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ESAB 100i Instruction Manual

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100i, 200i, 300i, and 400i
Plasma Systems
Instruction Manual
Article Number: 0560956430
Revision Date: 22/10/2018
Revision Number: AG
Language: ENGLISH

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  • Page 1 100i, 200i, 300i, and 400i Plasma Systems Instruction Manual Article Number: 0560956430 Revision Date: 22/10/2018 Revision Number: AG Language: ENGLISH...
  • Page 2 WE APPRECIATE YOUR BUSINESS! Congratulations on your new ESAB product. We are proud to have you as our customer and will strive to provide you with the best service and reliability in the industry. This product is backed by our extensive warranty and world-wide service network. To locate your nearest distributor or service agency call 1-800-ESAB-123, or visit us on the web at www.esab.com.
  • Page 3 While the information contained in this Manual represents the Manufacturer’s best judgment, the Manufacturer assumes no liability for its use. Plasma Cutting Power Supply with Automated Gas Control 100i / 200i / 300i / 400i Published by: ESAB Welding and Cutting Products.
  • Page 4 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,”...
  • Page 5 ASSUREZ-VOUS QUE CETTE INFORMATION EST DISTRIBUÉE À L’OPÉRATEUR. VOUS POUVEZ OBTENIR DES COPIES SUPPLÉMENTAIRES CHEZ VOTRE FOURNISSEUR. MISE EN GARDE 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...
  • Page 6 The RoHS Directive 2011/65/EC, entering into force 2 January 2013 Type of equipment PLASMA CUTTING POWER SUPPLY Type designation etc. 100i, 200i, 300i, and 400i Plasma Systems, from serial number ???? Brand name or trade mark ESAB Manufacturer or his authorised representative Name, address, telephone No: ESAB Group Inc.

  • Page 7: Table Of Contents

    TABLE OF CONTENTS SECTION 1: SAFETY ...................9 1.01 Safety Precautions - ENGLISH ................9 1.02 Précautions de sécurité - FRENCH CANADIAN ..........14 SECTION 2: SPECIFICATIONS ................19 2.01 General Description Of The System ..............19 2.02 Plasma Power Supply ..................19 2.03 Remote Arc Starter ...................19 2.04 Gas Control Module ..................19 2.05...
  • Page 8 TABLE OF CONTENTS SECTION 7: TORCH MAINTENANCE ..............71 7.01 Consumable Removal ..................71 7.02 O-Ring Lubrication ...................72 7.03 Parts Wear ......................73 7.04 Torch Consumables Installation ................74 7.05 Coolant Leak Trouble-Shooting ................76 SECTION 8: TORCH OPERATION ................79 8.01 Standard Cutting Up To 100 Amp ..............83 8.02 Standard Cutting 150 - 200 Amp ..............105 8.03...

  • Page 9: Section 1: Safety

    100i / 200i / 300i / 400i 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.
  • Page 10 100i / 200i / 300i / 400i 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.
  • Page 11 100i / 200i / 300i / 400i CYLINDER HANDLING -- Cylinders, if mishandled, can rupture and violently release gas. Sudden rupture of cylinder, valve, or relief device can injure or kill. Therefore: 1. Use the proper gas for the process and use the proper pressure reducing regulator designed to operate from the compressed gas cylinder.
  • Page 12 100i / 200i / 300i / 400i Meaning of symbols - As used throughout this manual: Means Attention! Be Alert! Your safety is involved. Means immediate hazards which, if not avoided, will result in immediate, serious per- DANGER sonal injury or loss of life.
  • Page 13 100i / 200i / 300i / 400i This Page Intentionally Blank 0560956430 SAFETY INSTRUCTIONS...

  • Page 14: Précautions De Sécurité - French Canadian

    100i / 200i / 300i / 400i 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 sup- plémentaires.
  • Page 15 100i / 200i / 300i / 400i 5. Assurez-vous de ne pas excéder la capacité de l’équipement. Par exemple, un câble de soudage surchargé peut surchauffer et provoquer un incendie. 6. Une fois les opérations terminées, inspectez l’aire de travail pour assurer qu’aucune étincelle ou projec- tion de métal incandescent ne risque de provoquer un incendie ultérieurement.
  • Page 16 100i / 200i / 300i / 400i LES VAPEURS ET LES GAZ -- peuvent causer un malaise ou des dommages corporels, plus particu- lièrement dans les espaces restreints. Ne respirez pas les vapeurs et les gaz. Le gaz de protection risque de causer l’asphyxie.
  • Page 17 100i / 200i / 300i / 400i 4. N’utilisez pas l’équipement de façon abusive. Gardez l’équipement à l’écart de toute source de chaleur, notamment des fours, de l’humidité, des flaques d’eau, de l’huile ou de la graisse, des atmosphères corrosives et des intempéries.
  • Page 18 100i / 200i / 300i / 400i 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...

  • Page 19: Section 2: Specifications

    100i / 200i / 300i / 400i SECTION 2: SPECIFICATIONS 2.01 General Description Of The System A typical plasma system configuration includes: • One Power Supply • Remote Arc Starter • Gas Control Module • Torch Valve Assembly • Precision Plasma Cutting Torch •...

  • Page 20: Specifications & Electrical Requirements

    100i / 200i / 300i / 400i 2.06 Specifications & Electrical Requirements 100i Specifications & Design Features Max OCV (U0) 425 vdc Minimum Output Current 5 Amps Max Output Current 100 Amps Output Voltage 60 - 180 vdc 100 Amp System...
  • Page 21 100i / 200i / 300i / 400i 100i Power Supply Input Power Input Current Suggested Sizes (See Note) Voltage Freq. 3-Ph 3-Ph Fuse (Amps) Wire (AWG) Wire (mm (Volts) (Hz) (kVA) (Amps) 3-Ph 3-Ph 3-Ph 50/60 40-45 400/400 CE 50/60...

  • Page 22: Power Supply Dimensions

    100i / 200i / 300i / 400i 2.07 Power Supply Dimensions 47.77 inch 1213 mm 35.97 inch 100A 420 lb / 190 kg 914 mm 200A 465 lb / 211 kg 300A 560 lb / 254 kg 27.6 inch 400A 580 lb / 263 kg...

