Thermal Dynamics 200 ULTRA-CUT Operating Manual
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Thermal Dynamics 200 ULTRA-CUT Operating Manual

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200
™
ULTRA-CUT
PLASMA CUTTING SYSTEM
Art # A-04816
Operating Manual
Rev. AD
Date: February 5, 2008
Manual # 0-5056
Operating Features:

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  • Page 1 ™ ULTRA-CUT PLASMA CUTTING SYSTEM Art # A-04816 Operating Manual Rev. AD Date: February 5, 2008 Manual # 0-5056 Operating Features:...
  • Page 2 YOU ARE IN GOOD COMPANY! The Brand of Choice for Contractors and Fabricators Worldwide. Thermal Dynamics is a Global Brand of manual and automation Plasma Cutting Products for Thermadyne Industries Inc. We distinguish ourselves from our competition through market- leading, dependable products that have stood the test of time.
  • Page 3 WARNINGS Read and understand this entire Manual and your employer’s safety practices before installing, operating, or servicing the equipment. While the information contained in this Manual represents the Manufacturer's best judge- ment, the Manufacturer assumes no liability for its use. Plasma Cutting Power Supply, Ultra-Cut ®...
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  • Page 5: Table Of Contents

    TABLE OF CONTENTS SECTION 1: GENERAL INFORMATION ....................1-1 1.01 Notes, Cautions and Warnings ..............1-1 1.02 Important Safety Precautions ............... 1-1 1.03 Publications ....................1-3 1.04 Declaration of Conformity ................1-5 1.05 Statement of Warranty .................. 1-6 SECTION 2: SPECIFICATIONS ....................2-1 2.01 General Description Of The System ..............
  • Page 6 TABLE OF CONTENTS (continued) SECTION 4: OPERATION ......................4-1 4.01 Power Supply Control Panel ................4-1 4.02 Start-Up Sequence ..................4-2 4.03 Gas Control Module Operation ..............4-3 4.04 Sequence Of Operation ................4-7 4.05 Gas Selection ....................4-9 4.06 Power Supply Status Codes ................ 4-10 4.07 Remote Arc Starter: Service Chart .............
  • Page 7 TABLE OF CONTENTS (continued) APPENDIX 1: Remote Arc Starter Schematic ................A-1 APPENDIX 2: Gas Control and Torch Valve Schematic ............. A-2 APPENDIX 3: Gas Control Module .................... A-4 APPENDIX 4: Gas Control Module PCB Layout ............... A-5 APPENDIX 5: Gas Control Display Interface PCB Layout ............A-6 APPENDIX 6: CCM CPU PCB Layout ..................

  • Page 9: General Information

    SECTION 1: GENERAL INFORMATION 1.01 Notes, Cautions and Warnings Throughout this manual, notes, cautions, and warnings are used to highlight important information. These highlights are categorized as follows: NOTE An operation, procedure, or background information which requires additional emphasis or is helpful in efficient operation of the system.
  • Page 10 • Always read the Material Safety Data Sheets (MSDS) that should be supplied with the material you are using. These MSDSs will give you the information regarding the kind and amount of fumes and gases that may be dangerous to your health. •...

  • Page 11: Publications

    NOISE Noise can cause permanent hearing loss. Plasma arc processes can cause noise levels to exceed safe limits. You must protect your ears from loud noise to prevent permanent loss of hearing. • To protect your hearing from loud noise, wear protective ear plugs and/or ear muffs. Protect others in the work- place.
  • Page 12 8. NFPA Standard 51, OXYGEN-FUEL GAS SYSTEMS FOR WELDING, CUTTING AND ALLIED PROCESSES, ob- tainable from the National Fire Protection Association, Batterymarch Park, Quincy, MA 02269 9. NFPA Standard 70, NATIONAL ELECTRICAL CODE, obtainable from the National Fire Protection Association, Batterymarch Park, Quincy, MA 02269 10.

  • Page 13: Declaration Of Conformity

    Rigorous testing is incorporated into the manufacturing process to ensure the manufactured product meets or exceeds all design specifications. Thermal Dynamics has been manufacturing products for more than 30 years, and will continue to achieve excellence in our area of manufacture.

  • Page 14: Statement Of Warranty

    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.

  • Page 15: Section 2: Specifications

    SECTION 2: SPECIFICATIONS 2.01 General Description Of The System A typical Ultra-Cut ® 200 system configuration includes: • One Power Supply • Remote Arc Starter • Gas Control Module • Torch Valve Assembly • Precision Plasma Cutting Torch • Set Of Connecting Leads •...

  • Page 16: Specifications & Electrical Requirements

    2.06 Specifications & Electrical Requirements Ultra-Cut® 200 Power Supply Specifications Maximum OCV (U 380 vdc Maximum Output Current 200 Amps Maximum Output Voltage 230 vdc 100% @ 200A, 180vdc (32 kW), Duty Cycle Rating @ 104F° (40°C) Ambient Temperature Operating range 14°F to 122°F (-10°C to + 50°C) Power Factor 0.70 @ 100 ADC Output...

  • Page 17: Power Supply Dimensions

    2.08 Power Supply Dimensions 27 inch 680 mm 41.25 inch 1050 mm 27.5 inch 33 inch 700 mm 840 mm Art # A-07182 37.75 inch 960 mm 433 lb / 196 kg Manual No. 0-5056 SPECIFICATIONS...

  • Page 18: Power Supply Rear Panel Features

    2.09 Power Supply Rear Panel Features Torch (Neg) Terminal AC Power Lamp Pilot (Pos) Terminal Input Power Circuit Breaker Terminals Panel Ground Terminals Gas Control Console Connector Terminal Cover CNC Connector Work Cable Terminal Remote Arc Starter Connector Terminal Cover Support Panel RETURN SUPPLY...

  • Page 19: Gas Requirements

    2.10 Gas Requirements The customer will provide all gases and pressure regulators. Gases must be of high quality. Pressure regulators shall be double stage. Ultra-Cut 200 Power Supply: Gas Pressures, Flows, and Quality Requirements Quality Minimum Pressure Flow 99.5% Purity 120 psi O2 (Oxygen) 75 scfh (2123 l/h)
  • Page 20 2.12 XT -300 Torch Specifications A. Torch Dimensions Art # A-08301 End Cap 19.00" 2.25" 482.68 mm 57.15 mm Mounting Tube 2.0" 15.50" 50.8 mm 393.78 mm 6.30" 160.10 mm 2.39" 60.81 mm 3.98" 101.1 mm 2.63" 66.8 mm 1.57" 39.96 mm 1.49"...
  • Page 21 B. Torch Leads Lengths Gas Lead Assemblies Length Feet Meters 3.05 10.6 15.2 22.8 30.4 38.2 45.7 53.3 C. Torch Parts (Generic Parts Shown) Art # A-04741 Plasma Gas Shield Gas Distributor Distributor Shield Cap 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.

