120V- TB4-4
AC 120V- Ret- TB4-3
AC 24V-TB4-2
AC 24V- Ret -TB4-1
(J10 Sht 2, B8)
(49)
(52)
(51)
(60)
(61)
(62)
(63)
TB4
7
6
5
4
3
2
1
ARC VOLTS (TORCH)
TIP VOLTS (PILOT)
WORK
120 VAC @ 100 ma.
24 VAC @ 1A
(+)
(-)
Tip
Work
RIBBON CABLE 40 ckt CCM (J23) - RELAY PCB (J4)
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 SIG-
24 NC
25 PILOT CURRENT SIG+
26 COMMON
27 WORK CURRENT SIG-
28 WORK CURRENT SIG+
29 NC
30 AMBIENT TEMP
31 COOLANT TEMP
* Used with 1 Torch Option
32 COMMON
33 -15 VDC
34 COMMON
35 24 VDC
36 COMMON
37 24 VDC
38 COMMON
39 24 VDC
40 COMMON
RIBBON CABLE 16 ckt
CCM ( J37) - DISPLAY
PCB (J17)
1,3,5,7
2,4,6,8
9,10 NC
11-16
RIBBON CABLE 10 ckt
RELAY PCB (J3) – PILOT PCB (J42)
1,2
24 VDC
COMMON
SERIAL DATA
24 VDC
3,4,7,10 COMMON
5 PILOT ENABLE +
6 PILOT ENABLE –
8 PILOT CURRENT SIG –
9 PILOT CURRENT SIG +
SHIELD
(+)
A
B
C
D
E
Rev Revision
00 Initial Design
A A
AB ECO 1 Torch Option
6
By Date
DAT 10/03/2012
D A T 9 / 1 6 / 2 0 1 4
DAT 10/17/2014
Rev
7
Revision By Date
8
The information contained herein is proprietary to Thermal Dynamics.
Not for release, reproduction or distribution without written consent.
Title SCHEMATIC
Ultra-Cut XT 300A CE 380-415 VAC
9
Art # A-11963_AD
Thermal Dynamics Corporation
2800 Airport Rd.
Denton, Texas 76207 USA
Date Printed
12/16/2014
Drawn
DAT
Size
C
Drawing Number
Date Revised
10/20/2014
Date
10/04/2012
Sheet
1 of 2
042X1352
10
F
0-5578 APPENDIX A-51
ULTRA-CUT 130 XT/200 XT/300 XT/400 XT
APPENDIX 28: System Schematic 300A, 380-415V PG 2
1 2 3 4 5
A
B
C
E
D
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
From Sys Bias J63
(Sht 1, F2)
(44A)
(43A)
MC1A
LS1
COOLANT LEVEL
3
J71
4
1
2
(90)
(89)
AMBIENT
TS2
COOLANT
TS1
FS1
COOLANT
J74
1
2
(84)
(83)
(92) (93)
(94)
(95) 0.7 GPM
J12
1 2 3 4
5 6 7 8
R2
4.7 30W
(87)
460V
400V
220V
T1
FL1
24V RET
24V
120V_2 RET
120V_2
120V-1 RET
120V_1
1
2
3
BLUE
RED
YELLOW
BLUE
RED
YELLOW r b g
6
5
4
3
2
1
J14
3
4
1
2
J49
(80)
(81)
(82)
(79)
(77)
CB2 5 A
(74)
CB3 5 A
(78)
(76)
(75)
(71)
CB4 5 A
(73)
(72)
To J100 of IM #1B
(Sht 1, C,D6)
J6
3
4
1
2
8
7
6
5
4
3
2
1
12
11
10
9
J9
J5 J7 J1
COOLANT FLOW SW
+5VDC
SIGNAL (pulse)
TORCH FLOW SENSOR
120VAC_2
24VAC
LEVEL SENSORS WORK CURRENT SENSOR
RELAY & INTERFACE PCB
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
J2
120VAC_1
BIAS TRANSFORMER
019X501700
TEMP SENSORS
Test Points
TP1, GND
TP2, -15V
TP3, +5VDC
TP4, +12V
TP5, +24V
TP6, +15V
TP7, +5VDC
1 TORCH INTERFACE
Refer to 1 Torch Module Schematic for Details
J11 J84
0 V
J31 - 30 CKT RIBBON J32 - 30 CKT RIBBON CPU PCB (CPU)
To J100 of IM #2A
(Sht 1, B,C6)
J33 - 30 CKT RIBBON J34 - 30 CKT RIBBON
J13
J13 to CB5 and to MC2
& MC3, also
J14, J16
all 18 AWG
(65A)
(64A)
MC3A
MC3B
(64B)
MC2A
MC2B
CHASSIS GND
(67)
Alternate fan.
100 & 200A units may use either this single larger fan (same as 300 & 400A units) or the 2 smaller fans shown above.
BK R
1
2
3
J72 C4
BN
R
FAN1
BL
(69)
(70)
(66)
(69)
(70)
(69)
J72
1
2
3
230 VAC _ SW _ RET
(A9)
FAN1
CHASSIS GND
(70)
230 VAC _ SW
(A9)
230 VAC_SW goes to J70
for HE 400
J35 - 30 CKT RIBBON J36 - 30 CKT RIBBON
M1
Torch Coolant Pump
J73
1
2
3
J16
1
2
3
FAN2
Harness from Pilot PCB J45
(Sht 1, B8)
(55)
(51)
(53)
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
7
8
9
5
6
1
2
3
4
10
11
12
13
14
J27
(37)
(38)
(39)
(40)
(41)
(42)
(29)
(30)
(31)
(32)
(33)
(34)
(35)
(36)
. 230V 400V 480V ERR
J62-12 (/VAC_IDAb) 0 1 0 1
J62-14 (/VAC_IDBb) 0 0 1 1
Measure relative to TP1 (24VDC_RET)
"0" = 10-12V "1" = 24V
7
8
5
6
3
4
1
2
J24
J28 30 CKT RECEPTACLE - BOTTOM ENTRY
19X501100
I-O PCB (CCM)
I / O PCB LEDS
----------------------------------------------
J28 30 CKT PIN HEADER
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
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)
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)
J85
F
A-52
Art # A-11964_AD
1 2 3
APPENDIX
4
0-5578
5
6 7 8 9 10
SA3
MC2 Fan Control
SA1
230 VAC _ SW
(D2)
230 VAC _ SW _ RET
(D2)
(70)
( 6 9 )
230 VAC to HE 400
230 VAC Ret
(70)
( 6 9 )
J70 - HE
5
6
7
3
4
1
2
J3
J29 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)
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
J8
ARC_SUPPRESSOR
SA4
ARC_SUPPRESSOR
MC3
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 (-)
TB1
8
7
6
5
4
3
2
1
12
11
10
9
OK to MOVE (+)
OK to MOVE (-)
PILOT is ON
PILOT is ON
Preflow ON (+)
Preflow ON (-)
Hold Start (+)
Hold Start (-)
TB2
8
7
6
5
4
3
2
1
12
11
10
9
Pump Motor Control
(96)
(98)
(99)
(97)
ARC_SUPPRESSOR
ENABLE
PLAS_ENABLE SW
PLAS_ EN_SW_RET
/ GAS PRESS OK
/ BASIC ID
W1
(133)
(134)
(137)
(139)
(138)
(143)
(140)
(141)
(136)
(135)
(132)
(153)
(130)
(131)
(112)
(114)
(121)
(122)
(124)
(129)
(128)
(123)
(125)
(126)
(127)
(152)
(154)
(155)
(60)
MC1
CHASSIS GND
120 VAC to RAS
120 VAC Ret
Art # A-11964_AD
(99)
(98)
J59 - RAS
9
10
11
12
13
14
7
8
5
6
3
4
1
2
3 - Key Plug
PILOT PCB
GND
J38
24 VDC
J4 -- 40 CKT RIBBON CABLE
1 2 3 4 5 6 7 8 9
RS 232 D-SUB
SERIAL PROG
PORT
3
4
1
2
5
6
J18
PROG
USB IC
J29 30 CKT RECEPTACLE - BOTTOM ENTRY
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.)
CONTROL OUTPUTS
7
8
5
6
3
4
1
2
9
10
11
12
J19
24 VAC
Spare
Digital
Inputs
Spare #1b NO
Spare
Digital
Inputs
/ Plasma Marking (-)
/ Plasma Marking (+)
TB3
8
7
6
5
4
3
2
1
12
11
10
9
120 VAC_1
120 VAC_2
HMI/GCM
J39
USB
PORT
18
17
16
15
14
13
12
11
10
9
8
7
6
5
4
3
2
1
J10
(100)
(101)
(102)
(104)
(106)
(108)
(109)
(110)
(111)
(113)
(61)
AC 24V GCM2
AC 120V - GCM
AC 24V - RET - GCM2
AC 120V- Ret- GCM
AC 120V- Ret- TB4-3
7
8
5
6
3
4
1
2
9
10
11
12
J20
USB Cable to Front Panel
1 2 3 4
GND
GND
Rx-
Tx+
Rx+
Tx-
3
4
1
2
5
6
J30
3
4
1
2
J47
(116)
(117)
(120)
(115)
(119)
(118)
J37
(62)
(60)
Harness
16 CKT RIBBON
120VAC
AC 24V GCM1
AC 24V-TB4-2
AC 120V- TB4-4
AC 24V Ret- GCM1
(63)
AC 24V- Ret -TB4-1
(62) 1
K1
2
4
3
(63) 5
INRUSH CONTROL
J23- 40 ckt ribbon cable
OK
+10V
GND
PSR
GAS ON
SPARE #1a
GND
GND
J26
13
14
15
16
9
10
11
12
17
18
7
8
5
6
3
4
1
2
J21
13
14
15
16
9
10
11
12
17
18
19
20
7
8
5
6
3
4
1
2
13
14
15
16
9
10
11
12
7
8
5
6
3
4
1
2
J22
(142)
(144)
(145)
(146)
(147)
(148)
(149)
(150)
(151)
(156)
(157)
(158)
(159)
Harness
J17
J54 - Remote HMI & CNC COMM
(100)
(101)
(102)
(109)
(108)
(115)
(116)
(117)
(118)
(119)
(120)
9
10
11
12
13
14
7
8
5
6
3
4
1
2
1 - 24 VAC
2 - 24 VAC Ret
3- Jumper to 24 VAC
5-HMI Plasma Enable SW
6-HMI Plasma Enable SW
7 - Key Plug
9 - GND
10 - GND
12 - Tx-
13 - Rx+
14 - Rx-
RS 485
/ 422
Comm
Display PCB
019X501800
AC 24V-GCM1
AC 24V Ret - GCM1
AC 24V-GCM2
AC 24V Ret-GCM2
J69
2
1
AC 120V - GCM
AC 120V- Ret- GCM
(104)
(111)
(166)
(167)
(106)
(113)
CHASSIS GND
(133)
(134)
(135)
(136)
(137)
(138)
(139)
(140)
(141)
(142)
(143)
(144)
(145)
(146)
(147)
(148)
(149)
(150)
(151)
(132)
(152)
(153)
(154)
(155)
(156)
(157)
(158)
(159)
(121)
(122)
(123)
(124)
(125)
(126)
(127)
(128)
(129)
(130)
(131)
(112)
(114)
(103)
(110)
29
30
31
32
25
26
27
28
33
34
35
36
37
21
22
23
24
17
18
19
20
13
14
15
16
9
10
11
12
7
8
5
6
3
4
1
2
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 **
10-
11-
GCM 1000 XT
Jumper
14-
15- 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
J15-1 to chassis used for
SC-11 cable shield
J15-13 connects SC-11 chassis to PS chassis.
J15-CNC
29
30
31
32
25
26
27
28
33
34
35
36
37
21
22
23
24
17
18
19
20
13
14
15
16
9
10
11
12
7
8
5
6
3
4
1
2
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 (-)
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
Rev
00
Revision
Initial Design
A A
AB ECO-B2687
By Date
DAT 10/03/2012
D A T 9 / 1 6 / 2 0 1 4
DAT 10/17/2014
Rev Revision By Date
Thermal Dynamics Corporation
2800 Airport Rd.
Denton, Texas 76207 USA
6 7 8
The information contained herein is proprietary to Thermal Dynamics.
Not for release, reproduction or distribution without written consent.
Title SCHEMATIC
Ultra-Cut XT 200A CE 380-415 VAC
9
Date Printed
12/16/2014
Drawn
DAT
Size
C
Drawing Number
Date Revised
11/20/2014
Date
10/4/2012
Sheet
2 of 2
042X1353
10
A
B
C
D
E
F
1 2 3 4 5
A
B
C
E
D
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
From Sys Bias J63
(Sht 1, F2)
(44A)
(43A)
MC1A
LS1
COOLANT LEVEL
3
J71
4
1
2
(90)
(89)
AMBIENT
TS2
COOLANT
TS1
FS1
COOLANT
J74
1
2
(84)
(83)
(92) (93)
(94)
(95) 0.7 GPM
J12
1 2 3 4
5 6 7 8
R2
4.7 30W
(87)
460V
400V
220V
T1
FL1
24V RET
24V
120V_2 RET
120V_2
120V-1 RET
120V_1
1
2
3
BLUE
RED
YELLOW
BLUE
RED
YELLOW r b g
6
5
4
3
2
1
J14
3
4
1
2
J49
(80)
(81)
(82)
(79)
(77)
CB2 5 A
(74)
CB3 5 A
(78)
(76)
(75)
(71)
CB4 5 A
(73)
(72)
To J100 of IM #1B
(Sht 1, C,D6)
J6
3
4
1
2
8
7
6
5
4
3
2
1
12
11
10
9
J9
J5 J7 J1
COOLANT FLOW SW
+5VDC
SIGNAL (pulse)
TORCH FLOW SENSOR
120VAC_2
24VAC
LEVEL SENSORS WORK CURRENT SENSOR
RELAY & INTERFACE PCB
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
J2
120VAC_1
BIAS TRANSFORMER
019X501700
TEMP SENSORS
Test Points
TP1, GND
TP2, -15V
TP3, +5VDC
TP4, +12V
TP5, +24V
TP6, +15V
TP7, +5VDC
1 TORCH INTERFACE
Refer to 1 Torch Module Schematic for Details
J11 J84
0 V
J31 - 30 CKT RIBBON J32 - 30 CKT RIBBON CPU PCB (CPU)
To J100 of IM #2A
(Sht 1, B,C6)
J33 - 30 CKT RIBBON J34 - 30 CKT RIBBON
J13
J13 to CB5 and to MC2
& MC3, also
J14, J16
all 18 AWG
(65A)
(64A)
MC3A
MC3B
(64B)
MC2A
MC2B
CHASSIS GND
(67)
Alternate fan.
100 & 200A units may use either this single larger fan (same as 300 & 400A units) or the 2 smaller fans shown above.
BK R
1
2
3
J72 C4
BN
R
FAN1
BL
(69)
(70)
(66)
(69)
(70)
(69)
J72
1
2
3
230 VAC _ SW _ RET
(A9)
FAN1
CHASSIS GND
(70)
230 VAC _ SW
(A9)
230 VAC_SW goes to J70
for HE 400
J35 - 30 CKT RIBBON J36 - 30 CKT RIBBON
M1
Torch Coolant Pump
J73
1
2
3
J16
1
2
3
FAN2
Harness from Pilot PCB J45
(Sht 1, B8)
(55)
(51)
(53)
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
7
8
9
5
6
1
2
3
4
10
11
12
13
14
J27
(37)
(38)
(39)
(40)
(41)
(42)
(29)
(30)
(31)
(32)
(33)
(34)
(35)
(36)
. 230V 400V 480V ERR
J62-12 (/VAC_IDAb) 0 1 0 1
J62-14 (/VAC_IDBb) 0 0 1 1
Measure relative to TP1 (24VDC_RET)
"0" = 10-12V "1" = 24V
7
8
5
6
3
4
1
2
J24
J28 30 CKT RECEPTACLE - BOTTOM ENTRY
19X501100
I-O PCB (CCM)
I / O PCB LEDS
----------------------------------------------
J28 30 CKT PIN HEADER
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
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)
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)
J85
F
Art # A-11964_AD
1 2 3 4
ULTRA-CUT 130 XT/200 XT/300 XT/400 XT
5
0-5578
6 7 8 9 10
SA3
MC2 Fan Control
SA1
230 VAC _ SW
(D2)
230 VAC _ SW _ RET
(D2)
(70)
( 6 9 )
230 VAC to HE 400
230 VAC Ret
(70)
( 6 9 )
J70 - HE
5
6
7
3
4
1
2
J3
J29 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)
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
J8
ARC_SUPPRESSOR
SA4
ARC_SUPPRESSOR
MC3
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 (-)
TB1
8
7
6
5
4
3
2
1
12
11
10
9
OK to MOVE (+)
OK to MOVE (-)
PILOT is ON
PILOT is ON
Preflow ON (+)
Preflow ON (-)
Hold Start (+)
Hold Start (-)
TB2
8
7
6
5
4
3
2
1
12
11
10
9
Pump Motor Control
(96)
(98)
(99)
(97)
ARC_SUPPRESSOR
ENABLE
PLAS_ENABLE SW
PLAS_ EN_SW_RET
/ GAS PRESS OK
/ BASIC ID
W1
(133)
(134)
(137)
(139)
(138)
(143)
(140)
(141)
(136)
(135)
(132)
(153)
(130)
(131)
(112)
(114)
(121)
(122)
(124)
(129)
(128)
(123)
(125)
(126)
(127)
(152)
(154)
(155)
(60)
MC1
CHASSIS GND
120 VAC to RAS
120 VAC Ret
Art # A-11964_AD
(99)
(98)
J59 - RAS
9
10
11
12
13
14
7
8
5
6
3
4
1
2
3 - Key Plug
PILOT PCB
GND
J38
24 VDC
J4 -- 40 CKT RIBBON CABLE
1 2 3 4 5 6 7 8 9
RS 232 D-SUB
SERIAL PROG
PORT
3
4
1
2
5
6
J18
PROG
USB IC
J29 30 CKT RECEPTACLE - BOTTOM ENTRY
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.)
