Download
Share
Print this page
Thermal Dynamics PRECISION 130 Operating Manual
  1. Manuals
  2. Brands
  3. Thermal Dynamics Manuals
  4. Welding System
  5. Precision 130
  6. Operating manual
Thermal Dynamics PRECISION 130 Operating Manual

Thermal Dynamics PRECISION 130 Operating Manual

Plasma cutting system automated gas control
Hide thumbs Also See for PRECISION 130:

Advertisement

Quick Links

Download this manual
PRECISION 130
PLASMA CUTTING
SYSTEM AUTOMATED
GAS CONTROL
Operating
Manual
®
Revision: AB
Issue Date: 03 October, 2024
MAX OUTPUT
INPUT POWER
130
3
PHASE
AMPS
VOLTAGE
VOLTAGE
VOLTAGE
400V 480V
380V
Thermal-Dynamics.com
Art # H-0046
Manual No.: 0-5691

Advertisement

loading
Need help?

Need help?

Do you have a question about the PRECISION 130 and is the answer not in the manual?

Questions and answers

Related Manuals for Thermal Dynamics PRECISION 130

Summary of Contents for Thermal Dynamics PRECISION 130

  • Page 1 ® MAX OUTPUT INPUT POWER PHASE AMPS VOLTAGE VOLTAGE VOLTAGE 400V 480V 380V PRECISION 130 PLASMA CUTTING SYSTEM AUTOMATED GAS CONTROL Operating Manual Art # H-0046 Revision: AB Issue Date: 03 October, 2024 Manual No.: 0-5691 Thermal-Dynamics.com...
  • Page 2 ® WE APPRECIATE YOUR BUSINESS! Congratulations on your new Thermal Dynamics product. We are proud to have you as our customer and will strive to provide you with the best service and reliability in the industry. This product is backed by our extensive warranty and world-wide service network. To locate your nearest distributor or service agency call 1-800-752-7622, or visit us on the web at www.
  • Page 3 While the information contained in this Manual represents the Manufac- turer’s best judgement, the Manufacturer assumes no liability for its use. Plasma Cutting Power Supply with Automated Gas Control, Precision 130 Operating Manual No. : 0-5691 Published by: Thermal Dynamics Corporation.
  • 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 This Page Intentionally Blank...
  • Page 7 The RoHS Directive 2011/65/EC, entering into force 2 January 2013 Type of equipment PLASMA CUTTING POWER SUPPLY Type designation etc. Precision 130, Plasma Systems, from serial number MXXXXXXXX Brand name or trade mark Thermal Dynamics Manufacturer or his authorised representative established within the EEA...
  • Page 8 This page intentionally blank.
  • Page 9 TABLE OF CONTENTS SECTION 1: SAFETY .......................11 1.01 Safety Precautions - ENGLISH ..................11 1.02 Précautions de sécurité - FRENCH CANADIAN ............16 SECTION 2: SPECIFICATIONS ....................21 2.01 General Description Of The System................21 2.02 Plasma Power Supply ....................... 21 2.03 Gas Control Module ......................
  • Page 10 TABLE OF CONTENTS 6.07 Power Supply Replacement Parts - Rear/ Front Panel .......... 68 6.08 Power Supply Replacement Parts - Upper Left Side..........69 6.09 Power Supply Replacement Parts - Lower Left Side ..........70 6.10 Power Supply Replacement Parts- Top ..............72 SECTION 7: TORCH MAINTENANCE ..................77 7.01 Consumable Removal ......................
  • Page 11 PRECISON 130 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 12 PRECISON 130 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 workplace. Noise levels should be measured to be sure the decibels (sound) do not exceed safe levels.
  • Page 13 PRECISON 130 If you develop momentary eye, nose, or throat irritation while operating, this is an indication that ventilation is not adequate. Stop work and take necessary steps to improve ventilation in the work area. Do not continue to operate if physical discomfort persists. Refer to ANSI/ASC Standard Z49.1 (see listing below) for specific ventilation recommendations.
  • Page 14 PRECISON 130 AWS C5.6 - “Recommended Practices for Gas Metal Arc Welding”. AWS SP - “Safe Practices” - Reprint, Welding Handbook. ANSI/AWS F4.1, “Recommended Safe Practices for Welding and Cutting of Containers That Have Held Hazardous Substances. ” CSA Standard - W117.2 = Safety in Welding, Cutting and Allied Processes. Meaning of symbols - As used throughout this manual: Means Attention! Be Alert! Your safety is involved.
  • Page 15 PRECISON 130 This Page Intentionally Blank 0-5691 SAFETY INSTRUCTIONS...
  • Page 16 PRECISON 130 1.02 Précautions de sécurité - FRENCH CANADIAN AVERTISSEMENT : Ces règles de sécurité ont pour but d’assurer votre protection. Ils récapitulent les infor- mations de précaution provenant des références dans la section des Informations de sécurité supplémentaires. Avant de procéder à l’installation ou d’utiliser l’unité, assurez-vous de lire et de suivre les précautions de sécurité...
