Thermal Dynamics Ultra-Cut 400 Operation Manual
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Thermal Dynamics Ultra-Cut 400 Operation Manual

Thermal Dynamics Ultra-Cut 400 Operation Manual

Plasma cutting system
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Manual Assembly Instructions
- Separate this sheet from the rest of the manual.
- Locate and remove 'Page 1' of this manual. Follow the directions on 'Page 1'.
- Locate the set of tabs for this manual.
- Locate the torch information section, which will become section 8 of this manual.
- Find the sheets saying 'Insert Section ___ tab here. Discard this sheet'. Insert the appropriate tabs
and discard the 'Insert Section ___ tab here. ' sheet.
- At Section 8, insert the torch information section.
-Insert the assembled manual sections and tabs into the 3-ring binder.
- Keep this manual with the power supply for installation, operation, maintenance, and replacement parts
information.
OPTIONAL:
Copy Section 8 (torch operational data) for operator convenience. This section includes data that will be
needed repeatedly for system operation, depending on the metal to be cut and the gases in use.
- Discard this sheet.
NOTE:
Power supply schematics are provided separately. The system operator may want to keep them with this
book or in a separate location.
Manual No. 0-5164 rev AG

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Summary of Contents for Thermal Dynamics Ultra-Cut 400

  • Page 1 Manual Assembly Instructions - Separate this sheet from the rest of the manual. - Locate and remove 'Page 1' of this manual. Follow the directions on 'Page 1'. - Locate the set of tabs for this manual. - Locate the torch information section, which will become section 8 of this manual. - Find the sheets saying 'Insert Section ___ tab here.
  • Page 2 Blank...
  • Page 3 COPY CENTER: COPY CENTER: Cut out one strip and use as spine label in binder. Discard extras. Cut out one strip and use as spine label in binder. Discard extras. Use next page as front cover insert in binder. Use next page as front cover insert in binder. Manual No.
  • Page 4 Blank...
  • Page 5 ™ ULTRA-CUT PLASMA CUTTING SYSTEM Art# A-09430 Operating Manual Rev. AG Date: April 10, 2012 Manual # 0-5164 Operating Features:...
  • Page 6 Blank...
  • Page 7 ™ ULTRA-CUT PLASMA CUTTING SYSTEM Art# A-09430 Operating Manual Rev. AG Date: April 10, 2012 Manual # 0-5164 Operating Features:...
  • Page 8 YOU ARE IN GOOD COMPANY! The Brand of Choice for Contractors and Fabricators Worldwide. Thermal Dynamics is a Global Brand of manual and automation Plasma Cutting Products for Thermadyne Industries Inc. We distinguish ourselves from our competition through market-leading, dependable products that have stood the test of time.
  • Page 9 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 judgement, the Manufacturer assumes no liability for its use. ® Plasma Cutting Power Supply, Ultra-Cut Operating Manual No.
  • Page 10 This page intentionally blank...
  • Page 11 Insert Table of Con- tents tab here. Discard this sheet.
  • Page 12 This page intentionally blank...

  • Page 13: 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 14 TABLE OF CONTENTS 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 First Time Operation Matching Gas Control to Lead Length ......4-7 4.05 Sequence Of Operation ...................
  • Page 15 TABLE OF CONTENTS 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: Gas Control Display Module PCB Layout ..........A-6 APPENDIX 6: CCM Input / Output PCB Layout ............
  • Page 16 TABLE OF CONTENTS This Page Intentionally Blank...

  • Page 17: General Information

    ULTRA-CUT 400 SECTION 1: different processes. You must be very careful when cutting or welding any metals which may contain one or more of the GENERAL INFORMATION following: Antimony Chromium Mercury Arsenic Cobalt Nickel 1.01 Notes, Cautions and Warnings Barium...

  • Page 18: Publications

    ULTRA-CUT 400 • Hydrogen gas may be formed and trapped under aluminum 1. OSHA, SAFETY AND HEALTH STANDARDS, 29CFR 1910, workpieces when they are cut underwater or while using a water obtainable from the Superintendent of Documents, U.S. table. DO NOT cut aluminum alloys underwater or on a water Government Printing Office, Washington, D.C.

  • Page 19: Note, Attention Et Avertissement

    ULTRA-CUT 400 15. ANSI Standard Z88.2, PRACTICE FOR RESPIRATORY PRO- • Eloignez toute fumée et gaz de votre zone de respiration. Gardez TECTION, obtainable from American National Standards votre tête hors de la plume de fumée provenant du chalumeau. Institute, 1430 Broadway, New York, NY 10018 • Utilisez un appareil respiratoire à alimentation en air si l’aération fournie ne permet pas d’éliminer la fumée et les gaz.

  • Page 20: Documents De Reference

    ULTRA-CUT 400 BRUIT INCENDIE ET EXPLOSION Le bruit peut provoquer une perte permanente de l’ouïe. Les procédés Les incendies et les explosions peuvent résulter des scories chaudes, de soudage à l’arc de plasma peuvent provoquer des niveaux sonores des étincelles ou de l’arc de plasma. Le procédé à l’arc de plasma supérieurs aux limites normalement acceptables.
  • Page 21 ULTRA-CUT 400 4. Norme ANSI Z87.1, PRATIQUES SURES POUR LA PROTECTION DES YEUX ET DU VISAGE AU TRAVAIL ET DANS LES ECOLES, disponible de l’Institut Américain des Normes Nationales (American National Standards Institute), 1430 Broadway, New York, NY 10018 5. Norme ANSI Z41.1, NORMES POUR LES CHAUSSURES PRO- TECTRICES, disponible auprès de l’American National Standards...

  • Page 22: Declaration Of Conformity

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

  • Page 23: 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 24 ULTRA-CUT 400 This Page Intentionally Blank GENERAL INFORMATION Manual 0-5164...
  • Page 25 ULTRA-CUT 400 Insert Section 2 tab here. Discard this sheet. Manual 0-5164 GENERAL INFORMATION...
  • Page 26 ULTRA-CUT 400 GENERAL INFORMATION 1-10 Manual 0-5164...