  • Page 22: Xttm-300 Torch Specifications

    125 psi ± 10 psi Operating Pressure 8.6 bar ± 0.7 bar Maximum Input Pressure 135 psi / 9.3 bar Gas flow 10 - 300 scfh G. Plasma Power Supply Used With: • Thermal Dynamics UltraCut ® Manual No. 0-5056 SPECIFICATIONS...

  • Page 23: Section 3: Installation

    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...

  • Page 24: System Layout

    3.02 System Layout Refer to section 3.05 for ground connections and ground cables. 175’ / 53.3 m Maximum Length 125’ / 38.1 m Maximum Length 100’ / 30.5 m Maximum Length Pilot Return Pilot Return Shield Negative Remote Coolant Supply Coolant Supply Coolant Return Coolant Return...

  • Page 25: Cables & Leads Identification

    3.03 Cables & Leads Identification #8 AWG Cable Pilot Return, Power Supply to Arc Starter #1 AWG Cable Negative Lead, Power Supply to Arc Starter Coolant Supply Lead, Green Green Power Supply to Arc Starter Coolant Return Lead, Power Supply to Arc Starter Control Cable, Power Supply to Arc Starter Ground Cable...

  • Page 26: Lift The Power Supply

    3.04 Lift the Power Supply WARNINGS Do not touch live electrical parts. Disconnect input power conductors from de-energized supply line before moving unit. FALLING EQUIPMENT can cause serious personal injury and equipment damage. Use all four lifting eyes when using lifting straps to lift the power supply. Use a forklift, crane, or hoist to lift the unit off the shipping pallet as shown.

  • Page 27: Remove The Connections Cover

    3.05 Remove the Connections Cover The primary power cable must be supplied by the end user and connected to the power supply. Remove the connections cover on the rear of the Power Supply. Use caution when removing the panel; there is a ground wire connected to the inside of the panel.
  • Page 28 Check / Adjust Input Voltage Configuration 1. The power supply includes a voltage configuration board which must be positioned to match the primary input voltage. Remove the power supply left side panel and locate the voltage configuration board. The input voltage configuration is shown at the top of the board.
  • Page 29 Connect Input Power and System Ground Cables 1. Carefully cut back the outer sheath on the primary input power cable to expose the individual cords. Cut back the insulation on the individual cords. Route the cable upward through leads bracket at the bottom of the rear panel, then through the connections cover support panel on the rear panel of the power supply.
  • Page 30 Ultra-Cut Star Ground on Cutting Table Auto-Cut O2 Remote Arc Power Supply Starter (RAS-1000) Gas Control Module Note: The gas control module can Primary location Torch Device be mounted on top of the power Cutting Machine / Gantry supply. #4 AWG If it is, it should be grounded Ground Cutting Table...
  • Page 31 Auto-Cut Basic System Without RAS Cutting Machine / Gantry Torch Auto-Cut GCM-1000 Device Power Supply Gas Control Module Cutting Table #4 AWG Ground (F) (Factory Installed) Ground Cable 1/0 Work Cable Customer Supplied Earth Ground 1/0 Ground Cable (F1) ‘Star’ Art # A-08254_AC 0 - 10 ft (0 - 3 m) Ideal Ground...

  • Page 32: Ground Connections

    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 ) wire or flat copper braid with cross section equal to or greater than 10 AWG connected to the cutting table frame.
  • Page 33 Creating An Earth Ground 1. To create a solid, low resistance, earth ground, drive a 1/2 in (12 mm) or greater diameter copper clad ground rod at least 6 - 8 ft (1.8 - 2.4 m) into the earth so that the rod contacts moist soil over most of its length. Depending on location, a greater depth may be required to obtain a low resistance ground (see NOTE).

  • Page 34: Connect Work Cable And Pilot And Negative Leads

    3.07 Connect Work Cable and Pilot and Negative Leads 1. Pass the ends of the work cable and pilot and negative leads upward through the leads bracket at the bottom edge of the rear panel, then through the openings in the connections cover support panel. 2.

  • Page 35: Connect Coolant Leads

    3.08 Connect Coolant Leads 1. Connect the color-coded coolant hoses to the coolant connections on the power supply rear panel. The supply line (out) is flagged green, the return line (in) is flagged red. COOLANT RETURN SUPPLY RETURN SUPPLY Coolant Connections GREEN To Remote Arc Starter Art # A-04800...

  • Page 36: Connect Control Cables For Cnc, Remote Arc Starter, And Gcm

    3.09 Connect Control Cables for CNC, Remote Arc Starter, and GCM 1. Connect one end of each cable to the power supply. 2. Connect the other end of the CNC cable to the CNC device. 3. The CNC cable shield must be attached to ground. Customer Wiring Access Hole To Gas Control Module...

  • Page 37: Connect Fiber Optic Cable (Type 2 Internal Control Module)

    3.10 Connect Fiber Optic Cable (Type 2 internal control module) CAUTION Check the type of internal control module. Use this section for connections to an internal control module without an external connections cover. Use the preceding section for connections to an internal module with an external connections cover.

  • Page 38: Set Switches On The Command - Control Module (Type 2 Module)

    3.11 Set Switches on the Command - Control Module (Type 2 Module) Compare the command - control module to the illustration. Follow instructions in this section for a module without an external connection cover. Remove the power supply right side. Set switches on the CCM (Command-Control Module) per the illustrations. Switch settings and connection details are provided in the Appendix.
  • Page 39 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 No external connection cover SW12 SW13 SW-6: OK-to-Move: Contact closure, 120VAC @ 1A (Factory default setting) or DC Volts (16-18vdc@ up to 100 ma.) SW-11: Analog Current Control.

  • Page 40: Height Control Connections

    3.12 Height Control Connections The terminal strip has Arc Volts (-) connection to power supply negative output TORCH terminal, Arc Volts (+) connection to power supply positive output WORK terminal. These are for a height control that requires connection to the full non-divided arc voltage. Also available on the terminal strip are 120VAC (120,0) and 24 VAC (24, 0).

  • Page 41: Gas Control Module Installation

    3.13 Gas Control Module Installation The Gas Control Module must be installed in a suitable location where it is easily accessible to the system operator. The unit must be mounted to a flat horizontal surface. If the Module is mounted to a gantry or to any other support subject to vibration or motion, the installer must fasten the module to the support securely.
  • Page 42 NOTE The unit must be mounted so that the Flowmeters are plumb. If the Flowmeters are not plumb, incorrect flow indications may occur. Preparation 1. Remove the screws securing the Cover Panel to the Module. 2. Carefully remove the cover from the module noting the attached ground wire. Remove the ground wire if needed.

  • Page 43: Fiber Optic Cable Installation

    3.14 Fiber Optic Cable Installation 1. Install the through-hole protector for the fiber-optic cable in the hole in connection panel on the back of the Module. 2. Pass the fiber-optic cable connector through the hole in connection panel on the back of the Module. Pass enough of the cable into the Module to allow the cable to loop upward as shown.
  • Page 44 3. Insert the fiber-optic cable connector into the receptacle on the vertically-mounted circuit board as shown. Circuit Board Fiber Optic Cable Art # A-04773 4. Tighten the through-hole protector for the fiber-optic cable. 5. Reinstall the Cover Panel making sure the ground wire is attached. Manual No.