CONTROL OUTPUTS
7
8
5
6
3
4
1
2
9
10
11
12
J19
24 VAC
Spare
Digital
Inputs
Spare #1b NO
Spare
Digital
Inputs
/ Plasma Marking (-)
/ Plasma Marking (+)
TB3
8
7
6
5
4
3
2
1
12
11
10
9
120 VAC_1
120 VAC_2
HMI/GCM
J39
USB
PORT
18
17
16
15
14
13
12
11
10
9
8
7
6
5
4
3
2
1
J10
(100)
(101)
(102)
(104)
(106)
(108)
(109)
(110)
(111)
(113)
(61)
AC 24V GCM2
AC 120V - GCM
AC 24V - RET - GCM2
AC 120V- Ret- GCM
AC 120V- Ret- TB4-3
7
8
5
6
3
4
1
2
9
10
11
12
J20
USB Cable to Front Panel
1 2 3 4
GND
GND
Rx-
Tx+
Rx+
Tx-
3
4
1
2
5
6
J30
3
4
1
2
J47
(116)
(117)
(120)
(115)
(119)
(118)
J37
(62)
(60)
Harness
16 CKT RIBBON
120VAC
AC 24V GCM1
AC 24V-TB4-2
AC 120V- TB4-4
AC 24V Ret- GCM1
(63)
AC 24V- Ret -TB4-1
(62) 1
K1
2
4
3
(63) 5
INRUSH CONTROL
J23- 40 ckt ribbon cable
OK
+10V
GND
PSR
GAS ON
SPARE #1a
GND
GND
J26
13
14
15
16
9
10
11
12
17
18
7
8
5
6
3
4
1
2
J21
13
14
15
16
9
10
11
12
17
18
19
20
7
8
5
6
3
4
1
2
13
14
15
16
9
10
11
12
7
8
5
6
3
4
1
2
J22
(142)
(144)
(145)
(146)
(147)
(148)
(149)
(150)
(151)
(156)
(157)
(158)
(159)
Harness
J17
J54 - Remote HMI & CNC COMM
(100)
(101)
(102)
(109)
(108)
(115)
(116)
(117)
(118)
(119)
(120)
9
10
11
12
13
14
7
8
5
6
3
4
1
2
1 - 24 VAC
2 - 24 VAC Ret
3- Jumper to 24 VAC
5-HMI Plasma Enable SW
6-HMI Plasma Enable SW
7 - Key Plug
9 - GND
10 - GND
12 - Tx-
13 - Rx+
14 - Rx-
RS 485
/ 422
Comm
Display PCB
019X501800
AC 24V-GCM1
AC 24V Ret - GCM1
AC 24V-GCM2
AC 24V Ret-GCM2
J69
2
1
AC 120V - GCM
AC 120V- Ret- GCM
(104)
(111)
(166)
(167)
(106)
(113)
CHASSIS GND
(133)
(134)
(135)
(136)
(137)
(138)
(139)
(140)
(141)
(142)
(143)
(144)
(145)
(146)
(147)
(148)
(149)
(150)
(151)
(132)
(152)
(153)
(154)
(155)
(156)
(157)
(158)
(159)
(121)
(122)
(123)
(124)
(125)
(126)
(127)
(128)
(129)
(130)
(131)
(112)
(114)
(103)
(110)
29
30
31
32
25
26
27
28
33
34
35
36
37
21
22
23
24
17
18
19
20
13
14
15
16
9
10
11
12
7
8
5
6
3
4
1
2
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 **
10-
11-
GCM 1000 XT
Jumper
14-
15- 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
J15-1 to chassis used for
SC-11 cable shield
J15-13 connects SC-11 chassis to PS chassis.
J15-CNC
29
30
31
32
25
26
27
28
33
34
35
36
37
21
22
23
24
17
18
19
20
13
14
15
16
9
10
11
12
7
8
5
6
3
4
1
2
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 (-)
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
Rev
00
Revision
Initial Design
A A
AB ECO-B2687
By Date
DAT 10/03/2012
D A T 9 / 1 6 / 2 0 1 4
DAT 10/17/2014
Rev Revision By Date
Thermal Dynamics Corporation
2800 Airport Rd.
Denton, Texas 76207 USA
6 7 8
The information contained herein is proprietary to Thermal Dynamics.
Not for release, reproduction or distribution without written consent.
Title SCHEMATIC
Ultra-Cut XT 200A CE 380-415 VAC
9
Date Printed
12/16/2014
Drawn
DAT
Size
C
Drawing Number
Date Revised
11/20/2014
Date
10/4/2012
Sheet
2 of 2
042X1353
10
A
B
C
D
E
F
APPENDIX A-53
ULTRA-CUT 130 XT/200 XT/300 XT/400 XT
APPENDIX 29: System Schematic 400A, 380-415V PG 1
1 2 3 4 5
E
F
A
B
C
D
(1)
(2)
(3)
1
2
IN1
EMI
FIL-
TER
PCB
OUT1
2
1
1
2
1
2
IN2
GND2B
OUT2
IN3 OUT3
2
1
2
1
(4)
(5)
(6)
(7)
(8)
(9)
L9
J105B
1
2
J104B
1
2
J103B
1
2
AC INPUT
INVERTER MODULE (IM) #3 (top)
IM #3 Section B
CHASSIS GND
Toriod Core
019X502700
(4)
W2A
380-415
VAC
INPUT
(Customer supplied power cord must pass through ferrite core assembly.)
L1
L2
L3
Earth
1
1
1
1
CHASSIS GND
(1)
(2)
(3)
(1)
(2)
(3)
1
2
IN1
EMI
FIL-
TER
PCB
OUT1
2
1
1
2
1
2
IN2
OUT2
IN3
GND2B
OUT3
2
1
2
1
CHASSIS GND
(5)
(6)
W2B
W2C
9
10
11
12
13
14
7
8
5
6
3
4
1
2
AC SUPPRESSION
J50
J51
019X504000
GND
J52
3
4
1
2
AC LINE
3
4
1
2
(10)
(11)
(12)
(13)
INTERNAL AC INDICATOR
CHASSIS GND
LT1
LT2
LT1 & LT2
INPUT POWER
NEON INDICATORS
Rear Panel & Internal
(7)
(8)
(9)
(7)
(8)
(9)
(7)
(8)
(9)
Toriod Core
(23)
(24)
L8
Toriod Core
L7
L6
(25)
Toriod Core
J105A
1
2
J104A
1
2
J103A
1
2
J105A
1
2
J104A
1
2
J103A
1
2
J105B
1
2
J104B
1
2
J103B
1
2
AC INPUT
019X502000
AC INPUT
019X502700
AC INPUT
019x502000
IM #3 Section A
INVERTER MODULE (IM) #2 (middle)
IM #2 Section B
IM #2 Section A (lower)
(1)
(2)
1
2
IN1
EMI
FIL-
TER
PCB
OUT1
2
1
(21)
W1A
(23)
L5
INVERTER MODULE (IM) #`1 (bottom)
1
2
2
1
(20)
W1B
(23)
(24) (24)
J105B
1
2
J104B
1
2
J103B
1
2
AC INPUT
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
(3)
1
2
IN2
GND2B
OUT2
2
1
(22) W1C
(25) (25)
Toriod Core 019x502700
IN3 OUT3
CHASSIS GND (23)
L4
J105A
1
2
J104A
AC INPUT IM #1 Section A (lower)
CB1
ON / OFF
16 A
F1
8A, 500V, SB
Art # A-11965_AD
(1) EMI
FIL-
TER
PCB
2
1
(20) (24) 1
2
(1-20)
(2-21)
(3-22)
(2)
1
2
1
2
IN1 OUT1
2
1
(21)
(25)
Toriod Core
J103A
1
2
WORK (+)
(86A)
(27A)
(85A)
(86B)
(27B)
(85B)
(3)
(FRONT PANEL)
F2
8A, 500V, SB
AC INPUT
13
14
15
16
9
10
11
12
17
18
7
8
5
6
3
4
1
2
1
2
J60
IN2
IN3
CHASSIS GND
J63
SYSTEM BIAS
SUPPLY PCB
019X501900
(43A)
GND2B
OUT2
OUT3
2
1
(22)
1 2 3 4 5 6 7 8 9 10 11 12
TO AUX TRANSFORMER
TO J12
T1 PRIMARY
(Sht 2, A1)
(44A)
019x502000
+24VDC
+ V
GND
System Bias LEDs & Test Points
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
(48)
J62
1
2
3
4
5
6
7
8
9
10
11
12
13
14
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
(Sht 2, 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
230V 400V 480V ERR
/VAC_IDAb 0 1 0 1
/VAC_IDBb 0 0 1 1
J61
Measure relative to TP1 (24VDC_RET)
"0" = 10-12V "1" = 24V
VOLTAGE SELECTION
Wire #48 from J61-1 to:
J61-2 for 208-230 VAC
J61-3 for 400 VAC
J61-4 for 480 VAC
(37)
(38)
(39)
(40)
(41)
(42)
(29)
(30)
(31)
(32)
(33)
(34)
(35)
(36)
Component Locations (not including PCB components)
To J27 on CCM I/O PCB
C4 Capacitor, fan starting, 8uf 440VAC (Sht 2, D2)
CB1 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
HCT1
Flow SW, 0.5 GPM (3.8 lpm), N.O. (Sht 2, A2)
Current Sensor, Hall Effect 200A, Work Lead
(Sht 1, C8)
K1 Relay, 24VAC, Inrush Control, (Sht2, B9)
L1 Inductor, (Sht 1, B7)
L3-9 Toriod Core Common Mode Ind (Sht1 B8, A-D3)
LS1 Level Switch, Coolant Tank (Sht 2, A3)
LT1, LT2 Indicator, Neon, 250V, AC Volts Present
(Sht 1, B2 & C2)
M1 Motor, Pump, ½ hp 230VAC, 50/60 Hz, 1Ph
(Sht 2, C2)
MC1 Relay, 120VAC, Inrush, coil (Sht2, B9)
contact (Sht2, A1)
MC2 Relay, 120 VAC, Fan Control, coil
(Coil at Sht 2, A7)(Contacts at Sht 2, D1)
MC3 Relay, 120 VAC, Pump Motor Control, coil
(Coil at Sht 2, A7)(Contacts at Sht 2, C1)
R2 Inrush, 4.7 Ohm, 30W (Sht2, A1)
R3,4 Ext RC, 100 ohm 55W (Sht1, A7)
SA1-4 Snubber, Contactor & Relay coils
(Sht 2, A8 & A9)
T1
TB4
Aux Transformer (Sht 2, B2)
Terminal Block (Sht 1, C9)
TS1 Temperature Sensor, NTC, Coolant Return
(Sht 2, A5)
TS2 Temperature Sensor, NTC, Ambient (Sht 2, A5)
W1 Contactor , Input (Coil Sht 2, A8), (Contacts C2)
W2 Contactor , Input (Coil Sht 2, A8), (Contacts A2)
1 2 3 4 5
A-54 APPENDIX 0-5578
6 7 8 9 10
TO CCM
(Sht 2, C3)
J100 -- 30 CKT RIBBON
ELECTRODE (-)
WORK (+)
OUTPUT
(49F)
5
4
3
2
1
J102B
TO CCM
CPU PCB
J35
(Sht 2, C3)
J100 -- 30 CKT RIBBON
ELECTRODE (-)
WORK (+)
OUTPUT
(49E)
5
4
3
2
1
J102A
(51F) PILOT BOARD LED'S
D2 PILOT ENABLE
D11 +5V
(50)
R3 & R4
TO CCM
CPU PCB
J34
(Sht 2, C3)
J100 -- 30 CKT RIBBON
ELECTRODE (-)
WORK (+)
OUTPUT
J100 -- 30 CKT RIBBON
ELECTRODE (-)
WORK (+)
OUTPUT
5
4
3
2
1
(49D)
J102B
TO CCM
CPU PCB
J33
(Sht 2, C3)
5
4
3
2
1
J102A
(49C)
TEST POINTS
TP1 GND
TP2 PILOT GATE
TP3 +5V
J58A
(49)
J43
ELECTRODE
PILOT PCB
J44
1
CHASSIS GND
J58C
J40
INVERTER
5
4
3
2
1
J42
(51F)
019X501600
1 2 3 4 5 6 7 8 9 10
TO J3 on RELAY PCB
(Sht 2, A5)
10 ckt Ribbon
1 2 3 4 5 6 7 8
(53)
TIP VOLTS
To J24 on I-O PCB
WORK (51)
(Sht 2, D3)
ARC VOLTS (55)
L1
J41
1
2
TIP
J45
TO I/O BOARD
(51) (51)
HCT1
Hall Effect Sensor
J16
J100 -- 30 CKT RIBBON
ELECTRODE (-)
WORK (+)
OUTPUT
TO CCM
CPU PCB
J32
(Sht 2, C3)
J102B
(49B)
5
4
3
2
1
TO CCM
CPU PCB
J31
(Sht 2, C3)
J100 -- 30 CKT RIBBON
ELECTRODE (-)
WORK (+)
OUTPUT
J102A
(49A)
5
4
3
2
1
(50)
J46-M
J46-F
TO J1 on RELAY PCB
(Sht 2, B9)
RIBBON CABLE 30 ckt.
CCM (J31-36) - INVERTER (J100)
1 READY +
2 READY -
3 INVERTER_FLT +
4 INVERTER_FLT -
5 OVERTEMP_FLT +
6 OVERTEMP_FLT -
7 PWR_PRESENT +
8 PWR_PRESENT -
9 OUT_COM (+3 to 5VDC)
10 VAC_SELA
11 VAC_SELB
12 IS_IDA
13 IS_IDB
14 IS_IDC
15 ENABLE +
16 ENABLE -
17 START2 +
18 START2 -
19 SPARE
20 SYNC_IN +
21 SYNC_IN -
22 NC
23 NC
24 47 OHM to COMM
25 DEMAND +
26 DEMAND -
27 47 OHM to COMM
28 CURRENT +
29 CURRENT -
30 47 OHM to COMM
(56)
(57)
(58)
(59) g w o b
TORCH
To TB4-7
To TB4-6 TIP
J41 (J87)
L3
(49)
(52)
To / From Optional
1 Torch Module
(Refer to 1 Torch section for details.)
TORCH
1
PILOT
1
RAS
CHASSIS GND
WORK
1
(+)
(-)
Tip
Work
TORCH
(Sht 1, A9)
TIP
(Sht 1, A9)
AC 120V- TB4-4
AC 120V- Ret- TB4-3
AC 24V-TB4-2
AC 24V- Ret -TB4-1
(J10 Sht 2, B8)
(49)
(52)
(51)
(60)
(61)
(62)
(63)
TB4
7
6
5
4
3
2
1
ARC VOLTS (TORCH)
TIP VOLTS (PILOT)
WORK
120 VAC @ 100 ma.
24 VAC @ 1A
RIBBON CABLE 40 ckt CCM (J23) - RELAY PCB (J4)
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 SIG-
24 NC
25 PILOT CURRENT SIG+
26 COMMON
27 WORK CURRENT SIG-
28 WORK CURRENT SIG+
29 NC
30 AMBIENT TEMP
31 COOLANT TEMP
* Used with 1 Torch Option
32 COMMON
33 -15 VDC
34 COMMON
35 24 VDC
36 COMMON
37 24 VDC
38 COMMON
39 24 VDC
40 COMMON
RIBBON CABLE 16 ckt
CCM ( J37) - DISPLAY
PCB (J17)
1,3,5,7
2,4,6,8
9,10 NC
11-16
RIBBON CABLE 10 ckt
RELAY PCB (J3) – PILOT PCB (J42)
1,2
24 VDC
COMMON
SERIAL DATA
24 VDC
3,4,7,10 COMMON
5 PILOT ENABLE +
6 PILOT ENABLE –
8 PILOT CURRENT SIG –
9 PILOT CURRENT SIG +
SHIELD
(+)
A
B
C
D
E
Rev
00
A A
AB
Revision
Initial Design
ECO-B2687
6
By Date
DAT 10/03/2012
D A T 9 / 1 6 / 2 0 1 4
DAT 10/17/2014
Rev
7
Revision By Date
8
The information contained herein is proprietary to Thermal Dynamics.
Not for release, reproduction or distribution without written consent.
Title SCHEMATIC
Ultra-Cut XT 400A CE 380-415 VAC
9
Art # A-11965_AD
Thermal Dynamics Corporation
2800 Airport Rd.
Denton, Texas 76207 USA
F
Date Printed
12/16/2014
Drawn
DAT
Size
C
Drawing Number
Date Revised
11/20/2014
Date 10/03/2012
Sheet
1 of 2
042X1341
10
1 2 3 4 5
E
F
A
B
C
D
(1)
(2)
(3)
1
2
IN1
EMI
FIL-
TER
PCB
OUT1
2
1
1
2
1
2
IN2
GND2B
OUT2
IN3 OUT3
2
1
2
1
(4)
(5)
(6)
(7)
(8)
(9)
L9
J105B
1
2
J104B
1
2
J103B
1
2
AC INPUT
INVERTER MODULE (IM) #3 (top)
IM #3 Section B
CHASSIS GND
Toriod Core
019X502700
(4)
W2A
380-415
VAC
INPUT
(Customer supplied power cord must pass through ferrite core assembly.)