  • Page 23: Power Supply Rear Panel Features

    100i / 200i / 300i / 400i 2.08 Power Supply Rear Panel Features TSC/Comm Customer Circuit Breakers Optional Ports GCM Connector CNC Connector J55 - GCM USER INPUT C.C.M. Coolant Return CAN IN J15 - CNC HEIGHT CONTROL CAN OUT...

  • Page 24: Gas Requirements

    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. 100i Power Supply: Gas Pressures, Flows, and Quality Requirements Quality...
  • Page 25 100i / 200i / 300i / 400i 300i Power Supply: Gas Pressures, Flows, and Quality Requirements Quality Minimum Pressure Flow 99.5% Purity 120 psi (Oxygen) 200 scfh (95 lpm) (Liquid recommended) 8.3 bar / 827 kPa 99.5% Purity (Liquid recommended)

  • Page 26: Gas Applications

    100i / 200i / 300i / 400i 2.10 Gas Applications MATERIAL MILD STEEL STAINLESS STEEL ALUMINUM GAS TYPE GAS TYPE GAS TYPE OPERATION PREFLOW PLASMA SHIELD PREFLOW PLASMA SHIELD PREFLOW PLASMA SHIELD 30A Cut 50A Cut 70A Cut 100A Cut...

  • Page 27: Torch Specifications

    100i / 200i / 300i / 400i 2.11 Torch Specifications A. Torch Dimensions Basic 400 Amp torch dimensions Basic 100 Amp torch dimensions 0560956430 SPECIFICATIONS...
  • Page 28 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. Torch Data Torch Ratings for use with 100i-400i Power Supply 104° F Ambient Temperature 40° C...

  • Page 29: Section 3: Installation

    100i / 200i / 300i / 400i 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. 100i Power Supply...

  • Page 30: Recommended Gas Supply Hose

    • 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. ESAB recommends the use of its coolants 7-3580 and 7-3581 (for low temperatures). Coolant Capabilities Cat. Number and Mixture...

  • Page 31: Lift The Power Supply

    100i / 200i / 300i / 400i 3.03 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.

  • Page 32: Install Consumable Torch Parts

    100i / 200i / 300i / 400i 3.04 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.
  • Page 33 100i / 200i / 300i / 400i 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 7. Slide the ohmic clip over the shield cup if using ohmic torch height sensing.
  • Page 34 100i / 200i / 300i / 400i 30 - 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...

  • Page 35: Section 4: Operation

    100i / 200i / 300i / 400i SECTION 4: OPERATION 4.01 Power Supply Control Panel AC Indicator Gas Indicator Status Indicator Temp Indicator DC Indicator Art # A-11541_AB 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.
  • Page 36 100i / 200i / 300i / 400i 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 (Vision T5; user installed Plasma Enable/E-Stop) in the “Enable” position 2.

  • Page 37: Ccm Status Codes

    100i / 200i / 300i / 400i 4.03 CCM Status Codes 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”...
  • Page 38 100i / 200i / 300i / 400i CCM Status Code Group 2 -- Plasma Power Supply Code Message Remedy / Comments Blown wall fuse, Blown unit fuse F1 or F2 or rear panel, Bad power cable connection; Missing AC Phase Defective System Bias PCB.
  • Page 39 100i / 200i / 300i / 400i CCM Status Code Group 2 -- Plasma Power Supply Code Message Remedy / Comments Inverter 3A Output Plasma work current high during cutting and attributed to Inverter Module 3 Section A Current High output high;...
  • Page 40 100i / 200i / 300i / 400i CCM Status Code Group 2 -- Plasma Power Supply Code Message Remedy / Comments Inverter Input Voltage fault; voltage out of range or missing phase at AC Input of Inverter 1A Input Inverter Module 1 Section A; Poor AC Power Quality; Defective W1 contactor; Loose or...
  • Page 41 100i / 200i / 300i / 400i CCM Status Code Group 2 -- Plasma Power Supply Code Message Remedy / Comments Inverter Module 3 Section A is over temperature; Operating with side panels removed, Inverter 3A Over Check for restricted air flow, clogged radiator; Defective fan; If problem persists replace Temp inverter module.
  • Page 42 100i / 200i / 300i / 400i CCM Status Code Group 3 -- Gas Controller Status & Protocol Code Message Remedy / Comments Problem with fiber optic cable to Gas Selection Console or Gas Control Unit; Dirt on fiber ends or in connectors; blow out with clean dry air. Fiber not locked into...
  • Page 43 100i / 200i / 300i / 400i CCM Status Code Group 4 -- Torch Coolant System Code Message Remedy / Comments Coolant Level low 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; Clogged filter;...
  • Page 44 100i / 200i / 300i / 400i CCM Status Code Group 6 -- CCM Code Message Remedy / Comments Analog Voltage Error Defective CCM, replace. ADC or DAC error Defective CCM, replace. Reserved No information available; Contact customer service Data Memory error Defective CCM, replace.

  • Page 45: Gas Selection Console Status Codes

    100i / 200i / 300i / 400i CCM Status Code Group 7 -- Options Code Message Remedy / Comments 1 Torch isolation contactor W5 appears closed when expected to be open. Isolation Contactor Fault Contacts may fused or, W5 could be energized, 24 VAC on it's coil, when it should not be due to faulty Relay PCB.
  • Page 46 100i / 200i / 300i / 400i Gas Selection Console Status Code Key Group 1 - Gas Selection Console Code Message Cause/Remedy Plasma Disabled Enable Plasma; Defective Gas Selection Console Power Supply (E-Stop relay) Check /replace Gas Selection Console power supply fuse (F2); Replace Gas Selection 24 VDC fault Console Power Supply;...
  • Page 47 100i / 200i / 300i / 400i Group 5 - Shorted Solenoid Faults Sol 1 – H35 Plasma Replace solenoid; Shorted wire harness; Defective Gas Selection Console Control PCB Sol 2 – Oxygen Plasma Replace solenoid; Shorted wire harness; Defective Gas Selection Console Control PCB Sol 3 –...

