Thermal Dynamics AUTO-CUT 30 O2 Operating Manual
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Thermal Dynamics AUTO-CUT 30 O2 Operating Manual

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30O
Operating Manual
2
AUTO-CUT
PLASMA CUTTING SYSTEM
Art# A-08584
Rev: AL
Issue Date: July 6, 2012
Operating Features:
300
AMP
™
Manual No.: 0-4818
208-
3
400
400
230
PHASE
V
V (CE)
V
460
600
V
V

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Summary of Contents for Thermal Dynamics AUTO-CUT 30 O2

  • Page 1 AUTO-CUT ™ PLASMA CUTTING SYSTEM Art# A-08584 Operating Manual Rev: AL Issue Date: July 6, 2012 Manual No.: 0-4818 Operating Features: 208- PHASE V (CE)
  • Page 2 . YOU ARE IN GOOD COMPANY! The Brand of Choice for Contractors and Fabricators Worldwide. Thermal Dynamics is a Global Brand of manual and automation Plasma Cutting Products for Thermadyne Industries Inc. We distinguish ourselves from our competition through market- l e a d i n g , d e p e n d a b l e p r o d u c t s t h a t h a v e s t o o d t h e t e s t o f t i m e .
  • Page 3 Manufacturer assumes no liability for its use. Plasma Cutting Power Supply, Auto-Cut ® Operating Manual No. 0-4818 Published by: Thermal Dynamics Corporation 82 Benning Street West Lebanon, New Hampshire, USA 03784 (603) 298-5711 www.thermal-dynamics.com © Copyright 2007, 2008, 2009, 2010, 2011, 2012 by Victor Technologies All rights reserved.
  • Page 4 This page 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 Gas Control Module Operation ..............4-3 4.04 Gas Control Sequence Of Operation ............. 4-7 4.05 Gas Selection ....................4-10 4.06 Power Supply Status Codes ................
  • Page 7 TABLE OF CONTENTS (continued) APPENDIX 1: Remote Arc Starter Schematic ................A-1 APPENDIX 2: Gas Control and Torch Valve Schematic ............. A-2 APPENDIX 3: Gas Control Module Plumbing Diagram ............... A-4 APPENDIX 4: Gas Control Module PCB Layout ............... A-5 APPENDIX 5: CCM Input / Output PCB Layout ................
  • Page 8 blank...

  • Page 9: General Information

    AUTOCUT 30O2 • Use an air-supplied respirator if ventilation is not adequate to SECTION 1: 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

    AUTOCUT 30O2 • 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

    AUTOCUT 30O2 THAT HAVE HELD HAZARDOUS SUBSTANCES, obtainable les consignes avant d’utiliser le matériel. Composez le + from the American Welding Society, 550 N.W. LeJeune Rd, 603-298-5711 ou votre distributeur local si vous avez des questions. Miami, FL 33126 15. ANSI Standard Z88.2, PRACTICE FOR RESPIRATORY PRO- TECTION, obtainable from American National Standards Institute, 1430 Broadway, New York, NY 10018 FUMÉE et GAZ...
  • Page 12 AUTOCUT 30O2 • Maintenez votre casque et vos lunettes de protection en bon état. • Réparez ou remplacez toute pièce usée ou endommagée. Remplacez toute lentille sale ou comportant fissure ou rognure. • Prenez des soins particuliers lorsque la zone de travail est humide •...

  • Page 13: Documents De Reference

    AUTOCUT 30O2 d’autres problèmes de reproduction. I l f a u t s e l a v e r l e s m a i n s a p r è s 13. Livret NWSA, BIBLIOGRAPHIE SUR LA SÉCURITÉ DU SOUDAGE, I l f a u t s e l a v e r l e s m a i n s a p r è...

  • Page 14: Declaration Of Conformity

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

  • Page 15: Statement Of Warranty

    90 Days Warranty repairs or replacement claims under this limited warranty must be submitted by an authorized Thermal Dynamics® repair facility within thirty (30) days of the repair. No transportation costs of any kind will be paid under this warranty. Transportation charges to send products to an authorized warranty repair facility shall be the responsibility of the customer.
  • Page 16 Australia Terms of Warranty – 2012 Effective 1st January 2012, all warranties against defects (also known as a manufacturer’s warranty) supplied with goods or services must comply with the new Australian consumer law regulations (2010). This Warranty Statement should be read in conjunction with the Warranty Schedule contained in the operating instructions of the product.

  • Page 17: Section 2: Specifications

    SECTION 2: SPECIFICATIONS 2.01 General Description Of The System A typical Auto-Cut ® system configuration includes: • One Power Supply • Remote Arc Starter • Gas Control Module • Torch Valve Assembly • Conventional Plasma Cutting Torch • Set Of Connecting Leads The components are connected at installation.

  • Page 18: Specifications & Electrical Requirements

    2.06 Specifications & Electrical Requirements Auto-Cut 30O Specifications & Design Features Max OCV (U 380 vdc Minimum Output Current 10 Amps Max Output Current 300 Amps Output Voltage 60 - 230 vdc Duty Cycle Rating 100% @ 300A, 180V, (54kW), Ambient Temperature 104F°...