L1
L2
L3
Earth
1
1
1
1
CHASSIS GND
(1)
(2)
(3)
(1)
(2)
(3)
1
2
IN1
EMI
FIL-
TER
PCB
OUT1
2
1
1
2
1
2
IN2
OUT2
IN3
GND2B
OUT3
2
1
2
1
CHASSIS GND
(5)
(6)
W2B
W2C
9
10
11
12
13
14
7
8
5
6
3
4
1
2
AC SUPPRESSION
J50
J51
019X504000
GND
J52
3
4
1
2
AC LINE
3
4
1
2
(10)
(11)
(12)
(13)
INTERNAL AC INDICATOR
CHASSIS GND
LT1
LT2
LT1 & LT2
INPUT POWER
NEON INDICATORS
Rear Panel & Internal
(7)
(8)
(9)
(7)
(8)
(9)
(7)
(8)
(9)
Toriod Core
(23)
(24)
L8
Toriod Core
L7
L6
(25)
Toriod Core
J105A
1
2
J104A
1
2
J103A
1
2
J105A
1
2
J104A
1
2
J103A
1
2
J105B
1
2
J104B
1
2
J103B
1
2
AC INPUT
019X502000
AC INPUT
019X502700
AC INPUT
019x502000
IM #3 Section A
INVERTER MODULE (IM) #2 (middle)
IM #2 Section B
IM #2 Section A (lower)
(1)
(2)
1
2
IN1
EMI
FIL-
TER
PCB
OUT1
2
1
(21)
W1A
(23)
L5
INVERTER MODULE (IM) #`1 (bottom)
1
2
2
1
(20)
W1B
(23)
(24) (24)
J105B
1
2
J104B
1
2
J103B
1
2
AC INPUT
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
(3)
1
2
IN2
GND2B
OUT2
2
1
(22) W1C
(25) (25)
Toriod Core 019x502700
IN3 OUT3
CHASSIS GND (23)
L4
J105A
1
2
J104A
AC INPUT IM #1 Section A (lower)
CB1
ON / OFF
16 A
F1
8A, 500V, SB
Art # A-11965_AD
(1) EMI
FIL-
TER
PCB
2
1
(20) (24) 1
2
(1-20)
(2-21)
(3-22)
(2)
1
2
1
2
IN1 OUT1
2
1
(21)
(25)
Toriod Core
J103A
1
2
WORK (+)
(86A)
(27A)
(85A)
(86B)
(27B)
(85B)
(3)
(FRONT PANEL)
F2
8A, 500V, SB
AC INPUT
13
14
15
16
9
10
11
12
17
18
7
8
5
6
3
4
1
2
1
2
J60
IN2
IN3
CHASSIS GND
J63
SYSTEM BIAS
SUPPLY PCB
019X501900
(43A)
GND2B
OUT2
OUT3
2
1
(22)
1 2 3 4 5 6 7 8 9 10 11 12
TO AUX TRANSFORMER
TO J12
T1 PRIMARY
(Sht 2, A1)
(44A)
019x502000
+24VDC
+ V
GND
System Bias LEDs & Test Points
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
(48)
J62
1
2
3
4
5
6
7
8
9
10
11
12
13
14
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
(Sht 2, 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
230V 400V 480V ERR
/VAC_IDAb 0 1 0 1
/VAC_IDBb 0 0 1 1
J61
Measure relative to TP1 (24VDC_RET)
"0" = 10-12V "1" = 24V
VOLTAGE SELECTION
Wire #48 from J61-1 to:
J61-2 for 208-230 VAC
J61-3 for 400 VAC
J61-4 for 480 VAC
(37)
(38)
(39)
(40)
(41)
(42)
(29)
(30)
(31)
(32)
(33)
(34)
(35)
(36)
Component Locations (not including PCB components)
To J27 on CCM I/O PCB
C4 Capacitor, fan starting, 8uf 440VAC (Sht 2, D2)
CB1 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
HCT1
Flow SW, 0.5 GPM (3.8 lpm), N.O. (Sht 2, A2)
Current Sensor, Hall Effect 200A, Work Lead
(Sht 1, C8)
K1 Relay, 24VAC, Inrush Control, (Sht2, B9)
L1 Inductor, (Sht 1, B7)
L3-9 Toriod Core Common Mode Ind (Sht1 B8, A-D3)
LS1 Level Switch, Coolant Tank (Sht 2, A3)
LT1, LT2 Indicator, Neon, 250V, AC Volts Present
(Sht 1, B2 & C2)
M1 Motor, Pump, ½ hp 230VAC, 50/60 Hz, 1Ph
(Sht 2, C2)
MC1 Relay, 120VAC, Inrush, coil (Sht2, B9)
contact (Sht2, A1)
MC2 Relay, 120 VAC, Fan Control, coil
(Coil at Sht 2, A7)(Contacts at Sht 2, D1)
MC3 Relay, 120 VAC, Pump Motor Control, coil
(Coil at Sht 2, A7)(Contacts at Sht 2, C1)
R2 Inrush, 4.7 Ohm, 30W (Sht2, A1)
R3,4 Ext RC, 100 ohm 55W (Sht1, A7)
SA1-4 Snubber, Contactor & Relay coils
(Sht 2, A8 & A9)
T1
TB4
Aux Transformer (Sht 2, B2)
Terminal Block (Sht 1, C9)
TS1 Temperature Sensor, NTC, Coolant Return
(Sht 2, A5)
TS2 Temperature Sensor, NTC, Ambient (Sht 2, A5)
W1 Contactor , Input (Coil Sht 2, A8), (Contacts C2)
W2 Contactor , Input (Coil Sht 2, A8), (Contacts A2)
1 2 3 4 5
0-5578
ULTRA-CUT 130 XT/200 XT/300 XT/400 XT
6 7 8 9 10
TO CCM
(Sht 2, C3)
J100 -- 30 CKT RIBBON
ELECTRODE (-)
WORK (+)
OUTPUT
(49F)
5
4
3
2
1
J102B
TO CCM
CPU PCB
J35
(Sht 2, C3)
J100 -- 30 CKT RIBBON
ELECTRODE (-)
WORK (+)
OUTPUT
(49E)
5
4
3
2
1
J102A
(51F) PILOT BOARD LED'S
D2 PILOT ENABLE
D11 +5V
(50)
R3 & R4
TO CCM
CPU PCB
J34
(Sht 2, C3)
J100 -- 30 CKT RIBBON
ELECTRODE (-)
WORK (+)
OUTPUT
J100 -- 30 CKT RIBBON
ELECTRODE (-)
WORK (+)
OUTPUT
5
4
3
2
1
(49D)
J102B
TO CCM
CPU PCB
J33
(Sht 2, C3)
5
4
3
2
1
J102A
(49C)
TEST POINTS
TP1 GND
TP2 PILOT GATE
TP3 +5V
J58A
(49)
J43
ELECTRODE
PILOT PCB
J44
1
CHASSIS GND
J58C
J40
INVERTER
5
4
3
2
1
J42
(51F)
019X501600
1 2 3 4 5 6 7 8 9 10
TO J3 on RELAY PCB
(Sht 2, A5)
10 ckt Ribbon
1 2 3 4 5 6 7 8
(53)
TIP VOLTS
To J24 on I-O PCB
WORK (51)
(Sht 2, D3)
ARC VOLTS (55)
L1
J41
1
2
TIP
J45
TO I/O BOARD
(51) (51)
HCT1
Hall Effect Sensor
J16
J100 -- 30 CKT RIBBON
ELECTRODE (-)
WORK (+)
OUTPUT
TO CCM
CPU PCB
J32
(Sht 2, C3)
J102B
(49B)
5
4
3
2
1
TO CCM
CPU PCB
J31
(Sht 2, C3)
J100 -- 30 CKT RIBBON
ELECTRODE (-)
WORK (+)
OUTPUT
J102A
(49A)
5
4
3
2
1
(50)
J46-M
J46-F
TO J1 on RELAY PCB
(Sht 2, B9)
RIBBON CABLE 30 ckt.
CCM (J31-36) - INVERTER (J100)
1 READY +
2 READY -
3 INVERTER_FLT +
4 INVERTER_FLT -
5 OVERTEMP_FLT +
6 OVERTEMP_FLT -
7 PWR_PRESENT +
8 PWR_PRESENT -
9 OUT_COM (+3 to 5VDC)
10 VAC_SELA
11 VAC_SELB
12 IS_IDA
13 IS_IDB
14 IS_IDC
15 ENABLE +
16 ENABLE -
17 START2 +
18 START2 -
19 SPARE
20 SYNC_IN +
21 SYNC_IN -
22 NC
23 NC
24 47 OHM to COMM
25 DEMAND +
26 DEMAND -
27 47 OHM to COMM
28 CURRENT +
29 CURRENT -
30 47 OHM to COMM
(56)
(57)
(58)
(59) g w o b
TORCH
To TB4-7
To TB4-6 TIP
J41 (J87)
L3
(49)
(52)
To / From Optional
1 Torch Module
(Refer to 1 Torch section for details.)
TORCH
1
PILOT
1
RAS
CHASSIS GND
WORK
1
(+)
(-)
Tip
Work
TORCH
(Sht 1, A9)
TIP
(Sht 1, A9)
AC 120V- TB4-4
AC 120V- Ret- TB4-3
AC 24V-TB4-2
AC 24V- Ret -TB4-1
(J10 Sht 2, B8)
(49)
(52)
(51)
(60)
(61)
(62)
(63)
TB4
7
6
5
4
3
2
1
ARC VOLTS (TORCH)
TIP VOLTS (PILOT)
WORK
120 VAC @ 100 ma.
24 VAC @ 1A
RIBBON CABLE 40 ckt CCM (J23) - RELAY PCB (J4)
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 SIG-
24 NC
25 PILOT CURRENT SIG+
26 COMMON
27 WORK CURRENT SIG-
28 WORK CURRENT SIG+
29 NC
30 AMBIENT TEMP
31 COOLANT TEMP
* Used with 1 Torch Option
32 COMMON
33 -15 VDC
34 COMMON
35 24 VDC
36 COMMON
37 24 VDC
38 COMMON
39 24 VDC
40 COMMON
RIBBON CABLE 16 ckt
CCM ( J37) - DISPLAY
PCB (J17)
1,3,5,7
2,4,6,8
9,10 NC
11-16
RIBBON CABLE 10 ckt
RELAY PCB (J3) – PILOT PCB (J42)
1,2
24 VDC
COMMON
SERIAL DATA
24 VDC
3,4,7,10 COMMON
5 PILOT ENABLE +
6 PILOT ENABLE –
8 PILOT CURRENT SIG –
9 PILOT CURRENT SIG +
SHIELD
(+)
A
B
C
D
E
Rev
00
A A
AB
Revision
Initial Design
ECO-B2687
6
By Date
DAT 10/03/2012
D A T 9 / 1 6 / 2 0 1 4
DAT 10/17/2014
Rev
7
Revision By Date
8
The information contained herein is proprietary to Thermal Dynamics.
Not for release, reproduction or distribution without written consent.
Title SCHEMATIC
Ultra-Cut XT 400A CE 380-415 VAC
9
Art # A-11965_AD
Thermal Dynamics Corporation
2800 Airport Rd.
Denton, Texas 76207 USA
F
Date Printed
12/16/2014
Drawn
DAT
Size
C
Drawing Number
Date Revised
11/20/2014
Date 10/03/2012
Sheet
1 of 2
042X1341
10
APPENDIX A-55
ULTRA-CUT 130 XT/200 XT/300 XT/400 XT
APPENDIX 30: System Schematic 400A, 380-415V PG 2
1 2 3 4 5
E
F
A
B
C
D
(1)
(2)
(3)
1
2
IN1
EMI
FIL-
TER
PCB
OUT1
2
1
1
2
1
2
IN2
IN3
GND2B
OUT2
OUT3
2
1
2
1
(4)
(5)
(6)
(7)
(8)
L9
J105B
1
2
J104B
1
2
J103B
1
2
AC INPUT
INVERTER MODULE (IM) #3 (top)
IM #3 Section B
CHASSIS GND
(9)
Toriod Core
019X502700
(4)
W2A
380-415
VAC
INPUT
(Customer supplied power cord must pass through ferrite core assembly.)
L1
L2
L3
Earth
1
1
1
1
CHASSIS GND
(1)
(2)
(3)
(1)
(2)
(3)
1
2
IN1
EMI
FIL-
TER
PCB
OUT1
2
1
1
2
1
2
IN2
IN3
GND2B
OUT2
OUT3
2
1
2
1
CHASSIS GND
(5)
(6)
W2B
W2C
9
10
11
12
13
14
7
8
5
6
3
4
1
2
AC SUPPRESSION
J50
J51
019X504000
GND
J52
3
4
1
2
AC LINE
3
4
1
2
(10)
(11)
(12)
(13)
INTERNAL AC INDICATOR
CHASSIS GND
LT1
LT2
LT1 & LT2
INPUT POWER
NEON INDICATORS
Rear Panel & Internal
(7)
(8)
(9)
(7)
(8)
(9)
Toriod Core
(7)
(8)
(9)
Toriod Core
(23)
(24)
L8
L7
L6
(25)
Toriod Core
J105A
1
2
J104A
1
2
J103A
1
2
J105B
1
2
J104B
1
2
J103B
1
2
J105A
1
2
J104A
1
2
J103A
1
2
AC INPUT
019X502000
AC INPUT
019X502700
AC INPUT
019x502000
IM #3 Section A
INVERTER MODULE (IM) #2 (middle)
IM #2 Section B
IM #2 Section A (lower)
(1)
(2)
1
2
IN1
EMI
FIL-
TER
PCB
OUT1
2
1
(21)
W1A
(23)
L5
INVERTER MODULE (IM) #`1 (bottom)
1
2
2
1
(20)
W1B
(23)
(24) (24)
J105B
1
2
J104B
1
2
J103B
1
2
AC INPUT
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
(3)
1
2
IN2
GND2B
OUT2
2
1
(22) W1C
(25) (25)
Toriod Core 019x502700
IN3 OUT3
CHASSIS GND (23)
L4
J105A
1
2
J104A
AC INPUT IM #1 Section A (lower)
CB1
ON / OFF
(1)
IN1
EMI
FIL-
TER
PCB
2
1
(20) (24) 1
2
(1-20)
(2-21)
(3-22)
(2)
1
2
1
2
OUT1
2
1
(21)
(25)
Toriod Core
J103A
1
2
WORK (+)
16 A
F1
8A, 500V, SB
Art # A-11966_AD
(86A)
(27A)
(85A)
(86B)
(27B)
(85B)
(3)
(FRONT PANEL)
F2
8A, 500V, SB
13
14
15
16
9
10
11
12
17
18
7
8
5
6
3
4
1
2
1
2
AC INPUT
J60
IN2
IN3
CHASSIS GND
J63
SYSTEM BIAS
SUPPLY PCB
019X501900
(43A)
GND2B
OUT2
OUT3
2
1
(22)
1 2 3 4 5 6 7 8 9 10 11 12
TO AUX TRANSFORMER
TO J12
T1 PRIMARY
(Sht 2, A1)
(44A)
019x502000
GND
System Bias LEDs & Test Points
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
(48)
J62
1
2
3
4
5
6
7
8
9
10
11
12
13
14
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
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
VAC_IDB a
/ VAC_IDB b
(Sht 2, E3)
Measure relative to TP1 (24VDC_RET)
"0" = 10-12V "1" = 24V
J61
VOLTAGE SELECTION
Wire #48 from J61-1 to:
J61-2 for 208-230 VAC
J61-3 for 400 VAC
J61-4 for 480 VAC
(35)
(36)
(37)
(38)
(39)
(40)
(29)
(30)
(31)
(32)
(33)
(34)
(41)
(42)
230V 400V 480V ERR
/VAC_IDAb 0 1 0 1
/VAC_IDBb 0 0 1 1
Component Locations (not including PCB components)
To J27 on CCM I/O PCB
C4 Capacitor, fan starting, 8uf 440VAC (Sht 2, D2)
CB1 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
HCT1
Flow SW, 0.5 GPM (3.8 lpm), N.O. (Sht 2, A2)
Current Sensor, Hall Effect 200A, Work Lead
(Sht 1, C8)
K1 Relay, 24VAC, Inrush Control, (Sht2, B9)
L1 Inductor, (Sht 1, B7)
L3-9 Toriod Core Common Mode Ind (Sht1 B8, A-D3)
LS1 Level Switch, Coolant Tank (Sht 2, A3)
LT1, LT2 Indicator, Neon, 250V, AC Volts Present
(Sht 1, B2 & C2)
M1 Motor, Pump, ½ hp 230VAC, 50/60 Hz, 1Ph
(Sht 2, C2)
MC1 Relay, 120VAC, Inrush, coil (Sht2, B9)
contact (Sht2, A1)
MC2 Relay, 120 VAC, Fan Control, coil
(Coil at Sht 2, A7)(Contacts at Sht 2, D1)
MC3 Relay, 120 VAC, Pump Motor Control, coil
(Coil at Sht 2, A7)(Contacts at Sht 2, C1)
R2 Inrush, 4.7 Ohm, 30W (Sht2, A1)
R3,4 Ext RC, 100 ohm 55W (Sht1, A7)
SA1-4 Snubber, Contactor & Relay coils
(Sht 2, A8 & A9)
T1
TB4
Aux Transformer (Sht 2, B2)
Terminal Block (Sht 1, C9)
TS1 Temperature Sensor, NTC, Coolant Return
(Sht 2, A5)
TS2 Temperature Sensor, NTC, Ambient (Sht 2, A5)
W1 Contactor , Input (Coil Sht 2, A8), (Contacts C2)
W2 Contactor , Input (Coil Sht 2, A8), (Contacts A2)
1 2 3 4 5
A-56 APPENDIX 0-5578
6 7 8 9 10
TO CCM
CPU PCB J36
(Sht 2, C3)
J100 -- 30 CKT RIBBON
ELECTRODE (-)
WORK (+)
OUTPUT
J100 -- 30 CKT RIBBON
ELECTRODE (-)
WORK (+)
OUTPUT
J100 -- 30 CKT RIBBON
ELECTRODE (-)
WORK (+)
OUTPUT
J100 -- 30 CKT RIBBON
ELECTRODE (-)
WORK (+)
OUTPUT
TO CCM
CPU PCB
J34
(Sht 2, C3)
5
4
3
2
1
(49D)
J102B
TO CCM
CPU PCB
J33
(Sht 2, C3)
5
4
3
2
1
J102A
(49C)
(49F)
5
4
3
2
1
J102B
TO CCM
CPU PCB
J35
(Sht 2, C3)
(51F) PILOT BOARD LED'S
D2 PILOT ENABLE
D11 +5V
R3 & R4
(49E)
5
4
3
2
1
J102A
(50)
TEST POINTS
TP1 GND
TP2 PILOT GATE
TP3 +5V
J58A
(49)
J43
ELECTRODE
PILOT PCB
J44
1
CHASSIS GND
J58C
5
4
3
2
1
J40
INVERTER
J42
(51F)
019X501600
1 2 3 4 5 6 7 8 9 10
TO J3 on RELAY PCB
(Sht 2, A5)
10 ckt Ribbon
1 2 3 4 5 6 7 8
(53)
TIP VOLTS
To J24 on I-O PCB
(Sht 2, D3)
WORK
ARC VOLTS
(51)
(55)
L1
J41
1
2
TIP
J45
TO I/O BOARD
(51) (51)
HCT1
Hall Effect Sensor
J16
J100 -- 30 CKT RIBBON
ELECTRODE (-)
WORK (+)
OUTPUT
TO CCM
CPU PCB
J32
(Sht 2, C3)
J102B
(49B)
5
4
3
2
1
TO CCM
CPU PCB
J31
(Sht 2, C3)
J100 -- 30 CKT RIBBON
ELECTRODE (-)
WORK (+)
J102A
(49A)
5
4
3
2
1
(50)
OUTPUT
J46-M
J46-F
TO J1 on RELAY PCB
(Sht 2, B9)
(56)
(57)
(58)
(59) g w o b
RIBBON CABLE 30 ckt.