  • Page 48: Gas Control Unit Status Codes

    100i / 200i / 300i / 400i 4.05 Gas Control Unit Status Codes Gas Control Unit Status Code Key Group 1 - Gas Control Unit Code Message Cause/Remedy Enable Plasma; Gas Selection Console Power Supply input fuse F1 blown (no lights on Gas Plasma Disabled Selection Console);...
  • Page 49 100i / 200i / 300i / 400i Group 5 - Plasma High Proportional Valve (V5) Valve open Check for open connection; Replace valve. Gas Control Unit inlet Supply Raise plasma inlet pressure; check for Gas Selection Console valve not open; restriction in gas pressure low supply / hoses.
  • Page 50 100i / 200i / 300i / 400i Group 9 - Shield H2O Proportional Valve (V2) Valve open Check for open connection; Replace valve. Gas Control Unit inlet Sup- Raise plasma inlet pressure; check for Gas Selection Console valve not open; restriction in gas sup- ply pressure low ply/hoses.

  • Page 51: Remote Arc Starter Trouble Shooting

    100i / 200i / 300i / 400i 4.06 Remote Arc Starter Trouble Shooting Arc Starter Trouble Shooting Symptom Cause Check Remedy Pilot return wire not connected at torch head or broken in torch Visual inspection, continuity check Connect Wire or replace leads.
  • Page 52 100i / 200i / 300i / 400i This Page Intentionally Blank. OPERATION 0560956430...

  • Page 53: Section 5: Maintenance

    100i / 200i / 300i / 400i 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.

  • Page 54: Coolant Replacement Procedure

    100i / 200i / 300i / 400i 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.

  • Page 55: Section 6: Replacement Assemblies & Parts

    100i / 200i / 300i / 400i SECTION 6: REPLACEMENT ASSEMBLIES & PARTS 6.01 Replacement Power Supply Complete Unit / Component Catalog Number 100i Power Supply, 480V 0559381162 100i Power Supply, 400V 0559381163 100i Power Supply, 400V CE 0559381164 200i Power Supply, 480V...

  • Page 56: System Layout 100 - 200 Amp

    100i / 200i / 300i / 400i 6.02 System Layout 100 - 200 Amp Refer to section 3.08 and 3.10 for ground connections and ground cables. 175’ / 53.3 m Maximum Length 100’ / 30.5 m Maximum Length 125’ / 38.1 m Maximum Length...

  • Page 57: System Layout 400 Amp

    100i / 200i / 300i / 400i 6.04 System Layout 400 Amp Refer to section 3.08 and 3.10 for ground connections and ground cables. 175’ / 53.3 m Maximum Length 50’ / 15.25 m Maximum Length 125’ / 38.1 m Maximum Length...

  • Page 58: Leads And Cables All Amperages

    100i / 200i / 300i / 400i 6.06 Leads And Cables All Amperages #8 AWG Cable Pilot Return, Power Supply to Arc Starter 3/0 AWG Cable (95 mm Negative Lead, Power Supply to Arc Starter Coolant Supply Lead, Green Green...
  • Page 59 100i / 200i / 300i / 400i 0560956430 PARTS LISTS...

  • Page 60: Power Supply External Replacement Parts

    100i / 200i / 300i / 400i 6.07 Power Supply External Replacement Parts Item # Description Catalog # Power and Leads Cable Cover 0559235533 Top Panel, 0559097300 Upper Side Covers 0559097301 Lower Left Side Panel 0559097304 Lower Right Side Panel...

  • Page 61: Power Supply Replacement Parts - Upper Right Side

    100i / 200i / 300i / 400i 6.08 Power Supply Replacement Parts - Upper Right Side Item # Description Ref. Des. Catalog # System Bias PCB 9-9253 Pilot PCB 9-9250 CCM Assembly 0559097335 Relays, Pump / Fan MC3 / MC2...

  • Page 62: Power Supply Replacement Parts - Lower Right Side

    100i / 200i / 300i / 400i 6.09 Power Supply Replacement Parts - Lower Right Side Item # Qty Description Ref. Des. Catalog # Coolant Tank Cap 8-5142 Coolant Tank 9-7306 Coolant level Sensor 9-7307 Pump, Coolant, Assembly (with motor)

  • Page 63: Power Supply Replacement Parts - Rear Panel

    100i / 200i / 300i / 400i 6.10 Power Supply Replacement Parts - Rear Panel Item # Qty Description Breaker Rating Circuit Rating Ref. Des. Catalog # Coolant Filter Assy 9-7320 Coolant Filter 9-7321 Fuse, 8A 500V - Time Delay (2 total)

  • Page 64: Power Supply Replacement Parts - Left Side

    100i / 200i / 300i / 400i 6.11 Power Supply Replacement Parts - Left Side Item # Description Ref. Des. Catalog # AC Suppresion PCB 9-9254 Main Contactor (2 total) W1, W2 9-7318 Inverter Module, Full, 480 VAC 9-7330 Inverter Module, Full, 400 VAC...
  • Page 65 100i / 200i / 300i / 400i 400 Amp Power Supply 200 Amp Power Supply Art # A-12185 Non CE 400 Amp Power Supply 200 Amp Power Supply Art # A-11943 CE ONLY 0560956430 PARTS LISTS...

  • Page 66: Automated Gas Control System Replacement Components

    100i / 200i / 300i / 400i 6.12 Automated Gas Control System Replacement Components Item # Description Catalog # Assy, Gas Selection Console 0559099491 Assy, Gas Control Unit 0559099443 Art # A-13242 Art # A-13243 PARTS LISTS 0560956430...

  • Page 67: Gas Selection Console Replacement Parts

    100i / 200i / 300i / 400i 6.13 Gas Selection Console Replacement Parts Item # Description Catalog # Gas Seletion Control assembly 0559099491 Solenoid 9-8264 Manifold subassembly (includes 15 of item 2) 9-7546 SMPS PCB 9-8263 Control PCB 9-7291 Not shown:...