  • Page 19: Power Supply Dimensions

    2.08 Power Supply Dimensions 27 inch 680 mm 52.25 inch 1030 mm 33 inch 27.5 inch 840 mm 700 mm 37.75 inch 960 mm 535 lb / 243 kg Art # A-06939 Manual No. 0-4818 Auto-Cut 300 SPECIFICATIONS...

  • Page 20: Power Supply Rear Panel Features

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

  • Page 21: Gas Specifications

    2.10 Gas Specifications The customer will provide all gases and pressure regulators. Gases must be of high quality. Pressure regulators shall be double stage. Auto-Cut 30O Power Supply: Gas Pressures, Flows, and Quality Requirements Quality Minimum Pressure Flow 99.5% Purity 120 psi (Oxygen) 200 scfh (5700 l/h)

  • Page 22: Xttm-301 Torch Specifications

    2.12 XT -301 Torch Specifications A. Torch Dimensions Art # A-08301 End Cap 19.00" 2.25" 482.68 mm 57.15 mm Mounting Tube 2.0" 15.50" 50.8 mm 393.78 mm 6.30" 160.10 mm 2.39" 60.81 mm 3.98" 101.1 mm 2.63" 66.8 mm 1.57" 39.96 mm 1.49"...
  • Page 23 B. Torch Gas Leads Lengths Gas Lead Assemblies Length Feet Meters 3.05 15.2 22.8 30.4 38.2 45.7 53.3 C. Torch Parts (Generic Parts Shown) Art # A-04741 Plasma Gas Shield Gas Distributor Distributor Shield Cap Electrode Shield Cup Cartridge Shield Shield Cup Shield Shield Gas...
  • Page 24 This Page Intentionally Blank Manual No. 0-4818 Auto-Cut 300 SPECIFICATIONS...

  • Page 25: Section 3: Installation

    Gas supply leads must be #8 (1/2 in. ) hose or larger Cooling System Requirements Coolant must be added to the system on installation. The amount required varies with torch leads length. Thermal Dynamics recommends its coolants 7-3580 and 7-3581 (for low temperatures). Coolant Capabilities Cat. Number and Mixture...

  • Page 26: System Layout

    3.02 System Layout Refer to section 3.05 for ground connections and ground cables. 50’ / 15.2 m Maximum Length 125’ / 38.1 m Maximum Length Pilot Return Pilot Return Negative Lead Shield Remote Coolant Supply Coolant Supply w/ Negative 300-A Starter Power Coolant Return...

  • Page 27: Cables & Leads Identification

    3.03 Cables & Leads Identification #8 AWG Cable Pilot Return, Power Supply to Arc Starter 2/0 (70 mm ) 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

    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: Primary Power Connections

    3.05 Primary Power Connections 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 Check / Adjust Input Voltage Configuration 1. The 230/460VAC 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 on the inverter module.
  • Page 31 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 the connections cover support panel on the rear panel of the power supply.
  • Page 32 200Amp or less Ultra-Cut Star Ground on Cutting Table Auto-Cut O2 Remote Arc Manufacturer Power Supply Starter (RAS-1000) Gas Control Module Note: The gas control module can Device Primary location Torch be mounted on top of the power Cutting Machine / Gantry supply.
  • Page 33 Auto-Cut Basic System Without RAS Cutting Machine / Gantry Torch Auto-Cut GCM-1000 Device Power Supply Gas Control Module Cutting Table #4 AWG Ground (F) (Factory Installed) Ground Cable 1/0 Work Cable Customer Supplied Earth Ground 1/0 Ground Cable (F1) ‘Star’ Art # A-08254_AC 0 - 10 ft (0 - 3 m) Ideal Ground...

  • Page 34: Ground Connections

    For Thermal Dynamics components (except Remote Arc Starter and Gas Control Module) it is recommended to use a minimum of 10 AWG (European 6 mm ) wire or flat copper braid with cross section equal to or greater than 10 AWG connected to the cutting table frame.
  • Page 35 C. Creating An Earth Ground 1. To create a solid, low resistance, earth ground, drive a 1/2 in (12 mm) or greater diameter copper clad ground rod at least 6 - 8 ft (1.8 - 2.4 m) into the earth so that the rod contacts moist soil over most of its length. Depending on location, a greater depth may be required to obtain a low resistance ground (see NOTE).

  • Page 36: Connect Work Cable And Pilot And Negative / Torch Leads

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

  • Page 37: Connect Coolant Leads

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

  • Page 38: Connect Control Cables For Cnc, Remote Arc Starter, And Gcm

    3.09 Connect Control Cables for CNC, Remote Arc Starter, and GCM 1. Connect one end of each cable to the power supply. 2. Connect the other end of the CNC cable to the CNC device. 3. The CNC cable shield must be attached to ground at the CNC end of the cable. Do not ground to the Plasma Power Supply.

  • Page 39: Connect Fiber Optic Cable To Ccm

    3.10 Connect Fiber Optic Cable to CCM 1. Remove the strain relief securing nut from the strain relief on the fiber optic cable(s). Loosen the strain relief dome nut from the strain relief. 2. Pass the cable connector through the appropriate opening. Slide the strain relief securing nut onto the cable.

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

    3.11 Set Switches on the Command - Control Module 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. 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.
  • Page 41 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, rated at 120VAC @ 1A Max. (Factory default setting) or DC Volts (16-18vdc@ up to 100 ma.) SW-11: Analog Current Control.