  • Page 27: Section 2: Specifications

    2.05 Precision Plasma Cutting Torch The torch delivers the controlled current to the work through the main arc, causing the metal to be cut. 2.06 Specifications & Electrical Requirements Ultra-Cut 400 Specifications & Design Features Max OCV (U0) 380 vdc Minimum Output Current...

  • Page 28: System Component Layout

    ULTRA-CUT 400 2.07 System Component Layout Ultra-Cut 400 Power Supply Input Power Input Current Suggested Sizes (See Note) Voltage Freq. 3-Ph 3-Ph Fuse (Amps) Wire (AWG) Wire (mm (Volts) (Hz) (kVA) (Amps) 3-Ph 3-Ph 3-Ph 50/60 300MCM 50/60 250MCM 50/60...

  • Page 29: Power Supply Dimensions

    ULTRA-CUT 400 2.08 Power Supply Dimensions 27 inch 680 mm 53 inch 1350 mm 33 inch 27.5 inch 840 mm 700 mm 37.75 inch 960 mm 627 lb / 285 kg Art # A-09449 Manual No. 0-5164 SPECIFICATIONS...

  • Page 30: Power Supply Rear Panel Features

    ULTRA-CUT 400 2.09 Power Supply Rear Panel Features Torch (Neg) Terminal AC Power Lamp Pilot (Pos) Terminal Input Power Circuit Breaker Terminals Panel Gas Control Console Connector Ground Terminals CNC Connector Remote Arc Starter Terminal Cover Work Cable Terminal Connector...

  • Page 31: Gas Requirements

    The customer will provide all gases and pressure regulators. Gases must be of high quality. Pressure regulators shall be double stage and installed within 3 meters from the Gas Console. Ultra-Cut 400 Power Supply: Gas Pressures, Flows, and Quality Requirements Quality...

  • Page 32: Gas Applications

    ULTRA-CUT 400 2.11 Gas Applications MATERIAL MILD STEEL STAINLESS STEEL ALUMINUM GAS TYPE GAS TYPE GAS TYPE OPERATION PREFLOW PLASMA SHIELD PREFLOW PLASMA SHIELD PREFLOW PLASMA SHIELD 30A Cut 50A Cut 70A Cut 100A Cut 150A Cut 200A Cut 250A Cut...

  • Page 33: Xt Torch Specifications

    ULTRA-CUT 400 2.12 XT Torch Specifications A. Torch Dimensions Basic 400 Amp torch dimensions Basic 100 Amp torch dimensions Manual No. 0-5164 SPECIFICATIONS...
  • Page 34 ULTRA-CUT 400 B. Torch Leads Lengths Torch Lead Assemblies Length Feet Meters 3.05 15.2 C. Torch Parts (Generic Parts Shown) Art # A-04741 Plasma Gas Shield Gas Distributor Distributor Shield Cap Electrode Cartridge Shield Cup D. Parts - In - Place (PIP) The torch is designed for use with a power supply which senses coolant return flow to confirm that torch parts are in place.
  • Page 35 ULTRA-CUT 400 F. XT Torch Data (with Ultra-Cut 400 Power Supply) ® XT Torch Ratings for use with Ultra-Cut 400 Power Supply Ambient 104° F Temperature 40° C Duty Cycle 100% @ 400 Amps Maximum Current 400 Amps Voltage (Vpeak)
  • Page 36 ULTRA-CUT 400 This Page Intentionally Blank SPECIFICATIONS 2-10 Manual No. 0-5164...
  • Page 37 ULTRA-CUT 400 Insert Sec 3 tab here, discard this sheet. Manual No. 0-5164 2-11 SPECIFICATIONS...

  • Page 39: Section 3: Installation

    • Oil or grease contamination from compressed or bottled air can cause fires in conjunction with oxygen. Cooling System Requirements Coolant must be added to the system on installation. The amount required varies with torch leads length. Thermal Dynamics recommends the use of its coolants 7-3580 and 7-3581 (for low temperatures). Manual No. 0-5164 INSTALLATION...

  • Page 40: System Layout

    ULTRA-CUT 400 Coolant Capabilities Cat. Number and Mixture Mixture Protects To 7-3580 ‘Extra-Cool™’ 25 / 75 10° F / -12° C 7-3581 ‘Ultra-Cool™’ 50 / 50 -27° F / -33° C 7-3582 ‘Extreme Cool™’ Concentrate* -76° F / -60° C * For mixing with D-I Cool™...

  • Page 41: Cables & Leads Identification

    ULTRA-CUT 400 3.03 Cables & Leads Identification #8 AWG Cable Pilot Return, Power Supply to Arc Starter 2/0 AWG Cable (70 mm 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...

  • Page 42: Lift The Power Supply

    ULTRA-CUT 400 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.

  • Page 43: Remove The Connections Cover

    ULTRA-CUT 400 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 44 ULTRA-CUT 400 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 and right side panel and locate the voltage configura- tion board.
  • Page 45 ULTRA-CUT 400 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 46: Connect Work Cable And Pilot And Negative Leads

    ULTRA-CUT 400 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.

  • Page 47: 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 48 ULTRA-CUT 400 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”...
  • Page 49 ULTRA-CUT 400 CAUTION No other connections should be made at the ground rod being tested. 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.

  • Page 50: Connect Coolant Leads

    ULTRA-CUT 400 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...

  • Page 51: Connect Cables For Cnc, Remote Arc Starter, Dmc-3000 And He 400

    ULTRA-CUT 400 3.09 Connect Cables for CNC, Remote Arc Starter, DMC-3000 and HE 400 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.