  • Page 68: Gas Control Unit Replacement Parts

    100i / 200i / 300i / 400i 6.14 Gas Control Unit Replacement Parts Item # Description Catalog # Gas Control Unit Assembly 0559099443 Gas Control Unit - PCB 9-8262 SMPS PCB 9-8263 Shield Gas P Valve 9-8267 Sensor, Pressure, 1/8mnpt (six total)

  • Page 69: Remote Arc Starter (Ras) Replacement Parts

    100i / 200i / 300i / 400i 6.15 Remote Arc Starter (RAS) Replacement Parts Item # Description Catalog # Complete RAS Assembly 0559039130 Pilot Cap Assembly 9-9423 Electronic Ignition Module 9-7342 Toroidal Coil 9-7343 Art # A-12066 0560956430 PARTS LISTS...
  • Page 70 100i / 200i / 300i / 400i This Page Intentionally Blank PARTS LISTS 0560956430...

  • Page 71: Section 7: Torch Maintenance

    100i / 200i / 300i / 400i 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...

  • Page 72: O-Ring Lubrication

    Cat. No. removed for clarity 9-3029 Outer Cartridge Art # A-09684_AD CAUTION Use only ESAB 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. TORCH INFORMATION 0560956430...

  • Page 73: Parts Wear

    100i / 200i / 300i / 400i 7.03 Parts Wear Replace the Gas Distributor if it is charred or cracked. Replace the Gas Distributor if the flange is damaged in any way. Replace the tip and/or electrode if they are worn.

  • Page 74: Torch Consumables Installation

    100i / 200i / 300i / 400i 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.
  • Page 75 100i / 200i / 300i / 400i 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.

  • Page 76: Coolant Leak Trouble-Shooting

    100i / 200i / 300i / 400i 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 im- properly. 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 77 100i / 200i / 300i / 400i Recommended Wear Depth for Electrode Amperage Plasma Gas Replacement Inch 0.04 0.04 0.04 0.04 0.08 0.04 0.04 0.08 0.04 0.04 0.08 0.08 0.06 0.08 0.08 0.06 0.08 0.08 0.06 0.06 0.08 0.08 0.08 0.08...
  • Page 78 100i / 200i / 300i / 400i This Page Intentionally Blank TORCH INFORMATION 0560956430...

  • Page 79: Section 8: Torch Operation

    100i / 200i / 300i / 400i SECTION 8: TORCH OPERATION Torch Parts Selection The application will determine which torch parts must be used. Refer to the cut charts for the proper torch parts to install for a selected application.
  • Page 80 100i / 200i / 300i / 400i Clockwise Left Side Cut Angle Scrap Right Side Cut Angle Counter- Clockwise Scrap Workpiece A-00512 Art # A-04182 Side Characteristics Of Cut To make a square - edged cut along an inside diameter of a circle, move the torch counterclockwise around the circle.
  • Page 81 100i / 200i / 300i / 400i General Definitions: Arc voltage Height Control Arc Voltage Voltage measurement between the electrode and the work piece which is used to control the torch to work distance during cutting. Cutting Height Distance between the plasma torch and the work piece during cutting.
  • Page 82 100i / 200i / 300i / 400i Understanding Time-line and Cutting Process of THC Arc Voltage Height Control (AHC) Pierce Height Measured from Ignition Height Piercing Moving the Plate Over Pierce Puddle Height Delay Before Arc Torch Height Controlled Voltage Control...