  • Page 42: Height Control Connections

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

  • Page 43: Install Gas Control Module

    3.13 Install Gas Control Module The Gas Control Module must be installed in a suitable location where it is easily accessible to the system operator. The unit must be mounted to a flat horizontal surface. If the Module is mounted to a gantry or to any other support subject to vibration or motion, the installer must fasten the module to the support securely.
  • Page 44 Preparation 1. Remove the screws securing the Cover Panel to the Module. 2. Remove the Cover from the Module. Remove the ground wire if needed. Gas Control Module Cover Remove Ground Wire Do not remove Art # A-06882 Cover Removal Manual No.

  • Page 45: Connect Fiber Optic Cable To Gas Control Module

    3.14 Connect Fiber Optic Cable to Gas Control Module 1. Install the through-hole protector for the fiber-optic cable in the hole in connection panel on the back of the Module. 2. Pass the fiber-optic cable connector through the hole in connection panel on the back of the Module. Pass enough of the cable into the Module to allow the cable to loop upward as shown.
  • Page 46 3. Insert the fiber-optic cable connector into the receptacle on the vertically-mounted circuit board as shown. Cable must snap into place. Circuit Board Fiber Optic Cable Art # A-04773 4. Tighten the through-hole protector for the fiber-optic cable. 5. Reinstall the Cover Panel. Manual No.

  • Page 47: Connect Control, Input, And Outputs To Gas Control Module

    3.15 Connect Control, Input, and Outputs to Gas Control Module 1. Make all other connections to the rear of the Module. The connections are labeled. The Module must be grounded; the grounding terminal is marked Use #4 AWG (European 21 mm ) (or thicker) wire for grounding.

  • Page 48: Install Remote Arc Starter

    3.16 Install Remote Arc Starter Site Location Select a clean, dry location with good ventilation and adequate working space around all components. Review the safety precautions in the front of this manual to be sure that the location meets all safety requirements. Interconnecting cables and hoses attach to the Arc Starter.
  • Page 49 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 50 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 51 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) Manual No. 0-4818 Auto-Cut 300 3-27 INSTALLATION...
  • Page 52 Art # A-09630 Pilot Return Cable from Power supply PILOT Return Cable (from Power Supply rear panel) NOTE: The pilot return cable has a strain relief connector that must be installed in the rear panel of the remote arc starter box. Art # A-09631 Control Cable from Power Supply rear panel Manual No.
  • Page 53 Output Connections 1. Refer to the illustrations. Make the following output connections to the Arc Starter. NOTE: For newer leads with only black wire, it must be connected to the pilot return. There are no inner shield wires. Pilot Lead Art # A-09632 Pilot Lead Connection Detail...
  • Page 54 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. Ensure that the ground wire is not crimped between the cover and the base. Upper screws (2 per side) Cover Ground Wire...
  • Page 55 Art # A-04758 Torch Leads 1 Nut and 1 Washer Remain in Place Ground Cable • Use a clamp to secure the Torch Lead Shield brass ring to the port on the Remote Arc Starter as shown. Art # A-04759 Torch Leads Shield Shield Clamp Coolant and Pilot Leads...
  • Page 56 Power Supply Rear Panel RETURN SUPPLY COOLANT RETURN SUPPLY Remote Arc Starter Remote Arc Starter - Input Connection Panel Art # A-04801 Manual No. 0-4818 Auto-Cut 300 3-32 INSTALLATION...

  • Page 57: Install Torch Valve

    3.17 Install Torch Valve General Information This assembly mounts as close as possible to the torch head. It accepts preflow, plasma, and shield gases from the Gas Control Module and supplies these gases to the Torch. Mounting 113.03 mm 4.450” 6.63 mm .261”...

  • Page 58: Prepare The Torch Head

    3. Connect the gas supply lines and the control cable connector from the Gas Control Module to the Valve Kit as shown. Hold the check valves stationary while attaching the gas lines. Torch Valve, Inlet Side Control Cable Connector Water Shield Inlet Shield Gas Inlet Preflow Gas Inlet Plasma Gas Inlet...

  • Page 59: Connect Torch

    3.19 Connect Torch Connect the Torch as follows: Coolant Supply, Coolant Return, and Pilot Leads Leads Cover Torch Leads End Cap Shield Gas Groove for O-Ring (Right Hand Thread) O-Ring Pilot Lead Insulating Paper To Torch Valve Plasma Gas (Left Hand Thread) Plasma Lead Plasma Lead Connector...
  • Page 60 1. Lay out the torch leads on a clean, dry working surface. 2. Hold the Torch Leads End Cap stationary. Pull approximately 18" (0.5 m) of leads through the End Cap. 3. Remove and discard the protective end caps from the Mounting Tube. 4.

  • Page 61: Install Consumable Torch Parts

    3.20 Install Consumable Torch Parts Install the consumable parts as follows to ensure proper operation. These steps will help ensure that parts are seated correctly. WARNINGS Do not install consumables into the Cartridge while the Cartridge is attached to the Torch Head. Keep foreign materials out of the consumables and Cartridge.
  • Page 62 Torch Head Torch Head O-Ring 0.063 - 0.083" (1.6 - 2.1 mm) Protrusion Art # A-08300_AB CAUTION Do not force the cartridge if it will not fully tighten. Remove the cartridge and gently clean parts and apply oxygen-compatible lubricant (supplied with the torch) to o-rings as needed. Manual No.
  • Page 63 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 64 300 Amp Parts Assembly Art # A-08302 1 - Assemble “B” 2 - Assemble “C” if not already done 3 - Assemble “B” to “C” 4 - Assemble “A” to “B - C” CAUTION In “C” there is an insulating sleeve that must be in place on the Cartrudge before the Shield Cup is attached.