  • Page 52: Handling And Installation Of Fiber Optics

    ULTRA-CUT 400 3.10 Handling and Installation of Fiber Optics General Information This kit is for proper handling and installation of Fiber Optic Cables used in Thermal Dynamics Ultra-Cut ® Auto-Cut O2 automated gas boxes and Gas Control Modules. ® Fiber Optic cable is used in place of wire because it offers far superior immunity to electrical noise but it is more delicate and requires careful handling.

  • Page 53: Correct Installation

    ULTRA-CUT 400 2. Don’t hook onto the fiber to pull on the cable. Art # A-09418 3. Once the fiber cable is installed in the CCM or gas control make sure the strain relief nut is securely tightened onto the hose so the hose can’t pull out of it like this:...
  • Page 54 ULTRA-CUT 400 Correct installation in CCM or Gas Control leaves a loop of fiber so there is no stress on the fiber where it exits the connector or the hose. sharp Sharp Bends bends Art # A-09421 DMC 3000 (part of DFC...
  • Page 55 ULTRA-CUT 400 Unplugging the fiber optic connector. Do not pull on the fiber! Art # A-09423 For the CCM grip the fiber connector front and back squeezing the latch lever and remove from the socket. Art # A-09424 Manual No. 0-5164 3-17 INSTALLATION...
  • Page 56 ULTRA-CUT 400 For the Gas controls where you can’t grip the back of the connector, press in on the latch lever and push away from the sockets. Or grip the sides of the connector with thumb and finger while using index finger to press on the latch.

  • Page 57: Connect Fiber Optic Cable (Type 3 Internal Control Module)

    ULTRA-CUT 400 3.11 Connect Fiber Optic Cable (Type 3 internal control module) CAUTION Check the type of internal control module. 1. Connect one end of each cable to the power supply as shown. a. 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.

  • Page 58: Set Switches On The Command - Control Module (Type 3 Module)

    ULTRA-CUT 400 3.12 Set Switches on the Command - Control Module (Type 3 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.
  • Page 59 ULTRA-CUT 400 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.)

  • Page 60: Height Control Connections

    ULTRA-CUT 400 3.13 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 61: Gas Control Module Installation

    ULTRA-CUT 400 3.14 Gas Control Module Installation The Gas Control Module must be installed in a suitable location where it is easily accessible to the system operator. The unit must be mounted to a flat horizontal surface. If the Module is mounted to a gantry or to any other support subject to vibration or motion, the installer must fasten the module to the support securely.
  • Page 62 ULTRA-CUT 400 Preparation 1. Remove the screws securing the Cover Panel to the Module. 2. Carefully remove the cover from the module noting the attached ground wire. Remove the ground wire if needed. Gas Control Module Cover Remove Ground Wire...

  • Page 63: Fiber Optic Cable Installation

    ULTRA-CUT 400 3.15 Fiber Optic Cable Installation 1. Install the through-hole protector for the fiber-optic cable in the hole in connection panel on the back of the Module. 2. Pass the fiber-optic cable connector through the hole in connection panel on the back of the Module.
  • Page 64 ULTRA-CUT 400 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 using hand tools.

  • Page 65: Gas Control Module: Control, Input, And Output Connections

    ULTRA-CUT 400 3.16 Gas Control Module: Control, Input, and Output Connections 1. Make all other connections to the rear of the Module. The connections are labeled. The Module must be grounded; the grounding terminal is marked Use #10 AWG (European 6 mm ) (or thicker) wire for ground- ing.

  • Page 66: He400 Cooler

    ULTRA-CUT 400 3.17 HE400 COOLER Used in series with the existing cooling system of the UltraCut series power supplies, the HE400 Cooler provides necessary additional water cooling for the torch head when cutting at over 300amps. The HE400 operates indepen- dently of the UltraCut pump and fans therefore it can start at any time.
  • Page 67 ULTRA-CUT 400 Match the colors of the hoses to the front panel label. Supply lines are green and return lines are red. Facing the unit as shown below, the left connections go to the UltraCut power supply, the right connections go to the RAS1000 arc starter.

  • Page 68: Install Remote Arc Starter

    ULTRA-CUT 400 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.
  • Page 69 ULTRA-CUT 400 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.

  • Page 70: Input Connections

    ULTRA-CUT 400 3. Position the Arc Starter on a flat, horizontal mounting surface. 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.
  • Page 71 ULTRA-CUT 400 Art # A-09628 Coolant Return (Red) Green Coolant Supply (Green) Copper plate Art # A-09629 Negative Cable from power supply. Negative Cables (from Power Supply rear panel) Manual No. 0-5164 3-33 INSTALLATION...
  • Page 72 ULTRA-CUT 400 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 INSTALLATION 3-34 Manual No. 0-5164...

  • Page 73: Output Connections

    ULTRA-CUT 400 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.
  • Page 74 ULTRA-CUT 400 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 75 ULTRA-CUT 400 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 brass ring to the port on the Remote Arc Starter as shown.
  • Page 76 ULTRA-CUT 400 Connect Control Cable 1. Connect the Remote Arc Starter cable to the Remote Arc Starter receptacle. COOLANT RETURN SUPPLY RETURN SUPPLY Art # A-09558 INSTALLATION 3-38 Manual No. 0-5164...

  • Page 77: Torch Valve Installation

    ULTRA-CUT 400 3.19 Torch Valve Installation General Information This assembly mounts as close as possible to the torch head. It accepts preflow, plasma, and shield gases from the Gas Control Module and supplies these gases to the Torch. Mounting 113.03 mm 4.450”...
  • Page 78 ULTRA-CUT 400 3. Connect the gas supply lines and the control cable connector from the Gas Control Module to the Valve Kit as shown. Hold the check valves stationary while attaching the gas lines. (XTL shown) Exhaust Muffler Control Cable WMS™...

  • Page 79: Connecting Torch

    ULTRA-CUT 400 3.20 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...