  • Page 45: Gas Control Module: Control, Input, And Output Connections

    3.15 Gas Control Module: Control, Input, and Output Connections 1. Make all other connections to the rear of the Module. The connections are labeled. The Module must be grounded; the grounding terminal is marked Use #10 AWG (European 6 mm ) (or thicker) wire for grounding.

  • Page 46: Install Remote Arc Starter

    3.16 Install Remote Arc Starter Site Location Select a clean, dry location with good ventilation and adequate working space around all components. Review the safety precautions in the front of this manual to be sure that the location meets all safety requirements. Interconnecting cables and hoses attach to the Arc Starter.
  • Page 47 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.
  • Page 48 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-04749 Input Connections 1. Refer to the illustrations. Make the following input connections to the Arc Starter. •...
  • Page 49 Coolant Return Green (Red) Coolant Supply (Green) Art # A-04751 Coolant Return (Red) Art # A-04752 Negative Cable from power supply Negative Cable (from Power Supply rear panel) Manual No. 0-5056 3-27 INSTALLATION...
  • Page 50 Art # A-04753 Pilot Return Cable from Power supply PILOT Return Cable (from Power Supply rear panel) Art # A-04755 Control Cable from Power Supply rear panel Manual No. 0-5056 3-28 INSTALLATION...
  • Page 51 Output Connections 1. Refer to the illustrations. Make the following output connections to the Arc Starter. Inner Shield Lead Pilot Lead Inner Shield Connection Detail Art # A-04933 Pilot Lead Connection Detail Pilot Return Cable and Inner Shield Lead (from Torch Leads) Manual No.
  • Page 52 Art # A-04757 Some items are removed for clarity. Coolant Return Fitting (Tagged with Red) Coolant Supply Fitting (Tagged with Green) Coolant Supply (Green) to Torch Coolant Return (Red) from Torch Coolant Supply and Return Hoses (from Torch) Reinstall the Arc Starter Cover. Ensure that the ground wire is not crimped between the cover and the base. Upper screws (4 per side) Cover Ground Wire...
  • Page 53 Art # A-04758 Torch Leads 1 Nut and 1 Washer Remain in Place Ground Cable • Use a clamp to secure the Torch Lead Shield braid to the port on the Remote Arc Starter as shown. Art # A-04759 Torch Leads Shield Shield Clamp Coolant and Pilot Leads to Torch Valve Assembly...
  • Page 54 Connect Control Cable 1. Connect the Remote Arc Starter cable to the Remote Arc Starter receptacle. Power Supply Rear Panel RETURN SUPPLY COOLANT RETURN SUPPLY Remote Arc Starter Remote Arc Starter - Input Connection Panel Art # A-04801 Manual No. 0-5056 3-32 INSTALLATION...

  • Page 55: Original & Xtl Torch Valve Installation

    3.17 Original & XTL Torch Valve Installation General Information This assembly mounts as close as possible to the torch head. It accepts preflow, plasma, and shield gases from the Gas Control Module and supplies these gases to the Torch. Mounting 113.03 mm 4.450”...
  • Page 56 3. Connect the gas supply lines and the control cable connector from the Gas Control Module to the Valve Kit as shown. Hold the check valves stationary while attaching the gas lines. (XTL shown) Exhaust Muffler Control Cable Water Inlet Shield Gas Inlet Preflow Gas Inlet Plasma Gas Inlet...

  • Page 57: Connecting Torch

    3.18 Connecting Torch Connect the Torch as follows: Coolant Supply, Coolant Return, and Pilot Leads Leads Cover Torch Leads End Cap Shield Gas (Right Hand Thread) Groove for O-Ring Pilot Lead O-Ring Mounting Tube To Torch Valve Plasma Gas (Left Hand Thread) Coolant Supply &...
  • Page 58 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.

  • Page 59: Install Consumable Torch Parts

    3.19 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.
  • Page 60 Torch Head Torch Head O-Ring 0.063 - 0.083" (1.6 - 2.1 mm) Protrusion Art # A-08300_AB Installing Assembled Cartridge Onto Torch Head 6. Slide the ohmic clip over the shield cup if using ohmic torch height sensing. Manual No. 0-5056 3-38 INSTALLATION...
  • Page 61 55 - 100 Amp Parts Assembly 1: Stack Parts 2: Press Cartridge onto Stacked Parts Electrode Plasma Gas Distributor O-Ring on Tip No Gaps Between Parts Shield Gas Cartridge Covers Distributor O-Ring on Torch Tip Shield Cap 4: Check Shield Cap Protrusion 3: Thread Shield Cup onto Cartridge Shield Cup Shield Cap...
  • Page 62 Connect the wire lead from the height finder to the ohmic clip if using ohmic torch height Ohmic Clip sensing. A-03393 NOTE Ohmic height sensing is not recommended with water shield. Water on the plate interferes electrically with the ohmic sensing circuit. Manual No.

  • Page 63: Complete The Installation

    3.20 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.
  • Page 64 NOTE Depending on the length of the torch leads, the system may require more coolant after turning the system ON for the first time. a. Place the ON/OFF Switch to ON. b. After about 30 seconds the system may shut down if the leads are not full of coolant. c.

  • Page 65: Section 4: Operation

    SECTION 4: OPERATION 4.01 Power Supply Control Panel Status Indicator AC Indicator Gas Indicator Temp Indicator DC Indicator Art # A-04862 AC Power Indicator Indicates AC power is being supplied to the system when the ON/OFF switch is in ON position. When switch is first set to ON, the indicator will blink, indicating gas purge at power on.

  • Page 66: Start-Up Sequence

    4.02 Start-Up Sequence 1. Connect system to primary input power. 2. Turn ON/OFF switch to ON (up) position. AC Indicator turns ON. POWER Art # A-04812 3. Check the AC indicator. If indicator does not light, reverse two phases of primary input power cable. If indicator is ON, system is ready to operate (pending fault checks by internal circuitry).

  • Page 67: Gas Control Module Operation

    4.03 Gas Control Module Operation Functional Overview The Gas Control Module provides all Plasma and Secondary gas selection and control instrumentation. There are various controls and indicators used to set gas pressures and flows. O2 - AIR O2 - O2 ENABLE H35 - N2 SET PREFLOW...