  • Page 65: Install Coolant

    3.21 Install Coolant 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 66 COOLANT RETURN SUPPLY RETURN SUPPLY Fill Range Coolant Tank Art # A-04803 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 67 3. Re-fill the reservoir and re-install the filler cap. 4. Purge coolant from the torch before firing the torch. Ensure there are no leaks before use. If leaks are evident, consult the coolant leak trouble-shooting guide in the maintenance section of this manual. Manual No.
  • Page 68 Intentionally Blank Manual No. 0-4818 Auto-Cut 300 3-44 INSTALLATION...

  • Page 69: Section 4: Operation

    SECTION 4: OPERATION 4.01 Power Supply Control Panel Status Indicator AC Indicator Gas Indicator Temp Indicator DC Indicator Art # A-04862 AC Power Indicator Indicates AC power is being supplied to the 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 70: Start-Up Sequence

    4.02 Start-Up Sequence 1. Connect system to primary input power. 2. Turn ON/OFF switch to ON (up) position. AC Indicator turns ON after about 5 seconds. POWER Art # A-04812 3. Check the AC indicator. If indicator is ON, system is ready to operate (pending fault checks by internal cir- cuitry).

  • Page 71: Gas Control Module Operation

    ENABLE - AIR H35 - N SET PREFLOW SET PLASMA AIR - AIR & SHIELD DISABLE TEST PLASMA POWER SUPPLY Thermal Dynamics MODE - AIR STATUS ENABLE H35 - N AMPS SET PREFLOW AMPS SET PLASMA AIR - AIR & SHIELD...
  • Page 72 Gas Control Module: Controls & Indicators 1. MODE Selection Switch SET PREFLOW SET PLASMA & SHIELD TEST MODE Thermal Dynamics MODE - AIR STATUS ENABLE H35 - N SET PREFLOW AMPS SET PLASMA AIR - AIR & SHIELD DISABLE TEST...
  • Page 73 2. GAS Selection Switch Selects combinations of plasma and shield gases. Each time the switch is changed it initiates a purge of the new gas. - AIR H35 - N AIR - AIR Thermal Dynamics - AIR STATUS ENABLE H35 - N AMPS...
  • Page 74 3. Amperage Control Adjusts the output amperage of the power supply. AMPS Thermal Dynamics MODE - AIR STATUS ENABLE H35 - N SET PREFLOW AMPS SET PLASMA AIR - AIR & SHIELD DISABLE TEST Automated PLASMA POWER Plasma Cutting System...

  • Page 75: Gas Control Sequence Of Operation

    4.04 Gas Control Sequence Of Operation Some operations vary depending on the revision of the gas control and it’s firmware (program). The gas control revision is found on the data tag. GCM 2000 revision AC or later with firmware version 3.1 (or later) includes a Status LED.
  • Page 76 Pressure and Flow Setting 1. Set the Preflow (Piloting) gas pressure. a. Set the Mode switch to “SET PREFLOW”. Refer to the torch section of the manual (cut charts section 8) for proper settings. b. Use the Preflow regulator knob to set preflow gas pressure. If the Mode switch is left in the “SET PREFLOW”...
  • Page 77 Cut Quality Cut quality requirements differ depending on application. For instance, nitride buildup and bevel angle may be major factors when the surface will be welded after cutting. Dross-free cutting is important when finish cut quality is desired to avoid a secondary cleaning operation. Cut quality will vary on different materials and thicknesses. Kerf Width Cut Surface Bevel Angle...

  • Page 78: Gas Selection

    Direction of Cut The plasma gas stream swirls as it leaves the torch to maintain a smooth column of gas. This swirl effect results in one side of a cut being more square than the other. Viewed along the direction of travel, the right side of the cut is more square than the left.
  • Page 79 3. Oxygen (O ) Plasma • Oxygen is recommended for cutting ferrous materials. • Provides faster cutting speeds. • Provides very smooth finishes and minimizes nitride buildup on cut surface (nitride buildup can cause difficulties in producing high quality welds if not removed). 4.

  • Page 80: Power Supply Status Codes

    4.06 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. After 4 seconds, the sequence repeats.
  • Page 81 Status Code Key Status Message Cause/Remedy Code System not Enabled or Missing Plasma Enable Off ; External E-Stop Activated or CCM AC Input Phase TB1-1&2 jumper missing; Missing AC Phase; No power to GCM 2000 or 2010 Gas Control, check GCM control cable connected, reset CP4 or CP5 circuit breaker in power supply, blown fuse F19 in GCM.
  • Page 82 Status Code Key (cond) Status Message Cause/Remedy Code Gas Control Communication If GCM 1000: Control cable not connected or Basic ID signal open. fault, Cannot establish GCM 2010 & 2000: Dirt on fiber ends or in connectors, blow out with clean Communication with gas dry air;...
  • Page 83 Status Code Key (cond) Status Message Cause/Remedy Code CANBUS Failure to If GCM 1000, Basic ID signal missing; Other gas controls, Fiber Acknowledge fault. disconnected or broken, Transceiver (what fiber plugs into) fault, replace Gas control PCB or CCM CANBUS Off due to Dirt on fiber ends or in connectors, blow out with clean dry air;...