  • Page 80: Install Consumable Torch Parts

    ULTRA-CUT 400 CAUTION The gas and coolant leads include compression fittings. Do not use sealant on these connections. Slowly apply pressure to the gas lines. Check for leaks at all connections before continuing. If there are no leaks, shut off the gas supplies and continue with installation.
  • Page 81 ULTRA-CUT 400 3. Stack the consumable parts together. Art # A-08303 Shield Shield Cup Retainer 1 - Assemble “A” 200 A only. 2 - Assemble “B”. 3 - Assemble “B” to “C”. 4 - Assemble “A” to “B-C” assembly. 4. Insert the stack of consumable parts into the cartridge. Ensure that the large O-ring on the torch tip fits completely into the cartridge.
  • Page 82 ULTRA-CUT 400 30 - 100 Amp Parts Assembly 1: Stack Parts 2: Press Cartridge onto Stacked Parts Electrode Plasma Gas Distributor O-Ring on Tip No Gaps Between Parts Shield Gas Cartridge Covers Distributor O-Ring on Torch Tip Shield Cap 4: Check Shield Cap Protrusion...
  • Page 83 ULTRA-CUT 400 Ohmic Clip Art # A-03393_AB NOTE Ohmic height sensing is not recommended with water shield. Water on the plate interferes electri- cally with the ohmic sensing circuit. Manual No. 0-5164 3-45 INSTALLATION...

  • Page 84: Complete The Installation

    ULTRA-CUT 400 3.22 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 85 ULTRA-CUT 400 NOTE Depending on the length of the torch leads, the system may require more coolant after turning the system ON for the first time. a. Place the ON/OFF Switch to ON. b. After about 4 minutes the system may shut down if the leads are not full of coolant.
  • Page 86 ULTRA-CUT 400 This Page Intentionally Blank INSTALLATION 3-48 Manual No. 0-5164...
  • Page 87 ULTRA-CUT 400 COPY CENTER: Insert Sec 4 tab here, discard this sheet. Manual No. 0-5164 3-49 INSTALLATION...
  • Page 88 Blank...

  • Page 89: Section 4: Operation

    ULTRA-CUT 400 SECTION 4: OPERATION 4.01 Power Supply Control Panel Gas Indicator Status Indicator AC 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 90: Start-Up Sequence

    ULTRA-CUT 400 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 91: Gas Control Module Operation

    ULTRA-CUT 400 4.03 Gas Control Module Operation Functional Overview The Gas Control Module provides all Plasma and Secondary gas selection and control instrumentation. There are various controls and indicators used to set gas pressures and flows. O2 - AIR O2 - O2...
  • Page 92 ULTRA-CUT 400 Gas Control Module: Controls & Indicators 1. MODE Selection Switch SET PREFLOW SET PLASMA & SHIELD TEST MODE O2 - AIR O2 - O2 ENABLE H35 -N SET PREFLOW F5 - N SET PLASMA AIR - AIR & SHIELD TEST DISABLE High Precision...
  • Page 93 ULTRA-CUT 400 2. GAS Selection Switch Selects combinations of plasma and shield gases. O2 - AIR O2 - O2 H35 -N F5 - N AIR - AIR O2 - AIR O2 - O2 ENABLE H35 -N SET PREFLOW F5 - N SET PLASMA &...
  • Page 94 ULTRA-CUT 400 4. Current Control Adjusts the output current of the power supply. High Precision Plasma Cutting System O2 - AIR O2 - O2 ENABLE H35 -N SET PREFLOW F5 - N SET PLASMA & SHIELD AIR - AIR DISABLE...

  • Page 95: First Time Operation Matching Gas Control To Lead Length

    ULTRA-CUT 400 4.04 First Time Operation Matching Gas Control to Lead Length For initial operation of GCM2010 with software version 2.1 or later. 1. Before applying AC power set the Power Supply ENABLE/DISABLE switch on the gas control module to DIS- ABLE.
  • Page 96 ULTRA-CUT 400 5. Use the AMPERAGE SET-UP control knob to set the desired amperage output. The module will update the amperage every 2 seconds after the last adjustment to the knob. The module keeps the set point in memory. 6. Place the MODE switch to the RUN position.
  • Page 97 ULTRA-CUT 400 Kerf Width The width of material removed during the cut. Nitride Build-up Nitride deposits which may remain on the cut edge of the carbon steel when nitrogen is present in the plasma gas stream. Nitride buildups may create difficulties if the steel is welded after the cutting process.

  • Page 98: Gas Selection

    ULTRA-CUT 400 4.06 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 sub- stantially reduce torch parts life.
  • Page 99 ULTRA-CUT 400 B. Shield Gases 1. Compressed Air Shield • Air shield is normally used when operating with air plasma. • Improves cut quality on some ferrous materials. • Inexpensive - reduces operating costs. 2. Nitrogen (N2) Shield • Nitrogen shield is used with Ar/H2 (H35) plasma.

  • Page 100: Power Supply Status Codes

    ULTRA-CUT 400 4.07 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 101 ULTRA-CUT 400 Fault Code Key Error Error Remedy / Comments Code 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 / wiring Wrong input voltage too small causing voltage drop; broken or loose power cable connec- tions. Inverter or Pilot Regulator Over Temperature Power Supply not Ready Less than 60 VDC; Defective inverter, shorted output; CCM voltage sense...
  • Page 102 ULTRA-CUT 400 Fault Code Key Error Error Remedy / Comments Code Coolant Level low Check coolant level, add as needed. Fault response time: Process Never started since last power cyle: Below 0.7 GPH Low coolant flow for 15 Seconds. Else below 0.5 GPH no delay or after 3 seconds if below 0.7 Possible cause: Suction leak introducing air into coolant, suspect rear panel filter seal; clogged filter; defective pump.

  • Page 103: Remote Arc Starter: Spark Gap Adjustment

    ULTRA-CUT 400 4.08 Remote Arc Starter: Spark Gap Adjustment 0.063" ± 0.002" 1.6 ± 0.05 mm Art # A-04857 Manual No. 0-5164 4-15 OPERATION...
  • Page 104 ULTRA-CUT 400 This page intentionally blank OPERATION 4-16 Manual No. 0-5164...
  • Page 105 ULTRA-CUT 400 COPY CENTER: Insert Sec 5 tab here. Discard this sheet. Manual No. 0-5164 4-17 OPERATION...
  • Page 106 This page intentionally blank...