  • Page 68: Gas Control Module: Controls & Indicators

    Gas Control Module: Controls & Indicators 1. MODE Selection Switch SET PREFLOW SET PLASMA & SHIELD TEST MODE O2 - AIR O2 - O2 ENABLE H35 -N SET PREFLOW F5 - N SET PLASMA & SHIELD AIR - AIR TEST DISABLE High Precision AMPERAGE...
  • Page 69 2. GAS Selection Switch Selects combinations of plasma and shield gases. O2 - AIR O2 - O2 H35 -N F5 - N AIR - AIR O2 - AIR O2 - O2 ENABLE H35 -N SET PREFLOW F5 - N SET PLASMA &...
  • Page 70 3. Amperage / Set-Up Knob Adjusts the output amperage of the torch. High Precision AMPERAGE Plasma Cutting System SET-UP O2 - AIR O2 - O2 ENABLE H35 -N SET PREFLOW F5 - N SET PLASMA AIR - AIR & SHIELD TEST DISABLE High Precision...

  • Page 71: Sequence Of Operation

    4.04 Sequence Of Operation 1. Set the Plasma Power Supply Enable / Disable switch to Disable. DANGER Alway shut off input power to the system before changing or inspecting torch parts. a. Change the torch parts if necessary. b. Set the Plasma Power Supply Enable / Disable switch (on the Gas Control Module) to Enable. The Module performs purges of 15 seconds, 11 seconds, and another 11 seconds.

  • Page 72: Nitride Build-Up

    Cut Quality Cut quality requirements differ depending on application. For instance, nitride build-up and bevel angle may be major factors when the surface will be welded after cutting. Dross-free cutting is important when finish cut quality is desired to avoid a secondary cleaning operation. Cut quality will vary on different materials and thicknesses. Kerf Width Cut Surface Bevel Angle...

  • Page 73: Gas Selection

    Direction of Cut The plasma gas stream swirls as it leaves the torch to maintain a smooth column of gas. This swirl effect results in one side of a cut being more square than the other. Viewed along the direction of travel, the right side of the cut is more square than the left.

  • Page 74: Power Supply Status Codes

    3. Oxygen (O ) Plasma • Oxygen is recommended for cutting ferrous materials. • Provides faster cutting speeds. • Provides very smooth finishes and minimizes nitride build-up on cut surface (nitride build-up can cause difficulties in producing high quality welds if not removed). 4.
  • Page 75 Status Code Key Status Message Cause/Remedy Code System not Enabled or Missing Plasma Enable Off ; External E-Stop Activated or CCM AC Input Phase TB1-1&2 jumper missing; Missing AC Phase; No power Pilot Ignition Failure Pilot did not start within 15 seconds. Preflow pressure too high;...
  • Page 76 Status Code Key (cond) Status Message Cause/Remedy Code Gas Control Communication If GCM 1000: Control cable not connected or Basic ID signal open. fault, Cannot establish GCM 2010 & 2000: Dirt on fiber ends or in connectors, blow out with clean Communication with gas dry air;...
  • Page 77 Status Code Key (cond) Status Message Cause/Remedy Code CANBUS Failure to If GCM 1000, Basic ID signal missing; Other gas controls, Fiber Acknowledge fault. disconnected or broken, Transceiver (what fiber plugs into) fault, replace Gas control PCB or CCM CANBUS Off due to Dirt on fiber ends or in connectors, blow out with clean dry air;...

  • Page 78: Remote Arc Starter: Service Chart

    4.07 Remote Arc Starter: Service Chart Arc Starter Service Chart Symptom Cause Check Remedy Flush system, Coolant has become conductive Use conductivity meter replace coolant. Pilot return wire not connected Visual inspection Connect Wire. Spark gap set too close Check with feeler gauge Set to 0.063"...

  • Page 79: Remote Arc Starter: Spark Gap Adjustment

    4.08 Remote Arc Starter: Spark Gap Adjustment 0.063" ± 0.002" 1.6 ± 0.05 mm Art # A-04857 Manual No. 0-5056 4-15 OPERATION...
  • Page 80 This page intentionally blank Manual No. 0-5056 4-16 OPERATION...

  • Page 81: Section 5: Maintenance

    SECTION 5: MAINTENANCE 5.01 Periodic Checks 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. Monthly Check cooling fan and radiator; clean as needed. Check gas hoses for cracks, leaks, or abrasion.

  • Page 82: Internal Coolant Filter Cleaning Procedure

    5.03 Internal Coolant Filter Cleaning Procedure The in-line filter screen should be cleaned periodically. To gain access to the In-Line Filter Assembly remove the right side panel (viewed from the front of unit) of the Power Supply. Remove the filter screen by unscrewing the filter holder from the In-Line Filter Assembly.

  • Page 83: Section 6: Replacement Assemblies & Parts

    SECTION 6: REPLACEMENT ASSEMBLIES & PARTS 6.01 Main Component / System Replacement Complete Unit / Component Catalog Number Ultra-Cut ® 200 Power Supply, 208/230V 3-9119-1 ® Ultra-Cut 200 Power Supply, 460V 3-9119-2 Ultra-Cut ® 200 Power Supply, 400V 3-9119-3 ® Ultra-Cut 200 Power Supply, 400V, (CE)

  • Page 84: System Layout

    6.02 System Layout Refer to section 3.05 for ground connections and ground cables. 175’ / 53.3 m Maximum Length 125’ / 38.1 m Maximum Length 100’ / 30.5 m Maximum Length Pilot Return Pilot Return Shield Negative Remote Coolant Supply Coolant Supply Coolant Return Coolant Return...

  • Page 85: Leads And Cables

    6.03 Leads and Cables #8 AWG Cable Pilot Return, Power Supply to Arc Starter #1 AWG Cable Negative Lead, Power Supply to Arc Starter Coolant Supply Lead, Green Green Power Supply to Arc Starter Coolant Return Lead, Power Supply to Arc Starter Control Cable, Power Supply to Arc Starter Ground Cable...
  • Page 86 Description Catalog # A,B,C,D,E Supply Lead Set, 4’ / 1.3 m (See Note 1) 4-3027 A,B,C,D,E Supply Lead Set, 10’ / 3.05 m (See Note 1) 4-3028 A,B,C,D,E Supply Lead Set, 15’ / 4.5 m (See Note 1) 4-3029 A,B,C,D,E Supply Lead Set, 25’...
  • Page 87 Description Catalog # Hose, Coolant Supply, (only), 50’ / 15.2 m 9-4786 Hose, Coolant Supply, (only), 75’ / 23 m 9-4787 Hose, Coolant Supply, (only), 100’ / 30.5 m 9-4788 Hose, Coolant Return, (only), 3’ / 1 m 9-4888 Hose, Coolant Return, (only), 10’ / 3.05 m 9-4889 Hose, Coolant Return, (only), 15’...
  • Page 88 Description Catalog # Assembly, Coolant Return Hose, 10’ / 3.05 m 9-4882 Assembly, Pilot Return, 3’ / 1 m 9-4945 Assembly, Pilot Return, 10’ / 3.05 m 9-4883 Assembly, Negative/Coolant Supply, 10’ / 3.05 m 9-4939 Assembly, Torch Lead, 3’ / 1 m 9-4884 Assembly, Torch Lead, 10’...
  • Page 89 Description Catalog # Control Cable, Power Supply to Gas Control Module, 75’ / 22.9 m 9-4911 Control Cable, Power Supply to Gas Control Module, 100’ / 30.5 m 9-4912 Control Cable, Power Supply to Gas Control Module, 125' / 38.1 m 9-4913 Control Cable, Power Supply to Gas Control Module, 150’...

