Thermal Dynamics ULTRA-CUT 400 XT Operating Instructions Manual
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Thermal Dynamics ULTRA-CUT 400 XT Operating Instructions Manual

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8
®
480V
ULTRA-CUT 400 XT
™
PLASMA CUTTING SYSTEM
Operating
Manual
Revision: AH Issue Date: May 27, 2015
Manual No.: 0-5275
Thermal-Dynamics.com

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Summary of Contents for Thermal Dynamics ULTRA-CUT 400 XT

  • Page 1 ® 480V ULTRA-CUT 400 XT ™ PLASMA CUTTING SYSTEM Operating Manual Revision: AH Issue Date: May 27, 2015 Manual No.: 0-5275 Thermal-Dynamics.com...
  • Page 2 ® WE APPRECIATE YOUR BUSINESS! Congratulations on your new Thermal Dynamics product. We are proud to have you as our customer and will strive to provide you with the best service and reliability in the industry. This product is backed by our extensive warranty and world-wide service network.
  • Page 3 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 400 XT ™ Operating Manual No. 0-5275 Published by: Thermal Dynamics Corporation.

  • Page 4: User Responsibility

    Be sure this information reaches the operator. You can get extra copies through your supplier. CAUTION These INSTRUCTIONS are for experienced operators. If you are not fully familiar with the principles of operation and safe practices for arc welding and cutting equipment, we urge you to read our booklet, “Precautions and Safe Practices for Arc Welding, Cutting, and Gouging,”...
  • Page 5 ASSUREZ-VOUS QUE CETTE INFORMATION EST DISTRIBUÉE À L’OPÉRATEUR. VOUS POUVEZ OBTENIR DES COPIES SUPPLÉMENTAIRES CHEZ VOTRE FOURNISSEUR. ATTENTION Les INSTRUCTIONS suivantes sont destinées aux opérateurs qualifiés seulement. Si vous n’avez pas une connaissance approfondie des principes de fonctionnement et des règles de sécurité pour le soudage à l’arc et l’équipement de coupage, nous vous suggérons de lire notre brochure «...
  • Page 6 This Page Intentionally Blank...

  • Page 7: Table Of Contents

    TABLE OF CONTENTS SECTION 1: SAFETY ..................1-1 1.01 Safety Precautions - ENGLISH ................ 1-1 1.02 Précautions de sécurité - FRENCH CANADIAN ..........1-6 SECTION 2: SPECIFICATIONS ................2-1 2.01 General Description Of The System ..............2-1 2.02 Plasma Power Supply ..................2-1 2.03 Remote Arc Starter ..................
  • Page 8 TABLE OF CONTENTS SECTION 4: OPERATION ................... 4-1 4.01 Power Supply Control Panel ................4-1 4.02 System Operation ................... 4-2 4.03 Gas Selection ....................4-4 4.04 GCM 2010 Gas Control Module Operation ............4-6 4.05 GCM 2010 First Time Operation Matching Gas Control to Lead Length ..4-10 4.06 GCM 2010 Sequence Of Operation ...............
  • Page 9 TABLE OF CONTENTS APPENDIX 7: CNC ..................A-8 CNC functions ....................... A-8 CNC Input / Output Descriptions ................. A-10 Simplified CNC Circuit ....................A-12 CNC Connections ......................A-14 CNC Cable Color Code ....................A-15 APPENDIX 8: CCM CPU PCB Layout ..............A-16 APPENDIX 9: CCM I/O PCB Layout ..............A-18 APPENDIX 10: Pilot PCB Layout ................A-20 APPENDIX 11: Relay and Interface PCB Layout ............A-22...
  • Page 10 TABLE OF CONTENTS This Page Intentionally Blank...