  • Page 83: Standard Cutting Up To 100 Amp

    100i / 200i / 300i / 400i 8.01 Standard Cutting Up To 100 Amp Flow Rates (SLPM / SCFH) Mild Steel O₂ Preflow 4 / 8 16 / 33 O₂ Plasma / O₂ Shield Cutflow 15 / 32 - / -...
  • Page 84 100i / 200i / 300i / 400i Stainless Steel Flow Rates (SLPM / SCFH) Preflow 22 / 47 Cutflow 40 / 85 Air Plasma / Air Shield Shield Cup Shield Gas Plasma Gas Cartridge Shield Cap Distributor Distributor Electrode Art # A-07958_AB...
  • Page 85 100i / 200i / 300i / 400i Stainless Steel Flow Rates N₂ (SLPM / SCFH) H₂O (GPH / LPH) Preflow 9 / 19 5 / 19 Cutflow N₂ Plasma / H₂O Shield 28 / 59 5 / 19 Shield Cup...
  • Page 86 100i / 200i / 300i / 400i Aluminum Flow Rates (SLPM / SCFH) Preflow 19 / 40 Cutflow 40 / 85 Air Plasma / Air Shield Shield Cup Shield Gas Plasma Gas Cartridge Shield Cap Distributor Distributor Electrode Art # A-07958_AB...
  • Page 87 100i / 200i / 300i / 400i Aluminum Flow Rates N₂ (SLPM / SCFH) H₂O (GPH / LPH) Preflow 9 / 19 4 / 15 Cutflow 21 / 44 4 / 15 N₂ Plasma / H₂O Shield Shield Cup Shield Gas...
  • Page 88 100i / 200i / 300i / 400i Mild Steel Flow Rates (SLPM / SCFH) O₂ Preflow - / - 30 / 63 Cutflow 6 / 14 12 / 26 O₂ Plasma / Air Shield Shield Cup Plasma Gas Shield Gas...
  • Page 89 100i / 200i / 300i / 400i Stainless Steel Flow Rates (SLPM / SCFH) Preflow 60 / 127 Cutflow 49 / 104 Air Plasma / Air Shield Shield Cup Plasma Gas Shield Gas Cartridge Shield Cap Distributor Distributor Electrode Art # A-07958_AB...
  • Page 90 100i / 200i / 300i / 400i Stainless Steel Flow Rates N₂ (SLPM / SCFH) H₂O (GPH / LPH) Preflow 17 / 37 4 / 15 Cutflow 18 / 38 4 / 15 N₂ Plasma / H₂O Shield Shield Cup...
  • Page 91 100i / 200i / 300i / 400i Aluminum Flow Rates (SLPM / SCFH) Preflow 60 / 128 Cutflow 50 / 106 Air Plasma / Air Shield Shield Cup Shield Gas Plasma Gas Cartridge Shield Cap Distributor Distributor Electrode Art # A-07958_AB...
  • Page 92 100i / 200i / 300i / 400i Aluminum Flow Rates N₂ (SLPM / SCFH) H₂O (GPH / LPH) Preflow 26 / 56 4 / 15 Cutflow 18 / 38 4 / 15 N₂ Plasma / H₂O Shield Shield Cup Shield Gas...
  • Page 93 100i / 200i / 300i / 400i Mild Steel Flow Rates (SLPM / SCFH) O₂ Preflow - / - 44 / 94 Cutflow O₂ Plasma / Air Shield 10 / 21 25 / 52 Shield Cup Shield Gas Plasma Gas...
  • Page 94 100i / 200i / 300i / 400i Stainless Steel Flow Rates (SLPM / SCFH) Preflow 66 / 139 Cutflow Air Plasma / Air Shield 52 / 110 Shield Cup Plasma Gas Shield Gas Cartridge Shield Cap Distributor Distributor Electrode Art # A-07958_AB...
  • Page 95 100i / 200i / 300i / 400i Stainless Steel Flow Rates N₂ (SLPM / SCFH) H₂O (GPH / LPH) Preflow 15 / 31 5 / 19 Cutflow 8 / 17 5 / 19 N₂ Plasma / H₂O Shield Shield Cup...
  • Page 96 100i / 200i / 300i / 400i Aluminum Flow Rates (SLPM / SCFH) Preflow 66 / 139 Cutflow 52 / 110 Air Plasma / Air Shield Shield Cup Shield Gas Plasma Gas Cartridge Shield Cap Distributor Distributor Electrode Art # A-07958_AB...
  • Page 97 100i / 200i / 300i / 400i Aluminum Flow Rates N₂ (SLPM / SCFH) H₂O (GPH / LPH) Preflow 15 / 31 5 / 19 Cutflow N₂ Plasma / H₂O Shield 8 / 17 5 / 19 Shield Cup Shield Gas...
  • Page 98 100i / 200i / 300i / 400i Mild Steel Flow Rates (SLPM / SCFH) 100A O₂ Preflow - / - 38 / 81 Cutflow 16 / 35 27 / 58 O₂ Plasma / Air Shield Shield Cup Shield Gas Plasma Gas...
  • Page 99 100i / 200i / 300i / 400i Stainless Steel Flow Rates (SLPM / SCFH) N₂ 100A Preflow - / - 62 / 132 Cutflow H35 Plasma / N₂ Shield 24 / 51 51 / 107 Shield Cup Plasma Gas Shield Gas...
  • Page 100 100i / 200i / 300i / 400i Stainless Steel Flow Rates 100A N₂ (SLPM / SCFH) H₂O (GPH / LPH) Preflow 17 / 35 7 / 26 Cutflow 14 / 29 7 / 26 N₂ Plasma / H₂O Shield Shield Cup...
  • Page 101 100i / 200i / 300i / 400i Aluminum Flow Rates (SLPM / SCFH) 100A N₂ Preflow - / - 62 / 132 Cutflow H35 Plasma / N₂ Shield 24 / 51 51 / 107 Shield Cup Plasma Gas Shield Gas...
  • Page 102 100i / 200i / 300i / 400i Aluminum Flow Rates 100A N₂ (SLPM / SCFH) H₂O (GPH / LPH) Preflow 17 / 35 7 / 26 Cutflow N₂ Plasma / H₂O Shield 14 / 29 7 / 26 Shield Cup...
  • Page 103 100i / 200i / 300i / 400i Chart is for Customer Settings Flow Rates (SLPM / SCFH) Make Copies as Desired O₂ Preflow Cutflow Shield Gas Shield Cup Shield Cap Plasma Gas Distributor Electrode Cartridge Distributor Manual Gas Control Advanced Torch Height Control (THC)
  • Page 104 100i / 200i / 300i / 400i This Page Intentionallly Blank TORCH DATA 100i-400i 0560956430...

  • Page 105: Standard Cutting 150 - 200 Amp

    100i / 200i / 300i / 400i 8.02 Standard Cutting 150 - 200 Amp Mild Steel Flow Rates (SLPM / SCFH) 150A O₂ Preflow - / - 100 / 213 Cutflow O₂ Plasma / Air Shield 59 / 126 81 / 171...
  • Page 106 100i / 200i / 300i / 400i Stainless Steel Flow Rates (SLPM / SCFH) N₂ 150A Preflow - / - 55 / 117 Cutflow H35 Plasma / N₂ Shield 16 / 33 37 / 78 Shield Cup Plasma Gas Shield Gas...
  • Page 107 100i / 200i / 300i / 400i Stainless Steel Flow Rates 150A N₂ (SLPM / SCFH) H₂O (GPH / LPH) Preflow 24 / 50 8 / 30 Cutflow 16 / 35 8 / 30 N₂ Plasma / H₂O Shield Shield Cup...
  • Page 108 100i / 200i / 300i / 400i Aluminum Flow Rates (SLPM / SCFH) 150A N₂ Preflow - / - 54 / 114 Cutflow 34 / 72 26 / 56 H35 Plasma / N₂ Shield Shield Cup Plasma Gas Shield Gas...
  • Page 109 100i / 200i / 300i / 400i Aluminum Flow Rates 150A N₂ (SLPM / SCFH) H₂O (GPH / LPH) Preflow 24 / 51 8 / 30 Cutflow N₂ Plasma / H₂O Shield 16 / 35 8 / 30 Shield Cup...
  • Page 110 100i / 200i / 300i / 400i Mild Steel Flow Rates (SLPM / SCFH) 200A O₂ Preflow - / - 162 / 343 Cutflow O₂ Plasma / Air Shield 42 / 89 133 / 281 Shield Gas Plasma Gas Cartridge...
  • Page 111 100i / 200i / 300i / 400i Stainless Steel Flow Rates (SLPM / SCFH) 200A N₂ Preflow - / - 73 / 154 Cutflow 35 / 74 49 / 103 H35 Plasma / N₂ Shield Shield Gas Plasma Gas Cartridge...
  • Page 112 100i / 200i / 300i / 400i Stainless Steel Flow Rates 200A N₂ (SLPM / SCFH) H₂O (GPH / LPH) Preflow 13 / 28 5 / 19 Cutflow N₂ Plasma / H₂O Shield 25 / 53 5 / 19 Shield Gas...
  • Page 113 100i / 200i / 300i / 400i Aluminum Flow Rates (SLPM / SCFH) 200A N₂ Preflow - / - 62 / 132 Cutflow H35 Plasma / N₂ Shield 33 / 71 44 / 94 Shield Cap Cartridge Assembly Shield Gas...
  • Page 114 100i / 200i / 300i / 400i Aluminum Flow Rates N₂ (SLPM / SCFH) H₂O (GPH / LPH) 200A Preflow 13 / 28 5 / 19 Cutflow N₂ Plasma / H₂O Shield 28 / 59 5 / 19 Shield Gas...
  • Page 115 100i / 200i / 300i / 400i Chart is for Customer Settings Flow Rates (SLPM / SCFH) O₂ Make Copies as Desired Preflow Cutflow Shield Gas Shield Retainer Shield Cap Plasma Gas Distributor Electrode Cartridge Distributor Manual Gas Control Advanced Torch Height Control (THC)
  • Page 116 100i / 200i / 300i / 400i This Page Intentionally Blank TORCH DATA 100i-400i 0560956430...