  • Page 17 PRECISON 130 Pour obtenir des informations supplémentaires, consultez le NFPA Standard 51B, “Fire Prevention in Use of Cutting and Welding Processes”, disponible au National Fire Protection Association, Batterymarch Park, Quincy, MA 02269. BRUIT -- Le bruit peut provoquer une perte permanente de l’ouïe. Les procédés de soudage à l’arc de plasma peuvent provoquer des niveaux sonores supérieurs aux limites normalement acceptables.
  • Page 18 PRECISON 130 D. Branchez le câble de masse à la pièce à traiter le plus près possible de la section à souder. E. Veillez à garder la source d’alimentation pour le soudage et les câbles à une distance appropriée de votre corps.
  • Page 19 PRECISON 130 Maintenez les câbles, les fils de mise à la terre, les branchements, le cordon d’alimentation et la source d’alimentation en bon état. N’utilisez jamais un équipement s’il présente une défectuosité quelconque. N’utilisez pas l’équipement de façon abusive. Gardez l’équipement à l’écart de toute source de chaleur, notamment des fours, de l’humidité, des flaques d’eau, de l’huile ou de la graisse, des atmosphères corrosives et des intempéries.
  • Page 20 PRECISON 130 Ce produit a été conçu pour la découpe au plasma seulement. MISE EN GARDE Toute autre utilisation pourrait causer des blessures et/ou endom- mager l’appareil. 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.
  • Page 21 PRECISION 130 SECTION 2: SPECIFICATIONS 2.01 General Description Of The System A typical Precision system configuration includes: • One Power Supply • Remote Gas Control • Precision Plasma Cutting Torch • Set Of Connecting Leads • Torch Spare Parts Kit The components are connected at installation.
  • Page 22 These are suggestions only. Always refer to your local and national codes that apply to your region for final determination of correct wire type and size. Precision 130 Specifications & Design Features Max OCV (U0) 400 - 450 VDC...
  • Page 23 PRECISION 130 2.06 Power Supply Dimensions 380V - 480V Input Voltage 31.93 inch 810.96 mm 130A_508 lb / 230 kg 29.51 inch (749.66 mm) 22.11 inch 561.54 mm Art # H-0047 0-5691 SPECIFICATIONS...
  • Page 24 PRECISION 130 2.07 Power Supply Rear Panel Features RGC connector Coolant Tank CNC connector Torch COMM connector Earth Ground Height control Work Cable RGC Hoses Power cable Plasma supply hose Shield supply hose Optional Ohmic sense wire Art # H-0052...
  • Page 25 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. Precision 130 Power Supply: Gas Pressures, Flows, and Quality Requirements Quality...
  • Page 26 PRECISION 130 2.09 Gas Applications MATERIAL MILD STEEL STAINLESS STEEL ALUMINUM GAS TYPE GAS TYPE GAS TYPE PRE- PRE- PRE- OPERATION PLASMA SHIELD PLASMA SHIELD PLASMA SHIELD FLOW FLOW FLOW 30A Cut H 2 0 H 2 0 50A Cut...
  • Page 27 PRECISION 130 2.10 XT Torch Specifications A. Torch Dimensions Mounting Tube 16.05” 407.67 mm 15,75” (400 mm) 52.832 mm 2.080” 160.02 mm 6.3” 46.228 mm 101.6 mm 1.82” 4.0” 31.877 mm 1.255” 18.669 mm Art # H-0072 0.735” 0-5691 SPECIFICATIONS...
  • Page 28 PRECISION 130 B. Torch Leads Lengths Torch Lead Assembly Lengths Feet Meters 10.8 15.2 C. Torch Parts (Generic Parts Shown) Art # A-04741_AB 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 29 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 30 PRECISION 130 3.02 System Layout 130 Amp Refer to section 3.08 and 3.10 for ground connections and ground cables. COMM Plasma supply Ground wire See Note Shield supply Plasma cut gas Plasma Gas supply Remote Shield Gas supply Shield cut gas...
  • Page 31 PRECISION 130 3.04 Leads and Cables All Amperage 1/0 (35’/50’) Cable Work Cable 35’/50’ Cable Torch lead 35’/50’ Hose Green Green Autogas lead 14 pin 16 pin Ground wire Green / Yellow 1/0 ( 25’/50’ ) (25’ / 50’) Cable...
  • Page 32 PRECISION 130 Leads Catalog numbers: Precision 130 Power supply Leads Lengths Description 25ft 35ft 50ft 1.2m 7.6m 10.6m 15.2m Work cable 9-9303 9-9304 Torch lead 4-3123 4-3124 Autogas lead 4-3121 4-3122 Ground wire 9-4933 9-4934 CNC interface 9-8312 9-8313 Ground wire #4...
  • Page 33 PRECISION 130 3.05 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. Art # H-0124 1. Tilt one side of the power supply at 150 from a solid surface.