  • Page 107: Section 5: Maintenance

    ULTRA-CUT 400 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. UC-AC Maintenance schedule Monthly Check cooling fan and radiator; clean as needed. Check gas hoses for cracks, leaks, or abrasion.

  • Page 108: Internal Coolant Filter Cleaning Procedure

    ULTRA-CUT 400 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 109: Remote Arc Starter: Service Chart

    ULTRA-CUT 400 5.05 Remote Arc Starter: Service Chart Arc Starter Service Chart Symptom Cause Check Remedy Coolant has become conduc- Flush system, Use conductivity meter tive replace coolant. Pilot return wire not connected Visual inspection Connect Wire. Spark gap set too close Check with feeler gauge Set to 0.063” ±0.002”...
  • Page 110 ULTRA-CUT 400 This Page Intentionally Blank MAINTENANCE Manual 0-5164...
  • Page 111 ULTRA-CUT 400 Insert Sec 6 tab here. Discard this sheet. Manual No. 0-5164 MAINTENANCE...
  • Page 112 ULTRA-CUT 400 This page is blank intentionally. MAINTENANCE Manual 0-5164...

  • Page 113: Section 6: Replacement Assemblies & Parts

    ULTRA-CUT 400 SECTION 6: REPLACEMENT ASSEMBLIES & PARTS 6.01 Replacement Power Supply Complete Unit / Component Catalog Number Ultra-Cut 400 Power Supply, 208/230V 3-9120-1 ® Ultra-Cut 400 Power Supply, 460V 3-9120-2 ® Ultra-Cut 400 Power Supply, 400V (CCC) 3-9120-3 ® Ultra-Cut 400 Power Supply, 400V, (CE) 3-9120-4 ®...

  • Page 114: System Layout

    ULTRA-CUT 400 6.02 System Layout Refer to section 3.05 for ground connections and ground cables. 175’ / 53.3 m Maximum Length 125’ / 38.1 m Maximum Length 50’ / 15.25 m Maximum Length Pilot Return Pilot Return #8 Shield Negative Cable...

  • Page 115: Leads And Cables

    ULTRA-CUT 400 6.04 Leads and Cables #8 AWG Cable Pilot Return, Power Supply to Arc Starter 2/0 AWG Cable (70 mm Negative Lead, Power Supply to Arc Starter Coolant Supply Lead, Green Green Power Supply to Arc Starter Coolant Return Lead,...
  • Page 116 ULTRA-CUT 400 Description Catalog # A,B,C,D,E Supply Lead Set, 4’ / 1.3 m (See Note 1) 4-3096 A,B,C,D,E Supply Lead Set, 10’ / 3.05 m (See Note 1) 4-3097 A,B,C,D,E Supply Lead Set, 15’ / 4.5 m (See Note 1)
  • Page 117 ULTRA-CUT 400 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 118 ULTRA-CUT 400 Description Catalog # Assembly, Torch Lead, 10’ / 3.05 m 4-5200 Assembly, Torch Lead, 15’ / 4.6 m 4-5201 Assembly, Torch Lead, 20’ / 6 m 4-5202 Assembly, Torch Lead, 25’ / 7.6 m 4-5203 Assembly, Torch Lead, 30’ / 9.1 m 4-5204 Assembly, Torch Lead, 35’...
  • Page 119 ULTRA-CUT 400 Description Catalog # Control Cable, Fiber Optic, 100’ / 30.5 m 9-4903 Control Cable, Fiber Optic, 125’ / 38.1 m 9-4904 Control Cable, Fiber Optic, 150’ / 45.7 m 9-4905 Control Cable, Fiber Optic, 175’ / 53.3 m 9-4906 Work Cable, 10’...
  • Page 120 ULTRA-CUT 400 Description Catalog # Pilot Gas/Pre-Flow Hose 125’ / 38.1 m 9-7081 Pilot Gas/Pre-Flow Hose 150’ / 45.7 m 9-4876 Pilot Gas/Pre-Flow Hose 175’ / 53.3 m 9-4877 Control Cable 10’ / 3.05 m 9-4878 Control Cable 15’ / 4.5 m 9-4753 Control Cable 25’...

  • Page 121: Power Supply External Replacement Parts

    ULTRA-CUT 400 6.05 Power Supply External Replacement Parts Item # Description Catalog # Power Supply Front Panel Power Supply Rear Panel Power Supply Top Panel, Blue 9-0445B Power Supply Right Side, Blue 9-0500B Power Supply Left Side, Blue 9-0501B Louver Panel...

  • Page 122: Power Supply Replacement Parts - Right Side

    ULTRA-CUT 400 6.06 Power Supply Replacement Parts - Right Side Item # Description Ref. Des. Catalog # Heat Exchanger Fan (used with radiator) FAN1,2 9-9338 Radiator 9-9339 NOTE: Heat Exchanger Fan is the same fan used with the Inverter and not the HE-400.

  • Page 123: Power Supply Replacement Parts - Right Side

    ULTRA-CUT 400 6.07 Power Supply Replacement Parts - Right Side Item # Description Ref. Des. Catalog # Output Filter PC PCB8 9-9341 Sensor, Work HCT2 9-9368 Magnetic Contactor, pilot 9-9343 Resistor 9-9340 Resistor 9-8170 Sensor, Pilot HCT1 9-9342 Magnetic Contactor 9-9364 * Not visible in photo.

  • Page 124: Power Supply Replacement Parts - Right Side

    ULTRA-CUT 400 6.08 Power Supply Replacement Parts - Right Side Item # Description Ref. Des. Catalog # PC Board 230/460VAC PCB4 9-9370 PC Board PCB3 9-9365 Internal Control PC Board PCB5 9-8169 Relay PC Board PCB7 9-9366 Art # A-09641...