  • Page 90: Power Supply External Replacement Parts

    6.05 Power Supply External Replacement Parts Item # Description Catalog # Power Supply Front Panel 9-9380 Power Supply Rear Panel 9-9381 Power Supply Top Panel 9-9382 Power Supply Right Side Panel 9-9383 Power Supply Left Side Panel 9-9384 Louver Panel 9-9385 Power Supply Connections Cover 9-9386...

  • Page 91: Power Supply Replacement Parts - Right Side

    6.06 Power Supply Replacement Parts - Right Side Item # Description Ref. Des. Catalog # Heat Exchanger Fan FAN1 9-9338 Radiator 9-9339 Art # A-08308 Manual No. 0-5056 Power Supply Parts List...

  • Page 92: Power Supply Replacement Parts - Right Side

    6.07 Power Supply Replacement Parts - Right Side Item # Description Ref. Des. Catalog # Output Filter PC PCB8 9-9341 Sensor HCT2 9-9368 Magnetic Contactor, pilot 9-9343 Resistor 9-9340 Resistor Capacitor Art # A-08309 Manual No. 0-5056 6-10 Power Supply Parts List...

  • Page 93: Power Supply Replacement Parts - Right Side

    6.08 Power Supply Replacement Parts - Right Side Item # Description Ref. Des. Catalog # Chopper Module 9-9389 Sensor HCT1 9-9342 Chopper Module HCT1 Art # A-08311 Manual No. 0-5056 6-11 Power Supply Parts List...

  • Page 94: Power Supply Replacement Parts - Front Panel

    6.09 Power Supply Replacement Parts - Front Panel Item # Description Ref. Des. Catalog # Main Power Switch (‘Circuit Protector’) 9-9344 for 230-400-460 VAC units Art # A-08312 Manual No. 0-5056 6-12 Power Supply Parts List...

  • Page 95: Power Supply Replacement Parts - Front Panel

    6.10 Power Supply Replacement Parts - Front Panel Item # Description Ref. Des. Catalog # PC Board PCB3 9-9365 PC Board 230/460VAC PCB4 9-9370 PC Board 600VAC PCB4 9-9492 Display PC Board PCB6 9-9347 PCB3 PCB4 PCB6 Art # A-08313 Manual No.

  • Page 96: Power Supply Replacement Parts - Right Side

    6.11 Power Supply Replacement Parts - Right Side Item # Description Ref. Des. Catalog # PCBoard 230-400-460VAC PCB1 9-9362 PCBoard 600VAC PCB1 9-9491 Magnetic Contactor MC1,MC3 9-9364 Art # A-08314 Manual No. 0-5056 6-14 Power Supply Parts List...

  • Page 97: Power Supply Replacement Parts - Rear Panel

    6.12 Power Supply Replacement Parts - Rear Panel Item # Description Breaker Rating Cicuit Rating Ref. Des. Catalog # Circuit Breaker (RAS) 125V, 2.5 A 120VAC @ 1A 9-9348 Circuit Breaker (’TDC’) 125V, 3.15A 24VAC @ 1A 9-9349 Circuit Breaker (AGC) 125V, 10A 24VAC @ 5A 9-9350...

  • Page 98: Power Supply Replacement Parts - Right Side

    6.13 Power Supply Replacement Parts - Right Side Item # Description Ref. Des. Catalog # Resistor 9-9363 Rectifier (Diode) 9-9345 Transformer 9-9355 for 230/460 VAC units Diode 9-9486 Terminal Strip Art # A-08310 Manual No. 0-5056 6-16 Power Supply Parts List...

  • Page 99: Power Supply Replacement Parts

    6.14 Power Supply Replacement Parts Item # Description Catalog # Inverter Module 208/230V 9-9360D Inverter Module 400V CE and 400V Non CE9-9482D Inverter Module 600V 9-9485D Art # A-04786 Manual No. 0-5056 6-17 Power Supply Parts List...

  • Page 100: Power Supply Replacement Parts - Right Side

    6.15 Power Supply Replacement Parts - Right Side Item # Description Ref. Des. Catalog # Sensor (Thermistor) 9-9361 Manual No. 0-5056 6-18 Power Supply Parts List...

  • Page 101: Power Supply Replacement Parts

    6.16 Power Supply Replacement Parts Item # Description Ref. Des. Catalog # Relay PC Board PCB7 9-9366 24 VDC Power Supply Internal Control PC Board PCB5 9-9346 Art # A-08315 Manual No. 0-5056 6-19 Power Supply Parts List...

  • Page 102: Power Supply Replacement Parts - Right Side

    6.17 Power Supply Replacement Parts - Right Side Item # Description Ref. Des. Catalog # Sensor (Level Switch) LSW1 9-9354 Motor 9-9381 Pump/Check Valve/Bypass Valve Assembly 9-9380 Bypass Valve (part of assembly) Pump (part of assembly) Sensor (Flow Indicator) 9-9359 Illustration is for Reference ONLY Art # A-08236 Manual No.

  • Page 103: Gas Control Module (Gcm-2010) Replacement Parts

    6.18 Gas Control Module (GCM-2010) Replacement Parts Item # Description Catalog # 7W Solenoid for O2 use 9-9393 Gas Selection Manifold Assembly 9-9391 Check Valve, 1/4 NPT .5 PSI 9-9390 Mode Switch Assembly 9-9406 Gas Selection Switch Assembly 9-9403 LCD Interface PC Board 9-9408 Rotary Encoder (Switch) 9-9398...

  • Page 104: Gas Control Module (Gcm-2010) Replacement Parts

    6.19 Gas Control Module (GCM-2010) Replacement Parts Item # Description Catalog # 1” Black Instrument Knob 9-4233 Water Flow Meter with Valve 9-7005 Toggle Switch, 2 position SPDT 9-3426 Pressure gauge, 2” diameter 8-6800 Pressure gauge, 2” diameter 8-4313 Flow Meter 8-6801 Not shown - Valve Assembly...

  • Page 105: Remote Arc Starter (Ras-1000) Replacement Parts

    6.20 Remote Arc Starter (RAS-1000) Replacement Parts Item # Description Catalog # Harness, Internal (Not Shown) 9-4956 Pilot Cap Assembly 9-4960 EMI Filter 9-1023 HF Water Cooled Coil Assembly 9-4958 HF Coil Assembly, Arc Starter 9-4959 Enclosure, Arc Starter Base 9-4961 Spark Gap/Cap Assembly HF 9-4957...

