Victor 100 ULTRA-CUT Operating Manual
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Victor 100 ULTRA-CUT Operating Manual

Plasma cutting system w/automated gas control
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100
Operating Manual
ULTRA-CUT
PLASMA CUTTING SYSTEM
W/AUTOMATED GAS CONTROL
Art # A-08579_AB
Rev. AL
Date: March 13, 2013
Operating Features:
™
Manual # 0-5132

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Summary of Contents for Victor 100 ULTRA-CUT

  • Page 1 ™ ULTRA-CUT PLASMA CUTTING SYSTEM W/AUTOMATED GAS CONTROL Art # A-08579_AB Operating Manual Rev. AL Date: March 13, 2013 Manual # 0-5132 Operating Features:...
  • 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 pro- vide you with the best service and reliability in the industry. This product is backed by our extensive warranty and world- wide service network.
  • 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. ®...
  • Page 4 Intentionally blank...

  • 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 ....................1-2 1.04 Note, Attention et Avertissement ..............1-3 1.05 Precautions De Securite Importantes ............1-3 1.06 Documents De Reference ................
  • 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 TSC-3000 Navigation Functions ..............4-2 4.04 TSC-3000 Initial Setup ONLY ................ 4-3 4.05 TSC-3000 Selecting New Process ..............4-4 4.06 TSC-3000 Selecting Recently Used Process ..........
  • Page 7 TABLE OF CONTENTS (continued) SECTION 7. TORCH MAINTENANCE..................7-1 7.01 Consumable Removal ................... 7-1 7.02 O-Ring Lubrication ..................7-2 7.03 Parts Wear ....................7-3 7.04 Torch Consumables Installation ..............7-4 7.05 Coolant Leak Trouble-Shooting ..............7-6 APPENDIX 1: Remote Arc Starter Schematic ................A-1 APPENDIX 2: DMC-3000 PCB Layout ..................
  • Page 8 TABLE OF CONTENTS (continued) NOTE SECTION 8. TORCH OPERATION, is provided separately.

  • Page 9: General Information

    ULTRA-CUT 100 SECTION 1: • Use an air-supplied respirator if ventilation is not adequate to remove all fumes and gases. GENERAL INFORMATION • The kinds of fumes and gases from the plasma arc depend on the kind of metal being used, coatings on the metal, and the different processes.

  • Page 10: Publications

    ULTRA-CUT 100 • Provide a fire watch when working in an area where fire hazards 1.03 Publications may exist. Refer to the following standards or their latest revisions for more infor- • Hydrogen gas may be formed and trapped under aluminum mation: workpieces when they are cut underwater or while using a water table.

  • Page 11: Note, Attention Et Avertissement

    ULTRA-CUT 100 THAT HAVE HELD HAZARDOUS SUBSTANCES, obtainable from the American Welding Society, 550 N.W. LeJeune Rd, FUMÉE et GAZ Miami, FL 33126 15. ANSI Standard Z88.2, PRACTICE FOR RESPIRATORY PRO- La fumée et les gaz produits par le procédé de jet de plasma peuvent TECTION, obtainable from American National Standards présenter des risques et des dangers de santé.
  • Page 12 ULTRA-CUT 100 • Utilisez la nuance de lentille qui est suggèrée dans le recommenda- • Montez et maintenez le matériel conformément au Code électrique tion qui suivent ANSI/ASC Z49.1: national des Etats-Unis. (Voir la page 5, article 9.) Nuance Minimum Nuance Suggerée •...

  • Page 13: Documents De Reference

    ULTRA-CUT 100 1.06 Documents De Reference 14. Norme AWSF4.1 de l’Association Américaine de Soudage, RECOMMANDATIONS DE PRATIQUES SURES POUR LA Consultez les normes suivantes ou les révisions les plus récentes ayant PRÉPARATION À LA COUPE ET AU SOUDAGE DE CONTENEURS été...

  • Page 14: Declaration Of Conformity

    ULTRA-CUT 100 1.07 Declaration of Conformity Manufacturer: Thermal Dynamics Corporation Address: 82 Benning Street West Lebanon, New Hampshire 03784 The equipment described in this manual conforms to all applicable aspects and regulations of the ‘Low Voltage Directive’ (2006/95 EC) and to the National legislation for the enforcement of this Directive.

  • Page 15: Statement Of Warranty

    ULTRA-CUT 100 1.08 Statement of Warranty ® LIMITED WARRANTY: Thermal Dynamics Corporation (hereinafter “Thermal”) warrants that its products will be free of defects in workmanship or material. Should any failure to conform to this warranty appear within the time period applicable to the Thermal products as stated below, Thermal shall, upon notification thereof and substantiation that the product has been stored, installed, operated, and maintained in accordance with Thermal’s specifications, instructions, recommendations and recognized standard industry practice, and not subject to misuse, repair, neglect, alteration, or accident, correct such defects by suitable repair or replacement, at Thermal’s sole option, of any components or parts...
  • Page 16 ULTRA-CUT 100 Manual 0-5132...

  • Page 17: Section 2: Specifications

    ULTRA-CUT 100 SECTION 2: SPECIFICATIONS 2.01 General Description Of The System A typical Ultra-Cut ® 100 system configuration will include: • One Power Supply • Remote Arc Starter • Gas Control Module • Torch Valve Assembly • Precision Plasma Cutting Torch •...

  • Page 18: Specifications & Electrical Requirements

    ULTRA-CUT 100 2.06 Specifications & Electrical Requirements Ultra-Cut 100 Specifications & Design Features Input Power & Current 208/230V - 460V, 1/3 ph, 50 / 60 Hz Max OCV (U 380 vdc Minimum Output Current 10 Amps Max Output Current 100 Amps Output Voltage 60 - 230 vdc Duty Cycle Rating...

  • Page 19: Power Supply Dimensions

    ULTRA-CUT 100 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-04793 37.75 inch 960 nm 343 lb / 156 kg Manual No. 0-5132 SPECIFICATIONS...

  • Page 20: Power Supply Rear Panel Features

    ULTRA-CUT 100 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...