  • Page 125: Power Supply Replacement Parts - Front Panel

    ULTRA-CUT 400 6.09 Power Supply Replacement Parts - Front Panel Item # Description Ref. Des. Catalog # Main Power Switch (‘Circuit Protector’) for 230-400-460 VAC units 9-9344 for 600 VAC units 9-9514 Relay, 110-120VAC DPDT 9-8171 Relay, 12VDC, 4PDT 9-8172 Art # A-09639 Manual No.

  • Page 126: Power Supply Replacement Parts - Front Panel

    ULTRA-CUT 400 6.10 Power Supply Replacement Parts - Front Panel Item # Description Ref. Des. Catalog # Display PC Board PCB6 9-9347 PCB6 Art # A-09644 Power Supply Parts List 6-20 Manual No. 0-5164...

  • Page 127: Power Supply Replacement Parts - Right Side

    ULTRA-CUT 400 6.11 Power Supply Replacement Parts - Right Side Item # Description Ref. Des. Catalog # PCBoard 230-400-460VAC PCB1 9-9362 Magnetic Contactor MC1,MC3,MC4,MC5 9-9364 Art # A-09643 Manual No. 0-5164 6-21 Power Supply Parts List...

  • Page 128: Power Supply Replacement Parts - Rear Panel

    ULTRA-CUT 400 6.12 Power Supply Replacement Parts - Rear Panel Item # Description Breaker Rating Circuit Rating Ref. Des. Catalog # Circuit Breaker (RAS) 125V, 2.5 A 120VAC @ 1A 9-9348 Circuit Breaker (’TDC’) 125V, 3.15A 24VAC @ 1A 9-9349...

  • Page 129: Power Supply Replacement Parts - Right Side

    ULTRA-CUT 400 6.13 Power Supply Replacement Parts - Right Side Item # Description Ref. Des. Catalog # Resistor 9-9363 Rectifier (Diode) 9-9345 Transformer 9-??? Transformer for 230/460 VAC units 9-9355 for 400/600 VAC units 9-??? Terminal Strip Art # A-09649_AB Manual No.

  • Page 130: Power Supply Replacement Parts

    ULTRA-CUT 400 6.14 Power Supply Replacement Parts Item # Description Catalog # Inverter Module 208/230V/460V 9-9360D Inverter Module 400V CE and 400V Non CE 9-9482D Not Shown: Inverter Cooling Fan 9-9338 NOTE: The Inverter Cooling Fan is the same fan used for internal Heat Exchanger cooling.

  • Page 131: Power Supply Replacement Parts - Right Side

    ULTRA-CUT 400 6.15 Power Supply Replacement Parts - Right Side Item # Description Ref. Des. Catalog # Thermistor, Coolant 9-9361 Art # A-09463 Manual No. 0-5164 6-25 Power Supply Parts List...

  • Page 132: Power Supply Replacement Parts - Right Side

    ULTRA-CUT 400 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 Bypass Valve (part of assembly) BYPV 9-8168 Motor MOT1 9-8166 Pump (part of assembly)

  • Page 133: Gas Control Module (Gcm-2010) Replacement Parts

    ULTRA-CUT 400 6.17 Gas Control Module (GCM-2010) Replacement Parts Item # Description Catalog # 7W Solenoid for O2 use 9-9393 Gas Selection Manifold Assembly 9-9391 Check Valve, 1/4 NPT .5 PSI 9-9390 Mode Switch Assembly 9-9406 Gas Selection Switch Assembly...

  • Page 134: Gas Control Module (Gcm-2010) Replacement Parts

    ULTRA-CUT 400 6.18 Gas Control Module (GCM-2010) Replacement Parts Item # Description Catalog # 1” Black Instrument Knob 9-4233 Water Flow Meter with Valve 9-7005 Toggle Switch, 2 position SPDT 9-3426 Pressure gauge, 2” diameter 8-6800 Pressure gauge, 2” diameter...

  • Page 135: Remote Arc Starter (Ras-1000) Replacement Parts

    ULTRA-CUT 400 6.19 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...

  • Page 136: Remote Arc Starter (Ras-1000) Replacement Parts

    ULTRA-CUT 400 6.20 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...

  • Page 137: Command & Control Module - Replacement Parts

    ULTRA-CUT 400 6.21 Command & Control Module - Replacement Parts Item # Description Catalog # Assembly, CCM (Ultra-Cut) 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. 0-5164 6-31 Power Supply Parts List...

  • Page 138: He 400 Heat Exchanger - Replacement Parts

    ULTRA-CUT 400 6.22 HE 400 Heat Exchanger - Replacement Parts Item # Description Catalog # Assembly, HE 400 Heat Exchanger 9-9416 8-6312 Radiator 8-1347 Capacitor 8-3263 Thermal Switch 9-1448 Art # A-09650 Power Supply Parts List 6-32 Manual No. 0-5164...
  • Page 139 Insert Sec 7 tab here. Discard this sheet.
  • Page 140 Blank...

  • Page 141: Torch Maintenance

    ULTRA-CUT 400 SECTION 7: TORCH MAINTENANCE 7.01 Consumable Removal 1. Use the removal tool to hold the Shield Cup & Cartridge Assembly stationary. Turn the Shield Cup to remove it from the Cartridge Assembly. Cartridge Tool Assembled Cartridge Art # A-04344_AB Shield Cup 2.

  • Page 142: O-Ring Lubrication

    Art # A-04071_AC 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. 7.03 Parts Wear Replace the Gas Distributor if it is charred or cracked.