  • Page 117: Standard Cutting 250 - 300 Amp

    100i / 200i / 300i / 400i 8.03 Standard Cutting 250 - 300 Amp Mild Steel Flow Rates (SLPM / SCFH) 250A O₂ Preflow - / - 160 / 339 Cutflow 36 / 76 132 / 279 O₂ Plasma / Air Shield...
  • Page 118 100i / 200i / 300i / 400i Mild Steel Flow Rates (SLPM / SCFH) O₂ 300A Preflow - / - 194 / 412 O₂ Plasma / Air Shield Cutflow 27 / 58 160 / 340 Shield Cup Cartridge Assembly Shield Gas...
  • Page 119 100i / 200i / 300i / 400i Stainless Steel Flow Rates (SLPM / SCFH) 300A N₂ Preflow - / - 74 / 157 Cutflow H35 Plasma / N₂ Shield 44 / 93 51 / 108 Shield Cap Cartridge Assembly Shield Gas...
  • Page 120 100i / 200i / 300i / 400i Stainless Steel Flow Rates 300A N₂ (SLPM / SCFH) H₂O (GPH / LPH) Preflow 23 / 48 8 / 30 Cutflow 63 / 134 8 / 30 N₂ Plasma / H₂O Shield Shield Gas...
  • Page 121 100i / 200i / 300i / 400i Aluminum Flow Rates (SLPM / SCFH) N₂ 300A Preflow - / - 74 / 156 Cutflow H35 Plasma / N₂ Shield 44 / 93 51 / 107 Shield Cap Cartridge Assembly Shield Gas...
  • Page 122 100i / 200i / 300i / 400i Aluminum Flow Rates N₂ (SLPM / SCFH) H₂O (GPH / LPH) 300A Preflow 23 / 48 8 / 30 Cutflow N₂ Plasma / H₂O Shield 63 / 134 8 / 30 Shield Gas...
  • Page 123 100i / 200i / 300i / 400i Chart is for Customer Settings Flow Rates (SLPM / SCFH) Make Copies as Desired O₂ Preflow Cutflow Shield Gas Shield Retainer Shield Cap Plasma Gas Distributor Electrode Cartridge Distributor Manual Gas Control Advanced Torch Height Control (THC)
  • Page 124 100i / 200i / 300i / 400i This Page Intentionally Blank TORCH DATA 100i-400i 0560956430...

  • Page 125: Standard Cutting 400 Amp

    100i / 200i / 300i / 400i 8.04 Standard Cutting 400 Amp Flow Rates (SLPM / SCFH) Mild Steel O₂ 400A Preflow - / - 232 / 491 O₂ Plasma / Air Shield Cutflow 33 / 70 203 / 430...
  • Page 126 100i / 200i / 300i / 400i Stainless Steel Flow Rates (SLPM / SCFH) N₂ 400A Preflow - / - 207 / 439 Cutflow H35 Plasma / N₂ Shield 47 / 100 173 / 367 Cartridge Assembly Shield Cup Shield Gas...
  • Page 127 100i / 200i / 300i / 400i Flow Rates Stainless Steel N₂ (SLPM / SCFH) H₂O (GPH / LPH) 400A Preflow 22 / 47 8 / 30 N₂ Plasma / H₂O Shield Cutflow 72 / 153 8 / 30 Cartridge Assembly...
  • Page 128 100i / 200i / 300i / 400i Aluminum Flow Rates (SLPM / SCFH) 400A N₂ Preflow - / - 207 / 439 Cutflow H35 Plasma / N₂ Shield 47 / 100 173 / 367 Cartridge Assembly Shield Cup Shield Gas...
  • Page 129 100i / 200i / 300i / 400i Aluminum Flow Rates N₂ (SLPM / SCFH) H₂O (GPH / LPH) 400A Preflow 22 / 47 8 / 30 N₂ Plasma / H₂O Shield Cutflow 72 / 153 8 / 30 Cartridge Assembly...
  • Page 130 100i / 200i / 300i / 400i This Page Intentionally Blank TORCH DATA 100i-400i 0560956430...
  • Page 131 Chart is for Customer Settings Flow Rates (SLPM / SCFH) Make Copies as Desired N₂ Preflow Cutflow Manual Gas Control Advanced Torch Height Control (THC) Basic THC CNC Control Pierce Pre Flow Cut Flow Rates / Pressures Pierce Elevation Control Height Travel Max Kerf Width @...
  • Page 132 This Page Intentionally Blank...