  • Page 11: Section 1: Safety

    ULTRA-CUT 400 XT SECTION 1: SAFETY 1.01 Safety Precautions - ENGLISH WARNING: These Safety Precautions are for your protection. They summarize precautionary information from the references listed in Additional Safety Information section. Before performing any installation or operating procedures, be sure to read and follow the safety precautions listed below as well as all other manuals, material safety data sheets, labels, etc.
  • Page 12 ULTRA-CUT 400 XT ELECTRICAL SHOCK -- Contact with live electrical parts and ground can cause severe injury or death. DO NOT use AC welding current in damp areas, if movement is confined, or if there is danger of falling. 1. Be sure the power source frame (chassis) is connected to the ground system of the input power.
  • Page 13 ULTRA-CUT 400 XT CYLINDER HANDLING -- Cylinders, if mishandled, can rupture and violently release gas. Sudden rupture of cylinder, valve, or relief device can injure or kill. Therefore: 1. Use the proper gas for the process and use the proper pressure reducing regulator designed to operate from the compressed gas cylinder.
  • Page 14 ULTRA-CUT 400 XT Meaning of symbols - As used throughout this manual: Means Attention! Be Alert! Your safety is involved. Means immediate hazards which, if not avoided, will result in immediate, serious per- DANGER sonal injury or loss of life.
  • Page 15 ULTRA-CUT 400 XT This Page Intentionally Blank Manual 0-5275 SAFETY INSTRUCTIONS...

  • Page 16: Précautions De Sécurité - French Canadian

    ULTRA-CUT 400 XT 1.02 Précautions de sécurité - FRENCH CANADIAN AVERTISSEMENT : Ces règles de sécurité ont pour but d’assurer votre protection. Ils récapitulent les informations de précaution provenant des références dans la section des Informations de sécurité sup- plémentaires. Avant de procéder à l’installation ou d’utiliser l’unité, assurez-vous de lire et de suivre les précautions de sécurité...
  • Page 17 ULTRA-CUT 400 XT 5. Assurez-vous de ne pas excéder la capacité de l’équipement. Par exemple, un câble de soudage surchargé peut surchauffer et provoquer un incendie. 6. Une fois les opérations terminées, inspectez l’aire de travail pour assurer qu’aucune étincelle ou projec- tion de métal incandescent ne risque de provoquer un incendie ultérieurement.
  • Page 18 ULTRA-CUT 400 XT LES VAPEURS ET LES GAZ -- peuvent causer un malaise ou des dommages corporels, plus particu- lièrement dans les espaces restreints. Ne respirez pas les vapeurs et les gaz. Le gaz de protection risque de causer l’asphyxie.
  • Page 19 ULTRA-CUT 400 XT 4. N’utilisez pas l’équipement de façon abusive. Gardez l’équipement à l’écart de toute source de chaleur, notamment des fours, de l’humidité, des flaques d’eau, de l’huile ou de la graisse, des atmosphères corrosives et des intempéries. 5. Laissez en place tous les dispositifs de sécurité et tous les panneaux de la console et maintenez-les en bon état.
  • Page 20 ULTRA-CUT 400 XT MISE EN GARDE L’équipement pourrait basculer s’il est placé sur une surface dont la pente dépasse 15°. Vous pourriez vous blesser ou endommager l’équipement de façon importante. 15° Art# A-12726 MISE EN GARDE Soulevez à l’aide de la méthode et des points d’attache illustrés afin d’éviter de vous blesser ou d’endommager...

  • Page 21: 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 XT™ Specifications & Design Features Max OCV (U0) 425 vdc...

  • Page 22: Power Supply Dimensions

    ULTRA-CUT 400 XT NOTE! * Suggested wire size based on United States NFPA 70 National Electrical Code 2011 edition published by the National Fire Prevention Association. Listings are from table 400.5(A)(2) for flex- ible cord of certain types rated for 75 deg C in ambient temperatures up to 30 deg C. Using wires of lower temperature rating or different insulation type may require larger wire size.

  • Page 23: Power Supply Rear Panel Features

    ULTRA-CUT 400 XT 2.08 Power Supply Rear Panel Features TSC/Comm Customer Optional Circuit Breakers Ports GCM Connector CNC Connector J55 - GCM USER INPUT Coolant Return C.C.M. J15 - CNC HEIGHT CONTROL Coolant Supply J54 - TSC /COMM J59 - RAS...

  • Page 24: Gas Requirements

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

  • Page 25: Xt Torch Specifications

    ULTRA-CUT 400 XT 2.11 XT Torch Specifications A. Torch Dimensions Basic 400 Amp torch dimensions Basic 100 Amp torch dimensions Manual 0-5275 SPECIFICATIONS...
  • Page 26 Coolant leakage from the torch also indicates that torch parts are absent or installed improperly. E. Type of Cooling Combination of gas stream through torch and liquid cooling. F. XT Torch Data XT Torch Ratings for use with Ultra-Cut 400 XT™ Power Supply Ambient 104° F Temperature 40° C...