  • Page 21: Gas Requirements

    ULTRA-CUT 100 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. The chart includes gases which may not be used in all applications. Ultra-Cut 100 Power Supply: Gas Pressures, Flows, and Quality Requirements Quality Minimum Pressure Flow...
  • Page 22 ULTRA-CUT 100 2.12 XT -300 Torch Specifications A. Torch Dimensions Art # A-04897 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 3.54" 89.87 mm 2.74" 69.55 mm 1.57"...

  • Page 23: Xttm-300 Torch Specifications

    ULTRA-CUT 100 B. Torch Specifications -300 Torch Ratings for use with Ultra-Cut 100 Power Supply Ambient 104° F Temperature 40° C Duty Cycle 100% @ 100 Amps Maximum Current 100 Amps Voltage (V 500V peak Arc Striking Voltage 10kV Up to 100 Amps, DC, Current Straight Polarity -300 Torch Gas Specifications...
  • Page 24 ULTRA-CUT 100 E. Parts - In - Place (PIP) The torch is designed for use with a power supply which senses coolant return flow to confirm that torch parts are in place. If coolant return flow to the power supply is absent or insufficient the power supply will not provide power to the torch.

  • Page 25: Section 3: Installation

    ULTRA-CUT 100 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. Ultra-Cut 100 Power Supply Input Power Input Current Suggested Sizes (See Note) Voltage...

  • Page 26: System Layout

    ULTRA-CUT 100 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...

  • Page 27: Cables & Leads Identification

    ULTRA-CUT 100 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...

  • Page 28: Lift The Power Supply

    ULTRA-CUT 100 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 29: Remove The Connections Cover

    ULTRA-CUT 100 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 30 ULTRA-CUT 100 Check / Adjust Input Voltage Configuration for 208/230 and 460V Systems 1. The 208/230 and 460 V 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.
  • Page 31 ULTRA-CUT 100 Connect Input Power and System Ground Cables 1. Carefully cut back the outer sheath on the primary input power cable to expose the individual wires. Cut back the insulation on the individual wires. Route the cable upward through 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 32: Connect Work Cable And Pilot And Negative Leads

    ULTRA-CUT 100 3.06 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 33: Ground Connections

    ULTRA-CUT 100 3.07 Ground Connections Star Ground on Cutting Table Remote Arc DPC-3000 Gas Control Starter (RAS-1000) Primary location Note: The DMC-3000 gas control TSC-3000 Internal Torch TSC-3000 can be mounted on top of the Cutting Machine / Gantry Remote power supply.
  • Page 34 ULTRA-CUT 100 3. The cutting machine frame is then connected to the “Star” point using 1/0 AWG (European 50 mm ) or larger wire. 4. The plasma power supply work cable (see NOTE) is connected to the cutting table at the single point “Star” ground. NOTE Do Not connect the work cable directly to the ground rod.
  • Page 35 ULTRA-CUT 100 This test assumes the 115 or 230 VAC source neutral is connected to the utility earth ground. Ground Rod WARNING NEUTRAL with other Earth Grounded Use extreme caution. This connections removed test uses live voltage. On 115V AC Line: 3VAC = 3 ohms 1VAC = 1 ohm 100W Incandescent...

  • Page 36: Connect Coolant Leads

    ULTRA-CUT 100 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...

  • Page 37: Connect Control Cables For Cnc, Remote Arc Starter, And Dmc-3000

    ULTRA-CUT 100 3.09 Connect Control Cables for CNC, Remote Arc Starter, and DMC- 3000 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 DMC-3000...

  • Page 38: Connect Tsc-3000 Cable And Dmc-3000 Fiber Optic Cable To Ccm

    ULTRA-CUT 100 3.10 Connect TSC-3000 Cable and DMC-3000 Fiber Optic Cable to 1. Remove the plastic plug in the CCM at the rear of the Power Supply labelled GCM/DCM. To TSC-3000 Fiber Optic To DMC-3000 RETURN SUPPLY Art # A-09134 CAUTION Avoid kinking, twisting, or bunching the fiber optic cable.
  • Page 39 ULTRA-CUT 100 3. Feed the Fiber Optic Cable plug and wires through the hole where the plastic plug was removed labelled GCM/DCM and slide the thin nut back over the Fiber Optic Cable. 4. Secure the thin nut on the through hole protector so both nut faces are tight against the sheet metal inside and out.

  • Page 40: Set Switches On The Command - Control Module

    ULTRA-CUT 100 3.11 Set Switches on the Command - Control 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 41 ULTRA-CUT 100 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 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 42: Height Control Connections

    ULTRA-CUT 100 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.
  • Page 43 ULTRA-CUT 100 Mounting Dimensions DMC-3000 Profile DMC-3000 Top 7.08 in [179.8 mm] 5.00 in [127.0 mm] 13.60 in [345.6 mm] .30 in [7.62 mm] 11.44 in [290.6 mm] 12.18 in [309.4 mm] Art # A-09138 Preparation 1. Remove the screws securing the Cover Panel to the Module. Remove 2 Screws Loosen or remove 2 screws Manual No.
  • Page 44 ULTRA-CUT 100 2. Carefully remove the cover from the module noting the attached wire harness that connects to J1. Remove the wire harness and then set the cover to the side. Art # A-09140 Cover Removal 3. Attach all hoses and cables to the back of the DMC-3000 except the Fiber Optic cable which will be covered a little later.
  • Page 45 ULTRA-CUT 100 NOTE All gas fittings are 1/4” and the air fitting is 3/8”. 4. Connect the ground cable to rear of DMC-3000 shown in previous illustration. 5. Connect Control cable from the Power Supply to J56 on the front of the DMC-3000 as shown below. The Fiber Optic cable will be covered a little later.