  • Page 34 PRECISION 130 NOTE: If there is a second power supply or other heat source venting into this space, then you will need to double the distance(s) shown. 3’ (0.91 m) 3’ (0.91 m) 3’ 3’ (0.91 m) (0.91 m) Art # H-0048...
  • Page 35 PRECISION 130 3.06 Connect Input Power and Ground Cables NOTE! Refer to section 3.01”Electric supply” for recommended wire size, fusing etc. 400 V System Remove left side panel using T25 Torx driver. Take note of the spots where paint is removed, that goes to the inside when reinstalling the panels.
  • Page 36 PRECISION 130 480 V/380-400-415 V Systems Power cord is wired directly to the L1, L2, L3 terminals of the contactor. Connect the safety ground cable to the lug on the rear panel. Contactor input terminals has upper and lower section.
  • Page 37 PRECISION 130 3.07 Connect Work Cable, Torch lead and Pilot wire Remove the top and right side panel to install torch, work and gas hoses. Insert the work lead through rear panel hole just below the torch leads entry and install on the copper bracket as indicated.
  • Page 38 PRECISION 130 Install pilot lead (white AWG 10 wire with yellow ring tongue) and torch supply hose. Art # H-0062 Insert the shield braid over the brass ring and secure with the included hose clamp. Art # H-0074 Connect the earth ground cable (1/0 AWG or larger recommended) below the shield braid in the rear panel.
  • Page 39 2. Grounding for components mounted on the cutting table (CNC controllers, height controllers, plasma remote controls, etc.) should follow the manufacturer’s recommendations for wire size, type, and connection point locations. For Thermal Dynamics components (except Gas Control Module) it is recommended to use a minimum of 10 AWG (Eu- ropean 6 mm ) wire or flat copper braid with cross section equal to or greater than 10 AWG connected to the cutting table frame.
  • Page 40 PRECISION 130 NOTE! Do Not connect the work cable directly to the ground rod. Do not coil up excess ground or power cables. Cut to proper length and reterminate as needed. 5. Make sure work cable and ground cables are properly connected. The work cable must have a solid connection to the cutting table.
  • Page 41 PRECISION 130 Obtain a power resistor of either 1200 (1.2K) ohms, 15-25W min, if using a 120V secondary or 2200 (2.2K) ohms, 25 -30W for a 220V secondary. 4. Assemble the transformer and power resistor in a metal box. Connect a 3 wire (w/GND) power cord with ground wire attached to the metal box for safety.
  • Page 42 PRECISION 130 3.09 Connect Cables for CNC, RGC, COMM and Height control 1. Connect one end of each cable to the power supply. 2. Connect the other end of the CNC cable to the CNC device. 3. The CNC cable shield must be attached to ground at the CNC end.
  • Page 43 PRECISION 130 3.10 Switch Settings Remove the left side panel of power supply. Set switches on CPU PCB and I/O Relay PCB as per the illustrations. Any changes made require a restart of power supply. CAUTION Printed circuit boards in the Command - CPU & I/O Relay are static - sensitive. Discharge any built-up static charges in your body or surroundings before touching the printed circuit boards.
  • Page 44 PRECISION 130 3.11 Arc Voltage / Height Control Connections The terminal strip provides connections to negative Arc Volts (Torch or electrode), Tip Volts (Pilot) and Work. These are for a height control that requires connection to the full non-divided arc voltage. Also available on the terminal strip are 120VAC and 24 VAC.
  • Page 45 PRECISION 130 3.12 Remote Gas Control (RGC) Installation The Remote Gas Control must be installed in a suitable location. If the Module is mounted to any support subject to vibration or motion, the installer must fasten the module to the support securely.
  • Page 46 PRECISION 130 3. Insert the plasma hose with green connects to the upper solenoid and shield hose (red) to the lower solenoid. Art # H-0065 3.13 Connecting Torch Connect the Torch as follows: Přívod chladícího média, Odvod chladícího média a a pilotní vedení...
  • Page 47 PRECISION 130 3. Remove and discard the protective end caps from the Mounting Tube. 4. Install the O-ring in the groove at the upper end of the Mounting Tube. 5. Install the Mounting Tube as follows: a. Position the Mounting Tube at the end of the leads assemblies as shown.
  • Page 48 PRECISION 130 3.14 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 49 PRECISION 130 Art # A-14038 8. Slide the ohmic clip over the shield cup if using ohmic torch height control sensing. Ohmic Clip Art # A-03393_AB 9. Connect the wire lead from the height finder to the ohmic clip. 0-5691...
  • Page 50 PRECISION 130 3.15 Voltage Divider for iHC & iCNC Torch Height Control For best plasma cutting performance it is necessary to maintain a constant height (standoff ) above the metal while cut- ting. Cutting tables use a Torch Height Control (THC), also called a Z axis control, most of which use feedback from the arc voltage to control the height.
  • Page 51 PRECISION 130 5. Ohmic Sense wire assembly, if used, it is installed from the V-D board to a hole provided near the bottom of the rear panel. Control Cable. The iHC board can be supplied with a wire harness and connector (shown in previous image), to be installed in the rear panel hole labeled “Height Control”...