CCM (J31-36) - INVERTER (J100)
1 READY +
2 READY -
3 INVERTER_FLT +
4 INVERTER_FLT -
5 OVERTEMP_FLT +
6 OVERTEMP_FLT -
7 PWR_PRESENT +
8 PWR_PRESENT -
9 OUT_COM (+3 to 5VDC)
10 VAC_SELA
11 VAC_SELB
12 IS_IDA
13 IS_IDB
14 IS_IDC
15 ENABLE +
16 ENABLE -
17 START2 +
18 START2 -
19 SPARE
20 SYNC_IN +
21 SYNC_IN -
22 NC
23 NC
24 47 OHM to COMM
25 DEMAND +
26 DEMAND -
27 47 OHM to COMM
28 CURRENT +
29 CURRENT -
30 47 OHM to COMM
TORCH
To TB4-7
To TB4-6 TIP
J41 (J87)
L3
(49)
(52)
To / From Optional
1 Torch Module
(Refer to 1 Torch section for details.)
TORCH
1
PILOT
1
RAS
CHASSIS GND
WORK
1
(+)
(-)
Tip
Work
TORCH
(Sht 1, A9)
TIP
(Sht 1, A9)
AC 120V- TB4-4
AC 120V- Ret- TB4-3
AC 24V-TB4-2
AC 24V- Ret -TB4-1
(J10 Sht 2, B8)
(49)
(52)
(51)
(60)
(61)
(62)
(63)
TB4
7
6
5
2
1
4
3
ARC VOLTS (TORCH)
TIP VOLTS (PILOT)
WORK
120 VAC @ 100 ma.
24 VAC @ 1A
RIBBON CABLE 40 ckt CCM (J23) - RELAY PCB (J4)
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 SIG-
24 NC
25 PILOT CURRENT SIG+
26 COMMON
27 WORK CURRENT SIG-
28 WORK CURRENT SIG+
29 NC
30 AMBIENT TEMP
31 COOLANT TEMP
* Used with 1 Torch Option
32 COMMON
33 -15 VDC
34 COMMON
35 24 VDC
36 COMMON
37 24 VDC
38 COMMON
39 24 VDC
40 COMMON
RIBBON CABLE 16 ckt
CCM ( J37) - DISPLAY
PCB (J17)
1,3,5,7
2,4,6,8
9,10 NC
11-16
RIBBON CABLE 10 ckt
RELAY PCB (J3) – PILOT PCB (J42)
1,2
24 VDC
COMMON
SERIAL DATA
24 VDC
3,4,7,10 COMMON
5 PILOT ENABLE +
6 PILOT ENABLE –
8 PILOT CURRENT SIG –
9 PILOT CURRENT SIG +
SHIELD
(+)
A
B
C
D
E
Art # A-11966_AD
Rev
00
A A
AB
Revision
Initial Design
ECO-B2687
6
By Date
DAT 10/03/2012
D A T 9 / 1 6 / 2 0 1
DAT 10/17/2014
4
Rev
7
Revision By Date
8
The information contained herein is proprietary to Thermal Dynamics.
Not for release, reproduction or distribution without written consent.
Title SCHEMATIC
Ultra-Cut XT 400A CE 380-415 VAC
9
Thermal Dynamics Corporation
2800 Airport Rd.
Denton, Texas 76207 USA
F
Date Printed
12/16/2014
Drawn
DAT
Size
C
Drawing Number
Date Revised
11/20/2014
Date
10/03/2012
Sheet
1 of 2
042X1341
10
1 2 3 4 5
E
F
A
B
C
D
(1)
(2)
(3)
1
2
IN1
EMI
FIL-
TER
PCB
OUT1
2
1
1
2
1
2
IN2
IN3
GND2B
OUT2
OUT3
2
1
2
1
(4)
(5)
(6)
(7)
(8)
L9
J105B
1
2
J104B
1
2
J103B
1
2
AC INPUT
INVERTER MODULE (IM) #3 (top)
IM #3 Section B
CHASSIS GND
(9)
Toriod Core
019X502700
(4)
W2A
380-415
VAC
INPUT
(Customer supplied power cord must pass through ferrite core assembly.)
L1
L2
L3
Earth
1
1
1
1
CHASSIS GND
(1)
(2)
(3)
(1)
(2)
(3)
1
2
IN1
EMI
FIL-
TER
PCB
OUT1
2
1
1
2
1
2
IN2
IN3
GND2B
OUT2
OUT3
2
1
2
1
CHASSIS GND
(5)
(6)
W2B
W2C
9
10
11
12
13
14
7
8
5
6
3
4
1
2
AC SUPPRESSION
J50
J51
019X504000
GND
J52
3
4
1
2
AC LINE
3
4
1
2
(10)
(11)
(12)
(13)
INTERNAL AC INDICATOR
CHASSIS GND
LT1
LT2
LT1 & LT2
INPUT POWER
NEON INDICATORS
Rear Panel & Internal
(7)
(8)
(9)
(7)
(8)
(9)
Toriod Core
(7)
(8)
(9)
Toriod Core
(23)
(24)
L8
L7
L6
(25)
Toriod Core
J105A
1
2
J104A
1
2
J103A
1
2
J105B
1
2
J104B
1
2
J103B
1
2
J105A
1
2
J104A
1
2
J103A
1
2
AC INPUT
019X502000
AC INPUT
019X502700
AC INPUT
019x502000
IM #3 Section A
INVERTER MODULE (IM) #2 (middle)
IM #2 Section B
IM #2 Section A (lower)
(1)
(2)
1
2
IN1
EMI
FIL-
TER
PCB
OUT1
2
1
(21)
W1A
(23)
L5
INVERTER MODULE (IM) #`1 (bottom)
1
2
2
1
(20)
W1B
(23)
(24) (24)
J105B
1
2
J104B
1
2
J103B
1
2
AC INPUT
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
(3)
1
2
IN2
GND2B
OUT2
2
1
(22) W1C
(25) (25)
Toriod Core 019x502700
IN3 OUT3
CHASSIS GND (23)
L4
J105A
1
2
J104A
AC INPUT IM #1 Section A (lower)
CB1
ON / OFF
(1)
IN1
EMI
FIL-
TER
PCB
2
1
(20) (24) 1
2
(1-20)
(2-21)
(3-22)
(2)
1
2
1
2
OUT1
2
1
(21)
(25)
Toriod Core
J103A
1
2
WORK (+)
16 A
F1
8A, 500V, SB
Art # A-11966_AD
(86A)
(27A)
(85A)
(86B)
(27B)
(85B)
(3)
(FRONT PANEL)
F2
8A, 500V, SB
13
14
15
16
9
10
11
12
17
18
7
8
5
6
3
4
1
2
1
2
AC INPUT
J60
IN2
IN3
CHASSIS GND
J63
SYSTEM BIAS
SUPPLY PCB
019X501900
(43A)
GND2B
OUT2
OUT3
2
1
(22)
1 2 3 4 5 6 7 8 9 10 11 12
TO AUX TRANSFORMER
TO J12
T1 PRIMARY
(Sht 2, A1)
(44A)
019x502000
GND
System Bias LEDs & Test Points
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
(48)
J62
1
2
3
4
5
6
7
8
9
10
11
12
13
14
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
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
VAC_IDB a
/ VAC_IDB b
(Sht 2, E3)
Measure relative to TP1 (24VDC_RET)
"0" = 10-12V "1" = 24V
J61
VOLTAGE SELECTION
Wire #48 from J61-1 to:
J61-2 for 208-230 VAC
J61-3 for 400 VAC
J61-4 for 480 VAC
(35)
(36)
(37)
(38)
(39)
(40)
(29)
(30)
(31)
(32)
(33)
(34)
(41)
(42)
230V 400V 480V ERR
/VAC_IDAb 0 1 0 1
/VAC_IDBb 0 0 1 1
Component Locations (not including PCB components)
To J27 on CCM I/O PCB
C4 Capacitor, fan starting, 8uf 440VAC (Sht 2, D2)
CB1 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
HCT1
Flow SW, 0.5 GPM (3.8 lpm), N.O. (Sht 2, A2)
Current Sensor, Hall Effect 200A, Work Lead
(Sht 1, C8)
K1 Relay, 24VAC, Inrush Control, (Sht2, B9)
L1 Inductor, (Sht 1, B7)
L3-9 Toriod Core Common Mode Ind (Sht1 B8, A-D3)
LS1 Level Switch, Coolant Tank (Sht 2, A3)
LT1, LT2 Indicator, Neon, 250V, AC Volts Present
(Sht 1, B2 & C2)
M1 Motor, Pump, ½ hp 230VAC, 50/60 Hz, 1Ph
(Sht 2, C2)
MC1 Relay, 120VAC, Inrush, coil (Sht2, B9)
contact (Sht2, A1)
MC2 Relay, 120 VAC, Fan Control, coil
(Coil at Sht 2, A7)(Contacts at Sht 2, D1)
MC3 Relay, 120 VAC, Pump Motor Control, coil
(Coil at Sht 2, A7)(Contacts at Sht 2, C1)
R2 Inrush, 4.7 Ohm, 30W (Sht2, A1)
R3,4 Ext RC, 100 ohm 55W (Sht1, A7)
SA1-4 Snubber, Contactor & Relay coils
(Sht 2, A8 & A9)
T1
TB4
Aux Transformer (Sht 2, B2)
Terminal Block (Sht 1, C9)
TS1 Temperature Sensor, NTC, Coolant Return
(Sht 2, A5)
TS2 Temperature Sensor, NTC, Ambient (Sht 2, A5)
W1 Contactor , Input (Coil Sht 2, A8), (Contacts C2)
W2 Contactor , Input (Coil Sht 2, A8), (Contacts A2)
1 2 3 4 5
ULTRA-CUT 130 XT/200 XT/300 XT/400 XT
0-5578
6 7 8 9 10
TO CCM
CPU PCB J36
(Sht 2, C3)
J100 -- 30 CKT RIBBON
ELECTRODE (-)
WORK (+)
OUTPUT
J100 -- 30 CKT RIBBON
ELECTRODE (-)
WORK (+)
OUTPUT
J100 -- 30 CKT RIBBON
ELECTRODE (-)
WORK (+)
OUTPUT
J100 -- 30 CKT RIBBON
ELECTRODE (-)
WORK (+)
OUTPUT
TO CCM
CPU PCB
J34
(Sht 2, C3)
5
4
3
2
1
(49D)
J102B
TO CCM
CPU PCB
J33
(Sht 2, C3)
5
4
3
2
1
J102A
(49C)
(49F)
5
4
3
2
1
J102B
TO CCM
CPU PCB
J35
(Sht 2, C3)
(51F) PILOT BOARD LED'S
D2 PILOT ENABLE
D11 +5V
R3 & R4
(49E)
5
4
3
2
1
J102A
(50)
TEST POINTS
TP1 GND
TP2 PILOT GATE
TP3 +5V
J58A
(49)
J43
ELECTRODE
PILOT PCB
J44
1
CHASSIS GND
J58C
5
4
3
2
1
J40
INVERTER
J42
(51F)
019X501600
1 2 3 4 5 6 7 8 9 10
TO J3 on RELAY PCB
(Sht 2, A5)
10 ckt Ribbon
1 2 3 4 5 6 7 8
(53)
TIP VOLTS
To J24 on I-O PCB
(Sht 2, D3)
WORK
ARC VOLTS
(51)
(55)
L1
J41
1
2
TIP
J45
TO I/O BOARD
(51) (51)
HCT1
Hall Effect Sensor
J16
J100 -- 30 CKT RIBBON
ELECTRODE (-)
WORK (+)
OUTPUT
TO CCM
CPU PCB
J32
(Sht 2, C3)
J102B
(49B)
5
4
3
2
1
TO CCM
CPU PCB
J31
(Sht 2, C3)
J100 -- 30 CKT RIBBON
ELECTRODE (-)
WORK (+)
J102A
(49A)
5
4
3
2
1
(50)
OUTPUT
J46-M
J46-F
TO J1 on RELAY PCB
(Sht 2, B9)
(56)
(57)
(58)
(59) g w o b
RIBBON CABLE 30 ckt.
CCM (J31-36) - INVERTER (J100)
1 READY +
2 READY -
3 INVERTER_FLT +
4 INVERTER_FLT -
5 OVERTEMP_FLT +
6 OVERTEMP_FLT -
7 PWR_PRESENT +
8 PWR_PRESENT -
9 OUT_COM (+3 to 5VDC)
10 VAC_SELA
11 VAC_SELB
12 IS_IDA
13 IS_IDB
14 IS_IDC
15 ENABLE +
16 ENABLE -
17 START2 +
18 START2 -
19 SPARE
20 SYNC_IN +
21 SYNC_IN -
22 NC
23 NC
24 47 OHM to COMM
25 DEMAND +
26 DEMAND -
27 47 OHM to COMM
28 CURRENT +
29 CURRENT -
30 47 OHM to COMM
TORCH
To TB4-7
To TB4-6 TIP
J41 (J87)
L3
(49)
(52)
To / From Optional
1 Torch Module
(Refer to 1 Torch section for details.)
TORCH
1
PILOT
1
RAS
CHASSIS GND
WORK
1
(+)
(-)
Tip
Work
TORCH
(Sht 1, A9)
TIP
(Sht 1, A9)
AC 120V- TB4-4
AC 120V- Ret- TB4-3
AC 24V-TB4-2
AC 24V- Ret -TB4-1
(J10 Sht 2, B8)
(49)
(52)
(51)
(60)
(61)
(62)
(63)
TB4
7
6
5
2
1
4
3
ARC VOLTS (TORCH)
TIP VOLTS (PILOT)
WORK
120 VAC @ 100 ma.
24 VAC @ 1A
RIBBON CABLE 40 ckt CCM (J23) - RELAY PCB (J4)
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 SIG-
24 NC
25 PILOT CURRENT SIG+
26 COMMON
27 WORK CURRENT SIG-
28 WORK CURRENT SIG+
29 NC
30 AMBIENT TEMP
31 COOLANT TEMP
* Used with 1 Torch Option
32 COMMON
33 -15 VDC
34 COMMON
35 24 VDC
36 COMMON
37 24 VDC
38 COMMON
39 24 VDC
40 COMMON
RIBBON CABLE 16 ckt
CCM ( J37) - DISPLAY
PCB (J17)
1,3,5,7
2,4,6,8
9,10 NC
11-16
RIBBON CABLE 10 ckt
RELAY PCB (J3) – PILOT PCB (J42)
1,2
24 VDC
COMMON
SERIAL DATA
24 VDC
3,4,7,10 COMMON
5 PILOT ENABLE +
6 PILOT ENABLE –
8 PILOT CURRENT SIG –
9 PILOT CURRENT SIG +
SHIELD
(+)
A
B
C
D
E
Art # A-11966_AD
Rev
00
A A
AB
Revision
Initial Design
ECO-B2687
6
By Date
DAT 10/03/2012
D A T 9 / 1 6 / 2 0 1
DAT 10/17/2014
4
Rev
7
Revision By Date
8
The information contained herein is proprietary to Thermal Dynamics.
Not for release, reproduction or distribution without written consent.
Title SCHEMATIC
Ultra-Cut XT 400A CE 380-415 VAC
9
Thermal Dynamics Corporation
2800 Airport Rd.
Denton, Texas 76207 USA
F
Date Printed
12/16/2014
Drawn
DAT
Size
C
Drawing Number
Date Revised
11/20/2014
Date
10/03/2012
Sheet
1 of 2
042X1341
10
APPENDIX A-57
ULTRA-CUT 130 XT/200 XT/300 XT/400 XT
APPENDIX 31: ADVANCED TROUBLESHOOTING
System Overview
The Auto-Cut 200 & 300 XT, PAK200i & Ultra-Cut 100, 130, 200,
300 & 400 XT 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 130A unit uses 2 sections. 130/2 = 65A per section.
A 100A unit uses 2 sections. 100/2 = 50A per section.
Unit configurations.
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. The 100 and 130A systems use 1 full IM. The 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.
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 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
A-58 APPENDIX
Art # 12299
Art # 12300
0-5578
ULTRA-CUT 130 XT/200 XT/300 XT/400 XT as INV with the number and section (INV 1A, INV 1B, etc.). 100 and 130A units 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. Ultra-Cut 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 Ultra-Cut XT using the Auto Gas Control, DFC 3000, 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.
2nd INVERTER SECTION
(INV 1 B)
Art # 12301
1st INVERTER SECTION
(INV 1 A)
PILOT SW (IGBT)
(+)
TIP
WORK (+)
0-5578 APPENDIX A-59
ULTRA-CUT 130 XT/200 XT/300 XT/400 XT
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.
Differences between various models.
Auto-Cut 200, PAK200i and 300 XT units use the basic gas control/arc start circuits consisting of single gas inlets, one for
Plasma, one for Gas Shield. Also included with the Auto-Cut 300 XT and optional for the Auto-Cut 200XT is a third inlet providing water for the H2O Mist shield.
There is a pressure regulator and gauge for each gas inlet and water flow meter/control when the H2O Mist option is used.
All 3 are turned on/off with control solenoids. Changing gas types requires connecting different gasses to the rear panel and setting the gas switch on the rear panel to match the plasma gas type. There is no separate pilot (Preflow) gas at this time.