  • Page 143: Torch Consumables Installation

    ULTRA-CUT 400 7.04 Torch Consumables Installation W ARNINGS Do not install consumables into the Cartridge while the Cartridge is attached to the T orch H ead. Keep foreign materials out of the consumables and Ca Handle all parts carefully to avoid damage, which may affect tor ch per formance.
  • Page 144 ULTRA-CUT 400 2, Remove the Removal Tool from the Cartridge and install the assembled Cartridge onto the Torch Head. CAUTION The cartridge assembly must cover the O-Ring on the torch head. Do not force the cartridge if it will not tighten fully. Remove the cartridge assembly and gently clean the threads on the torch head with a wire brush.

  • Page 145: Coolant Leak Trouble-Shooting

    ULTRA-CUT 400 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 146 ULTRA-CUT 400 Torch Electrodes Art # A-09653 Recommended Wear Depth for Electrode Amperage Plasma Gas Replacement Inch 0.04 0.04 0.04 0.04 0.08 0.04 0.04 0.08 0.04 0.08 0.04 0.08 0.08 0.06 0.08 0.08 0.06 0.08 0.08 0.06 0.06 0.08 0.08 0.08...
  • Page 147 ULTRA-CUT 400 Insert Section 8 and Section 8 tab here. Discard this sheet. Manual 0-5164 TORCH INFORMATION...

  • Page 149: Appendix 1: Remote Arc Starter Schematic

    ULTRA-CUT 400 APPENDIX 1: Remote Arc Starter Schematic Manual 0-5164 APPENDIX...

  • Page 150: Appendix 2: Gas Control And Torch Valve Schematic

    ULTRA-CUT 400 APPENDIX 2: Gas Control and Torch Valve Schematic ULTRACUT GCM 2010 GAS CONTROL O2 - AIR MODE MODE O2 - O2 H35 - N2 SET PREFLOW F5 - N2 SET CUTFLOW AIR - AIR TEST N2 - H2O...
  • Page 151 <OrgAddr3> Shield ECO-B587 01/06/08 Date: Date: Date: Information Proprietary to THERMAL DYNAMICS CORPORATION. Information Proprietary to THERMAL DYNAMICS CORPORATION. Information Proprietary to THERMAL DYNAMICS CORPORATION. Gas Shield Wednesday, January 26, 2005 Wednesday, January 26, 2005 Wednesday, January 26, 2005 Not For Release, Reproduction, or Distribution without Written Consent.

  • Page 152: Appendix 3: Gas Control Module Plumbing Diagram

    ULTRA-CUT 400 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 153: Appendix 4: Gas Control Module Pcb Layout

    ULTRA-CUT 400 APPENDIX 4: Gas Control Module PCB Layout TP10 TP11 TP12 TP15 TP13 Art # A-07621 TP19 TP18 TP14 TP16 Manual 0-5164 APPENDIX...

  • Page 154: Appendix 5: Gas Control Display Module Pcb Layout

    ULTRA-CUT 400 APPENDIX 5: Gas Control Display Module PCB Layout 19X2220 REV LCD INTERFACE C 2005 Art # A-06904 APPENDIX Manual 0-5164...

  • Page 155: Appendix 6: Ccm Input / Output Pcb Layout

    ULTRA-CUT 400 APPENDIX 6: CCM Input / Output PCB Layout D1 D2 TP15 TP11 TP12 SW11 SW12 Art # A-09187_AB TP13 TP2 SW13 TP14 TP10 Manual 0-5164 APPENDIX...

  • Page 156: Appendix 7: Ccm Cpu Pcb Layout

    ULTRA-CUT 400 APPENDIX 7: CCM CPU PCB Layout TP10 TP11 TP13 TP12 TP14 TP15 Switches Art # A-09186_AC POST OK TO AUTO PILOT FLOW FLOW FUNC CONT MOVE/D All switches are shown in the OFF position APPENDIX Manual 0-5164...

  • Page 157: Appendix 8: Cnc - Control Module Pcb Connections

    ULTRA-CUT 400 APPENDIX 8: CNC - Control Module PCB Connections These points are jumpered together at the factory. TB1-1 E-Stop (Com) Remove the jumper to use existing E-Stop circuits. TB1-2 E-Stop TB1-3 OK 2 Contacts 24V Max TB1-4 Stop Latched...
  • Page 158 ULTRA-CUT 400 This Page Intentionally Blank APPENDIX A-10 Manual 0-5164...

  • Page 159: Appendix 9: Cnc

    ULTRA-CUT 400 APPENDIX 9: CNC CNC functions CNC I/O circuits provide at least 1000V galvanic isolation from the plasma power supply. While the CNC circuits are isolated from the power supply, many of the signal returns on J15 and TB1 & 2 are com- mon to each other.

  • Page 160: Cnc Input / Output Descriptions

    ULTRA-CUT 400 Pilot On (Relay Contacts NO) TB2-6; TB2-8 Function Connection OK to Move (Contacts or DC Volts) TB2-10(-); TB2-12(+) Plasma Marking Remote Select TB3-1: TB3-2 CNC Input / Output Descriptions E-Stop input— Requires closed connection rated for 35ma. @ 20VDC for unit to operate.

  • Page 161: Simplified Cnc Circuit

    ULTRA-CUT 400 +10V @ 10ma. For Remote CC Pot – Previously CCM versions if one wanted to use a potentiometer for the Re- mote 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 162: Cnc Connections

    ULTRA-CUT 400 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 163 ULTRA-CUT 400 Manual 0-5164 A-15 APPENDIX...

  • Page 164: Appendix 10: Schematic, 230-460V Power Supply

    ULTRA-CUT 400 APPENDIX 10: Schematic, 230-460V Power Supply MC3-A MC3-A MC3-B MC3-B 100A INVERTER MODULE # 1 (top) N (-) N (-) MC3-C MC3-C CN1-230V CN1-230V INRUSH INRUSH MC1-A MC1-A MC1-B MC1-B MC1-C MC1-C P (+) P (+) CN4 - PCB12...
  • Page 165 Date: Date: Date: LED7 ON = MISSING PHASE Information Proprietary to THERMAL DYNAMICS CORPORATION. Information Proprietary to THERMAL DYNAMICS CORPORATION. Information Proprietary to THERMAL DYNAMICS CORPORATION. Wednesday, February 10, 2010 Not For Release, Reproduction, or Distribution without Written Consent. Not For Release, Reproduction, or Distribution without Written Consent.