  • Page 133: Bevel Cutting Up To 400 Amp

    100i / 200i / 300i / 400i 8.05 Bevel Cutting Up To 400 Amp Mild Steel Flow Rates (SLPM / SCFH) 100A Bevel Cut O₂ Preflow - / - 38 / 81 Cutflow 16 / 35 27 / 58 O₂ Plasma / Air Shield...
  • Page 134 100i / 200i / 300i / 400i Mild Steel Flow Rates (SLPM / SCFH) 150A Bevel Cut O₂ Preflow - / - 100 / 213 Cutflow O₂ Plasma / Air Shield 59 / 126 81 / 171 Shield Cup Cartridge Assembly...
  • Page 135 100i / 200i / 300i / 400i Mild Steel Flow Rates (SLPM / SCFH) 200A Bevel Cut O₂ Preflow - / - 162 / 343 Cutflow O₂ Plasma / Air Shield 42/89 133 / 281 Shield Cup Cartridge Assembly Shield Gas...
  • Page 136 100i / 200i / 300i / 400i Mild Steel Flow Rates (SLPM / SCFH) O₂ 300A Bevel Cut Preflow - / - 194 / 412 Cutflow 27 / 58 160 / 340 O₂ Plasma / Air Shield Shield Cup Cartridge Assembly...
  • Page 137 100i / 200i / 300i / 400i Flow Rates (SLPM / SCFH) Mild Steel O₂ 400A Bevel Cut Preflow - / - 232 / 491 O₂ Plasma / Air Shield Cutflow 33 / 70 203 / 430 Shield Cup Cartridge Assembly...
  • Page 138 100i / 200i / 300i / 400i Stainless Steel Flow Rates (SLPM / SCFH) 400A Bevel Cut N₂ Preflow - / - 207 / 439 Cutflow 47 / 100 173 / 367 H35 Plasma / N₂ Shield Cartridge Assembly Shield Cup...
  • Page 139 100i / 200i / 300i / 400i Flow Rates Stainless Steel N₂ (SLPM / SCFH) H₂O (GPH / LPH) 400A Bevel Cut Preflow 22 / 47 8 / 30 N₂ Plasma / H₂O Shield Cutflow 72 / 153 8 / 30...
  • Page 140 100i / 200i / 300i / 400i Aluminum Flow Rates (SLPM / SCFH) 400A Bevel Cut N₂ Preflow - / - 207 / 439 Cutflow 47 / 100 173 / 367 H35 Plasma / N₂ Shield Shield Cap Cartridge Assembly...
  • Page 141 100i / 200i / 300i / 400i Flow Rates Aluminum N₂ (SLPM / SCFH) H₂O (GPH / LPH) 400A Bevel Cut Preflow 22 / 47 8 / 30 N₂ Plasma / H₂O Shield Cutflow 72 / 153 8 / 30...
  • Page 142 100i / 200i / 300i / 400i Chart is for Customer Settings Flow Rates (SLPM / SCFH) Make Copies as Desired N₂ Preflow Cutflow Manual Gas Control Advanced Torch Height Control (THC) Basic THC CNC Control Pierce Pre Flow Cut Flow Rates / Pressures...

  • Page 143: Robotic Cutting Up To 30 Amp

    100i / 200i / 300i / 400i 8.06 Robotic Cutting Up to 30 Amp Flow Rates (SLPM / SCFH) Mild Steel 15A ROBOTIC COMPATIBLE Preflow 5 / 10 12 / 25 Plasma / O Shield Cutflow 8 / 18 0 / 0...
  • Page 144 100i / 200i / 300i / 400i Flow Rates (SLPM / SCFH) Mild Steel 20-30A ROBOTIC COMPATIBLE Preflow 5 / 10 16 / 34 Plasma / O Shield Cutflow 15 / 32 0 / 0 Shield Cup Plasma Gas Shield Gas...

  • Page 145: Torch Parts List

    100i / 200i / 300i / 400i 8.07 Torch Parts List Returns If a product must be returned for service, contact your authorized distributor. Materials returned without proper authorization will not be accepted. Ordering Information Order replacement parts by catalog number and complete description of the part or assembly. Also include the model and serial number of the machine or torch.
  • Page 146 100i / 200i / 300i / 400i Consumables O-Rings (up to 150 Amps) Shield Cap Tips Up to 100 Amps Electrode O-Ring 9-9039 O-Ring 9-9035 O-Ring 9-9061 O-Ring 9-9060 150 Amp Tip 200 Amp Tip Art # A-07161_AB O-Ring 9-9038...
  • Page 147 100i / 200i / 300i / 400i Cartridge Assembly (0559211300) Consumables Cartridge Assembly Art # A-09241_AB iSeries Baffle Shield Cup Cartridge Body Older Cartridge Assembly 400 Amp (0559211400) Consumables Art # A-09618_iSeries Outer Cartridge, 400A Thread Ring Speedlok Retaining Ring...
  • Page 148 100i / 200i / 300i / 400i New Cartridge Assembly 400 Amp (0559211400) Consumables Art # A-10925_iSeries Thread Ring Outer Cartridge, 400A Speedlok Retaining Ring Cartridge Body Tool, Torchhead, XT Not Sold Seperately Assembly Procedure 400A Cartridge is assembled in the following steps: 1.
  • Page 149 100i / 200i / 300i / 400i Torch Replacement Parts Standard Cutting Torch Description Catalog Number Torch Head Assembly 0559211002 Coolant Check Valve Assembly 9-4846 Torch Positioning Tube (includes hardware kit 9-4847) 9-4700 Positioning Tube Hardware Kit (O-Ring) 9-4847 Plasma & Shield Leads Assembly (to Torch Valve)
  • Page 150 100i / 200i / 300i / 400i Global Pro Bevel Torch Description Catalog Number iSeries Global Pro Torch Assembly 0559211013 Torch Head Assembly 0559211002 Coolant Check Valve Assembly 9-4846 Torch Positioning Tube (includes hardware kit 9-4847) 9-4703 Positioning Tube Hardware Kit (O-Ring)
  • Page 151 100i / 200i / 300i / 400i Global Pro HD Bevel Torch Description Catalog Number iSeries Global Pro HD Torch Assembly 0559211012 Torch Head Assembly 0559211002 Coolant Check Valve Assembly 9-4846 Torch Positioning Tube (includes hardware kit 9-4847) 9-4700 Positioning Tube Hardware Kit (O-Ring)

  • Page 152: Patent Information

    100i / 200i / 300i / 400i 8.08 Patent Information This product may be protected by one or more of the following U.S. Patent Nos.: 6852944; 6919526; 694616; 6989505; 6998566; 7005600; 7019254; 7071443; 7126080; 7132619; 7737383 TORCH DATA 100i-400i 0560956430...