The Auto-Cut 200 XT, Auto-Cut 300 XT and PAK200i Arc starter is the conventional spark gap type with water cooled coil that we’ve used for several years. This arc starter injects the HF onto the torch electrode via the negative lead with the return via the tip and pilot lead. The Ultra-Cut XT units use the remote arc starter, RAS 1000 XT. In place of the spark gap the RAS 1000
XT uses a solid state ignition module to create the HF pulses which are injected onto the tip and return via the electrode, the opposite direction of that used in the Auto-Cut, Auto-Cut XT and the older RAS 1000 used with the Ultra-Cut units.
The AC 200 XT and PAK200i have the gas control and arc starter built into the main enclosure in the area that is used for the top inverter module in other units of this family. The AC 300 XT has a separate gas control/Arc Starter that sits on top of the main enclosure very similar to the GCM 1000 of our earlier Auto-Cut models. It is in fact called a GCM 1000 XT .
Both Auto-Cut XT and the PAK200i models have an analog current control (Potentiometer). On the front panel of the main unit for the AC 200 XT and PAK200i and in the upper box, the GCM 1000 XT, for the AC 300 XT version. In either case the amperage setting is displayed on the front panel digital display.
Both Auto-Cut models have the gas mode switch on the rear, for the AC 300 XT next to the gas inlets of the GCM 1000 XT.
On the AC 200 XT it’s near the connectors, fuses & circuit breakers. The switch should be set according to the type of gas,
AIR/O2 or N2, H35 or other non-oxidizing gas, being used for the plasma. The PAK200i does not have this switch.
In the AC 200 XT and PAK200i, the Pilot board is mounted on the upper section of the second inverter module (IM#2) the
½ module, in the place of the second or “B” section if it was a full module. The AC 300 XT and all Ultra-Cut XT models have the Pilot board on the opposite side from the inverters, the “circuit breaker” side, in the upper rear behind the CCM module.
Refer to the Replacement Parts section of the manual for illustrations showing the locations.
Ultra-Cut XT units, 100, 200, 300 & 400A units all can use either the GCM 2010 “manual” Gas control or the DFC 3000 Auto
Gas Control.
These gas controls remain unchanged from earlier Ultra-Cut units.
Ultra-Cut XT units use the same flow switch, FS1, as the Auto-Cut XT units to detect and prevent operation when coolant flow is below the minimum of 0.75 GPM (2.8 l/m). However, the Ultra-Cut XTs include a coolant flow sensor, FL1, which also measures the flow and can detect if there are gas bubbles in the coolant which can reduce consumable part life. Detecting bubbles or low flow from FL1 will NOT prevent cutting but will show a code as a warning that something is not right. The code is E406.
Ultra-Cut XTs have standard consumables for cutting currents lower than those used for Auto-Cut XT, 15A vs. 55A as well as marking at lower currents. To improve operation at these lower currents an additional output inductor, L1, is added in series with the 1st inverter section (IM#1A).
Optional 1Torch module
Starting early in 2015 all the Auto-Cut 300 XT and Ultra-Cut XT models may be ordered from the factory with an optional module allowing connecting an SL100 “1Torch” that cuts at a fixed 100A. The module is built into the XT supply front panel just above the coolant tank filler cover. Connect a shop air supply and an SL100 torch and you can use this torch with its relatively low cost consumables to hand cut scrap or whatever you wish without wearing the higher cost consumables of the XT torch.
A-60 APPENDIX 0-5578
Status codes.
ULTRA-CUT 130 XT/200 XT/300 XT/400 XT
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
Group 2
Group 3
Group 4
Group 5
Group 6
Group 7
Plasma Process -- Relating to pilot, transfer, torch voltages, etc.
Plasma Power Supply -- Primarily the Inverter Sections
Interface to Gas controls -- Mainly the DFC 3000
Cooling System -- The liquid cooling system for the torch and inverters
CCM -- Communications port to the gas controls
CCM -- Status
Accessories – 1Torch
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.
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.
0-5578 APPENDIX A-61
ULTRA-CUT 130 XT/200 XT/300 XT/400 XT
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.
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 Ultra-Cut XT & Auto-Cut 300XT. The Auto-Cut 200XT which uses a 14 pin CNC does not have the
Plasma Enable in the cable. 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.
• Input voltage too high, power not applied to GCM 2010.
• 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. This can cause the GCM 2010 to not satisfy the Plasma Enable circuit and falsely report (E101) as the fault.
A-62 APPENDIX 0-5578
ULTRA-CUT 130 XT/200 XT/300 XT/400 XT
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.
Plasma Enable from Gas Control or TSC 3000
If the External or CNC Plasma Enable is satisfied, D2 is on, a relay K7 on the CCM I/O PCB energizes supplying +15V to another relay K1 on the I/O board. An active low signal, /Plasma Enable-HMI, comes from TSC 3000 Plasma Enable switch via the Relay PCB or if TSC 3000 is not installed the signal originates on the Relay PCB. This signal applies ground to the K1 relay energizing it and lighting the LED, D3 on the I/O board. K1’s contacts go back to the Relay board and the Gas control connector J55 to allow turning on relays and solenoids on those devices. The AC 200 XT does not use the separate Gas Control or the TSC 3000.
Simplified schematic, all connectors are not shown.
Refer to unit schematics for details.
CCM I/O PCB
XT Power Supply
When the circuit between J54-1 & 3 is closed (jumper, etc.) K7 is energized and requires a Plasma Enable SW or equivlant to enable the plasma.
With J54-1 & 3 open K7 is denergized and it's NC contacts complete the Plasma Enable-HMI circuit.
1
K6
+15VDC
D2
GREEN
2
4
3
RELAY PCB
24 VAC
24 VAC
J54
-1
-3
J61
-1
-3
TSC 3000
J54
-1
-3
J25 iCNC
XT 2 &
XT 242
J54
-1
-3
J30 iCNC
XT 211
5
PLASMA ENABLE - CNC
D3
GREEN
PS_ENABLE
1
8
K1
2
3
4
5
6
To
Relay
PCB
7
PLASMA ENABLE
To Gas
Control
GND
1
K7
2
4
3
5
HMI PLASMA
ENABLE BYPASS
/PLASMA ENABLE - HMI
-6
-5
-6
-5
Plasma
Enable
SW
-6
-5
GCM 2010
(or jumper in other gas controls)
-22
-15
-6
-5
GCM 1000 XT
(AC 300 XT
DMC 3000)
-25
-20
Plasma Enable SW
J26-6
J26-7
J55
-1
-2
J56
-1
-2
J56
-1
-2
Jumper in
AC 200 XT Art # 12304
If a TSC 3000 is not connected or unit is an Auto-Cut, K7 on the Relay PCB is de-energized and GND is connected through its normally closed contacts. If the TSC is connected, 24 VAC through a jumper in the TSC 3000 energizes K7, opening its NC contacts and now GND connects through the TDC 3000 Plasma Enable switch. The GND obtained by either path passes through the GCM 2010 Plasma Enable switch or through a jumper (J56-1 to J56-2) present in the other gas controls (GCM 1000 XT or DMC 3000) and is connected to the coil of K1 on the I/O PCB. If the CNC Plasma Enable is also active (D2 is on) +15V will be connected to K1’s coil through the relay K7 on the I/O PCB. This energizes K1 and turns on D3, Plasma Enable LED. The contacts of K1 go back to the Relay board and to the Gas control to enable power to connect to relays and solenoids in those items.
0-5578 APPENDIX A-63
ULTRA-CUT 130 XT/200 XT/300 XT/400 XT
Troubleshooting:
1. If both D2 and D3 are on and you still have 101 fault replace the CCM. Otherwise go to step 2 except if it’s an
AC 200 XT skip to step 4.
2. If D3 is not on and there is a TSC 3000 in use remove its cable from J54. K7 on the Relay board will de-energize and satisfy the Plasma Enable to K1. If D3 is now on problem was in the TSC 3000 or its cable. Otherwise reconnect the cable.
3. For an Ultra-Cut with DFC 3000 or GCM 2010 or an Auto-Cut 300 with a GCM 1000 XT remove the cable from
J55 the gas control connector and jumper pins 1 & 2. If D3 is on now problem is in the Gas Control or its cable.
If D3 still not on replace the Gas Control cable.
4. If neither of the above steps works, on the CCM I/O board, jumper J26-7 to GND (TP1 on I/O). If D2 is on and D3 still does not light then replace the CCM.
5. If D3 does light in the above step find the 40 pin ribbon cable plugged in to the top of the CCM. Confirm that it is plugged in to both the CCM and the Relay board and the connector tabs are locked in place. Now using the spare receptacle measure voltage between GND (TP1 on I/O) and the ribbon cable pin 12. It should be zero V.
If not, if it’s something like 10-15VDC, the ribbon cable is open or the Relay board is defective.
GCM 2010 PLASMA ENABLE / E-STOP SIMPLIFIED CIRCUIT
XT PLASMA SUPPLY
RELAY BOARD
AC24V GCM1 15
GCM 2010 GAS CONTROL
AC24V Ret - GCM1 7
J10 GAS
CONTROL
CABLE
GCM 2010 CONTROL BOARD
F20
1A
CCM I/O BOARD
3
(103)
(112)
16
14
16
14
(56)
(58)
12
15
K1
PLASMA ENABLE
4
(110)
(114)
17 13
(57)
(59)
13
D13
GREEN
1
K?
4
5
15
J55
15
J56
J5
16
2
J26
E-STOP
Art # 12306
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 1000 XT or GCM 1000 XT or the arc starter built in to the AC 200 XT) 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.
A-64 APPENDIX 0-5578
ULTRA-CUT 130 XT/200 XT/300 XT/400 XT
XT Torch or 1Torch option:
• Pilot board not enabled.
• Pilot board defective.
• Relay board defective.
• Work lead current sensor defective.
• CCM defective.
• W4, tip isolation contactor, not energized for automation cutting, refer to 700 code group.
1Torch ONLY:
• W5, 1Torch Isolation Contactor, not energized for 1Torch cutting, refer to 700 code group.
Troubleshooting:
1. Determine if the problem is a lack of HF (Arc Starter) or if it’s due to the pilot circuit.
Auto-cut XT Arc Starter (inside main chassis for AC200 XT; in the GCM1000XT for AC300XT) has open spark gap. If the spark gap is firing it is receiving power. A few early Ultra-Cut XT units were shipped with the RAS1000 Arc Starter.
Troubleshoot them the same as the GCM1000XT below. Most Ultra-Cut XT units now use the RAS1000XT Arc Starter which doesn’t use a spark gap and is covered in the next section.
Arc starter with Spark Gap (Auto-Cut)
No spark at spark gap
1. Check that spark gap is set for 0.062” +/- 0.002”. If gap is too high there may not be enough voltage from T1 to fire the gap.
2. Check for power to the high frequency (HF) transformer (T2 in AC 200 XT; T1 in GCM1000XT) during the 15 seconds following prefow (ignition phase). Arc starter power comes through the rear panel circuit breaker CB4, make sure it isn’t tripped. a. For the GCM1000XT (AC300XT) 120 VAC from J59-7 & 9 on the power supply rear panel connects to J58-7 & 9 on the GCM 1000XT. See diagram below. From J58 on the GCM1000XT it goes directly to the line filter and passes through the filter to primary of T1. During the ignition phase, check for 120 VAC on the T1 side of the line filter. b. For AC200XT the HF transformer T2 has insulated Faston (also known as push on , stab-on, spade, etc.) on its primary wires. Disconnect these and measure for 120 VAC on the harness side during ignition phase.
3. If 120 VAC not present go to step 4.
a. If 120 VAC is present and still no spark, T1 (T2 in AC200XT) may be bad. Remove power and measure resistance of T1 (T2 in AC200XT) primary and secondary. The primary should measure about 3-7 ohms. The secondary about 25-35 K ohms. If either measurement not correct replace T1 (T2 in AC200XT).
b. If T1 (T2 in AC200XT) measures OK, check for shorted capacitors C1-C3 (very unlikely).
4. No 120 VAC to T1 (T2 in AC200XT) primary during the ignition phase (15 seconds following Preflow) check for 120
VAC into the line filter (GCM1000XT only). If it’s there replace the filter. If 120 VAC isn’t present at the line filter or if this is an AC 200XT go to step 5 in section Either Arc Starter below.
0-5578 APPENDIX A-65
ULTRA-CUT 130 XT/200 XT/300 XT/400 XT
Arc starter without Spark Gap (Ultra-Cut)
1. Check for power to the RAS 1000XT’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 1000 XT 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.
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.
A-66 APPENDIX 0-5578
CCM I/O Board
TO RELAY BOARD
/ RAS ON
TP1
GND
J23
23
24
25
26
27
28
29
16
17
18
19
20
21
22
9
10
11
12
13
14
15
5
6
7
8
1
2
3
4
30
31
32
33
34
35
36
37
38
39
40
ULTRA-CUT 130 XT/200 XT/300 XT/400 XT
J4
25
26
27
28
29
30
31
32
21
22
23
24
16
17
18
19
20
37
38
39
40
33
34
35
36
9
10
11
12
13
14
15
4
5
6
7
8
1
2
3
Relay & Interface Board
From I/O PCB
24VDC_SW
D21
1
K2
120 VAC_1
From J9-1
120 VAC_RET
From J9-7
D23
GREEN
5
RF ON
3
4 120 VAC to RAS
RAS CONTROL
16
15
14
9
8
7
13
12
11
10
6
5
4
3
2
1
J8
TP1
GND
(99)
(98)
T2
(99)
(98)
AC200XT only
6.5K 1W
6.5K 1W
120 / 6000 VAC
J59 - RAS
(Rear Panel)
7
8
9
10
11
12
13
14
3
4
5
6
1
2
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 AC 300 XT and all Ultra-Cut XTs or on the upper section of the second inverter module in an AC 200 XT and 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. Ultra-Cut XT or Auto-Cut 300 XT: connect a jumper wire from TB4-7 (arc volts) to TB4-6 (tip volts). b. Auto-Cut 200 or Pak200i: connect jumper from the negative buss bar by the HF coil to where the pilot wires attach to the gas fitting on the torch bulkhead panel.
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.
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
0-5578 APPENDIX A-67
ULTRA-CUT 130 XT/200 XT/300 XT/400 XT 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:
104
• Preflow gas pressure too high, for manual gas controls check cut charts for proper setting. For DFC 3000 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.
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 3000 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.
A-68 APPENDIX 0-5578
ULTRA-CUT 130 XT/200 XT/300 XT/400 XT o If system is Auto-Cut XT, current control is an analog voltage from the GCM 1000 XT or the AC 200 XT front panel pot. The current control setting will be shown on the front panel 4 digit display. SW8-2 should be off and SW11 set to up position. With pot at max, check for 3.3V on CCM I/O PCB TP9 (TP1 common). While turning the pot toward minimum TP9 voltage should vary linearly to zero V.
GCM 1000 XT
(AC 300 XT)
R1
10K
J56
7
8
5
6
9
10
11
12
3
4
1
2
13
14
15
16
J55
9
10
7
8
5
6
3
4
1
2
11
12
13
14
15
16
(125)
(126)
(127)
AC 200 XT
R1
10K
J26
12
11
10
9
8
7
16
15
14
13
6
5
4
3
2
1
Auto-Cut XT Power Supply
+10.0V
Divide
by 3.
CCM
TP9
1
SW11
2
3
0-3.3VDC
TP1 GND
GND
From Remote analog Current
Control GND
Art # 12309
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:
107
• 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.
Tip saver fault for Pak200i only.
Torches with exposed tips can be damaged if the tip touches the work while cutting. Tip saver reduces the current to a level that the tip can handle for a while. Fault occurs with the Pak200i torch if the tip has contacted the work longer than
15 seconds. The 1Torch with the current reduced by the tip saver circuit is not limited in the time it can touch the work.
108 Tip to Electrode Voltage Fault
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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 DFC 3000 or in the CCM code if using the GCM 2010 or for Auto-Cut XT gas controls (GCM 1000XT or the built in one in the AC 200 XT).
New for the Auto-Cut XT units is a switch on the rear of the power supply that needs to be set according to the plasma gas. If using an oxidizing gas (O2 or Air) set it as indicated for those gasses (left if AC 200 XT or up for AC300XT) or if using a non-oxidizing gas (N2, H35 or other inert gas) set it to the right or down as indicated for those gas types.. This switch adjusts the range of voltage for the gas type to better protect the torch. A wrong setting could result in false setting of the 108 code.
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 (GCM 2010, DPC, GCM 1000 XT) 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 DFC 3000 a faulty component would be expected to set a fault code in either the DPC or DMC. 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 DFC 3000.
• 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 DFC 3000 only. It means the operator hasn’t loaded the cutting process from either the TSC 3000 or 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 DMC is still in the process of downloading a new cutting process. This should only occur with the DFC 3000 if you apply CNC Start before the download process is finished. The optional 1Torch can be started while the automation process is being loaded.
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Group 2 – Plasma Power Supply codes
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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.
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.
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I/O PCB
3 phase AC
CB1
ON / OFF
F1
F2
J60-9,18
J60-5,14
J60-1,10
SYSTEM BIAS PCB
+V
GND
J62
8
9
10
11
12
13
14
5
6
7
1
2
3
4
Missing Phase a
Missing Phase b
J27
8
9
10
11
12
13
14
5
6
7
1
2
3
4
1
U?
2
HCPL-817
4
3
Missing Phase
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 Ultra-Cut or Auto-Cut 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.
202-204 Not 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 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.
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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:
206
• The negative lead goes from the rear of the power supply to the remote arc starter or to the GCM 1000 XT in the case of the AC 3000 XT. o Cable pinched in or exiting the power track o Short inside the Arc Starter such as a wire coming loose and grounding to the chassis. o 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.
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 defective. 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.
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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:
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.
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• 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.
210–211 Output 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:
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
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• 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.
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.
225-230 Inverter 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.
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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.
231-236 Inverter 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: 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
/VAC_IDAb
/VAC_IDBb
230V 400V 480V ERR
0
0
1
0
0
1
1
1
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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.
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, 380-415V 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.
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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 and the TSC 3000 (if used) will reset. Communication with the cutting table may be interrupted. With the DFC 3000 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
• 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 J62-8) 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.
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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.
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.
241-246 Inverter 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.
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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.
247-252 Inverter 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).
• 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.
253-258 Inverter 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.
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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.
259-264 Inverter 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:
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.