  • Page 166: Appendix 10: Schematic, 230-460V, Power Supply Cont

    ULTRA-CUT 400 APPENDIX 10: Schematic, 230-460V, Power Supply Cont. PCB 5 WK-6276A (partial) INTERFACE PCB INPUT CONTACTORS CN12 CN12 CN13 CN13 CN14 CN14 RY1-1 RY1-1 MC2=PILOT CONTACTOR LSW1-1 LSW1-1 COOLANT TEMP (ON COOLANT RETURN) SW_LIQUID_LEVEL_NC SW_LIQUID_LEVEL_NC FLOW_TURBINE_PULSE FLOW_TURBINE_PULSE CN29 CN29...
  • Page 167 603-298-5711 603-298-5711 Date: Date: Date: Information Proprietary to THERMAL DYNAMICS CORPORATION. Information Proprietary to THERMAL DYNAMICS CORPORATION. Information Proprietary to THERMAL DYNAMICS CORPORATION. Wednesday, February 10, 2010 Not For Release, Reproduction, or Distribution without Written Consent. Not For Release, Reproduction, or Distribution without Written Consent.

  • Page 168: Appendix 11: Schematic, Ccc 400V Power Supply

    ULTRA-CUT 400 APPENDIX 11: Schematic, CCC 400V Power Supply MC3-A MC3-A MC3-B MC3-B 100A INVERTER MODULE # 1 (top) CN1-200V CN1-200V N (-) N (-) (NOT USED) MC3-C MC3-C INRUSH INRUSH MC1-A MC1-A MC1-B MC1-B MC1-C MC1-C P (+) P (+)
  • Page 169 Date: Date: Date: LED7 ON = MISSING PHASE Information Proprietary to THERMAL DYNAMICS CORPORATION. Information Proprietary to THERMAL DYNAMICS CORPORATION. Information Proprietary to THERMAL DYNAMICS CORPORATION. Wednesday, February 10, 2010 Not For Release, Reproduction, or Distribution without Written Consent. Not For Release, Reproduction, or Distribution without Written Consent.

  • Page 170: Appendix 11: Schematic, Ccc 400V Power Supply Cont

    ULTRA-CUT 400 APPENDIX 11: Schematic, CCC 400V Power Supply Cont. PCB 5 WK-6276A (partial) INTERFACE PCB INPUT CONTACTORS CN12 CN12 CN13 CN13 CN14 CN14 RY1-1 RY1-1 MC2=PILOT CONTACTOR LSW1-1 LSW1-1 COOLANT TEMP (ON COOLANT RETURN) SW_LIQUID_LEVEL_NC SW_LIQUID_LEVEL_NC FLOW_TURBINE_PULSE FLOW_TURBINE_PULSE CCM MODULE...
  • Page 171 Date: Date: Date: Wednesday, February 10, 2010 Information Proprietary to THERMAL DYNAMICS CORPORATION. Information Proprietary to THERMAL DYNAMICS CORPORATION. Information Proprietary to THERMAL DYNAMICS CORPORATION. Not For Release, Reproduction, or Distribution without Written Consent. Not For Release, Reproduction, or Distribution without Written Consent.

  • Page 172: Appendix 12: Schematic, Ce 400V Power Supply

    ULTRA-CUT 400 APPENDIX 12: Schematic, CE 400V Power Supply NFC4 NFC4 MC3-A MC3-A 100A INVERTER MODULE # 1 (top) CN1- (not used) CN1- (not used) FILTER FILTER MC3-B MC3-B INRUSH INRUSH MC3-C MC3-C N (-) N (-) NFC1 NFC1 MC1-A...
  • Page 173 603-298-5711 LED7 ON = MISSING PHASE Date: Date: Date: Information Proprietary to THERMAL DYNAMICS CORPORATION. Information Proprietary to THERMAL DYNAMICS CORPORATION. Information Proprietary to THERMAL DYNAMICS CORPORATION. LED8 ON = WRONG INPUT VOLTAGE FAULT Wednesday, February 10, 2010 Not For Release, Reproduction, or Distribution without Written Consent.

  • Page 174: Appendix 12: Schematic, Ce 400V Power Supply Cont

    ULTRA-CUT 400 APPENDIX 12: Schematic, CE 400V Power Supply Cont. PCB 5 WK-6276A (partial) INTERFACE PCB INPUT CONTACTORS CN12 CN12 CN13 CN13 CN14 CN14 RY1-1 RY1-1 MC2=PILOT CONTACTOR LSW1-1 LSW1-1 COOLANT TEMP (ON COOLANT RETURN) SW_LIQUID_LEVEL_NC SW_LIQUID_LEVEL_NC FLOW_TURBINE_PULSE FLOW_TURBINE_PULSE CCM MODULE...
  • Page 175 603-298-5711 Date: Date: Date: OK to MOVE + Information Proprietary to THERMAL DYNAMICS CORPORATION. Information Proprietary to THERMAL DYNAMICS CORPORATION. Information Proprietary to THERMAL DYNAMICS CORPORATION. Wednesday, February 10, 2010 Not For Release, Reproduction, or Distribution without Written Consent. Not For Release, Reproduction, or Distribution without Written Consent.

  • Page 176: Appendix 13: Publication History

    ULTRA-CUT 400 APPENDIX 13: PUBLICATION HISTORY Cover Date Change(s) Sept. 8, 2010 First issue Oct. 28, 2010 Added EMC fi lter information to section 3 and corrected TSC-3000 part numbers per ECOB1844 Jan. 13, 2011 Corrected part numbers for “S” cables in section 6 per ECOB1889.
  • Page 177 This Page Intentionally Blank...
  • Page 178 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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