  • Page 84: Remote Arc Starter: Service Chart

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

  • Page 85: Remote Arc Starter: Spark Gap Adjustment

    4.08 Remote Arc Starter: Spark Gap Adjustment 0.063" ± 0.002" 1.6 ± 0.05 mm Art # A-04857 Manual No. 0-4818 Auto-Cut 300 4-17 OPERATION...
  • Page 86 Intentionally Blank...

  • Page 87: Section 5: Maintenance

    SECTION 5: MAINTENANCE 5.01 General Maintenance Checks Perform the following checks periodically to ensure proper system performance. Power Supply Maintenance Schedule Daily Check coolant level; add coolant as needed. Check gas hose connections and pressures. Monthly Check cooling fan and radiator; clean as needed. Check gas hoses for cracks, leaks, or abrasion.

  • Page 88: Internal Coolant Filter Cleaning Procedure

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

  • Page 89: Section 6: Replacement Assemblies & Parts

    SECTION 6: REPLACEMENT ASSEMBLIES & PARTS 6.01 Replacement Power Supply Complete Unit / Component Catalog Number Auto-Cut® 30O Power Supply, 208/230V 3-9115-1 Auto-Cut® 30O Power Supply, 460V 3-9115-2 Auto-Cut® 30O Power Supply, 400V 3-9115-3 Auto-Cut® 30O Power Supply, 400V, (CE) 3-9115-4 Auto-Cut®...

  • Page 90: Recommended Gas Supply Hose

    6.02 Auto-Cut 30O System Layout Refer to section 3.05 for ground connections and ground cables. 50’ / 15.2 m Maximum Length 125’ / 38.1 m Maximum Length Pilot Return Pilot Return Negative Lead Shield Remote Coolant Supply Coolant Supply w/ Negative 300-A Starter Power...
  • Page 91 Catalog Numbers for Auto-Cut 30O Cables and Leads A,B,C, H,Q,R, F1** D,E* Fiber Supply Ground Torch Optic Work Lead Negative Ground Wire, Torch Lead Lead Control Control Cable Control Lead Wire Lead Set Cable Cable (X 2) Cable Length 9-4923 9-4931 9-4907 9-4898...
  • Page 92 #8 AWG Cable Pilot Return, Power Supply to Arc Starter 2/0 (70 mm ) 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 93: Power Supply External Replacement Parts

    6.04 Power Supply External Replacement Parts Item # Description Catalog # Power Supply Front Panel Power Supply Rear Panel Power Supply Top Panel 9-0445G/9-0455B Power Supply Right Side 9-0500G/9-0500B Power Supply Left Side 9-0501G/9-0501B Louver Panel Power Supply Connections Cover Lifting Eye 9-9373 Art # A-08281_AB...

  • Page 94: Power Supply Replacement Parts - Right Side

    6.05 Power Supply Replacement Parts - Right Side Item # Description Ref. Des. Catalog # Heat Exchanger Fan FAN1, FAN2 9-9338 Radiator 9-9339 Art # A-08283 Manual No. 0-4818 Auto-Cut 300 Parts List...

  • Page 95: Power Supply Replacement Parts - Right Side

    6.06 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-04777_AB Manual No. 0-4818 Auto-Cut 300 Parts List...

  • Page 96: Power Supply Replacement Parts - Front Panel

    6.07 Power Supply Replacement Parts - Front Panel Item # Description Ref. Des. Catalog # Main Power Switch (‘Circuit Protector’) 9-9344 for 230/460 VAC units Art # A-04779_AB Manual No. 0-4818 Auto-Cut 300 Parts List...

  • Page 97: Power Supply Replacement Parts - Right Side

    6.08 Power Supply Replacement Parts - Right Side Item # Description Ref. Des. Catalog # Chopper Module 9-9389 Sensor HCT1 9-9342 Chopper Module HCT1 Art # A-07064_AB Manual No. 0-4818 Auto-Cut 300 Parts List...

  • Page 98: Power Supply Replacement Parts - Rear Panel

    6.09 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 9-9350...

  • Page 99: Power Supply Replacement Parts - Right Side

    6.10 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-04785_AC Manual No. 0-4818 Auto-Cut 300 6-11 Parts List...

  • Page 100: Power Supply Replacement Parts

    6.11 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 Art # A-08284 Manual No. 0-4818 Auto-Cut 300 6-12 Parts List...

  • Page 101: Power Supply Replacement Parts - Right Side

    6.12 Power Supply Replacement Parts - Right Side Item # Description Ref. Des. Catalog # Sensor, (Thermistor) 9-9361 Art # A-04787 Manual No. 0-4818 Auto-Cut 300 6-13 Parts List...

  • Page 102: Power Supply Replacement Parts - Left Side

    6.13 Power Supply Replacement Parts - Left Side 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-08286 Manual No.

  • Page 103: Power Supply Replacement Parts - Left Side

    6.14 Power Supply Replacement Parts - Left Side Item # Description Ref. Des. Catalog # PCBoard 230/460 and 400VAC PCB1 9-9362 PCBoard 600 VAC PCB1 9-9491 Magnetic Contactor MC1,MC3,MC4 9-9364 Art # A-08285_AB Manual No. 0-4818 Auto-Cut 300 6-15 Parts List...