  • Page 46: Dpc-3000 Gas Pressure Control Installation

    ULTRA-CUT 100 3.14 DPC-3000 Gas Pressure Control Installation The DPC-3000 Gas Control must be installed in a suitable location close to the Torch such as the gantry. The unit must be mounted to a flat horizontal surface. If the Module is mounted to any support subject to vibration or motion, the installer must fasten the module to the support securely.
  • Page 47 ULTRA-CUT 100 Preparation 1. Remove the screws securing the Cover Panel to the Module. Remove 2 Screws Loosen or remove 2 screws 2. Carefully remove the cover from the module noting the attached wire harness that connects to J4. Remove the wire harness and then set the cover to the side.
  • Page 48 ULTRA-CUT 100 3. Attach all hoses and cables to the back of the DPC-3000 except the Fiber Optic cable which will be covered a little later. Avoid turning any fittings already mounted in the unit by placing a wrench on it before tightening the hose fitting to it.

  • Page 49: Fiber Optic Cable Installation From Ccm To Dmc-3000

    ULTRA-CUT 100 3.15 Fiber Optic Cable Installation from CCM to DMC-3000. 1. Remove outer thin nut from through hole protector at the end of Fiber Optic Cable (L) that is connectsed to the CCM. CAUTION Avoid kinking, twisting, or bunching the fiber optic cable. The cable can be damaged by being forced into tight-radius turns.
  • Page 50 ULTRA-CUT 100 4. Secure the thin nut on the through hole protector so both nut faces are tight against the sheet metal inside and out. Art # A-09149 5. Plug the Fiber Optic Cable into the PCB as shown below. Make sure the locking tabs are engaged. Fiber Optic Cable to/from Fiber Optic Cable to/from CCM plugs in here...
  • Page 51 ULTRA-CUT 100 Art # A-09151 After Manual No. 0-5132 3-27 INSTALLATION...

  • Page 52: Fiber Optic Cable Installation From Dmc-3000 To Dpc-3000

    ULTRA-CUT 100 3.16 Fiber Optic Cable Installation From DMC-3000 to DPC-3000 1. Remove outer thin nuts from through hole protector at both ends of Fiber Optic Cable (L) that connects between the DCM-3000 and DPC-3000. CAUTION Avoid kinking, twisting, or bunching the fiber optic cable. The cable can be damaged by being forced into tight-radius turns.
  • Page 53 ULTRA-CUT 100 4. Secure each of the thin nuts on the through hole protectors so both nut faces are tight against the sheet metal inside and out. 5. Plug the Fiber Optic Cable into the PCB as shown below for the DMC-3000. Make sure the locking tabs are engaged.

  • Page 54: Install Tsc-3000 Touch Screen Control

    ULTRA-CUT 100 3.17 Install TSC-3000 Touch Screen Control Mounting Dimensions TSC-3000 Profile TSC-3000 Top 1.11 in [28.2 mm] 2.35 in [59.69 mm] 6.99 in 5.58 in [177.5 mm] [141.7 mm] .25 in [6.35 mm] 10.83 in [275.0 mm] 11.80 in [299.7 mm] Art # A-09156 12.45 in...

  • Page 55: Install Remote Arc Starter

    ULTRA-CUT 100 3.18 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 56 ULTRA-CUT 100 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 57 ULTRA-CUT 100 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-09626 Input Connections 1. Refer to the illustrations. Make the following input connections to the Arc Starter. •...
  • Page 58 ULTRA-CUT 100 Art # A-09628 Coolant Return (Red) Green Coolant Supply (Green) Copper plate Art # A-09629 Negative Cable from power supply. Negative Cable (from Power Supply rear panel) INSTALLATION 3-34 Manual No. 0-5132...
  • Page 59 ULTRA-CUT 100 Art # A-09630 Pilot Return Cable from Power supply PILOT Return Cable (from Power Supply rear panel) Art # A-09631 Control Cable from Power Supply rear panel Manual No. 0-5132 3-35 INSTALLATION...
  • Page 60 ULTRA-CUT 100 Output Connections 1. Refer to the illustrations. Make the following output connections to the Arc Starter. NOTE For newer leads with only one black wire, it must be connected to the pilot return.There are no inner shield wires. Pilot Lead Art # A-09632 Pilot Lead...
  • Page 61 ULTRA-CUT 100 Art # A-09633 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.
  • Page 62 ULTRA-CUT 100 The Arc Starter must be grounded; the grounding terminal is marked . Refer to the previous section for grounding details. 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...
  • Page 63 ULTRA-CUT 100 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.

  • Page 64: Connecting Torch

    ULTRA-CUT 100 3.19 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 65: Install Consumable Torch Parts

    ULTRA-CUT 100 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 66 ULTRA-CUT 100 1. Check the appropriate cut chart for the right combination of parts for the cutting application. 2. Stack the consumable parts together. Art # A-09200 1 - Assemble “B”. 2 - Assemble “B” to “C”. 3 - Assemble “A” to “B-C” assembly. 3.
  • Page 67 ULTRA-CUT 100 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 68 ULTRA-CUT 100 Connect the wire lead from the height finder to the ohmic clip if using ohmic torch height Ohmic Clip sensing. Art # A-03393_AB NOTE Ohmic height sensing is not recommended with water shield. Water on the plate interferes electrically with the ohmic sensing circuit.

  • Page 69: Complete The Installation

    ULTRA-CUT 100 3.21 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 70 ULTRA-CUT 100 2. After the complete system has been installed, check that the coolant has been pumped through the system as follows (see NOTE): NOTE Depending on the length of the torch leads, the system may require more coolant after turning the system ON for the first time.

  • Page 71: Section 4: Operation

    ULTRA-CUT 100 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 inverters when the ON/OFF switch is in ON position. When switch is first set to ON, the indicator stays off until the inrush cycle is complete and the correct voltage is confirmed.

  • Page 72: Start-Up Sequence

    ULTRA-CUT 100 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 after about 5 seconds. POWER Art # A-04812 3. Check the AC indicator. If the inverter modules are correctly configured for the input voltage and the switch is ON, then voltage has been applied to the inverter modules (input contactors are ON).

  • Page 73: Tsc-3000 Initial Setup Only

    ULTRA-CUT 100 4.04 TSC-3000 Initial Setup ONLY Initial steps required before First operation only. Note 400 Amp system requires a Height Controller with Elevation Height (EH) feature. ENTER/CHANGE PASSWORD HOME When power is turned on TSC 3000 goes to the Home screen.