  • Page 52 3.16 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 53 PRECISION 130 SECTION 4: OPERATION 4.01 System Operation This section contains operating information which is specific to the power supply. WARNING Review the safety precautions in Section 1. If the power supply cord has a plug or is not permanently connected to power, be sure the power to the outlet is disconnected when inserting the plug into the outlet.
  • Page 54 CNC Start signal, gas will preflow for about 3 seconds, ignites the pilot and immediately transfers to the cutting arc. Precision 130 sends OK to Move (relay closure) to the table controller and after programmed pierce delay table starts motion cutting out the programmed part.
  • Page 55 PRECISION 130 a) If you chose to shut OFF power for inspecting or changing consumables, or any other purpose, the system does not remember what you were doing last so you will have to go through the complete sequence from the beginning starting with step 1.
  • Page 56 PRECISION 130 4.03 Gas Selection A. Plasma Gases 1. Air Plasma • Can be used on all materials with good results but high precision quality. 2. Argon/Hydrogen (H35) Plasma • Recommended for use on 3/4 in (19 mm) and thicker stainless steel. Recommended for 1/2 inch (12 mm) and thicker nonferrous materials.
  • Page 57 PRECISION 130 C. Water shield and purging: When switching from a non-water shield to a water shield: • Power down (or disable) the power supply before replumbing. The previous gas supply line must be disconnected and replaced with a water supply line at the shield supply inlet on the back of the power supply.
  • Page 58 The codes are separated into logical groups; 100; 200; 300; 400 & 600. Other groups and other individual code numbers that don’t apply to the Precision 130 have been omitted. The possible causes are listed in the order thought to be most likely to occur and/or easiest to test. PCBs and torch are hardest and most expensive to replace, also least likely to fail, so are listed last.
  • Page 59 PRECISION 130 System Fault & Status Code Group 2 -- Plasma Power Supply Code Message Remedy / Comments Missing phase from incoming power; Open wall fuse, Open fuse F1 or F2 inside Missing AC Phase P130, Bad power cable connection; Problem with connector or wire harness to System Bias PCB at J60;...
  • Page 60 PRECISION 130 System Fault & Status Code Group 2 -- Plasma Power Supply Code Message Remedy / Comments Invalid AC Voltage Selection; Damaged or loose connection at J61 of System Bias BIAS VAC Invalid Supply; Defective System Bias PCB System Bias PCB detected AC Voltage is higher than Power Supply rated Voltage;...
  • Page 61 PRECISION 130 System Faults & Status Code Group 3 -- Gas Controller Status & Protocol Code Message Remedy / Comments RGC Gas Control cable not connected (either end) or defective; RF (arcstart- er) interference; make sure RGC chassis is grounded per the manual; move Gas control communica- torch lead away from RGC or its control cable.
  • Page 62 PRECISION 130 System Faults & Status Code Group 6 - CPU PCB Code Message Remedy / Comments Analog Voltage Error Defective CPU board, replace. ADC or DAC error Defective CPU board, replace. Data Memory error Defective CPU board, replace. Program memory fault Defective CPU board, replace.
  • Page 63 PRECISION 130 SECTION 5: MAINTENANCE 5.01 General Maintenance Perform the following checks periodically to ensure proper system performance: month month month month year years years years 2880 3840 4800 hours hours hours hours hours hours hours hours LUBRICATE CARTRIDGE O-RING...
  • Page 64 PRECISION 130 5.02 Coolant Drain Procedure NOTE! Materials required for coolant drain procedure are “Pressure regulator, One touch fittings, Hose and Portable hand pump”. 1. Remove the top and right panels of the power supply. 2. Remove the coolant tank cap.
  • Page 65 PRECISION 130 3. Disconnect the torch return hose from torch interface assembly. 4. Connect the torch return hose to pressure regulator. Art # H-0077 5. Disconnect the Inlet hose from pump. 6. Attach hose to pump inlet hose. Place drain end into bucket.
  • Page 66 PRECISION 130 7. Connect air hose to pressure regulator. WARNING! Ensure Pressure regulator is shut. 8. Set pressure regulator to 10 psi or less to drain coolant into tank. Coolant will drain into bucket. WARNING! Do not exceed 10 psi.
  • Page 67 PRECISION 130 10. Disconnect Pump Outlet Hose from Torch Block. Turn Pump On. 11. Drain hose into bucket. Art # H-0081 0-5691 MAINTENANCE...
  • Page 68 PRECISION 130 This Page Intentionally Blank MAINTENANCE 0-5691...
  • Page 69 PRECISION 130 SECTION 6: REPLACEMENT ASSEMBLIES & PARTS 6.01 Replacement Power Supply Complete Unit / Component CatalogNumber Precision 130, 480V 3-1300-2 Precision 130, 380/415V 3-1300-3 Precision 130, 400V, CE 3-1300-4 Remote gas control (RGC) 9-9835 0-5691 PARTS LISTS...