  • Page 104: Power Supply Replacement Parts - Right Side

    6.15 Power Supply Replacement Parts - Right Side Item # Description Ref. Des. Catalog # Relay PC Board PCB7 9-9366 24 VDC Power Supply DCS1 9-9493 Internal Control PC Board PCB5 9-9346 Art # A-04784_AB Manual No. 0-4818 Auto-Cut 300 6-16 Parts List...

  • Page 105: Power Supply Replacement Parts - Right Side

    6.16 Power Supply Replacement Parts - Right Side Item # Description Ref. Des. Catalog # Inline filter 8-3460 Sensor (Coolant Flow) 9-9359 Pump/Check Valve/Bypass Valve Assembly 9-9380 Bypass Valve (part of assembly) Call Motor MOT1 9-9381 Pump (part of assembly) Call Sensor (Level Switch) LSW1...

  • Page 106: Replacement Parts

    6.17 Command & Control Module Type 2 - Replacement Parts Item # Description Catalog # Assembly, CCM (Auto-Cut) 9-9418 Plate, CCM Face 9-9419 Panel, CCM Mount Call Harness, CCM I/O Board 9-9421 Art # A-06867 Manual No. 0-4818 Auto-Cut 300 6-18 Parts List...
  • Page 107 This page is blank intentionally. Manual No. 0-4818 Auto-Cut 300 6-19 Parts List...

  • Page 108: Gas Control Module (Gcm-2000) Replacement Parts

    6.18 Gas Control Module (GCM-2000) Replacement Parts Item # Description Catalog # Solenoid 9-9393 Gas Selection Manifold Assembly Call Check Valve, 1/4 NPT 0.5 PSI 9-9390 Mode Selection Switch Assembly 9-9406 Flowmeter, 0-150 8-6801 Not shown - Valve Assembly 9-9382 Tube 9-9383 Knob...
  • Page 109 Thermal Dynamics STATUS ENABLE - AIR AMPS SET PREFLOW H35 - N SET PLASMA AIR - AIR & SHIELD DISABLE TEST Automated PLASMA MODE POWER SUPPL Y Plasma Cutting System SHIELD PREFLOW PLASMA MIST PRESSURE 2000 FLOW Art # A-06894_AB Manual No.

  • Page 110: Torch Valve Assembly Replacement Parts

    6.19 Torch Valve Assembly Replacement Parts Item # Description Catalog # Torch Valve Assembly 9-9436 Control Cable Harness 9-9479 Fuel B Fitting Call Check Valve 9-7006 Fitting Call Fitting Call #6 JIC Fitting Call 1/8 NPT Str. Tee 8-0352 1/4 NPT Str. Elbow 8-3369 Adapter Call...

  • Page 111: Remote Arc Starter (Ras-1000) Replacement Parts

    6.20 Remote Arc Starter (RAS-1000) Replacement Parts Item # Description Catalog # Harness, Internal (Not Shown) 9-4956 Pilot Cap Assembly 9-9423 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 112: Remote Arc Starter (Ras-1000) Replacement Parts

    6.21 Remote Arc Starter (RAS-1000) Replacement Parts Item # Description Catalog # Retainer, ABS Wall 9-4964 (Outer) Torch Lead Ground Assembly 9-4955 Bracket, Bulkhead Holder 9-4963 Cover, Arc Starter 9-4962 Strain Relief, large 9-7571 Strain Relief, small 8-7072 Coolant Leads, from Power Supply Art # A-09635 Manual No.

  • Page 113: Torch Maintenance

    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 114: O-Ring Lubrication

    Cat. No. 9-3026 Cat. No. 9-3025 Art # A-04066_AC CAUTION Use only Thermal Dynamics No. 9-4893 O-Ring Lubricant (Christo Lube MCG-129) with this torch part. Use of other lubricants may cause irreparable damage to the torch. Manual 0-4818 Auto-Cut 300 TORCH MAINTENANCE...

  • Page 115: Parts Wear

    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 Manual 0-4818 Auto-Cut 300...

  • Page 116: Coolant Leak Trouble-Shooting

    7.04 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 117: Appendix 1: Remote Arc Starter Schematic

    APPENDIX 1: Remote Arc Starter Schematic Manual 0-4818 Auto-Cut 300 APPENDIX...

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

    APPENDIX 2: Gas Control and Torch Valve Schematic SET PREFLOW O2 - AIR SET CUTFLOW H35 - N2 TEST AIR - AIR N2 - H2O MODE MODE To CCM Jumper Programs Software for GCM 2000 STATUS STATUS (10) (12) (13) (14) (15) FIBER-...
  • Page 119 ECO-B587 01/06/08 Date: Date: Date: Shield Information Proprietary to THERMAL DYNAMICS CORPORATION. Information Proprietary to THERMAL DYNAMICS CORPORATION. Information Proprietary to THERMAL DYNAMICS CORPORATION. Monday, February 21, 2005 Monday, February 21, 2005 Monday, February 21, 2005 Not For Release, Reproduction, or Distribution without Written Consent.