  • Page 74: Tsc-3000 Selecting New Process

    ULTRA-CUT 100 4.05 TSC-3000 Selecting New Process Select new standard process by material; thickness; amperage (1) or enter process # using pop-up number pad (2). SELECT MATERIAL, THICKNESS HOME Material – Scroll to select, Thickness – Scroll to select, Accept & advance (1). Select process by # (2) or by name (3).

  • Page 75: Tsc-3000 Selecting Recently Used Process

    ULTRA-CUT 100 4.06 TSC-3000 Selecting Recently Used Process Home screen shows some of the most recently used processes with the last one used highlighted. Select the highlighted process by pressing the Green arrow or scroll with up/down arrows to select another recent process then press the green arrow. HOME TORCH CONSUMABLES TORCH CONSUMABLES...

  • Page 76: Tsc-3000 Creating A Custom Process

    ULTRA-CUT 100 4.07 TSC-3000 Creating a Custom Process Considerable effort has been made to define the best parameters for each cutting and marking process. However for various reasons, variations in material composition, variations in cutting table performance, user preferences, etc. you may desire to modify one or more processes.
  • Page 77 ULTRA-CUT 100 HOME CUSTOM PROCESS SETUP Customize Recent Cut. Highlight the process closest to what you want to use then press CUSTOM CUTS button. Select NEW CUT then MATERIAL & THICKNESS. TORCH CONSUMABLES LIST SELECT MATERIAL/THICKNESS Select value to change using UP/DN arrows.

  • Page 78: Back Up And Restoration Of Custom Processes

    ULTRA-CUT 100 4.08 Back up and Restoration of Custom Processes. Users can create their own custom cut processes. These can be lost by accidentally deleting them on the TDC 3000 or they can be over written when updating programs. They can also be lost if the DSC 3000 should be replaced. We recommend you back up your custom processes every time a new one is created.
  • Page 79 ULTRA-CUT 100 Restoring Custom Processes: During file backup (see previous process) a folder and sub folders called “TD” were placed on your flash drive. You should copy this folder with its subfolders to some secure place. Making more than one copy is advised. If the need arises to restore from this backup, place the entire TD folder in the root directory (not in another folder) on a USB flash drive and plug it into the USB port on the TDC 3000.
  • Page 80 ULTRA-CUT 100 Renaming Custom Files You cannot rename the files while on the TSC 3000 but once you backup a file on the flash drive you can use a computer to rename the file on the flash drive and perform the restore to put the renamed file back on the TSC 3000. 1.

  • Page 81: Sequence Of Operation

    ULTRA-CUT 100 4.09 Sequence of Operation Ultracut with DFC 3000 using TSC 3000 The purpose of this section is to explain the steps an operator should follow when using the DFC 3000 with the TSC 3000 touch screen control panel for a specific cutting process. Also included are steps to follow for changing torch consumables.
  • Page 82 ULTRA-CUT 100 3. Turn on 3 phase power at the main disconnect (Plasma Enable on TSC 3000 Disabled). a) AC indicator on front panel does not come on, pump and fans do not start. b) Approximately 10 sec after power up the front panel DC indicator will blink twice indicating this is an Ultracut.
  • Page 83 ULTRA-CUT 100 10. Changing torch consumables: Following a consumables change or inspection the system will initiate a purge of the gas. This serves two purposes: Remove the coolant that gets into the consumables when they have been removed. If the gas type has changed “Purge” removes the old gas from the lines and replaces it with the new gas.

  • Page 84: Gas Selection

    ULTRA-CUT 100 4.10 Gas Selection A. Plasma Gases 1. Air Plasma • Most often used on ferrous or carbon base materials for good quality at faster cutting speeds. • Air plasma is normally used with air shield. • Only clean, dry air is recommended for use as plasma gas. Any oil or moisture in the air supply will substan- tially reduce torch parts life.
  • Page 85 ULTRA-CUT 100 B. Shield Gases 1. Compressed Air Shield • Air shield is normally used when operating with air plasma and oxygen plasma. • Improves cut quality on some ferrous materials. • Inexpensive - reduces operating costs. 2. Nitrogen (N2) Shield •...

  • Page 86: Power Supply Status Codes

    ULTRA-CUT 100 4.11 Power Supply Status Codes 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 indicator on the control panel flashes a 2-part code to indicate a code group and then a particular condition within the group.
  • Page 87 ULTRA-CUT 100 CCM Status Code Code Message Remedy / Comments Group 2 -- Plasma Power Supply Missing AC Phase Blown fuse, Broken or loose connection on power cable Inverter(s) not configured correctly for input voltage; Poor power quality (brownouts, dropouts); Input power capacity / Wrong input voltage wiring too small causing voltage drop;...
  • Page 88 ULTRA-CUT 100 CCM Status Code Code Message Remedy / Comments Group 4 -- Torch Coolant System Coolant Level low Check coolant level, add as needed. Fault response time: Process Never started since last power cyle: Below 0.7 GPH for 15 Seconds. Else below 0.5 Low coolant flow GPH no delay or after 3 seconds if below 0.7 GPH Possible cause: Suction leak introducing air into coolant,...

  • Page 89: Dmc-3000 Status Codes

    ULTRA-CUT 100 4.12 DMC-3000 Status Codes Status Code indicators: 1. At power up, RED & GREEN indicators flash program firmware revision number in a 2 digit code as explained below. Following the revision code 2. Green indicator · On steady = OK, communication established. ·...
  • Page 90 ULTRA-CUT 100 DMC Status Code Key Code Message Cause/Remedy Group 1 - DMC Plasma Disabled Enable Plasma; Defective DMC Power Supply (E-Stop relay) Check /replace DMC power supply fuse (F2); Replace DMC Power Supply; Replace DMC 24 VDC fault control PCB 5 VDC fault Check /replace DMC power supply;...