  • Page 70 PRECISION 130 6.02 System Layout 130 Amp Refer to section 3.08 and 3.10 for ground connections and ground cables. COMM Plasma supply Ground wire See Note Shield supply Plasma cut gas Plasma Gas supply Remote Shield Gas supply Shield cut gas...
  • Page 71 PRECISION 130 6.03 Leads And Cables All Amperages 1/0 (35’/50’) Cable Work Cable 35’/50’ Cable Torch lead 35’/50’ Hose Green Green Autogas lead 14 pin 16 pin Ground wire Green / Yellow 1/0 ( 25’/50’ ) (25’ / 50’) Cable...
  • Page 72 PRECISION 130 Leads Catalog numbers: Precision 130 Power supply Leads Lengths Description 25ft 35ft 50ft 1.2m 7.6m 10.6m 15.2m Work cable 9-9303 9-9304 Torch lead 4-3123 4-3124 Autogas lead 4-3121 4-3122 Ground wire 9-4933 9-4934 CNC interface 9-8312 9-8313 Ground wire #4...
  • Page 73 PRECISION 130 6.04 Power Supply Replacement Parts-Panel Item # Description Catalog # Panel,Rear,Pwr Sup 9-1344 Panel,Front,Pwr Sup 9-1345 Panel,Side Pwr Sup 9-1335 Pnl, Radiator Side 9-1337 Panel,Top Pwr Sup 9-1336 Screw Combi Mrt M5x12 Purchase locally Foot 0465415001 M6 X 1 X 30mm Hex Head Bolt, Grade 5, Zinc Plated...
  • Page 74 PRECISION 130 6.05 Power Supply Replacement Parts - Upper Right Side Item # Description Catalog # Screw Combi Mrt M5x12 Purchase locally Ass’y Fan/Heat Exchanger 9-1333 Egt Module 9-7342 Screw,Socket Head,M4x0.7,10,ZP Purchase locally Washer, Split Lock, M4 ZP Purchase locally...
  • Page 75 PRECISION 130 6.06 Power Supply Replacement Parts - Lower Right Side Item # Description Catalog # Ass´y, Coolant Motor Pump 9-1330 M6-1.0 Kepnut W/Star Washer Purchase locally 1/4 Plain Regular Washer Purchase locally 2, 3 Art # H-0084 0-5691 PARTS LISTS...
  • Page 76 PRECISION 130 6.07 Power Supply Replacement Parts - Rear/ Front Panel Item # Description Catalog # Plug, 0.875” Hole Purchase locally 3/8-16 Hex Nut,Brass Purchase locally 3/8 External Star Washer, Zinc Purchase locally #8-16 X 5/8 T20 Pan Head Plast...
  • Page 77 PRECISION 130 6.08 Power Supply Replacement Parts - Upper Left Side Item # Description Catalog # Ass’y, Pilot Module 9-9827 Screw Combi Mrt M5x12 Purchase locally Power Resistor, Pilot 9-1346 Screw, M5-0.8 X 40mm Phillips Pan Hd Purchase locally Standoff, M/F,M4x30mm Purchase locally I/O &...
  • Page 78 PRECISION 130 6.09 Power Supply Replacement Parts - Lower Left Side Item # Description Catalog # Contactor / Capacitor Assembly 9-7318 Nut, Keps, M4 Purchase Locally Machine, Hex Head Purchase Locally Bolt, M6-1.0 X 90mm Steel-Zinc Purchase Locally Washer, Split Lock, M6 ZP...
  • Page 79 PRECISION 130 Art # H-0087 0-5691 PARTS LISTS...
  • Page 80 PRECISION 130 6.10 Power Supply Replacement Parts- Top Item # Description Catalog # Screw,Hex Head,M6x1x35,ZP Purchase Locally Nut,M6x1.0,14mm Spring Washer Purchase Locally Nut, M5x0.8 W/ 10mm Flt Washer Purchase Locally Bolt, M6-1.0 X 20mm Steel-Zinc Purchase Locally M5 X 0.8 X 16mm...
  • Page 81 PRECISION 130 SECTION 7: TORCH MAINTENANCE 7.01 Consumable Removal 1. Use the removal tool to hold the Shield Cup & Cartridge Assembly stationary. Turn the Shield Cup to remove it from the Cartridge Assembly. Cartridge Tool Assembled Cartridge Art # A-04344_AB Shield Cup 2.
  • Page 82 PRECISION 130 7.02 O-Ring Lubrication Lubricate all three O-Rings on the Cartridge Assembly and all three O-Rings on the Torch Head periodically with O-Ring Lubricant supplied. Remove the snap ring on the cartridge assembly and slide the locking ring downward for access to the O-Ring under the locking ring.
  • Page 83 PRECISION 130 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 a ect torch performance.
  • Page 84 PRECISION 130 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 gen- tly clean the threads on the torch head with a wire brush.