265-270 Inverter 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.
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• 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.
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
Also refer to GCM 2010 Status Codes at the end of this Group 3 codes section.
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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 GCM 2010, DMC or DPC not connected or broken.
• Defective control board or power supply in the Gas Control
• Defective CCM
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 DMC 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
303
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.
Gas Pressure fault
Gas pressure faults only show up when you try to start the torch, not during purging or setting flows .
With the Auto-Cut 200 XT and the Auto-Cut 300 XT (GCM 1000 XT), the gas pressure sensor is only on the plasma gas and is in series with Run/Set switch. A 303 code here indicates either plasma gas missing or very low pressure, less than 50 PSI, or RUN/SET switch is in SET position.
Starting with GCM2010 revision AG we measure inlet pressure of both plasma and shield gas at the inlet of the gas selection manifold. If pressure is either too low or too high it sets 303 code. Earlier revision should not display 303 code. GCM2010 will display which gas is the problem and its actual pressure. The pressure at the point where it is measured should be in the range of 100-135 PSI. Exception is for shield gas if the Gas switch is set to Pressure then the min pressure can be 85 PSI.
In the GCM 2010 Gas Control, on the main PCB, measure between test points TP1 (ground) and TP18 (shield) and TP19
(plasma) to measure the output of the pressure sensors. Voltage should be between 2.6V to 3.5V for 100-135 PSI. With shield switch set to pressure low limit is 2.1V. Whichever gas is outside those limits will be the one causing the fault. Remember the pressure may drop during operation, set the code, then recover displaying L303 when you are measuring it.
304
• To test for faulty pressure sensor or inadequate gas supply with too much restriction. On the GCM 2010 place the Mode switch to SET Plasma & Shield, turn the mechanical pressure regulators to max pressure and compare mechanical gauges with the pressure display. If the pressure display doesn’t approximately match the gauge the sensor is likely defective. If the gauge and the pressure display both show low pressure the supply to the gas control has too much restriction. Perhaps the hose is too long or too small.
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”. If it is a GCM 2010 the Mode switch may not be set to the RUN mode.
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Code 304 combined with 204 & 402 when the Plasma Enable on the GCM 2010 gas control is set to disable can indicate a fault in the CCM I/O PCB. When switching back to Enabled the pump will not restart so continues to display 4-2 indicating no coolant flowing.
Normally the code during a disable should be 101. Circuits on the I/O PCB detect the Plasma Enable is disabled and send signal to the microcontroller in the CCM. If a fault in the CCM prevents that signal from getting sent to the microcontroller it doesn’t know the system is disabled so it sets these other 3 codes.
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.
308 Mismatch between the CCM and gas control type.
The Auto-Cut XT CCM is designed to work with the GCM 1000 (AC 300 XT) or the built in gas control of the AC 200 XT.
Attempting to use a GCM 2010 or DFC 3000 Auto Gas Control on an Auto-Cut will result in a 308 code. Similarly attempting to use a CCM from an Auto-Cut XT in an Ultra-Cut XT supply will also result in a 308 code.
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 DFC 3000 Auto Gas Faults.
These different codes displayed on the power simply indicate one of the Auto Gas modules (DPC for codes 310 or 311;
DMC 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.
GCM 2010 Status Codes
GCM 2000 has an LED on the front panel which blinks various codes.
GCM 2010 has LCD display which displays many of the Status messages. However, there are a few relating to communications that aren’t clear.
When there is a communication error it will be displayed but once it has recovered the display will show what the error was by displaying:
^E4 – Low level CAN bus error where the CCM did not acknowledge receiving a message from the Gas Control.
^E5 – Low level CAN bus error where the bus is off.
^E6 – CAN bus communication (the fiber-optic) has timed out.
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 1000 XT, the remote arc starter.
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Exceptions are the Ultra-Cut 400 XT which has an additional external heat exchanger and the Auto-Cut 200 XT which has an internal arc starter.
For the Ultra-Cut 400 XT the HE 400 XT external heat exchanger is placed between the plasma power supply and the
RAS 1000 XT with the supply coolant passing through the radiator for extra cooling.
In the Auto-Cut 200 XT coolant goes to the water cooled HF (high frequency) coil and then to the torch supply lead attached to the internal torch connection bulkhead.
For the coolant return in most systems the return from the Torch goes to the RAS 1000 XT and on to the return fitting on the rear of the power supply. In the Ultra-Cut 400 XT the return from the RAS1000XT first passes through the HE
400 XT then to the rear panel of the power supply. For the Auto-Cut 200 XT the coolant returns from the torch to the torch bulkhead inside the unit.
Coolant returning from the torch is routed through the rear panel filter then through the radiator (internal heat exchanger) and through the flow switch. Ultra-Cut models also have a flow sensor in series with 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.
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. PAK 200i uses a different flow SW set for 0.25 GPM (0.95 65 liter/min.).
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
A-86 APPENDIX 0-5578
ULTRA-CUT 130 XT/200 XT/300 XT/400 XT 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 XT 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.
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. Exception is AC 200 XT where the fans are on whenever power is on. 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:
1. Check for air blowing out of the unit. Remember, except for the AC 200 XT, 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).
0-5578 a. If using the external HE400XT heat exchanger, optional for 300A, 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.
APPENDIX A-87
ULTRA-CUT 130 XT/200 XT/300 XT/400 XT
2. Fans are powered by 230 VAC. The 230 VAC for the fan(s) is switched by the MC2 control relay (except the AC 200
XT where the fan(s) is powered directly from the T1 transformer at J13).
CCM I/O PCB
To test fan relay jump TP2 to TP1.
TP2
TP1
J4-19
Relay PCB
24 VAC
+24
1
K4
D24
5
Fan Bias Control
2
4
3
J8
13
14
15
16
9
10
11
12
7
8
5
6
3
4
1
2
230 VAC from T1
J13
(65A)
MC2A
(64A)
MC2B
(69)
(70)
(69)
(70)
(161)
SA3
MC2
Fan Control
ARC_SUPPRESSOR
(160)
CHASSIS GND
To J70-3
J72
1
2
3
R
C4
BN
R
J73
1
2
3
BK
FAN1
BL
(70)
To J70-2
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 (switch on 2010 or TSC 3000), 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 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.
A-88 APPENDIX 0-5578
ULTRA-CUT 130 XT/200 XT/300 XT/400 XT
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. 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.
0-5578 APPENDIX A-89
ULTRA-CUT 130 XT/200 XT/300 XT/400 XT
CCM I/O PCB
To test Pump relay jump TP3 to TP1.
TP3
TP1
J4-13
Relay PCB
24 VAC
+24
1
K5
D27
5
Coolant Pump Control
2
4
3
J8
13
14
15
16
9
10
11
12
7
8
5
6
3
4
1
2
J13
230 VAC from T1
MC3A
(65B)
(66)
J16
1
2
3
(64B)
MC3B CHASSIS GND
(67)
M1
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. For the Auto-Cut 200 XT connect the gauge in place of the torch coolant supply hose on the torch connection bulkhead. This is a #5 JIC fitting.
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:
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:
A-90 APPENDIX 0-5578
ULTRA-CUT 130 XT/200 XT/300 XT/400 XT
• 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. Ultra-Cut 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.
The 5 Group relates to CANBUS (Fiber optic) communication errors
501 CANBUS Failure to Acknowledge fault.
The CCM communicates with the gas controls (except GCM 1000 XT) over a fiber-optic cable using the CANBUS protocol. The CCM is looking for a signal from the gas control (GCM 2010 or DMC) over the fiber-optic link. No signal has been detected. Communication with the DPC which is relayed through the DMC sets a different code, 301, if there is a problem with it.
Possible causes:
• Gas control is GCM 1000 XT (Auto-Cut 300XT) which has no fiber-optic, with Basic ID problem.
• CANBUS / Fiber-optic problem to either the GCM 2010 or the DMC (part of DFC 3000).
• Control Cable to DMC or GCM 2010 defective.
• Gas control (DMC or GCM 2010) main PCB blown fuse or defective.
• DMC power supply PCB blown fuse or defective.
• CCM defective.
Troubleshooting:
0-5578 APPENDIX A-91
ULTRA-CUT 130 XT/200 XT/300 XT/400 XT
1. GCM 1000XT (also called a Basic Gas Control) does not use CANBUS (fiber-optic) communication. A jumper in the gas control connector J56 pins 8 & 9, gives the signal “Basic ID” telling the CCM not to expect any CANBUS. If somewhere this circuit is open, in the Gas Control cable, connector pins, connection from the rear panel GCM connector, J55, to the CCM (J26) CCM will expect to see a CANBUS connection and report this error because there is no
CANBUS connected.
2. DFC 3000. 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 DMC & DPC if there is no power to the DMC main board, the green power light on the DMC 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 DMC 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 DMC power supply which supplies several voltages could be missing one or more and still have some blue
LEDs lighted. Check for voltages.
3. GCM 2010.
4. 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
Test the fiber:
Note that the fiber goes from black on one end to blue on the other. Shine a bright light into one end and you should be able to see light from the other end. This tells you the light is getting through but doesn’t prove it is strong enough.
The CCM is the communication master. It transmits then expects a reply from the Gas Control Module (GCM). The GCM does not transmit on its own, only in response to a request from the CCM.
The black end of the fiber cable is inserted into the transmitter which is the gray housing on the PCB. The other end of the transmitting fiber is blue and goes into the receiver with the black housing.
A few seconds after power is turned on and when the pump has started up the CCM will try to transmit continuously for a while. You can unplug the fiber from the CCM and should see the transmitter red LED on the CCM PCB blinking. It
A-92 APPENDIX 0-5578
ULTRA-CUT 130 XT/200 XT/300 XT/400 XT may stop after a while so recycle power before deciding it isn’t working. If no light, check one of the other transmitter/ receiver pairs. If none of them blink the problem is in the CCM.
If at least one transmitter blinks plug the fiber back into that one then at the Gas Control end of the fiber (unplugged) you should see the red light coming out of the blue end.
The Gas Control transmitter does not transmit except in response to a request from the CCM so you will not see any light from the GCM transmitter with the cable unplugged. However, if you turn the connector 90 deg and insert the blue end into the receiver (black housing), leaving transmitter open, then the GCM should receive the requests from the CCM and should blink it’s transmitter (gray housing) in response. If not, problem is likely on the GCM board assuming it has power.
It is still possible even though you see the red light coming out the GCM end of the fiber that dirt in the transmitter or receiver or on the fiber ends or the fiber is damaged so the light even though visible is not strong enough for the GCM board. If all else fails replace the fiber cable and both CCM and GCM PCB.
502 CANBUS off due to excessive errors.
See 501 code for troubleshooting CANBUS faults.
503 CANBUS Data Error Warning.
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.
601-611 Various 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, DMC 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.
0-5578 APPENDIX A-93
ULTRA-CUT 130 XT/200 XT/300 XT/400 XT
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.
615-617 No Update File for CCM, DPC or DMC found
Program files for the CCM, DMC & DPC may be updated through the plasma supply’s USB port. The GCM2010 is updated by other means. For a unit with GCM 2010 the CCM may still be updated using the USB. Program update files are in the format Cx_x_0.S (CCM); Mx_x_0.S (DMC) and Px_x_0.S (DPC).
If the Bootloader finds there are 3 devices, CCM, DMC & 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 DMC; 617 for DPC).
Try another flash drive or if you know this one is OK (it works with a computer), then replace the CCM.
Group 7 codes relate to the optional 1Torch module
Simplified power schematic:
For more details and troubleshooting refer to the XT 1Torch Module & Interconnections schematic 042X1366.
A-94 APPENDIX 0-5578
To NEG OUTPUT
BUSS BAR #49
(219A)
10 AWG (219B)
(219C)
W5
L4
L3
L2
L1
ULTRA-CUT 130 XT/200 XT/300 XT/400 XT
ATC
1TORCH MODULE
10 AWG (223A)
T4
(223B)
T3
(223C)
T2
12 AWG (224B)
T1
+
WORK
1TORCH
J86
RELAY PCB
J85
J11
J84
PILOT PCB
Q2
J41
TIP
2
1
FGA30N120FTD
J40
3
4
1
2
5
INVERTER
(220C)
(220D)
From INV 1A +
W4-A
W4-B
(52B-1)
(52B-2)
J87
1
2
TIP
(52A-1)
(52A-2)
WORK
Automation Torch
Operation of the 1Torch and its interlock circuits.
The 1Torch may be operated as soon as the power supply finishes its start up sequence. Downloading an automation process is not required. The 1Torch may be used while an automation process is downloading and purging. The 1Torch may not be operated when the automation torch is in preflow, pilot/cut or post flowing. It must be idle, not performing any cutting related processes before using the 1Torch.
Circuit conditions prior to pressing 1Torch trigger:
1. When the automation torch is operating, preflow, pilot/cut, postflow, K200 (1Torch module) is open preventing the signal from the 1Torch trigger (Start) from passing to the Relay board.
2. When the automation torch is idle K200 is energized, ready for the signal from 1Torch START SW to be applied.
3. Initially both K201 and W5 are not energized. W4, added to XT supply when 1Torch option is installed, is energized, via NC aux contacts on W5. W4 connects automation torch tip to pilot whenever the 1Torch is not enabled.
When the 1Torch trigger is pressed an interlock circuit first determines if the 1Torch consumables are in place and making proper contact as required to start a pilot.
1. -15V (J85-3) is applied to the 1Torch electrode via K201 NC contacts and returns from the tip on J85-1 where measurement is taken by U13A on the Relay Board. The signal “/Pressure OK 1Torch” on pin 6 of the 40 pin ribbon cable (between Relay and I/O boards (J4, J23)) is used for both the interlock and for confirming gas pressure. When this signal is pulled low during the parts continuity test, it indicates it’s OK to energize the 1Torch. There is an LED,
D35, called T-E CONTACT that when on, indicates this test is satisfied. No continuity will set the fault code 702.
2. Once it is confirmed the consumables are in place, K201 and W5 are energized and W5’s normally closed auxiliary contact (W5 AUX) opens de-energizing W4 isolating the automation torch tip from the 1Torch tip. If for some reason
K201 does not energize or if the PS2 pressure switch is shorted closed, it will set fault 703.
3. Now the 1Torch gas solenoid is turned on and gas should flow causing the 1Torch start cartridge to move away from the tip. At the same time the inverter is energized to put out open circuit voltage. If the start cartridge has separated from the tip the XT supply will detect the open circuit voltage between tip and electrode. If there is not
0-5578 APPENDIX A-95
ULTRA-CUT 130 XT/200 XT/300 XT/400 XT enough air pressure, at least 35 PSI, the Pressure fault 704 will be set. If pressure is above 35 PSI and the cartridge does not separate then the Start Cartridge fault 705 is set.
4. Assuming there is enough gas pressure (should be 70-85 PSI) and the start cartridge works properly, gas is then shut off, the parts come together and pilot current flows through them, gas is turned on again and the parts separate drawing an arc between them which is blown out of the tip by the gas flow.
Interlock measurements during XT Automation torch operation:
1. Regardless of whether a 1Torch is plugged into the ATC, -15 V is applied via K201 to the 1Torch electrode circuit
(ATC negative terminal) as previously explained. If W5, which should be open, has any of its 3 negative contacts closed (welded or stuck on) the -15V will be measured by U13B giving the signal “Contactor Fault 1Torch”. If the contactor fault is not detected it’s Ok to energize the automation torch.
2. If a 1Torch is plugged in and it parts are in place making contact, the -15V will also be seen on the tip circuit and if the W5 Pilot (tip) contact is closed (welded or stuck on), U13D will detect the -15V and give the signal “Contactor
Fault 1Torch”. “Contactor Fault 1Torch” sets the 701 fault code. If contactor fault is not detected it’s OK to energize the automation torch. There is a green LED, D40, on the Relay board that is on when the circuit is satisfied, not in fault condition.
Troubleshooting the 1Torch module.
First read the descriptions above. This guide assumes you have a copy of the XT 1Torch module & Interconnections
Schematic 42X1366. The 1Torch Module is mounted in the XT front panel with screws that accept Torx T25 driver or 8 mm socket. If the procedure requires you to remove it, the wires are long enough to allow removing the module far enough from the panel to also remove the cover. You will have to support the module with something while working on it.
Removing and opening the 1Torch module.
Should troubleshooting/repair require accessing the inside of the 1Torch module this is what is required. First remove the right side panels and make sure the connector J86 on the back of module is plugged in. There are 6 screws in the module’s front panel, 4 attach it to the panel and 2 hold the cover, remove them all. Pull the module out of the front panel until you can access its cover screws, 2 on each side and 2 in the rear. The harness and cables remain connected.
The rear of the cover is slotted so you only have to loosen those screws. You will need to support the module while doing this.
No Fault Codes showing. Some problems may not result in fault codes such as:
1. Failure to respond to the 1Torch Trigger. To operate the 1Torch trigger the automation torch must be in idle state, not preflow, post-flowing, etc. When the XT automation torch is idle K200 in the 1Torch module should be energized connecting the torch trigger through to the Relay Board and CCM. On the CCM I/O board find D70, 1Torch Start
LED, just to the left of J28. This should light whenever the 1Torch trigger is pressed. If not, check that the shield cup and consumables are in place. Check that the 1Torch ATC connector is fully seated. a. If D70 is not on, first remove J11 from the Relay Board. Measure for 400-800 ohms (do not use meter’s diode scale) between pins 2 & 3 of the J11 harness connector. If open or shorted then problem is in the 1Torch module. b. If resistance at J11-2&3 is OK reconnect J11 and measure the voltage on J11-2 relative to TB1 on the Relay Board.
It should be 24VDC. Next measure on J11-3. This should be low, less than 2 volts. If it’s not low but instead is
24VDC then K200 is not turned on and the problem may be in the Relay board or the CCM. c. Measure pin 5 on the 40 pin ribbon cable (J23/J4), if it is high, about 15VDC, the CCM may be faulty, not detecting that the automation torch is idle. If pin 5 is low, less than 2VDC, and J11-3 was not low then the Relay board is faulty.