  • Page 91: Dpc-3000 Status Codes

    ULTRA-CUT 100 4.13 DPC-3000 Status Codes DPC Status Code Key Code Message Cause/Remedy Group 1 - DPC Enable Plasma; DMC Power Supply input fuse F1 blown (no lights on Plasma Disabled DMC); Defective DMC Power Supply (E-Stop relay). Defective DPC Power Supply (E-Stop relay).
  • Page 92 ULTRA-CUT 100 DPC Status Code Key Code Message Cause/Remedy Group 6 - Plasma Low Proportional Valve (V4) Valve open Check for open connection; Replace valve. DPC inlet Supply Raise plasma inlet pressure; check for DMC valve not open; restriction in gas pressure low supply/hoses.

  • Page 93: Section 5: Maintenance

    ULTRA-CUT 100 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. Monthly Check cooling fan and radiator; clean as needed. Check gas hoses for cracks, leaks, or abrasion.

  • Page 94: Internal Coolant Filter Cleaning Procedure

    ULTRA-CUT 100 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 95: Remote Arc Starter: Service Chart

    ULTRA-CUT 100 5.05 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 96: Remote Arc Starter: Spark Gap Adjustment

    ULTRA-CUT 100 5.06 Remote Arc Starter: Spark Gap Adjustment 0.063" ± 0.002" 1.6 ± 0.05 mm Art # A-04857 MAINTENANCE Manual No. 0-5132...

  • Page 97: Section 6: Replacement Assemblies & Parts

    ULTRA-CUT 100 SECTION 6: REPLACEMENT ASSEMBLIES & PARTS 6.01 Main Component / System Replacement Complete Unit / Component Catalog Number ® Ultra-Cut 100 Power Supply, 208/230V 3-9116-1 ® Ultra-Cut 100 Power Supply, 460V 3-9116-2 ® Ultra-Cut 100 Power Supply, 400V 3-9116-3 ®...

  • Page 98: System Layout

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

  • Page 99: Leads And Cables

    ULTRA-CUT 100 6.04 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 100 ULTRA-CUT 100 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 101 ULTRA-CUT 100 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’...
  • Page 102 ULTRA-CUT 100 Description Catalog # Assembly, Torch Lead, 10’ / 3.05 m 4-3053 Assembly, Torch Lead, 15’ / 4.6 m 4-3009 Assembly, Torch Lead, 20’ / 6 m 4-3010 Assembly, Torch Lead, 25’ / 7.6 m 4-3011 Assembly, Torch Lead, 30’ / 9.1 m 4-3012 Assembly, Torch Lead, 35’...
  • Page 103 ULTRA-CUT 100 Description Catalog # Control Cable, Fiber Optic, 3’ / 1 m 9-4898 Control Cable, Fiber Optic, 15’ / 4.5 m 9-4899 Control Cable, Fiber Optic, 25’ / 7.6 m 9-4900 Control Cable, Fiber Optic, 35’ / 10.6 m 9-9335 Control Cable, Fiber Optic, 50’...
  • Page 104 ULTRA-CUT 100 Description Catalog # Shield Gas Hose 10’ / 3.05 m 9-7277 Shield Gas Hose 15’ / 4.5 m 9-7278 Shield Gas Hose 25’ / 7.6 m 9-7279 Shield Gas Hose 35’ / 10.6 m 9-7280 Shield Gas Hose 50’ / 15.2 m 9-7281 Shield Gas Hose 75’...
  • Page 105 ULTRA-CUT 100 Description Catalog # Water Shield 10’ / 3.05 m 9-6985 Water Shield 15’ / 4.5 m 9-6986 Water Shield 25’ / 7.6 m 9-6988 Water Shield 35’ / 10.6 m 9-6996 Water Shield 50’ / 15.2 m 9-6992 Water Shield 75’...

  • Page 106: Power Supply External Replacement Parts

    ULTRA-CUT 100 6.05 Power Supply External Replacement Parts Item # Description Catalog # Power Supply Front Panel Power Supply Rear Panel Power Supply Top Panel 9-0445B/9-0445G Power Supply Right Side 9-0442B/9-0442G Power Supply Left Side 9-0443B/9-0443G Louver Panel Power Supply Connections Cover Lifting Eye 9-9373 Art # A-06888_AB...

  • Page 107: Power Supply Replacement Parts - Right Side

    ULTRA-CUT 100 6.06 Power Supply Replacement Parts - Right Side Item # Description Ref. Des. Catalog # Heat Exchanger Fan FAN1 9-9338 Radiator 9-9339 NOTE: Heat Exchanger Fan is the same fan used with the Inverter Art # A-08308 Manual No. 0-5132 6-11 Power Supply Parts List...
  • Page 108 ULTRA-CUT 100 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 Power Supply Parts List 6-12 Manual No.

  • Page 109: Power Supply Replacement Parts - Right Side

    ULTRA-CUT 100 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. 0-5132 6-13 Power Supply Parts List...

  • Page 110: Power Supply Replacement Parts - Front Panel

    ULTRA-CUT 100 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 Power Supply Parts List 6-14 Manual No. 0-5132...
  • Page 111 ULTRA-CUT 100 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 112: Power Supply Replacement Parts - Right Side

    ULTRA-CUT 100 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 9-9364 ONLY 1 for this unit Art # A-08314 Power Supply Parts List 6-16 Manual No.

  • Page 113: Power Supply Replacement Parts - Rear Panel

    ULTRA-CUT 100 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 @ 2A 9-9349 Circuit Breaker (AGC) 125V, 10A 24VAC @ 5A...

  • Page 114: Power Supply Replacement Parts - Right Side

    ULTRA-CUT 100 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 Power Supply Parts List 6-18 Manual No.

  • Page 115: Power Supply Replacement Parts

    ULTRA-CUT 100 6.14 Power Supply Replacement Parts Item # Description Catalog # Inverter Module 208/230V 9-9360D Inverter Module 400V CE and 400V Non CE 9-9482D Inverter Module 600V 9-9485D Not Shown: Inverter Cooling Fan 9-9338 NOTE: The Inverter Cooling Fan is the same fan used for Heat Exchanger cooling. Art # A-04786_AB Manual No.

  • Page 116: Power Supply Replacement Parts - Right Side

    ULTRA-CUT 100 6.15 Power Supply Replacement Parts - Right Side Item # Description Ref. Des. Catalog # Sensor (Thermistor) 9-9361 Art # A-04787 Power Supply Parts List 6-20 Manual No. 0-5132...