  • Page 85 PRECISION 130 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 86 PRECISION 130 Torch Electrodes Art # A-09653 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 0.08 0.04 0.08 0.08 0.06 0.08 0.08 TORCH INFORMATION 0-5691...
  • Page 87 PRECISION 130 APPENDIX 1: CNC CNC Functions CNC I/O circuits provide at least 1000V galvanic isolation from the plasma power supply. While the CNC circuits are isolated from the power supply, many of the signal returns on J15 and TB1 are common to each other.
  • Page 88 PRECISION 130 CNC Input / Output Descriptions E-Stop input— Requires closed connection rated for 35ma. @ 24VDC for unit to operate. Factory installed jumper between TB1-1&2 must be removed when connecting user supplied E-Stop circuit. Divided Arc Voltage output — Arc Voltage signal is isolated from plasma supply. Max Divided Arc Voltage signal level depends on actual arc voltage times divide ratio however can not exceed approximately 12 V.
  • Page 89 PRECISION 130 CNC Connections Cutting Machine CNC Cable Power Supply * ..... Plasma Enable (+) ....Plasma Enable (-) ....Source, 24 VDC, 10 ma. START/STOP ....Divided Arc V (-) ....Divided Arc V (+) ....Pre Flow ON (+) ....
  • Page 90 PRECISION 130 CNC Cable Color Code TABLE 1: CABLE ITEM#4 COLOR CODE TABLE COLOR SIGNAL DESCRIPTION LOCATION PLASMA ENABLE (+) BLACK WHITE PLASMA ENABLE (-) CNC START (+) GREEN CNC START (-) ORANGE DIVIDED ARC VOLTAGE (+) BLUE DIVIDED ARC VOLTAGE (-)
  • Page 91 PRECISION 130 This page is intentionally blank. 0-5691 APPENDIX...
  • Page 92 PRECISION 130 APPENDIX 2: CPU PCB LAYOUT APPENDIX 0-5691...
  • Page 93 PRECISION 130 CPU PCB Test Points +24V +3.3V +5.0V TP25 TP26 TP31 3.30V_REF LED Reference RS 422 R X D* RS 422 T X D* 3.3V_ISO NORMAL OPERATION* PLASMA ENABLED PLASMA ARC ON 3.3V 3.30V_REF 5V_ISO * BLINKING 0-5691 APPENDIX...
  • Page 94 PRECISION 130 APPENDIX 3: I/O PCB LAYOUT APPENDIX 0-5691...
  • Page 95 PRECISION 130 I/O & Relay PCB Test Points /FAN ENABLE /COOLANT FLOW ON /COOLANT PUMP ENABLE V/D_ISO_GND TP10 GND_ISO TP11 PILOT ENABLE TP15 24VDC TP19 WORK CURRENT TP20 PILOT CURRENT LED Reference CNC PLASMA ENABLE CNC START PILOT PREFLOW ON...
  • Page 96 PRECISION 130 APPENDIX 4: PILOT PCB LAYOUT = Test Point Art # A-11677_AB APPENDIX 0-5691...
  • Page 97 PRECISION 130 Pilot PCB Test Points PILOT GATE LED Reference Green PILOT ENABLE Green 0-5691 APPENDIX...
  • Page 98 PRECISION 130 APPENDIX 5: SYSTEM BIAS PCB LAYOUT = Test Point Art # A-11680_AB APPENDIX 0-5691...
  • Page 99 PRECISION 130 System Bias PCB Test Points 24VDC DC INPUT POSITIVE Vcc1 Vcc2 GATE PRIMARY GND +12V PRIMARY P_ISOL_GND TP10 DC SENSE POSITIVE LED Reference MISSING PHASE AC V HIGH AC V LOW Green VAC_IDA Green +12V PRIMARY Green VAC_IDB...
  • Page 100 PRECISION 130 APPENDIX 6: CONTROL AND FAULT PCB LAYOUT = Test Point Art # H-0093 APPENDIX 0-5691...
  • Page 101 PRECISION 130 Control and Fault PCB Test Points TP22 +12VDC TP23 +5VDC TP24 TP25 A_OUT1 TP26 B_OUT1 TP27 TP28 I_SNS1 TP29 GATE 2+ TP30 I_DMD1 0.5V-6.7V TP31 GATE 2- TP32 -12VDC TP33 START 2 TP34 SHDN TP35 ENABLE TP36 READY IN...
  • Page 102 PRECISION 130 APPENDIX 7: CAP BIAS PCB LAYOUT Art # A-15171 APPENDIX 0-5691...
  • Page 103 PRECISION 130 APPENDIX 8: REMOTE GAS CONTROL (RGC) PCB LAYOUT 0-5691 APPENDIX...
  • Page 104 PRECISION 130 APPENDIX 9: GATE DRIVE PCB LAYOUT TP206 TP207 TP205 TP204 TP202 TP203 TP201 TP200 Art # A-15175 APPENDIX 0-5691...