2. W5 Contactor not energized. This will actually show a fault code 102, failure to pilot, after a few seconds because if
W5 isn’t on, power will not be connected to the 1Torch so there will be no pilot.
a. Measure for 24VAC on J11-1 to J11-12. If OK you will have to open the 1Torch module to investigate further. b. If no 24VAC check that the rear panel circuit breaker CB3 is not tripped. Next measure the signal “/Contactor
Enable 1Torch” on pin 20 of the 40 pin ribbon cable (J23/J4). It should be low, less than 2VDC. If it is, the Relay
Board is faulty. If pin 20 is not low the CCM is likely the cause.
3. W4 Contactor does not close when system is in idle or automation mode. This will prevent piloting with XT torch and sets 102 code after 15 seconds of trying to pilot.
A-96 APPENDIX 0-5578
ULTRA-CUT 130 XT/200 XT/300 XT/400 XT
Bypass the W4 to see if that allows XT torch pilot. Remove J41 (2 pin connector from W4 to the Pilot board) from the
Pilot board. Remove connector J41(J87) that has wires 52A-1 & 52A-2, connecting to J87 on the other side of W4 and plug it into J41 on the Pilot board. This returns the unit to the way it was without the 1Torch Option. If it pilots now there was a problem with W4. The XT automation torch may be operated with W4 bypassed.
Troubleshoot W4.
1. W4 coil measures 10-15 ohms at room temperature, typically 12-13 ohms. Remove one wire #210 or 210A from the coil before measuring resistance. If open or shorted replace W4.
2. W4 is powered by 24VAC. On the Relay Board J11 measure between pin 10 (wire 210A on W4 coil) and 12. Should have 24 VAC, if not check that the circuit breaker CB3 on the rear panel is not tripped. a. Remove power and remove J11 from the Relay Board. Measure resistance from the J11 harness connector to the other side of W4 coil (wire 210). It should have continuity, near zero ohms. If not the normally closed W5 auxiliary contact (W5 AUX) may be open. You will have to open the 1Torch module. Refer to the section Removing and opening the 1Torch module near the beginning of this section.
b. Determine if W5 is stuck on keeping its AUX SW open. Find the contactor; it’s big and black. In the middle of the cover is a rectangular hole with a slightly recessed plastic piece in it. This should move down and spring back up freely as you push and release it. If not replace the contactor. The AUX contact is on the side of the contactor toward the rear of the box. Determine if it is properly secured to the contactor. It snaps in place. If it is defective and cannot be fixed you have to replace the complete contactor.
701 Isolation Contactor (W5) Fault.
This fault occurs if one or more of W5 contacts are closed when they should not be. Either because W5 is energized when it shouldn’t be due to a faulty circuit board or the contact(s) is physically stuck.
1. 1Torch tip contacting work piece or earth ground a. If the 1Torch standard standoff tip is touching work or ground at power up the pump will not start, will not prime the cooling system. If while priming, the tip contacts work or ground the pump stops. Both cases show
E701 fault which in this case is not W5 fault but is an artifact of the circuit that checks for the W5 fault. b. After priming is finished the standoff tip contacting work does not stop the pump but does show E701. c. Drag cutting with 1Torch. For best consumable life, drag cutting should use the special Drag Shield Cap or the
Shield Cup Standoff guide which does not allow tip to work contact, does not set the 701 fault and allows cutting at the full 100A.
With the standard standoff tip, if it comes in contact with the work the current is reduced to 40A to prevent damage to the tip. You may drag cut this way at the reduced current but tip life may be reduced. With the standoff tip, because of the 701 fault, you must trigger the 1Torch with the tip above the work to start the preflow. At this Point the tip may be brought into contact with the work for cutting at reduced current.
2. W5 is not energized or stuck.
a. The Relay board LED, D40, should be on when W5 is OK. If it is not on, remove J84 from the Relay board. If D40 still does not come on the Relay board is defective. b. If D40 is on with J84 removed and you still get a 701 fault, measure the 40 pin ribbon cable (CCM J23 to Relay
J4) pin 20, relative TP1 on either the CCM or the Relay board. If pin 20 is low, less than 2VDC, then the CCM is likely at fault. If pin 20 is high with J84 removed the Relay board is bad.
3. W5 is energized. Before disassembling the 1Torch Module to inspect W5, look on the Relay Board to see if the green
LED, D26, just above K3, is on. This would indicate the Relay Board or perhaps the CCM is turning W5 on when it shouldn’t be. You could also measure for 24 VAC coming from the Relay Board at J11-1 and J11-12. a. On the 40 pin ribbon cable (CCM J23 to Relay J4) if pin 20 is low, less than 2V, relative to TP1 on either the CCM or the Relay Board then the CCM is turning on W5. Replace the CCM.
0-5578 APPENDIX A-97
ULTRA-CUT 130 XT/200 XT/300 XT/400 XT b. If pin 20 is high, about 15VDC, but D26 is on, the Relay board is defective.
4. W5 is not energized but is stuck closed. You will have to open the module to inspect and probably replace W5.
Remove all power from unit before disassembling. a. Find the contactor; it’s big and black. In the middle of the cover is rectangular hole with a slightly recessed plastic piece in it. This should move down and spring back up freely as you push and release it. If not replace the contactor. Remove the contactor cover, 2 screws, and inspect the contacts. They should not be burned excessively and should move freely. If not replace the contactor.
702 Contact Start Consumable Fault.
As explained above, a circuit on the Relay Board applies -15VDC to the electrode and expects to see that voltage on the tip insuring the electrode, start cartridge and tip are in place and making electrical contact.
1. Most common cause for this fault is arcing and pitting of the contact surface of the start cartridge and tip. These can be cleaned, or if too bad should be replaced. Do not use sand paper as the sand particles may get into the start cartridge.
2. On the Relay Board, green LED, D35, should be on when parts are making contact.
a. If D35 is on, measure on pin 11 of the 40 pin ribbon cable for a low, less than 2 VDC relative to TP1 of the Relay
Board. If low then CCM or the 40 pin ribbon is faulty. b. If D35 is off remove J85 from the Relay Board and measure for minus 12-15 VDC on pin 3 of J85 PCB header. If not there the Relay Board is defective. If voltage is present plug J85 back in and measure pin 3 again. If the voltage is not there now there is a short in the module or the wires. c. Assuming the voltage is OK at J85-3, measure at J85-1. This should be more negative than -5V. If it is then the
Relay Board is defective.
3. Problem inside the 1Torch Module. Refer to the Removing and opening the 1Torch module near the beginning of this section for directions to open the module. a. Find the W5 contactor. With power applied and the system at idle, measure from W5’s main terminal T2, 3 or 4.
With meter negative lead on TP1 of either the XT Relay Board or the CCM boards. Should measure more than
-5VDC negative, normally -12 to -15VDC. If the voltage isn’t there measure for it on K201-5. If not there then perhaps the wire harness between J85 and J86 is bad or wire from J86 to K201. b. Confirm that K201 is not energized by measuring across its coil, pin 7 to pin 8. Should be zero but if it’s 24 VDC then the Relay Board is defective. c. If voltage was OK at K201-5, measure from TP1 to K201-1. If not there K201’s NC contact is open or the diode
D201 is open. D202 in the wire 223/223D under shrink tubing.
703 Detection circuit fault.
1. When the 1Torch trigger is pressed, circuits check for the consumable parts being in place (explained under 702 code). With the consumables in place and K201not energized, the signal “/Pressure OK 1Torch” on the Relay Board will be low. As soon as K201 is energized, the tip with the -15VDC is no longer connected to J85-1 so D35 goes out. Since the gas solenoid SOL4 has not been turned on yet, the signal “/Pressure OK 1Torch” should go high. This checks that K201 is functioning and the pressure switch PS2 is normally open. If either of these is not correct you get the 703 fault. All this happens very quickly so it is nearly impossible to measure with a meter and will need to use a process of elimination. a. Remove the 3 pin connector J85 from the Relay Board. Press the 1Torch trigger. You should get the 702 fault.
If instead you get 703 the PS2 is shorted closed. This is an unlikely failure. b. If you still get 703 with J85 removed, you will need to determine if the Relay Board is trying to turn on K201 or if the board is defective. Reconnect J85. In response to the fault even if the Relay board turns K201 on it will immediately turn it off again. Your meter should detect a momentary voltage pulse or just flicker if the voltage is being applied properly. i. Measure between TP1 (common) on the Relay board and J11-9. Each time you trigger the torch the meter should flicker. If it does you will need to open the 1Torch Module to investigate problems there. Refer to
A-98 APPENDIX 0-5578
ULTRA-CUT 130 XT/200 XT/300 XT/400 XT the Removing and opening the 1Torch module near the beginning of this section for directions to open the module. If there is no sign of voltage at J11-9 the Relay Board may be faulty but first we need to check that
K201 coil or D202 isn’t shorted. ii. Remove power. Remove J11 from the Relay Board. On the J11 harness connector measure for resistance of
400-800 ohms between pins 8 & 9. Do not use the meters diode scale. If resistance is less than 400 ohms reverse your leads, you may be measuring the diode D202. If you measure a short, much lower than 400 ohms, that may be the cause of not seeing any movement of the meter. iii. A short or an open will require opening the 1Torch Module to determine the cause. Refer to the Removing and opening the 1Torch module near the beginning of this section for directions to open the module. In the case of a short determine if the D202 is bad or if the relay coil is shorted or open. K201 is the relay toward the front of the module; K200 is the one to the rear.
704 Pressure Fault
Normal 1Torch operating pressure is 70-85 PSI. However minimum pressure to satisfy the pressure switch is 35 PSI.
When the 1Torch trigger is pressed and the tests to determine that the consumables are in place (702) and detection circuit is working (703) then the gas solenoid SOL4 is turned on. If the inlet gas pressure is above 35 PSI the pressure
SW PS1 should close. Inlet Pressure below 35 PSI or the gas regulator not set above 35 PSI will result in the 704 fault.
1. Confirm that an air supply capable of 70-85 PSI is connected into the inlet fitting of the 1Torch Module. If an optional filter is used on the air line check that it is not plugged.
2. Trigger the torch momentarily to start the preflow. Adjust the regulator on the 1Torch Module clockwise to increase the pressure to at least 70 PSI (up to 85 PSI for longer leads.)
3. If no pressure shows on the gauge the solenoid may be defective or the Relay Board is not turning it on. a. First see if D2, Torch Gas ON LED on the Relay Board lights when pressing the torch SW. If not there is a problem on the Relay Board or the CCM. If D2 is on skip to step 3c. b. On the 40 ribbon cable between the CCM and the Relay Board (J23-J4) measure pin 4 relative to TP1. It should be low, less than 2VDC, when pressing the 1Torch trigger. If it does not go low the CCM (or the ribbon cable) is faulty. If pin 4 is low or goes low when the torch trigger is pressed but D2 on the Relay Board is not on, then the Relay Board is bad. c. If D2 on the Relay Board is on, with the torch SW pressed, you need to see if the Relay Board is supplying power to the solenoid coil. First set up for measurement of 24 VAC between pins 13 & 14 on J11 of the Relay Board.
Press the 1Torch trigger. If no voltage the Relay Board may be bad. d. If there was 24VAC in the previous measurement disconnect J11 and measure the resistance between pins 13
& 14 of the J11 harness connector. It should be about 21 ohms. This is the solenoid coil resistance. If it’s open or the resistance is significantly less indicating the coil may be shorted you will have to replace the solenoid assembly. The snubber RC, SA201, is NOT part of the solenoid assembly so do not discard it, you will need it on the new solenoid. Refer to the Removing and opening the 1Torch module near the beginning of this section for directions to open the module.
705 Start Cartridge Fault.
As explained in the section Operation of the 1Torch and its interlock circuits, during the preflow time the gas pressure should cause the Start Cartridge to separate from the tip. After a slight delay allowing time for separation, the inverter is enabled to provide open circuit voltage which is measured and must be over 200 volts. If the cartridge does not move, does not separate from the tip or something else is causing a tip to electrode short it will set the 705 code. Also since it uses power from the inverter for this test, if the inverter does not put out OCV the measured voltage will be low and the 705 fault is set.
1. If the DC indicator on the unit front panel flashes momentarily each time you press the 1Torch trigger it’s a good sign the inverter is OK. Also try using the XT automation torch, if that works the inverter is good.
2. The most likely problem is the start cartridge is stuck. Disassemble the consumables and see if the cartridge moves freely. Try a new cartridge and new tip.
This completes the Advanced Troubleshooting information.
0-5578 APPENDIX A-99
ULTRA-CUT 130 XT/200 XT/300 XT/400 XT
This Page Intentionally Blank
A-100 APPENDIX 0-5578
ULTRA-CUT 130 XT/200 XT/300 XT/400 XT
APPENDIX 32: SL100
0-5578 APPENDIX A-101
ULTRA-CUT 130 XT/200 XT/300 XT/400 XT
INTERCONNECTION
D
1 2 3 4
Interconnection to XT Power Supply (Simplified)
A
B
C
I/O PCB
+15 VDC
R?
10K
R?
10K
J4
29
30
31
32
25
26
27
28
21
22
23
24
17
18
19
20
37
38
39
40
33
34
35
36
13
14
15
16
9
10
11
12
7
8
5
6
3
4
1
2
R?
1K
WORK
EARTH
+24 VDC L4 500uH
Relay PCB (simplified)
/ Start 1 Torch
/ Gas Sol ON 1 Torch
/ Main torch Idle 1 Torch
/ Press OK 1 Torch
L4 500uH
R9 100.0
Contactor Fault 1Torch
/ Contactor Enable 1 Torch
C5
0.1uF
50V
L4 500uH
24 VDC (-)
1 Torch Contactor ON
D?
GBU404
24 VAC Ret
24 VDC (+)
5
K3 (Existing)
4
1
3
/ Contactor Enable 1 Torch 2
CONTACTOR CONTROL 1-TOR
5
K8
4
1
3
/ Gas Sol ON 1 Torch 2
Gas SOL Control
24 VAC
1 Torch Gas ON
24 VDC (-)
24 VDC (+)
24 VAC
9
10
11
12
13
14
7
8
5
6
3
4
1
2
J11
3
2
1
J85
D38
D41
D40
GREEN
T-E CONTACT
GREEN
D35
D35 ON = 1 Torch consumables present and in contact. OK to enable 1 Torch
1 TORCH CONTACTOR OK
D40 ON = W5 open,
OK to enable automation.
-15
MICROSMD005F
MRA4007
1
-
+
U13A
LM293
2
3
-4.8 VDC
255K
255K
2
U13B
LM339
+
4
-4.8 VDC
5
14
U13C
+
-
LM339
8
9
-4.8 VDC
13
U13D
LM339
+
10
-4.8 VDC
11
255K
255K
255K
255K
3
4
1
2
5
J84
Harness connector to Relay
PCB
(215)
(216)
(219)
(220)
(201)
(202)
(203)
(204)
(205)
(206)
(207)
(208)
(209)
(210A)
(212)
(213)
(214)
NEG
PILOT
5
E
PILOT PCB
Q2
J41
1
2
TIP
J41
2
1
FGA30N120FTD
J40
3
4
1
2
5
INVERTER
From INV 1A +
W4-A
(220C)
( 2 2 0 D )
W4-B
(52B-1)
(52B-2)
W4 Added to XT Supply for 1 Torch Option
J87
1
2
J41 (J87)
2
1
(52A-1)
( 5 2 A 2 )
Automation Torch
WORK
F
A-102
Art # A-12792_AB
1 2 3
APPENDIX
4 5
0-5578
6 7 8 9
Optional 1 Torch Module
XT 1 TORCH MODULE
Snubber
(210A)
W4
(210)
W4, energized whenever
1 Torch cutting is NOT enabled, is de-energized when 1 Torch is enabled
(W5 energized) to isolate the automation tip from the 1 Torch tip when cutting with 1 Torch.
(219)
(220)
13
14
15
16
9
10
11
12
17
18
19
20
7
8
5
6
3
4
1
2
J86
(201)
(202)
(203)
(204)
(205)
(206)
(207)
(208)
(209)
(210)
(212)
(213)
(214)
(215)
(216)
(201)
(202)
(203)
(204)
(205)
(206)
(207)
(208)
(209)
(210)
(212)
(213)
(214)
(215)
(216)
(219)
(220)
1 Torch Contactor ON (24VAC)
+24VDC
/ Main Torch Idle
/ 1 Torch START
/1 Torch START Ret (Common)
/ 1 Torch Press OK Ret (Common)
/ 1 Torch Press OK
24 VDC (-)
24 VDC (+)
24 VAC Ret
24 VAC Ret
24 VAC
ELECTRODE
TIP
(213)
(206)
PS2
(207)
35 PSI
(214)
ELECTRODE
TIP
(203)
SA200
Snubber
(212)
W5
(201)
(202)
D200
1N4007
1A
Relay under control of
CCM isolates torch Start wires (for noise) when
Automation cutting.
K200
(208)
(205)
(204)
(209)
D201
1N4007
(221)
(222)
24 VDC coil
K201
1A
Energized with W5
Isolates test ckt. when W5 closed
To NEG OUTPUT
BUSS BAR #49
(219C)
(219B)
(219A)
10 AWG
14 AWG (220A)
(220B)
(220)
(219)
(210)
W5 AUX
*
(212A)
1A
D202
1N4007
1000V
W5
L4
L3
L2
L1
T4
T3
T2
T1
10 AWG
12 AWG
(223A)
(223B)
(223C)
(224B)
(225)
7
8
5
6
3
4
1
2
ATC CONNECTOR
7
8
5
6
3
4
1
2
-
+
1TORCH SL100 w/ 100A Consumables
PIP SWITCH
TORCH SWITCH
WORK
10
A
B
C
D
Rev
AA ECO-B2687
Revision By Date
DAT 10/20/2014
Rev Revision
6 7
1 Torch Module Component Locations
D200
D201
D202
K200
K201
SA200
SA201
PS2
SOL4
W4
Diode, 1A, 1kv
Diode, 1A, 1kv
Diode, 1A, 1kv
Relay, DPDT, 24VDC coil (B9)
Relay, DPDT, 24VDC coil (B9)
RC Snubber,
RC Snubber,
(A9)
(B9)
(C9)
(C8)
(B8)
Pressure SW, 35 PSI, N. O (B8)
Solenoid, 24VAC (B8)
Contactor, Pilot Isolation,
40A 2P, 24VAC coil (6B, E3)
W5 Contactor, 1 Torch Isolation,
40A 4P, 24 VAC coil (8D, 8C)
By Date
8
The information contained herein is proprietary to Thermal Dynamics.