  • Page 117: Power Supply Replacement Parts

    ULTRA-CUT 100 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. 0-5132 6-21 Power Supply Parts List...

  • Page 118: Power Supply Replacement Parts - Right Side

    ULTRA-CUT 100 6.17 Power Supply Replacement Parts - Right Side Item # Description Ref. Des. Catalog # Sensor (Level Switch) LSW1 9-9354 Motor MOT1 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...

  • Page 119: Dfc-3000 Automated Gas Control System Replacement Componants

    ULTRA-CUT 100 6.18 DFC-3000 Automated Gas Control System Replacement Componants Item # Description Catalog # Assy, DMC-3000, Demo 9-9491D Assy, DPC-3000, Demo 9-9443D Assy, TSC-3000, Fixed Mounting, Demo (Not Shown) 9-9444D Assy, TSC-3000, Remote, Demo 9-9490D Art # A-09135_AB Manual No. 0-5132 6-23 Power Supply Parts List...

  • Page 120: Dmc-3000 Gas Control Module Replacement Parts

    ULTRA-CUT 100 6.19 DMC-3000 Gas Control Module Replacement Parts Item # Description Catalog # DMC-3000 assembly 9-9491D Solenoid 9-8264 Manifold subassembly (includes 15 or item 2) 9-7546 SMPS PCB 9-8263 Control PCB 9-7291 There are 15 total Power Supply Parts List 6-24 Manual No.

  • Page 121: Dpc-3000 Gas Control Module Replacement Parts

    ULTRA-CUT 100 6.20 DPC-3000 Gas Control Module Replacement Parts Item # Description Catalog # Assy, DPC-3000, Demo 9-9443D DPC-PCB 9-8262 SMPS PCB 9-8263 Shield Gas P Valve 9-8267 Sensor, Pressure, 1/8mnpt (six total) 9-8269 Solenoid 9-8264 Plasma Lo and Pre-Flow P Valve 9-8268 DPC Manifold Fully Assembled 9-7658...

  • Page 122: Tsc-3000 Touch Screen Control Remote And Internal Replacement Parts

    ULTRA-CUT 100 6.21 TSC-3000 Touch Screen Control Remote and Internal Replacement Parts Item # Description Catalog # Assy, TSC-3000, Remote, Demo 9-9490D Assy, TSC-3000, Internal, Demo 9-944 Touch Panel Computer 9-7543 Switch, Rocker SPST 9-1042 Ribbon Cable HMI to Interface 9-7547 USB Panel Mount Extension 9-7545...

  • Page 123: Remote Arc Starter (Ras-1000) Replacement Parts

    ULTRA-CUT 100 6.22 Remote Arc Starter (RAS-1000) Replacement Parts Item # Description Catalog # Harness, Internal (Not Shown) 9-4956 Pilot Cap Assembly 9-9423 EMI Filter 9-1023 HF Water Cooled Coil Assembly 9-4958 HF Transformer Assembly, Arc Starter 9-4959 Enclosure, Arc Starter Base 9-4961 Spark Gap/Cap Assembly HF 9-4957...
  • Page 124 ULTRA-CUT 100 6.23 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 Strain Relief, large 9-7571 Strain Relief, small 8-7072 Coolant Leads, from Power Supply Art # A-09635...

  • Page 125: Command & Control Module For Auto Gas Control - Replacement Parts

    ULTRA-CUT 100 6.24 Command & Control Module For Auto Gas Control - Replacement Parts Item # Description Catalog # Assembly, CCM, Auto Gas, Demo 9-9417D Plate, CCM Face 9-9419 Panel, CCM Mount Not Available Harness, CCM I/O Board 9-9421 Art # A-06867_AB Manual No.
  • Page 126 ULTRA-CUT 100 Intentionally Blank Power Supply Parts List 6-30 Manual No. 0-5132...

  • Page 127: Section 7. Torch Maintenance

    ULTRA-CUT 100 SECTION 7. TORCH MAINTENANCE 7.01 Consumable Removal 1. Use the Cartridge 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 128: O-Ring Lubrication

    ULTRA-CUT 100 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. O-Rings Torch Head Cat.

  • Page 129: Parts Wear

    ULTRA-CUT 100 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. Good Tip Worn Tip Good Electrode Worn Electrode Art # A-04745_AB...

  • Page 130: Torch Consumables Installation

    ULTRA-CUT 100 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 131 ULTRA-CUT 100 2. Remove the Cartridge 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 132: Coolant Leak Trouble-Shooting

    ULTRA-CUT 100 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 133: Appendix 1: Remote Arc Starter Schematic

    ULTRA-CUT 100 APPENDIX 1: Remote Arc Starter Schematic Manual 0-5132 APPENDIX...

  • Page 134: Appendix 2: Dmc-3000 Pcb Layout

    ULTRA-CUT 100 APPENDIX 2: DMC-3000 PCB Layout D-17 D_E1 D_E15 Art # A-09188_AB APPENDIX Manual 0-5132...

  • Page 135: Appendix 3: Dpc-3000 Pcb Layout

    ULTRA-CUT 100 APPENDIX 3: DPC-3000 PCB Layout TP11 TP10 Art # A-09189_AB Manual 0-5132 APPENDIX...

  • Page 136: Appendix 4: Tsc-3000 Pcb Layout

    ULTRA-CUT 100 APPENDIX 4: TSC-3000 PCB Layout D14 D15 Art # A-09190_AB APPENDIX Manual 0-5132...

  • Page 137: Appendix 5: Ccm Input / Output Pcb Layout

    ULTRA-CUT 100 APPENDIX 5: CCM Input / Output PCB Layout D1 D2 TP15 TP11 TP12 SW11 SW12 Art # A-09187_AB TP13 TP14 TP2 SW13 TP10 Manual 0-5132 APPENDIX...