  • Page 106: Remote Arc Starter (Ras-1000) Replacement Parts

    6.21 Remote Arc Starter (RAS-1000) Replacement Parts Item # Description Catalog # Retainer, ABS Wall 9-4964 (Outer) Torch Lead Ground Assembly 9-4955 Bracket, Bulkhead Holder 9-4963 Cover, Arc Starter 9-4962 Coolant Leads, Art # A-04899 from Power Supply Manual No. 0-5056 6-24 Power Supply Parts List...

  • Page 107: Command & Control Module Type 2 - Replacement Parts

    6.22 Command & Control Module Type 2 - Replacement Parts Item # Description Catalog # Assembly, CCM (Ultra-Cut) 9-9417 Plate, CCM Face 9-9419 Panel, Mount Not Available Harness, CCM I/O Board 9-9421 Art # A-06867 NOTE This page covers parts for Command & Control module without an external connections cover. See previous page for Command &...

  • Page 108: Xtl Torch Valve Assembly External Replacement Parts

    6.23 XTL Torch Valve Assembly External Replacement Parts NOTE The XTL Torch Valve Assembly requires Firmware versions 3.2 or higher for the C.C.M. and 3.1 or higher for the GCM 2010. It also requires the resetting of DIP switches in the C.C.M.. Item #QtyDescription Catalog # Torch Valve Assembly 4-3054...

  • Page 109: Xtl Torch Valve Assembly Internal Replacement Parts

    6.24 XTL Torch Valve Assembly Internal Replacement Parts NOTE The XTL Torch Valve Assembly requires Firmware versions 3.2 or higher for the C.C.M. and 3.1 or higher for the GCM 2010. It also requires the resetting of DIP switches in the C.C.M.. Item # Description Catalog #...
  • Page 110 Intentionally Blank Manual No. 0-5056 6-28 Power Supply Parts List...

  • Page 111: Section 7: Torch Maintenance

    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 re- move it from the Cartridge Assembly. Cartridge Tool Assembled Cartridge Art # A-04344 Shield Cup 2.

  • Page 112: O-Ring Lubrication

    Art # A-07087 Art # A-04066 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. 7.03 Parts Wear Replace the Gas Distributor if it is charred or cracked.

  • Page 113: Torch Consumables Installation

    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.
  • Page 114 2, Remove the Removal Tool from the Cartridge and install the assembled Cartridge onto the Torch Head. CAUTION The cartridge assembly must cover the O-Ring on the torch head. Do not force the cartridge if it will not tighten fully. Remove the cartridge assembly and gently clean the threads on the torch head with a wire brush.

  • Page 115: Coolant Leak Trouble-Shooting

    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.
  • Page 116 This page is blank intentionally. TORCH INFORMATION Manual 0-5056...

  • Page 117: Appendix 1: Remote Arc Starter Schematic

    APPENDIX 1: Remote Arc Starter Schematic Manual 0-5056 APPENDIX...

  • Page 118: Appendix 2: Gas Control And Torch Valve Schematic

    APPENDIX 2: Gas Control and Torch Valve Schematic ULTRACUT GCM 2010 GAS CONTROL O2 - AIR MODE MODE O2 - O2 H35 - N2 SET PREFLOW F5 - N2 SET CUTFLOW AIR - AIR TEST N2 - H2O N2 - N2 (10) To CCM (13)
  • Page 119 Preflow Shield ECO-B587 01/06/08 Date: Date: Date: Information Proprietary to THERMAL DYNAMICS CORPORATION. Information Proprietary to THERMAL DYNAMICS CORPORATION. Information Proprietary to THERMAL DYNAMICS CORPORATION. Wednesday, January 26, 2005 Wednesday, January 26, 2005 Wednesday, January 26, 2005 Gas Shield Not For Release, Reproduction, or Distribution without Written Consent.

  • Page 120: Appendix 3: Gas Control Module

    APPENDIX 3: Gas Control Module New Plasma Inlet SOL11 Pressure Sensor SOL5 TVA & XTL-TVA Atmosphere SOL4 PLASMA SOL19 SOL18 Pressure SOL14 Sensor SOL3 SOL2 SOL1 PLASMA SOL6 SOL15 PREFLOW SHIELD SOL16 SOL7 SOL12 SOL 18 & 19 in XTL-TVA only.

  • Page 121: Appendix 4: Gas Control Module Pcb Layout

    APPENDIX 4: Gas Control Module PCB Layout TP10 TP11 TP12 TP15 TP13 Art # A-07621 TP19 TP18 TP14 TP16 Manual 0-5056 APPENDIX...

  • Page 122: Appendix 5: Gas Control Display Interface Pcb Layout

    APPENDIX 5: Gas Control Display Interface PCB Layout 19X2220 REV LCD INTERFACE C 2005 Art # A-06904 Manual 0-5056 APPENDIX...

  • Page 123: Appendix 6: Ccm Cpu Pcb Layout

    APPENDIX 6: CCM CPU PCB Layout Note: Switch Settings May Vary. POST OK TO AUTO PILOT FLOW FLOW FUNC CONT MOVE/D CPU/COMMUNICATIONS Switches POST OK TO AUTO PILOT FLOW FLOW FUNC CONT MOVE/D C 2004 TDC 19X2169 REV +5.0V TEMP SENSE TPAD1 +3.3VA...

  • Page 124: Appendix 7: Ccm Input / Output Pcb Layout

    APPENDIX 7: CCM Input / Output PCB Layout SW11 TP11 TP12 J5 J5 J6 J6 J7 J7 J8 J8 J4 J4 PILOT V PILOT V L2 L2 R224 R224 R2 R2 TP12 TP12 J1 J1 R225 R225 CC POT CC POT U1 U1 R4 R4 H6 H6...

  • Page 125: Appendix 8: Cnc - Control Module Pcb Connections

    APPENDIX 8: CNC - Control Module PCB Connections These points are jumpered together at the factory. TB1-1 E-Stop (Com) Remove the jumper to use existing E-Stop circuits. TB1-2 E-Stop TB1-3 TB1-4 Stop Latched TB1-5 Start / Stop Ret TB1-6 Start / Stop or Start Latched (NO) TB1-7 Divided Arc Voltage (-) TB1-8...

  • Page 126: Cnc Functions

    CNC functions. CNC I/O circuits provide at least 1000V galvanic isolation from the plasma power supply. While the CNC circuits are isolated from the power supply, many of the signal returns on J15 and TB1 & 2 are common to each other. J15 pins 1, 4, 5 & 10 and TB1-1, 5, 7, 9, and TB2-1 & 3 are all common. J15 pin 12 and TB2-10 are also connected to the others when SW6 (OK to Move select) is set for voltage.

  • Page 127: Cnc Input / Output Descriptions

    CNC Input / Output Descriptions E-Stop input— Requires closed connection rated for 35ma. @ 20VDC for unit to operate. Factory installed jumper between TB1-1&2 must be removing when connecting user supplied E-Stop circuit. Start/Stop input—Switch (momentary or sustained) rating 35ma. @ 20 VDC Start / Stop circuit configurations.