Not for release, reproduction or distribution without written consent.
Title SCHEMATIC
XT 1 Torch Module & Interconnections
9
Art # A-12792_AB
Thermal Dynamics Corporation
2800 Airport Rd.
Denton, Texas 76207 USA
Date Printed
12/16/2014
Drawn
D Tatham
Size
C
Drawing Number
Date Revised
11/20/2014
Date
5/29/2014
Sheet
1 of 1
042X1366
10
F
E
E
D
1 2 3 4
Interconnection to XT Power Supply (Simplified)
A
B
C
I/O PCB
+15 VDC
R?
10K
R?
10K
J4
29
30
31
32
25
26
27
28
21
22
23
24
17
18
19
20
37
38
39
40
33
34
35
36
13
14
15
16
9
10
11
12
7
8
5
6
3
4
1
2
R?
1K
WORK
EARTH
+24 VDC L4 500uH
Relay PCB (simplified)
/ Start 1 Torch
/ Gas Sol ON 1 Torch
/ Main torch Idle 1 Torch
/ Press OK 1 Torch
L4 500uH
R9 100.0
Contactor Fault 1Torch
/ Contactor Enable 1 Torch
C5
0.1uF
50V
L4 500uH
24 VDC (-)
1 Torch Contactor ON
D?
GBU404
24 VAC Ret
24 VDC (+)
5
K3 (Existing)
4
1
3
/ Contactor Enable 1 Torch 2
CONTACTOR CONTROL 1-TOR
5
K8
4
1
3
/ Gas Sol ON 1 Torch 2
Gas SOL Control
24 VAC
1 Torch Gas ON
24 VDC (-)
24 VDC (+)
24 VAC
9
10
11
12
13
14
7
8
5
6
3
4
1
2
J11
3
2
1
J85
D38
D41
D40
GREEN
T-E CONTACT
GREEN
D35
D35 ON = 1 Torch consumables present and in contact. OK to enable 1 Torch
1 TORCH CONTACTOR OK
D40 ON = W5 open,
OK to enable automation.
-15
MICROSMD005F
MRA4007
1
-
+
U13A
LM293
2
3
-4.8 VDC
255K
255K
2
U13B
LM339
+
4
-4.8 VDC
5
14
U13C
+
-
LM339
8
9
-4.8 VDC
13
U13D
LM339
+
10
-4.8 VDC
11
255K
255K
255K
255K
3
4
1
2
5
J84
Harness connector to Relay
PCB
(215)
(216)
(219)
(220)
(201)
(202)
(203)
(204)
(205)
(206)
(207)
(208)
(209)
(210A)
(212)
(213)
(214)
NEG
PILOT
5
PILOT PCB
Q2
J41
1
2
TIP
J41
2
1
FGA30N120FTD
J40
3
4
1
2
5
INVERTER
From INV 1A +
W4-A
(220C)
( 2 2 0 D )
W4-B
(52B-1)
(52B-2)
W4 Added to XT Supply for 1 Torch Option
J87
1
2
J41 (J87)
2
1
(52A-1)
( 5 2 A 2 )
Automation Torch
WORK
F
Art # A-12792_AB
1 2 3 4 5
ULTRA-CUT 130 XT/200 XT/300 XT/400 XT
6 7 8 9
Optional 1 Torch Module
XT 1 TORCH MODULE
Snubber
(210A)
W4
(210)
W4, energized whenever
1 Torch cutting is NOT enabled, is de-energized when 1 Torch is enabled
(W5 energized) to isolate the automation tip from the 1 Torch tip when cutting with 1 Torch.
(219)
(220)
13
14
15
16
9
10
11
12
17
18
19
20
7
8
5
6
3
4
1
2
J86
(201)
(202)
(203)
(204)
(205)
(206)
(207)
(208)
(209)
(210)
(212)
(213)
(214)
(215)
(216)
(201)
(202)
(203)
(204)
(205)
(206)
(207)
(208)
(209)
(210)
(212)
(213)
(214)
(215)
(216)
(219)
(220)
1 Torch Contactor ON (24VAC)
+24VDC
/ Main Torch Idle
/ 1 Torch START
/1 Torch START Ret (Common)
/ 1 Torch Press OK Ret (Common)
/ 1 Torch Press OK
24 VDC (-)
24 VDC (+)
24 VAC Ret
24 VAC Ret
24 VAC
ELECTRODE
TIP
(213)
(206)
PS2
(207)
35 PSI
(214)
ELECTRODE
TIP
(203)
SA200
Snubber
(212)
W5
(201)
(202)
D200
1N4007
1A
Relay under control of
CCM isolates torch Start wires (for noise) when
Automation cutting.
K200
(208)
(205)
(204)
(209)
D201
1N4007
(221)
(222)
24 VDC coil
K201
1A
Energized with W5
Isolates test ckt. when W5 closed
To NEG OUTPUT
BUSS BAR #49
(219C)
(219B)
(219A)
10 AWG
14 AWG (220A)
(220B)
(220)
(219)
(210)
W5 AUX
*
(212A)
1A
D202
1N4007
1000V
W5
L4
L3
L2
L1
T4
T3
T2
T1
10 AWG
12 AWG
(223A)
(223B)
(223C)
(224B)
(225)
7
8
5
6
3
4
1
2
ATC CONNECTOR
7
8
5
6
3
4
1
2
-
+
1TORCH SL100 w/ 100A Consumables
PIP SWITCH
TORCH SWITCH
WORK
10
A
B
C
D
0-5578
Rev
AA ECO-B2687
Revision By Date
DAT 10/20/2014
Rev
6 7
Revision
1 Torch Module Component Locations
D200
D201
D202
K200
K201
SA200
SA201
PS2
SOL4
W4
Diode, 1A, 1kv
Diode, 1A, 1kv
Diode, 1A, 1kv
Relay, DPDT, 24VDC coil (B9)
Relay, DPDT, 24VDC coil (B9)
RC Snubber,
RC Snubber,
(A9)
(B9)
(C9)
(C8)
(B8)
Pressure SW, 35 PSI, N. O (B8)
Solenoid, 24VAC (B8)
Contactor, Pilot Isolation,
40A 2P, 24VAC coil (6B, E3)
W5 Contactor, 1 Torch Isolation,
40A 4P, 24 VAC coil (8D, 8C)
E
By Date
8
The information contained herein is proprietary to Thermal Dynamics.
Not for release, reproduction or distribution without written consent.
Title SCHEMATIC
XT 1 Torch Module & Interconnections
9
Art # A-12792_AB
Thermal Dynamics Corporation
2800 Airport Rd.
Denton, Texas 76207 USA
Date Printed
12/16/2014
Drawn
D Tatham
Size
C
Drawing Number
Date Revised
11/20/2014
Date
5/29/2014
Sheet
1 of 1
042X1366
10
F
APPENDIX A-103
ULTRA-CUT 130 XT/200 XT/300 XT/400 XT
APPENDIX 33: HE 400 XT CONNECTION
1 2 3 4 5
A
6
A
C
B
J71
5
6
7
3
4
1
2
GND
(6)
(3)
TS1
130F
(2)
(6A)
GND
J72
1
2
3
FAN ASSEMBLY
R
C4
BN
G/Y
BK
FAN1
R BL
B
C
D
Rev
AA ECO-B2687
Revision
1 2
By
DAT
Date
8/20/2014
Art # A-12793_AB
The information contained herein is proprietary to Thermal Dynamics.
Not for release, reproduction or distribution without written consent.
Title SCHEMATIC
HE400XT
3 4 5
Thermal Dynamics Corporation
2800 Airport Rd.
Denton, Texas 76207 USA
Date Printed
12/16/2014
Drawn
DAT
Date Revised
11/25/2014
Date
8/20/2014
Size
A
Drawing Number
Sheet
042X1667
1 of 1
6
D
A-104 APPENDIX 0-5578
ULTRA-CUT 130 XT/200 XT/300 XT/400 XT
APPENDIX 34: SL100 Torch Option
Preparations for Operation
NOTE!
Automated and manual plasma cutting cannot be performed at the same time. The 1Torch trigger is ignored when automation cutting is in process, and XT start signal is ignored during hand cutting.
Operators must wait until postflow is complete before cutting with the alternate torch
At the start of each operating session:
WARNING
Disconnect primary power at the source before assembling or disassembling power supply, torch parts, or torch and leads assemblies.
NOTE!
The 1Torch connection for the hand held torch is not available as an add on. This is a factory installed only item.
Torch Connections
If necessary, connect the torch to the Power Supply. Connect only the Thermal Dynamics model SL100 Manual Torch to this power supply. Maximum torch leads length is 100 feet / 30.5 m, including extensions.
1. Align the ATC male connector (on the torch lead) with the female receptacle. Push the male connector into the female receptacle. The connectors should push together with a small amount of pressure.
2. Secure the connection by turning the locking nut clockwise until it clicks. DO NOT use the locking nut to pull the connection together. Do not use tools to secure the connection.
2
0-5578
Art # A-12761
Connecting the Torch to the Power Supply
APPENDIX A-105
ULTRA-CUT 130 XT/200 XT/300 XT/400 XT
Torch Parts Selection
The output of the power supply is fixed at 100 Amps. Torch is assembled with 100 Amp parts from the factory.
Refer to the SL100 torch manual for details.
Drag cutting with 1Torch.
For best consumable life, drag cutting should use the special Drag Shield Cap or the Shield Cup Standoff guide which does not allow tip to work contact, and allows cutting with the full 100A
With the standard standoff 100A tip, if it comes in contact with the work the current is reduced to 40A to prevent damage to the tip. You may drag cut this way at the reduced current but tip life may be somewhat reduced.
With the standoff tip you must trigger the 1Torch with the tip above the work to start the preflow or you will get a 701 fault. Once in preflow the tip may be brought into contact with the work for cutting at reduced current.
Parts - In - Place (PIP)
The torch includes a ‘Parts - In - Place’ (PIP) circuit. When the shield cup is properly installed, it closes a switch. The torch will not operate if this switch is open.
Torch Switch
To ATC PIP Switch Shield Cup
Parts - In - Place Circuit Diagram for Hand Torch
Preflow
After the torch trigger is pulled, the air will flow for 2 seconds. This allows possible contamination to be eliminated from the torch before the arc is established.
Postflow
After the torch trigger is released the arc will stop and the air will flow for 20 seconds. This allows the operator to safely switch modes at the XT power supply which will not allow the automated cutting to occur.
Pilot Arc
When the torch leaves the workpiece the pilot arc restarts instantly, and the cutting arc restarts instantly when the pilot arc contacts the workpiece.
Foldback Feature
The unit will automatically drop the cutting current down to 45 amps if the exposed tip touches the plate while cutting.
This will dramatically improve tip parts life.
A-106 APPENDIX 0-5578
Connecting Air Supply to Unit
ULTRA-CUT 130 XT/200 XT/300 XT/400 XT
The SL100 torch option needs a separate air supply from that of the XT power supply. The connection is the same for compressed air or high pressure cylinders. Refer to the following two subsections if an optional air line filter is to be installed.
1. Connect the air line to the inlet port. The illustration shows typical fittings as an example.
NOTE!
For a secure seal, apply thread sealant to the fitting threads, according to manufacturer’s instructions. Do not use Teflon tape as a thread sealer, as small particles of the tape may break off and block the small air passages in the torch.
Inlet Port
1/4 NPT or ISO-R to 1/4” (6mm) Fitting
Hose Clamp
Gas Supply
Hose
Art # A-12759
Air Connection to Inlet Port
Check Air Quality
Air must be free of oil and moisture. To test the quality of air:
1. Pull trigger momentarily to initiate gas/air flow.
2. Place a welding filter lens in front of the torch and turn ON the air. Do not start an arc!
Any oil or moisture in the air will be visible on the lens.
Air Pressure Control
The Pressure + Control is used to set the air pressure. Pull the torch trigger momentarily to start gas flow. To adjust the pressure pull the knob out and push in to lock.
1. Ensure source meets requirements.
Inlet Pressure: 90 psi min. - 120 psi max. (6.2 bar min - 8.3 bar max).
Inlet Flow: 6.7 CFM (189 lpm).
0-5578 APPENDIX A-107
ULTRA-CUT 130 XT/200 XT/300 XT/400 XT
2. Check connections and turn air supply ON.
3. For cutting, adjust output air pressure from 70 - 85 psi / 4.8 - 5.9 bar. Refer to the chart for pressure setting details.
Gas Pressure Settings
Leads
Length
Up to 25'
(7.6 m)
SL100
(Hand Torch)
70 psi
4.8 bar
Each additional
25' (7.6 m)
Add 5 psi
0.4 bar
Installing Optional Single - Stage Air Filter
An optional filter kit is recommended for improved filtering with compressed air, to keep moisture and debris out of the torch.
1. Attach the Single - Stage Filter Hose to the Inlet Port.
2. Attach the Filter Assembly to the filter hose.
3. Connect the air line to the Filter. The illustration shows typical fittings as an example.
NOTE!
For a secure seal, apply thread sealant to the fitting threads, according to the maker’s instructions. Do Not use
Teflon tape as a thread sealer, as small particles of the tape may break off and block the small air passages in the torch. Connect as follows:
A-108
Inlet Port
Regulator/Filter
Assembly
Art # A-12760
Hose Clamp
Gas Supply
Hose
1/4 NPT to 1/4"
(6mm) Fitting
Single Stage Air Filter Attachment
APPENDIX 0-5578
Replacement parts
ULTRA-CUT 130 XT/200 XT/300 XT/400 XT
2
3
4
1 5
6
Art # A-12762
Description BOM ID Qty Name
9-7379
9-6319
9-1044
1
2
3
1
1
Contactor
Solenoid Assy
1 Pressure Switch
Description BOM ID Qty Name
8-6800
9-9509
9-7380
4
5
6
1
1
2
Pressure Gauge
Regulator
Relay
0-5578 APPENDIX A-109
ULTRA-CUT 130 XT/200 XT/300 XT/400 XT
Qty Description
1
1
1
2
Single - Stage Filter Kit (includes Filter & Hose)
Replacement Filter Body
Replacement Filter Hose (not shown)
Replacement Filter Element
Housing
7-7507
9-7740
9-7742
9-7741
Filter
Element
(Cat. No. 9-7741)
Spring
O-ring
(Cat. No. 9-7743)
Cover
Barbed
Fitting
Assembled Filter
Art # A-02476
Optional Single-Stage Filter Element Replacement
These instructions apply to power supplies where the optional Single-Stage Filter has been installed.
When the Filter Element becomes completely saturated it will not be able to supply the required pressure to the SL100 module/torch. The Filter Element can be removed from its housing, dried, and reused. Allow 24 hours for Element to dry.
Refer to Section 6, Parts List, for replacement filter element catalog number.
1. Remove power from power supply.
2. Shut OFF air supply and bleed down system before disassembling Filter to change Filter Element.
3. Disconnect gas supply hose.
4. Turn the Filter Housing Cover counter-clockwise and remove it. The Filter Element is located inside the Housing.
5. Remove the Filter Element from the Housing and set Element aside to dry.
6. Wipe inside of housing clean, then insert the replacement Filter Element open side first.
7. Replace Housing on Cover.
8. Reattach gas supply.
NOTE!
If unit leaks between housing and cover, inspect the O-Ring for cuts or other damage.
A-110 APPENDIX 0-5578
STATEMENT OF WARRANTY
LIMITED WARRANTY: Thermal Dynamics
® Corporation (hereinafter “Thermal”) warrants that its products will be free of defects in workmanship or material. Should any failure to conform to this warranty appear within the time period applicable to the Thermal products as stated below, Thermal shall, upon notification thereof and substantiation that the product has been stored, installed, operated, and maintained in accordance with Thermal’s specifications, instructions, recommendations and recognized standard industry practice, and not subject to misuse, repair, neglect, alteration, or accident, correct such defects by suitable repair or replacement, at Thermal’s sole option, of any components or parts of the product determined by Thermal to be defective.
THIS WARRANTY IS EXCLUSIVE AND IS IN LIEU OF ANY WARRANTY OF MERCHANTABILITY OR FITNESS FOR A
PARTICULAR PURPOSE.
LIMITATION OF LIABILITY: Thermal shall not under any circumstances be liable for special or consequential damages, such as, but not limited to, damage or loss of purchased or replacement goods, or claims of customers of distributor (hereinafter “Purchaser”) for service interruption. The remedies of the Purchaser set forth herein are exclusive and the liability of Thermal with respect to any contract, or anything done in connection therewith such as the performance or breach thereof, or from the manufacture, sale, delivery, resale, or use of any goods covered by or furnished by Thermal whether arising out of contract, negligence, strict tort, or under any warranty, or otherwise, shall not, except as expressly provided herein, exceed the price of the goods upon which such liability is based.
THIS WARRANTY BECOMES INVALID IF REPLACEMENT PARTS OR ACCESSORIES ARE USED WHICH MAY IMPAIR THE
SAFETY OR PERFORMANCE OF ANY THERMAL PRODUCT.
THIS WARRANTY IS INVALID IF THE PRODUCT IS SOLD BY NON-AUTHORIZED PERSONS.
The limited warranty periods for this product shall be: A maximum of three (3) years from date of sale to an authorized distributor and a maximum of two (2) years from date of sale by such distributor to the Purchaser, and with further limitations on such two (2) year period (see chart below).
Parts Labor
Auto-Cut XT™ and Ultra-Cut XT™ Power Supplies and Components 2 Years 1 Year
Torch And Leads
XT
TM
300 / XT
TM -301 Torch (Excluding Consumable Parts) 1 Year 1 Year
Repair/Replacement Parts 90 Days 90 Days
Warranty repairs or replacement claims under this limited warranty must be submitted by an authorized Thermal Dynamics® repair facility within thirty (30) days of the repair. No transportation costs of any kind will be paid under this warranty. Transportation charges to send products to an authorized warranty repair facility shall be the responsibility of the customer. All returned goods shall be at the customer’s risk and expense. This warranty supersedes all previous Thermal warranties.
Effective October 23, 2012
Thermal Dynamics / thermal-dynamics.com
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