  • Page 120: Appendix 3: Gas Control Module Plumbing Diagram

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

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

    APPENDIX 4: Gas Control Module PCB Layout TP10 TP11 TP12 TP13 TP15 Art # A-07621 TP19 TP18 TP16 TP14 Manual 0-4818 Auto-Cut 300 APPENDIX...

  • Page 122: Appendix 5: Ccm Input / Output Pcb Layout

    APPENDIX 5: CCM Input / Output PCB Layout Note: Switch Settings May Vary. POST OK TO AUTO PILOT FLOW FLOW FUNC CONT MOVE/D CPU/COMMUNICATIONS Switches POST OK TO AUTO PILOT FLOW FLOW FUNC CONT MOVE/D C 2004 TDC 19X2169 REV +5.0V TEMP SENSE...

  • Page 123: Appendix 6: Cnc - Control Module Pcb Connections

    APPENDIX 6: CNC - Control Module PCB Connections TP11 SW11 TP12 J5 J5 J6 J6 J7 J7 J8 J8 J4 J4 PILOT V PILOT V R224 R224 L2 L2 R2 R2 TP12 TP12 J1 J1 R225 R225 CC POT CC POT U1 U1 R4 R4 H6 H6...
  • Page 124 This page intentionally blank Manual 0-4818 Auto-Cut 300 APPENDIX...

  • Page 125: Appendix 7: Cnc - Control Module Pcb Connections

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

  • Page 126: Cnc Functions

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

  • Page 127: Cnc Input / Output Descriptions

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

  • Page 128: Simplified Cnc Circuit

    Simplified CNC Circuit. CCM Module SUSTAINED START / STOP ALL SW OFF for 50:1 (default) TB1-5 Active LOW Logic Input E-STOP Ret (-) START / STOP SW12-1 ON = 16.7:1 (SC-11) E-STOP input (+) SW12-2 ON = 30:1 Active LOW Logic Input TB1-6 STOP (NC) SW12-3 ON = 40:1...
  • Page 129 This page intentionally blank Manual 0-4818 Auto-Cut 300 A-13 APPENDIX...

  • Page 130: Appendix 8: Schematic, 230-460V Unit

    APPENDIX 8: Schematic, 230-460V Unit 100A INVERTER MODULE # 1 (top) N (-) N (-) CN1-230V CN1-230V INRUSH INRUSH MC1-A MC1-A MC1-B MC1-B MC1-C MC1-C P (+) P (+) CN4 - PCB12 CN4 - PCB12 CN2-460V CN2-460V MC3-A MC3-A 100A INVERTER MODULE # 2 (middle) N (-) N (-) MC3-B...
  • Page 131 603-298-5711 ECO-B646 GAC 10/31/07 Date: Date: Date: Information Proprietary to THERMAL DYNAMICS CORPORATION. Information Proprietary to THERMAL DYNAMICS CORPORATION. Information Proprietary to THERMAL DYNAMICS CORPORATION. Tuesday, October 03, 2006 Tuesday, October 03, 2006 Tuesday, October 03, 2006 Not For Release, Reproduction, or Distribution without Written Consent.

  • Page 132: Appendix 8: Schematic, 230-460V Unit Cont

    APPENDIX 8: Schematic, 230-460V Unit Cont. PCB 5 WK-5602 (partial) INTERFACE PCB LED1 LED1 INPUT CONTACTORs LEVEL LEVEL CN12 CN12 CN13 CN13 CN14 CN14 PILOT CONTACTOR MC1 AUX MC1 AUX MC3 AUX MC3 AUX MC4 AUX MC4 AUX LSW1-1 LSW1-1 COOLANT TEMP (ON COOLANT RETURN)
  • Page 133 603-298-5711 ECO-B646 GAC 10/31/07 Date: Date: Date: Information Proprietary to THERMAL DYNAMICS CORPORATION. Information Proprietary to THERMAL DYNAMICS CORPORATION. Information Proprietary to THERMAL DYNAMICS CORPORATION. Tuesday, October 03, 2006 Tuesday, October 03, 2006 Tuesday, October 03, 2006 Not For Release, Reproduction, or Distribution without Written Consent.

  • Page 134: Appendix 9: Schematic, Ccc 400V Unit

    APPENDIX 9: Schematic, CCC 400V Unit 100A INVERTER MODULE # 1 (top) N (-) N (-) CN1- (not used) CN1- (not used) INRUSH INRUSH MC1-A MC1-A MC1-B MC1-B MC1-C MC1-C P (+) P (+) CN4 - PCB12 CN4 - PCB12 CN2-400V CN2-400V MC3-A...
  • Page 135 603-298-5711 ECO-B646 GAC 10/31/07 Date: Date: Date: Information Proprietary to THERMAL DYNAMICS CORPORATION. Information Proprietary to THERMAL DYNAMICS CORPORATION. Information Proprietary to THERMAL DYNAMICS CORPORATION. Tuesday, October 03, 2006 Tuesday, October 03, 2006 Tuesday, October 03, 2006 Not For Release, Reproduction, or Distribution without Written Consent.