  • Page 105 PRECISION 130 APPENDIX 10: INVT OUTPUT PCB LAYOUT TP301_1 TP302 TP303 GND PWM 1 +5V-1 +12VDC TP304 TP301 PCB Common (GND) Art # A-15176 0-5691 APPENDIX...
  • Page 106 PRECISION 130 APPENDIX 11: SCU_IOT PCB SW3 & SW4_ADDRESS SELECT WIFI ANT CONN D1_WIFI D11_DIAG SW5_CONFIG D10_SERIAL TP6_+24V TP1_GND TP3_+5V Art # H-0095 D16_+5V TP5_LGND TP2_+3.3V TP4_LVCC D15_+3.3V APPENDIX 0-5691...
  • Page 107 PRECISION 130 APPENDIX 12: COOLING DIAGRAM 0-5691 APPENDIX...
  • Page 108 PRECISION 130 APPENDIX 13: SCU_IOT PCB HARNESS SCHEMATIC I-O_RELAY PCB +24V_UF 24VDC CPU PCB 17X2283 871759 GREEN GREEN VIOLET VIOLET TX- (RS422/RS485) ORANGE ORANGE TX+ (RS422/RS485) BLACK BLACK RX- (RS422) RX+ (RS422) J49-B J47-A TX_2- (RS422/RS485) TX_2+ (RS422/RS485) RX_2- (RS422)
  • Page 109 PRECISION 130 SCU_IOT PCB (19X511501 = PCB w/o EtherCAT) * Not currently Used in P130 DIGITAL OUT Machine * (N.O. Relay Contacts) Digital Inputs * Revision Date 420 National Buisness Parkway 2024 5th Floor Annapolis Junction, MD 20701 Date Printed...
  • Page 110 PRECISION 130 APPENDIX 14: INVERTER SCHEMATIC CAP BIAS PCB 19X512100 J100 TP112 +12VP To SECONDARY T100 +12VDC HI-POT HARNESS D106 +V REG GREEN +12VP Primary HiPot BIAS J101 +12V SUPPLY D103 harness 3 AC phases TP 101_1 GREEN +12V Harness...
  • Page 111 PRECISION 130 NTC2 SNUBBER J303 T1 _ 400 VAC or 480 VAC OUTPUT OUTPUT PCB 19X512300 E303 INDUCTOR TP303 NTC1 IGBT +5V-1 J302 SNUBBER AND OUTPUT DIODE PCB 19X512600 E304 E601 D601 /OVERTEMP E706 E604 E300 4700pF V660LA100BP VS-HFA220FA120 OUTPUT...
  • Page 112 PRECISION 130 APPENDIX 15: SYSTEM SCHEMATIC P130 400 VAC CE PG1&2 400 VAC INPUT L1, L2, L3 represent (97) terminal block on 120 VAC_W1 (Sht2 A8) inside of rear panel Power cord (customer (96) 120 VAC _ RET (Sht2 A8)
  • Page 113 PRECISION 130 Ignition Unit SIG 3.51 120VAC 120VAC RET (99) AC 120V (Sht 2, B8) (98) AC 120V_RET (Sht 2, B8) RF CAP BOARD 9-9423 CGND TO CPU PCB J32 4700 pf TEST POINTS (Sht 2, E4) PILOT BOARD LED'S...
  • Page 114 PRECISION 130 TO PILOT PCB J42 AMBIENT COOLANT (Sht 1, C7) 10 CKT RIBBON COOLANT LEVEL (93) (94) From Sys Bias V Select Adapter Harness (Sht 1, F2) (95) (92) (83) (84) INRUSH PCB (PARTIAL) INRUSH (MC1) 0.7 GPM TEMP SENSOR...
  • Page 115 PRECISION 130 (62) AC 24V- Ret-to J95-10 (Sht 1, E9) INRUSH PCB (PARTIAL) To J94-9 on INRUSH (106) FAN CONTROL(MC2) PCB sht 1 (C10) AC 120V- RGC (C9) (60) PUMP CONTROL(MC3) AC 120V- to J95-7 (Sht 1, D9) TEST (63)
  • Page 116 PRECISION 130 APPENDIX 16: SYSTEM SCHEMATIC P130 380-415 OR 480 VAC NON CE PG1&2 (97) 120 VAC_W1 (Sht2 A8) (96) 120 VAC _ RET (Sht2 A8) L1,2,3 represent the contactor input ARC_SUPPRESSOR terminals.Contactor input has upper and lower section. Power cable goes in lower section, J105B other wires in upper section.
  • Page 117 PRECISION 130 Ignition Unit SIG 3.51 120VAC 120VAC RET (99) AC 120V (Sht 2, B8) (98) AC 120V_RET (Sht 2, B8) RF CAP BOARD 9-9423 CGND TO CPU PCB J32 4700 pf TEST POINTS (Sht 2, E4) PILOT BOARD LED'S...
  • Page 118 PRECISION 130 TO PILOT PCB J42 AMBIENT COOLANT (Sht 1, C7) From Sys Bias V Select Adapter 10 CKT RIBBON Harness (Sht 1, F2) COOLANT LEVEL (93) (94) (95) (92) INRUSH PCB (PARTIAL) (43B) (83) (84) INRUSH (MC1 0.7 GPM...