  • Page 138: Appendix 6: Ccm Cpu Pcb Layout

    ULTRA-CUT 100 APPENDIX 6: CCM CPU PCB Layout TP10 TP11 TP13 TP12 TP14 TP15 Switches Art # A-09186_AB POST OK TO AUTO PILOT FLOW FLOW FUNC CONT MOVE/D APPENDIX Manual 0-5132...
  • Page 139 ULTRA-CUT 100 TB1-1 E-Stop (Com) These points are jumpered together at the factory. Remove the jumper to use existing E-Stop circuits. TB1-2 E-Stop TB1-3 OK 2 Contacts 24V Max 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 140: Appendix 7: Cnc

    ULTRA-CUT 100 APPENDIX 7: CNC A7.01 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.

  • Page 141: A7.02 Cnc Input / Output Descriptions

    ULTRA-CUT 100 Function Connection OK to Move (Contacts or DC Volts) TB2-10(-); TB2-12(+) Plasma Marking Remote Select TB3-1: TB3-2 A7.02 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.

  • Page 142: A7.03 Simplified Cnc Circuit

    ULTRA-CUT 100 +10V @ 10ma. For Remote CC Pot – Previously CCM versions if one wanted to use a potentiometer for the Remote Analog Current Control (CC) input an external 10 V supply was required for Pot High.. Now an isolated (from main plasma circuits) 10V supply is provided.

  • Page 143: A7.04 Cnc Connections

    ULTRA-CUT 100 A7.04 CNC Connections. Cutting Machine CNC Cable Power Supply ..Source, 16 VDC, 10 ma. START/STOP ... Divided Arc V (-) ..Divided Arc V (+) ..Arc V (-) through 100K *** ..Arc V (+) through 100K *** Remote Analog Current Control (-) ..

  • Page 144: Appendix 8: Serial Communications

    ULTRA-CUT 100 APPENDIX 8: SERIAL COMMUNICATIONS A8.01 Cables and Switch Settings for 2 and 4 Wire The CCM communicates with the TSC 3000 (touch screen HMI panel) using RS 485 (2 wire, half duplex). When a CNC controller is used in place of the TSC the CCM can be reconfigured for RS 422 (4 wire, half duplex) if supported by the CNC.
  • Page 145 ULTRA-CUT 100 Recommend using the 4 wire when possible as it is easier to troubleshoot if there is a problem. Note that CCM Tx+ connects to CNC Rx+ and CCM TX- connects to CNC RX- for 4 wire half duplex. If using 2 wire RS 485 connect CCM Tx+ (also called D+ or Data +) to CNC Tx+ and CCM Tx- (also called D- or Data- ) to CNC Tx-.

  • Page 146: Appendix 9: Schematic, 230-460V, Chopper Pilot

    ULTRA-CUT 100 APPENDIX 9: Schematic, 230-460V, Chopper Pilot 100A INVERTER MODULE 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 ON / OFF CN6 16 CKT C.P1 C.P1...
  • Page 147 ULTRA-CUT 100 Power Supply NEG ARC VOLTS Rear Panel (C7 & A9, Sht 2) TORCH (-) PCB 8 WK-5687 2 UF 2 UF & RF CAPS WORK WORK PILOT REGULATOR (CHOPPER) BIAS POWER FAN3 FAN3 PILOT REG. HCT1 HCT1 PILOT (CHOPPER ) HALL SENSOR THS1...

  • Page 148: Appendix 9: Schematic, 230-460V, Chopper Pilot Cont

    ULTRA-CUT 100 APPENDIX 9: Schematic, 230-460V, Chopper Pilot Cont. PCB 5 WK-5602 (partial) INTERFACE PCB LED1 LED1 LEVEL LEVEL INPUT CONTACTOR CN12 CN12 CN13 CN13 CN14 CN14 PILOT MC1 AUX MC1 AUX CONTACTOR LSW1-1 LSW1-1 COOLANT TEMP (ON COOLANT RETURN) SW_LIQUID_LEVEL_NC SW_LIQUID_LEVEL_NC FLOW_TURBINE_PULSE...
  • Page 149 ULTRA-CUT 100 INTERNAL TERMINAL STRIP (Not in all units) PCB6 DISPLAY 0V-A (24V ret) WK-5603 24 VAC @ 1A AC24V-GCM (E2) 0V-B (120V ret) GREEN GREEN 120 VAC @ 100ma. AC120V-GCM CN23 CN23 CN24 CN24 +15V YELLOW YELLOW TEMP TEMP / AC / TEMP WORK...

  • Page 150: Appendix 10: Schematic, Ccc 400V, W/ Chopper Pilot

    ULTRA-CUT 100 APPENDIX 10: Schematic, CCC 400V, w/ Chopper Pilot 100A INVERTER MODULE 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 CN6 16 CKT ON / OFF...
  • Page 151 ULTRA-CUT 100 Power Supply Rear Panel NEG ARC VOLTS (C7 & A9,Sht 2) TORCH (-) PCB 8 WK-5687 2 UF 2 UF & RF CAPS WORK WORK PILOT REGULATOR (CHOPPER) BIAS POWER FAN3 FAN3 PILOT REG. HCT1 HCT1 PILOT (CHOPPER ) HALL SENSOR PCB1 THS1...

  • Page 152: Appendix 10: Schematic, Ccc 400V, W/ Chopper Pilot Cont

    ULTRA-CUT 100 APPENDIX 10: Schematic, CCC 400V, w/ Chopper Pilot Cont. PCB 5 WK-5602 (partial) INTERFACE PCB LED1 LED1 LEVEL LEVEL INPUT CONTACTOR CN12 CN12 CN13 CN13 CN14 CN14 PILOT MC1 AUX MC1 AUX CONTACTOR LSW1-1 LSW1-1 COOLANT TEMP (ON COOLANT RETURN) SW_LIQUID_LEVEL_NC SW_LIQUID_LEVEL_NC...
  • Page 153 ULTRA-CUT 100 INTERNAL TERMINAL STRIP (Not in all units) PCB6 DISPLAY 0V-A (24V ret) WK-5603 24 VAC @ 1A AC24V-GCM (E2) 0V-B (120V ret) GREEN GREEN 120 VAC @ 100ma. AC120V-GCM CN23 CN23 CN24 CN24 +15V YELLOW YELLOW TEMP TEMP / AC / TEMP WORK...