  • Page 136: Appendix 9: Schematic, Ccc 400V Unit Cont

    APPENDIX 9: Schematic, CCC 400V Unit Cont. PCB 5 WK-5602 (partial) INTERFACE PCB LED1 LED1 INPUT CONTACTORs LEVEL LEVEL CN12 CN12 CN13 CN13 CN14 CN14 PILOT CONTACTOR MC1 AUX MC1 AUX MC3 AUX MC3 AUX MC4 AUX MC4 AUX LSW1-1 LSW1-1 COOLANT TEMP (ON COOLANT...
  • Page 137 603-298-5711 ECO-B646 GAC 10/31/07 Date: Date: Date: Information Proprietary to THERMAL DYNAMICS CORPORATION. Information Proprietary to THERMAL DYNAMICS CORPORATION. Information Proprietary to THERMAL DYNAMICS CORPORATION. Tuesday, October 03, 2006 Tuesday, October 03, 2006 Tuesday, October 03, 2006 Not For Release, Reproduction, or Distribution without Written Consent.

  • Page 138: Appendix 10: Schematic, Ce 400V Unit

    APPENDIX 10: Schematic, CE 400V Unit 100A INVERTER MODULE # 1 (top) CN1- (not used) CN1- (not used) INRUSH INRUSH NFC1 NFC1 MC1-A MC1-A MC1-B MC1-B FILTER FILTER MC1-C MC1-C CN4 - PCB12 CN4 - PCB12 CN2-400V CN2-400V NFC2 NFC2 MC3-A MC3-A 100A INVERTER MODULE # 2 (middle)
  • Page 139 603-298-5711 ECO-B646 GAC 10/31/07 Date: Date: Date: Information Proprietary to THERMAL DYNAMICS CORPORATION. Information Proprietary to THERMAL DYNAMICS CORPORATION. Information Proprietary to THERMAL DYNAMICS CORPORATION. Tuesday, October 03, 2006 Tuesday, October 03, 2006 Tuesday, October 03, 2006 Not For Release, Reproduction, or Distribution without Written Consent.

  • Page 140: Appendix 10: Schematic, Ce 400V Unit Cont

    APPENDIX 10: Schematic, CE 400V Unit Cont. PCB 5 WK-5602 (partial) INTERFACE PCB LED1 LED1 INPUT CONTACTORs LEVEL LEVEL CN12 CN12 CN13 CN13 CN14 CN14 PILOT CONTACTOR MC1 AUX MC1 AUX MC3 AUX MC3 AUX MC4 AUX MC4 AUX LSW1-1 LSW1-1 COOLANT TEMP (ON COOLANT...
  • Page 141 603-298-5711 ECO-B646 GAC 10/31/07 Date: Date: Date: Information Proprietary to THERMAL DYNAMICS CORPORATION. Information Proprietary to THERMAL DYNAMICS CORPORATION. Information Proprietary to THERMAL DYNAMICS CORPORATION. Tuesday, October 03, 2006 Tuesday, October 03, 2006 Tuesday, October 03, 2006 Not For Release, Reproduction, or Distribution without Written Consent.

  • Page 142: Appendix 11: Schematic, Csa 600V Unit

    APPENDIX 11: Schematic, CSA 600V Unit 100A INVERTER MODULE # 1 (top) N (-) N (-) CN1- (not used) CN1- (not used) INRUSH INRUSH MC1-A MC1-A MC1-B MC1-B MC1-C MC1-C P (+) P (+) CN4 - PCB12 CN4 - PCB12 CN2-600V CN2-600V MC3-A...
  • Page 143 603-298-5711 ECO-B646 GAC 10/31/07 Date: Date: Date: Information Proprietary to THERMAL DYNAMICS CORPORATION. Information Proprietary to THERMAL DYNAMICS CORPORATION. Information Proprietary to THERMAL DYNAMICS CORPORATION. Tuesday, October 03, 2006 Tuesday, October 03, 2006 Tuesday, October 03, 2006 Not For Release, Reproduction, or Distribution without Written Consent.

  • Page 144: Appendix 11: Schematic, Csa 600V Unit Cont

    APPENDIX 11: Schematic, CSA 600V Unit Cont. PCB 5 WK-5602 (partial) INTERFACE PCB LED1 LED1 INPUT CONTACTORs LEVEL LEVEL CN12 CN12 CN13 CN13 CN14 CN14 PILOT CONTACTOR MC1 AUX MC1 AUX MC3 AUX MC3 AUX MC4 AUX MC4 AUX LSW1-1 LSW1-1 COOLANT TEMP (ON COOLANT...
  • Page 145 603-298-5711 ECO-B646 GAC 10/31/07 Date: Date: Date: Information Proprietary to THERMAL DYNAMICS CORPORATION. Information Proprietary to THERMAL DYNAMICS CORPORATION. Information Proprietary to THERMAL DYNAMICS CORPORATION. Tuesday, October 03, 2006 Tuesday, October 03, 2006 Tuesday, October 03, 2006 Not For Release, Reproduction, or Distribution without Written Consent.

  • Page 146: Appendix 12: Publication History

    APPENDIX 12: Publication History Cover Date Rev. Change(s) Dec. 10, 2007 First issue Jan. 14, 2008 Added 600VAC PCB1to parts list. Also added flow meter parts per ECOB704 to parts list. Jan. 28, 2008 Per ECOB738 added GCM plumbing diagram to Appendix. Feb.
  • Page 147 This Page Intentionally Blank...
  • Page 148 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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