  • Page 128: Simplified Cnc Circuit

    Simplified CNC Circuit. CCM Module SUSTAINED START / STOP ALL SW OFF for 50:1 (default) TB1-5 Active LOW Logic Input E-STOP Ret (-) START / STOP SW12-1 ON = 16.7:1 (SC-11) E-STOP input (+) SW12-2 ON = 30:1 Active LOW Logic Input TB1-6 STOP (NC) SW12-3 ON = 40:1...
  • Page 129 This page intentionally blank Manual 0-5056 A-13 APPENDIX...

  • Page 130: Appendix 9: Schematic: 230/460V Unit W/ Chopper Pilot W/ Diode

    APPENDIX 9: Schematic: 230/460V Unit w/ Chopper Pilot w/ Diode 100A INVERTER MODULE # 1 (top) N (-) N (-) CN1-230V CN1-230V INRUSH INRUSH MC1-A MC1-A MC1-B MC1-B MC1-C MC1-C P (+) P (+) CN4 - PCB12 CN4 - PCB12 CN2-460V CN2-460V MC3-A...
  • Page 131 603-298-5711 ECO-B646 GAC 10/31/07 Date: Date: Date: Information Proprietary to THERMAL DYNAMICS CORPORATION. Information Proprietary to THERMAL DYNAMICS CORPORATION. Information Proprietary to THERMAL DYNAMICS CORPORATION. Tuesday, October 03, 2006 Tuesday, October 03, 2006 Tuesday, October 03, 2006 Not For Release, Reproduction, or Distribution without Written Consent.

  • Page 132: Appendix 9: Schematic: 230/460V Unit W/ Chopper Pilot W/ Diode Continued

    APPENDIX 9: Schematic: 230/460V Unit w/ Chopper Pilot w/ Diode Continued PCB 5 WK-5602 (partial) INTERFACE PCB LED1 LED1 INPUT CONTACTORs LEVEL LEVEL CN12 CN12 CN13 CN13 CN14 CN14 PILOT CONTACTOR MC1 AUX MC1 AUX MC3 AUX MC3 AUX LSW1-1 LSW1-1 COOLANT TEMP (ON COOLANT...
  • Page 133 603-298-5711 ECO-B646 GAC 10/31/07 Date: Date: Date: Information Proprietary to THERMAL DYNAMICS CORPORATION. Information Proprietary to THERMAL DYNAMICS CORPORATION. Information Proprietary to THERMAL DYNAMICS CORPORATION. Tuesday, October 03, 2006 Tuesday, October 03, 2006 Tuesday, October 03, 2006 Not For Release, Reproduction, or Distribution without Written Consent.

  • Page 134: Appendix 10: Schematic: 230/460V Unit W/ Resistor Pilot

    APPENDIX 10: Schematic: 230/460V Unit w/ Resistor Pilot 100A INVERTER MODULE # 1 (top) N (-) N (-) CN1-230V CN1-230V INRUSH INRUSH MC1-A MC1-A MC1-B MC1-B MC1-C MC1-C P (+) P (+) CN4 - PCB12 CN4 - PCB12 CN2-460V CN2-460V MC3-A MC3-A 100A INVERTER MODULE # 2 (bottom)
  • Page 135 603-298-5711 ECO-B646 GAC 10/31/07 Date: Date: Date: Information Proprietary to THERMAL DYNAMICS CORPORATION. Information Proprietary to THERMAL DYNAMICS CORPORATION. Information Proprietary to THERMAL DYNAMICS CORPORATION. Tuesday, October 03, 2006 Tuesday, October 03, 2006 Tuesday, October 03, 2006 Not For Release, Reproduction, or Distribution without Written Consent.

  • Page 136: Appendix 10: Schematic: 230/460V Unit W/ Resistor Pilot Continued

    APPENDIX 10: Schematic: 230/460V Unit w/ Resistor Pilot Continued PCB 5 WK-5602 (partial) INTERFACE PCB LED1 LED1 INPUT CONTACTORs LEVEL LEVEL CN12 CN12 CN13 CN13 CN14 CN14 PILOT CONTACTOR MC1 AUX MC1 AUX MC3 AUX MC3 AUX LSW1-1 LSW1-1 COOLANT TEMP (ON COOLANT RETURN) SW_LIQUID_LEVEL_NC...
  • Page 137 603-298-5711 ECO-B646 GAC 10/31/07 Date: Date: Date: Information Proprietary to THERMAL DYNAMICS CORPORATION. Information Proprietary to THERMAL DYNAMICS CORPORATION. Information Proprietary to THERMAL DYNAMICS CORPORATION. Tuesday, October 03, 2006 Tuesday, October 03, 2006 Tuesday, October 03, 2006 Not For Release, Reproduction, or Distribution without Written Consent.

  • Page 138: Appendix 11: Schematic: Ccc 400V Unit W/ Chopper Pilot

    APPENDIX 11: Schematic: CCC 400V Unit w/ Chopper Pilot 100A INVERTER MODULE # 1 (top) N (-) N (-) CN1- not used CN1- not used INRUSH INRUSH MC1-A MC1-A MC1-B MC1-B MC1-C MC1-C P (+) P (+) CN4 - PCB12 CN4 - PCB12 CN2 400V CN2 400V...
  • Page 139 603-298-5711 ECO-B646 GAC 10/31/07 Date: Date: Date: Information Proprietary to THERMAL DYNAMICS CORPORATION. Information Proprietary to THERMAL DYNAMICS CORPORATION. Information Proprietary to THERMAL DYNAMICS CORPORATION. Tuesday, October 03, 2006 Tuesday, October 03, 2006 Tuesday, October 03, 2006 Not For Release, Reproduction, or Distribution without Written Consent.

  • Page 140: Appendix 11: Schematic: Ccc 400V Unit W/ Chopper Pilot Continued

    APPENDIX 11: Schematic: CCC 400V Unit w/ Chopper Pilot Continued PCB 5 WK-5602 (partial) INTERFACE PCB LED1 LED1 INPUT CONTACTORs LEVEL LEVEL CN12 CN12 CN13 CN13 CN14 CN14 PILOT CONTACTOR MC1 AUX MC1 AUX MC3 AUX MC3 AUX LSW1-1 LSW1-1 COOLANT TEMP (ON COOLANT RETURN)
  • Page 141 603-298-5711 ECO-B646 GAC 10/31/07 Date: Date: Date: Information Proprietary to THERMAL DYNAMICS CORPORATION. Information Proprietary to THERMAL DYNAMICS CORPORATION. Information Proprietary to THERMAL DYNAMICS CORPORATION. Tuesday, October 03, 2006 Tuesday, October 03, 2006 Tuesday, October 03, 2006 Not For Release, Reproduction, or Distribution without Written Consent.