  • Page 154: Appendix 11: Schematic, Ce 400V, Chopper Pilot

    ULTRA-CUT 100 APPENDIX 11: Schematic, CE 400V, Chopper Pilot 100A INVERTER MODULE N (-) N (-) CN1-not used CN1-not used INRUSH INRUSH NFC1 NFC1 MC1-A MC1-A MC1-B MC1-B FILTER FILTER MC1-C MC1-C P (+) P (+) CN4 - PCB12 CN4 - PCB12 CN2-400V CN2-400V CN6 16 CKT...
  • Page 155 ULTRA-CUT 100 Power Supply NEG ARC VOLTS Rear Panel (C7 & A9,Sht 2) TORCH (-) PCB 8 WK-5687 2 UF 2 UF & RF CAPS WORK WORK PILOT REGULATOR (CHOPPER) BIAS POWER FAN3 FAN3 PILOT REG. HCT1 HCT1 PILOT (CHOPPER ) HALL SENSOR PCB1 THS1...

  • Page 156: Appendix 11: Schematic, Ce 400V, Chopper Pilot Cont

    ULTRA-CUT 100 APPENDIX 11: Schematic, CE 400V, Chopper Pilot Cont. PCB 5 WK-5602 (partial) INTERFACE PCB LED1 LED1 LEVEL LEVEL INPUT CONTACTOR CN12 CN12 CN13 CN13 CN14 CN14 PILOT MC1 AUX MC1 AUX CONTACTOR LSW1-1 LSW1-1 COOLANT TEMP (ON COOLANT RETURN) SW_LIQUID_LEVEL_NC SW_LIQUID_LEVEL_NC...
  • Page 157 ULTRA-CUT 100 INTERNAL TERMINAL STRIP (Not in all units) PCB6 DISPLAY 0V-A (24V ret) WK-5603 24 VAC @ 1A AC24V-GCM (E2) 0V-B (120V ret) GREEN GREEN 120 VAC @ 100ma. AC120V-GCM CN23 CN23 CN24 CN24 +15V YELLOW YELLOW TEMP TEMP / AC / TEMP WORK...

  • Page 158: Appendix 12: Schematic, Csa 600V, Chopper Pilot

    ULTRA-CUT 100 APPENDIX 12: Schematic, CSA 600V, Chopper Pilot 100A INVERTER MODULE 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 CN6 16 CKT ON / OFF C.P1...
  • Page 159 ULTRA-CUT 100 Power Supply Rear Panel NEG ARC VOLTS (C7 & A9,Sht 2) TORCH (-) PCB 8 (C2, Sht 2) WK-5687 N2 P1 2 UF 2 UF & RF CAPS WORK WORK PILOT REGULATOR (CHOPPER) BIAS POWER FAN3 FAN3 PILOT REG. HCT1 HCT1 PILOT...

  • Page 160: Appendix 12: Schematic, Csa 600V, Chopper Pilot Cont

    ULTRA-CUT 100 APPENDIX 12: Schematic, CSA 600V, Chopper Pilot Cont. PCB 5 WK-5602 (partial) INTERFACE PCB LED1 LED1 LEVEL LEVEL INPUT CONTACTOR CN12 CN12 CN13 CN13 CN12 CN12 CN14 CN14 PILOT MC1 AUX MC1 AUX CONTACTOR LSW1-1 LSW1-1 COOLANT TEMP (ON COOLANT RETURN) SW_LIQUID_LEVEL_NC...
  • Page 161 ULTRA-CUT 100 INTERNAL TERMINAL STRIP (Not in all units) PCB6 DISPLAY 0V-A (24V ret) WK-5603 24 VAC @ 1A AC24V-GCM (E2) 0V-B (120V ret) GREEN GREEN 120 VAC @ 100ma. AC120V-GCM CN23 CN23 CN24 CN24 +15V YELLOW YELLOW TEMP TEMP / AC / TEMP WORK...

  • Page 162: Appendix 13: Schematic, Dfc-3000 Auto Gas Box System

    ULTRA-CUT 100 APPENDIX 13: Schematic, DFC-3000 Auto Gas Box System DMC3000 - MANIFOLD CONTROLLER ASSEMBLY 19X2367 755x000 ULTRACUT POWER SUPPLY CONTROL CABLE (JMP) PLASMA ENABLE + 120VAC DMC PLASMA ENABLE - 120VAC DMC RET (2a) 19X2384 SMPS +24; +/-12; +5 E_STOP NO F1 1.6A SB F1 1.6A SB...
  • Page 163 ULTRA-CUT 100 DPC3000 - PRESSURE CONTROL ASSEMBLY 19X2370 REAR PANEL INDICATORS POWER LED (GRN) POWER LED (GRN) STATUS LED (RED) STATUS LED (RED) MANIFOLD P3 - HWID P3 - HWID DPC3000 CONTROL PCB 19X2382 SW1-1 SW1-1 MANAFOLD ID (WHT) (BLK) SW1-2 SW1-2 (WHT)

  • Page 164: Appendix 14: Publication History

    ULTRA-CUT 100 APPENDIX 14: PUBLICATION HISTORY Cover Date Cover Date Change(s) Change(s) Cover Date Cover Date Cover Date Change(s) Change(s) Change(s) May 14, 2009 First issue Sept. 29, 2009 Updated Appendix with new CNC Functions information and updated input power cable charts sections 2 and 3 and system schematics with serial communi cation connector and updated TB1 and TB3 information in Appendix 7 per ECOB1535.
  • Page 165 This Page Intentionally Blank...
  • Page 166 THE AMERICAS Denton, TX USA U.S. Customer Care Ph: 1-800-426-1888 (tollfree) Fax: 1-800-535-0557 (tollfree) International Customer Care Ph: 1-940-381-1212 Fax: 1-940-483-8178 Miami, FL USA Sales Office, Latin America Ph: 1-954-727-8371 Fax: 1-954-727-8376 Oakville, Ontario, Canada Canada Customer Care Ph: 1-905-827-4515 Fax: 1-800-588-1714 (tollfree) EUROPE Chorley, United Kingdom...

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