  • Page 153: Appendix 1: Cooling Diagram

    100i / 200i / 300i / 400i APPENDIX 1: Cooling Diagram 0560956430 APPENDIX...
  • Page 154 100i / 200i / 300i / 400i APPENDIX 2: System Schematic 100A, 380-415V PG 1 INVERTER MODULE (IM) #1 J105B IM #1 Section B (upper) A C IN PU T (23) (23) J100 -- 30 C K T R IB B ON...
  • Page 155 100i / 200i / 300i / 400i TORCH (49) (49) PILOT BOARD TES T POIN TS TORCH LED'S TP 1 G N D (49) To TB 4-7 TP 2 PILO T G ATE D2 PILOT ENABLE TP 3 +5V D11 +5V...

  • Page 156: Appendix 2: System Schematic 100A, 380-415V

    100i / 200i / 300i / 400i APPENDIX 3: System Schematic 100A, 380-415V PG 2 J12 = Mini-Fit Jr AMBIENT COOLANT 400 VAC -- Single 18 AWG in pins 1 & 4 480 VAC -- Single 18 AWG in pins 1 & 8...
  • Page 157 100i / 200i / 300i / 400i Fan Control TO PILOT PCB J70 - HE (70) 230 VAC to HE 400 (70) (Sht 1, B8) 230 VAC _ SW (D2) (96) (69) 230 VAC Ret (69) 230 VAC _ SW _ RET...

  • Page 158: Appendix 4: System Schematic 200A, 380-415V

    100i / 200i / 300i / 400i APPENDIX 4: System Schematic 200A, 380-415V PG 1 INVER T ER MO DULE (IM) #2 half module (middle position) J105A A C IN PU T (23) IM # 2 Se ction A (l ower)
  • Page 159 100i / 200i / 300i / 400i TORCH (49) PI LOT BO AR D LED 'S TES T POIN TS (49) TOR C H TP 1 G N D To TB 4-7 D2 PI LOT EN ABL E TP 2 PILO T G ATE...

  • Page 160: Appendix 5: System Schematic 200A, 380-415V

    100i / 200i / 300i / 400i APPENDIX 5: System Schematic 200A, 380-415V PG 2 AMBIENT J12 = Mini-Fit Jr COOLANT 400 VAC -- Single 18 AWG in pins 1 & 4 (90) 480 VAC -- Single 18 AWG in pins 1 & 8...
  • Page 161 100i / 200i / 300i / 400i TO PILOT PCB Fan Control J70 - HE Sht 1, B8) (70) 230 VAC to HE 400 (70) 230 VAC _ SW (D2) (69) 230 VAC Ret (69) 230 VAC _ SW _ RET...

  • Page 162: Appendix 6: System Schematic 300A, 380-415V

    100i / 200i / 300i / 400i APPENDIX 6: System Schematic 300A, 380-415V PG 1 INVERTER MODULE (IM) #3 (top) AC INPUT IM #3 Section B (upper) J105B J100 -- 30 CKT RIBBON J104B J103B 019X502700 J105A AC INPUT IM #3 Section A (lower)
  • Page 163 100i / 200i / 300i / 400i TO CCM CPU PCB J36 (Sht 2, C3) TORCH (49F) (49) ELECTRODE (-) (51F) PILOT BOARD LED'S TEST POINTS TORCH WORK (+) TP1 GND (49) To TB4-7 TP2 PILOT GATE D2 PILOT ENABLE...

  • Page 164: Appendix 7: System Schematic 300A, 380-415V

    100i / 200i / 300i / 400i APPENDIX 7: System Schematic 300A, 380-415V PG 2 J12 = Mini-Fit Jr AMBIENT COOLANT 400 VAC -- Single 18 AWG in pins 1 & 4 (90) 480 VAC -- Single 18 AWG in pins 1 & 8...
  • Page 165 100i / 200i / 300i / 400i TO PILOT PCB Fan Control J70 - HE (70) 230 VAC to HE 400 (70) 230 VAC _ SW (96) (D2) (69) 230 VAC Ret (69) 230 VAC _ SW _ RET (D2)

  • Page 166: Appendix 8: System Schematic 400A, 380-415V

    100i / 200i / 300i / 400i APPENDIX 8: System Schematic 400A, 380-415V PG 1 INVERTER MODULE (IM) #3 (top) AC INPUT IM #3 Section B (upper) J105B J100 -- 30 CKT RIBBON J104B J103B 019X502700 J105A AC INPUT IM #3 Section A (lower)
  • Page 167 100i / 200i / 300i / 400i TO CCM CPU PCB J36 (Sht 2, C3) TORCH (49F) (49) ELECTRODE (-) (51F) PILOT BOARD LED'S TEST POINTS TORCH TP1 GND WORK (+) (49) To TB4-7 TP2 PILOT GATE D2 PILOT ENABLE...

  • Page 168: Appendix 9: System Schematic 400A, 380-415V

    100i / 200i / 300i / 400i APPENDIX 9: System Schematic 400A, 380-415V PG 2 J12 = Mini-Fit Jr AMBIENT COOLANT 400 VAC -- Single 18 AWG in pins 1 & 4 (90) 480 VAC -- Single 18 AWG in pins 1 & 8...
  • Page 169 100i / 200i / 300i / 400i TO PILOT PCB Fan Control J70 - HE (96) (70) 230 VAC to HE 400 (70) 230 VAC _ SW (D2) (D2) (69) 230 VAC Ret (69) 230 VAC _ SW _ RET...

  • Page 170: Appendix 10: Scu Interface For Iseries

    100i / 200i / 300i / 400i APPENDIX 10: SCU Interface for iSeries APPENDIX 0560956430 A-18...
  • Page 171 100i / 200i / 300i / 400i This Page Intentionally Blank 0560956430 APPENDIX...
  • Page 172 Customer // Technical Support (843) 664-4405 (800) ESAB-123 (372-2123) ESAB Welding and Cutting Products 2800 Airport Road Denton TX, 76207 http://www.esab.com ESAB Cutting Systems – Canada 6010 Tomken Road Mississauga, Ontario Canada L5T 1X9 Phone: (905) 670-0220 Fax: (905) 670-4879...

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