  • Page 119 PRECISION 130 (62) AC 24V- Ret- to J95-10 (Sht 1, E9) INRUSH PCB (PARTIAL) To J94-9 on INRUSH (106) FAN CONTROL(MC2) PCB sht 1 (C10) AC 120V- RGC (C9) (60) PUMP CONTROL(MC3) AC 120V- to J95-7 (Sht 1, D9) TEST...
  • Page 120 PRECISION 130 APPENDIX 17: SYSTEM SCHEMATIC P130 REMOTE GAS CONTROL (RGC) 24 VDC IMR-90_24ST AC/N AC/L 0 VDC 120 VAC_RET 24 VDC 24 VDC_SW CHASSIS GND RGC Control PCB CAN BUS +24VDC LOGIC SUPPLY BUS_H BUS_L LGND PROGRAM +24V_FUSED CHASSIS GND...
  • Page 121 PRECISION 130 APPENDIX 18: SCU_IOT GATEWAY OPTION NOTE! The information in this section is based on the optional SCU_IoT hardware already being installed. If you have purchased this as an add-on, you will need to follow the instructions that came with your kit for the physical installation before proceeding.
  • Page 122 PRECISION 130 TD-UC Systems Application (APP) After installing the TD-UC Systems APP it shows the main menu. The main menu options are as shown here: Art # A-15196 Configuration The system needs to be configured to an existing plasma power supply first.
  • Page 123 PRECISION 130 Plasma Power Source SCU_IoT node serial number (see sticker on bottom right of SCU_IoT PCB inside machine). The circled number in the photo shows the serial number of that specific PCB. A matching sticker will be on the antenna mounted on the top of the machine as seen in the second photo.
  • Page 124 PRECISION 130 Router Wi-Fi access point (SSID): FT24 1) Click Configuration 2) Click Plasma System Configuration 3) Click +Add plasma system 4) Select Guided Mode Art # A-15200 APPENDIX 0-5691...
  • Page 125 PRECISION 130 5) Enter serial number from sticker 6) Go to WiFi settings. On Android phones pull down the top menu and go to WiFi. On iPhones go back to home screen and then to Wifi settings. 7) select the local access point from the IOT node of the power source with name “UC_IOT_xxxxx” (the xxxxx is the 5 digit serial number of the device).
  • Page 126 PRECISION 130 9) Select the access point of your router (SSID). In this example WiFi access point FT24 is used. 10) Enter router password of FT24 (*yourpassword*). If you do not know the password, ask the Network Administrator. 11) The setup procedure will now test the password. For this step it will reset the local access point “UC_IOT_22222”.
  • Page 127 PRECISION 130 12) Deactivate Wifi and reconnect to access point “UC_IOT_22222” Art # A-15203 0-5691 APPENDIX...
  • Page 128 PRECISION 130 13) The setup procedure will now attempt to connect to the router (named FT24 in this example). If the password is correct it will show the next screen. 14) Now connect your phone to the router accesspoint (FT24 in this example). Go to settings and select that Wifi acces point.
  • Page 129 PRECISION 130 15) The last step is to enter a name for the plasma power source. It could be any name or just the same serial number (UC_IOT_22222 in this example). 16) The machine setup is now complete and after selecting the new machine in the main menu (bottom right) the connection status should show “Good”...
  • Page 130 PRECISION 130 A18.02 Setup of Wi-Fi direct connection This feature allows the direct connection to the machines local Wi-Fi network. The advantage of this connection mode is that no external router is required. The disadvantage is that the phones Wi-Fi is connected to the machine only and the phone will not have access to the internet.
  • Page 131 PRECISION 130 Plasma Power Source SCU_IoT node serial number (see sticker on bottom right of SCU_IoT PCB inside machine). The circled number in the photo shows the serial number of that specific PCB. A matching sticker will be on the antenna mounted on the top of the machine as seen in the second photo.
  • Page 132 PRECISION 130 5) In the following screen enter the name of the machine. It is suggested to enter the serial number followed by _direct or _local, to identify the machine with a direct connection. (22222_direct in this example) 6) The IP address is fixed: 192.168.4.1 7) The Port is fixed: 8080 8) Select Hose Length and Torch Style according to the power source setup.
  • Page 133 PRECISION 130 A18.03 Process Setup / Cutchart Download. 1.) Press Process Setup in the main menu. 2.) Then select Material, Thickness, Amperage, Gas and Cutting Quality from the drop-down box. To clear the selection, click the Reset button. A summary of the download parameters is shown.
  • Page 134 PRECISION 130 A18.04 Run Modes NOTE! Each SCU_IoT PC Board leaves the factory with the DIP switch SW5 set for Routing Mode. All modes are not available on all systems. PCB looks like this for DIP Switch: Art # H-0123...
  • Page 135 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 136 Thermal Dynamics thermal-dynamics.com...