  • Page 142: Appendix 12: Schematic: Ce 400V Unit W/ Chopper Pilot

    APPENDIX 12: Schematic: CE 400V Unit w/ Chopper Pilot 100A INVERTER MODULE # 1 (top) CN1- not used CN1- not used INRUSH INRUSH N (-) N (-) NFC1 NFC1 MC1-A MC1-A MC1-B MC1-B FILTER FILTER MC1-C MC1-C P (+) P (+) CN4 - PCB12 CN4 - PCB12 CN2 400V...
  • Page 143 603-298-5711 ECO-B646 GAC 10/31/07 Date: Date: Date: Information Proprietary to THERMAL DYNAMICS CORPORATION. Information Proprietary to THERMAL DYNAMICS CORPORATION. Information Proprietary to THERMAL DYNAMICS CORPORATION. Tuesday, October 03, 2006 Tuesday, October 03, 2006 Tuesday, October 03, 2006 Not For Release, Reproduction, or Distribution without Written Consent.

  • Page 144: Appendix 12: Schematic: Ce 400V Unit W/ Chopper Pilot Continued

    APPENDIX 12: Schematic: CE 400V Unit w/ Chopper Pilot Continued PCB 5 WK-5602 (partial) INTERFACE PCB LED1 LED1 INPUT CONTACTORs LEVEL LEVEL CN12 CN12 CN13 CN13 CN14 CN14 PILOT CONTACTOR MC1 AUX MC1 AUX MC3 AUX MC3 AUX LSW1-1 LSW1-1 COOLANT TEMP (ON COOLANT RETURN)
  • Page 145 603-298-5711 ECO-B646 GAC 10/31/07 Date: Date: Date: Information Proprietary to THERMAL DYNAMICS CORPORATION. Information Proprietary to THERMAL DYNAMICS CORPORATION. Information Proprietary to THERMAL DYNAMICS CORPORATION. Tuesday, October 03, 2006 Tuesday, October 03, 2006 Tuesday, October 03, 2006 Not For Release, Reproduction, or Distribution without Written Consent.

  • Page 146: Appendix 13: Schematic: Ce 400V Unit W/ Resistor Pilot

    APPENDIX 13: Schematic: CE 400V Unit w/ Resistor Pilot 100A INVERTER MODULE # 1 (top) CN1- not used CN1- not used INRUSH INRUSH N (-) N (-) NFC1 NFC1 MC1-A MC1-A MC1-B MC1-B FILTER FILTER MC1-C MC1-C P (+) P (+) CN4 - PCB12 CN4 - PCB12 CN2 400V...
  • Page 147 603-298-5711 ECO-B646 GAC 10/31/07 Date: Date: Date: Information Proprietary to THERMAL DYNAMICS CORPORATION. Information Proprietary to THERMAL DYNAMICS CORPORATION. Information Proprietary to THERMAL DYNAMICS CORPORATION. Tuesday, October 03, 2006 Tuesday, October 03, 2006 Tuesday, October 03, 2006 Not For Release, Reproduction, or Distribution without Written Consent.

  • Page 148: Appendix 13: Schematic: Ce 400V Unit W/ Resistor Pilot Continued

    APPENDIX 13: Schematic: CE 400V Unit w/ Resistor Pilot Continued PCB 5 WK-5602 (partial) INTERFACE PCB LED1 LED1 INPUT CONTACTORs LEVEL LEVEL CN12 CN12 CN13 CN13 CN14 CN14 PILOT CONTACTOR MC1 AUX MC1 AUX MC3 AUX MC3 AUX LSW1-1 LSW1-1 COOLANT TEMP (ON COOLANT RETURN)
  • Page 149 603-298-5711 ECO-B646 GAC 10/31/07 Date: Date: Date: Information Proprietary to THERMAL DYNAMICS CORPORATION. Information Proprietary to THERMAL DYNAMICS CORPORATION. Information Proprietary to THERMAL DYNAMICS CORPORATION. Tuesday, October 03, 2006 Tuesday, October 03, 2006 Tuesday, October 03, 2006 Not For Release, Reproduction, or Distribution without Written Consent.

  • Page 150: Appendix 14: Schematic: Csa 600V Unit W/ Chopper Pilot

    APPENDIX 14: Schematic: CSA 600V Unit w/ Chopper Pilot 100A INVERTER MODULE # 1 (top) N (-) N (-) CN1- not used CN1- not used INRUSH INRUSH MC1-A MC1-A MC1-B MC1-B MC1-C MC1-C P (+) P (+) CN4 - PCB12 CN4 - PCB12 CN2 600V CN2 600V...
  • Page 151 603-298-5711 ECO-B646 GAC 10/31/07 Date: Date: Date: Information Proprietary to THERMAL DYNAMICS CORPORATION. Information Proprietary to THERMAL DYNAMICS CORPORATION. Information Proprietary to THERMAL DYNAMICS CORPORATION. Tuesday, October 03, 2006 Tuesday, October 03, 2006 Tuesday, October 03, 2006 Not For Release, Reproduction, or Distribution without Written Consent.

  • Page 152: Appendix 14: Schematic: Csa 600V Unit W/ Chopper Pilot Continued

    APPENDIX 14: Schematic: CSA 600V Unit w/ Chopper Pilot Continued PCB 5 WK-5602 (partial) INTERFACE PCB LED1 LED1 INPUT CONTACTORs LEVEL LEVEL CN12 CN12 CN13 CN13 CN14 CN14 PILOT CONTACTOR MC1 AUX MC1 AUX MC3 AUX MC3 AUX LSW1-1 LSW1-1 COOLANT TEMP (ON COOLANT RETURN)
  • Page 153 603-298-5711 ECO-B646 GAC 10/31/07 Date: Date: Date: Information Proprietary to THERMAL DYNAMICS CORPORATION. Information Proprietary to THERMAL DYNAMICS CORPORATION. Information Proprietary to THERMAL DYNAMICS CORPORATION. Tuesday, October 03, 2006 Tuesday, October 03, 2006 Tuesday, October 03, 2006 Not For Release, Reproduction, or Distribution without Written Consent.

  • Page 154: Appendix 15: Publication History

    APPENDIX 15: PUBLICATION HISTORY Cover Date Change(s) Jan. 7, 2008 First issue Jan. 14, 2008 Added flow meter replacement parts per ECOB704. Jan. 28, 2008 Per ECOB738 updated GCM plumbing diagram in Appendix. Feb. 5, 2008 Per ECOB646 added input terminal strip information to sections 3 and 6. Manual 0-5056 A-38 APPENDIX...

  • Page 155: Global Customer Service Contact Information

    Global Customer Service Contact Information Thermadyne USA Thermadyne Asia Sdn Bhd 2800 Airport Road Lot 151, Jalan Industri 3/5A Rawang Integrated Industrial Park - Jln Batu Arang Denton, Tx 76207 USA 48000 Rawang Selangor Darul Ehsan Telephone: (940) 566-2000 800-426-1888 West Malaysia Fax: 800-535-0557 Telephone: 603+ 6092 2988...
  • Page 156 Corporate Headquarters 16052 Swingley Ridge Road Suite 300 St. Louis, MO 63017 Telephone: 636-728-3000 Email: TDCSales@Thermadyne.com www.thermadyne.com...

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