  • Page 27: Section 3: Installation

    Cooling System Requirements Coolant must be added to the system on installation. The amount required varies with torch leads length. Victor Thermal Dynamics recommends the use of its coolants 7-3580 and 7-3581 (for low temperatures). Coolant Capabilities Cat. Number and Mixture...

  • Page 28: System Layout

    ULTRA-CUT 400 XT 3.02 System Layout Refer to section 3.04 for ground connections and ground cables. 175’ / 53.3 m Maximum Length 50’ / 15.25 m Maximum Length 125’ / 38.1 m Maximum Length Pilot Return Pilot Return #8 Shield...

  • Page 29: Recommended Gas Supply Hose

    ULTRA-CUT 400 XT 3.03 Recommended Gas Supply Hose Item # Description Catalog # 3/8”Gray Synflex Hose. No fittings included. Catalog number per foot 9-3616 3.04 Leads and Cables All Amperage #8 AWG Cable Pilot Return, Power Supply to Arc Starter...

  • Page 30: Lift The Power Supply

    ULTRA-CUT 400 XT 3.05 Lift the Power Supply WARNING Do not touch live electrical parts. Disconnect input power conductors from de-energized supply line before moving unit. FALLING EQUIPMENT can cause serious personal injury and equipment damage. Use a forklift, crane, or hoist to lift the unit off the shipping pallet as shown. Keep the power supply steady and vertical. Do not lift it any further than necessary to clear the shipping pallet.

  • Page 31: Connect Input Power And Ground Cables

    ULTRA-CUT 400 XT 3.06 Connect Input Power and Ground Cables Connect Input Power and System Ground Cables 1. Remove the input power cover to the right of the coolant filter at the rear of the power supply. To do this remove the two screws then lift up and pull away.

  • Page 32: Connect Work Cable And Pilot And Negative Leads

    ULTRA-CUT 400 XT 3.07 Connect Work Cable and Pilot and Negative Leads 1. Remove the output power cover to the left of the coolant filter at the rear of the power supply. To do this remove the two screws then lift up and pull away.

  • Page 33: Ground Connections

    2. Grounding for components mounted on the cutting table (CNC controllers, height controllers, plasma remote controls, etc.) should follow the manufacturer’s recommendations for wire size, type, and connection point locations. For Thermal Dynamics components (except 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 34 ULTRA-CUT 400 XT 5. Make sure work cable and ground cables are properly connected. The work cable must have a solid connection to the cutting table. The work and ground connections must be free from rust, dirt, grease, oil and paint. If necessary grind or sand down to bare metal.
  • Page 35 ULTRA-CUT 400 XT An excellent ground measures 1 ohm or less. Up to 3 ohms is often acceptable, higher reduces the effectiveness of the EMI suppression. R = 1.2K, 15W (2.2K, 25W for 220 VAC) Ground Rod with other connections removed...

  • Page 36: Connect Coolant Leads

    ULTRA-CUT 400 XT 3.09 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. J55 - GCM...

  • Page 37: Connect Cables For Cnc, Remote Arc Starter, Gcm And He 400

    ULTRA-CUT 400 XT 3.10 Connect Cables for CNC, Remote Arc Starter, GCM 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 at the CNC end.

  • Page 38: Handling And Installation Of Fiber Optics

    ULTRA-CUT 400 XT 3.11 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 and Auto-Cut O2 ® ® automated gas boxes and Gas Control Modules.
  • Page 39 ULTRA-CUT 400 XT Avoid the following: 1. If you need to pull the cable through a power track do not fold the fiber back on itself making a sharp bend where it exits the hose. Art # A-09417 2. Don’t hook onto the fiber to pull on the cable.

  • Page 40: Correct Installation

    ULTRA-CUT 400 XT Correct installation: Correct way to pull the cable is to use a snake or a wire or another cable and attach it securely to the hose behind the strain relief. Then secure the fiber connector to the pulling device leaving some slack in the fiber. Keep the protective end covers on the fiber until you are ready to connect it to the PCB in the CCM or gas control.

  • Page 41: Set Switches On The Command - Control Module

    ULTRA-CUT 400 XT 3.12 Set Switches on the Command - Control Module Remove the power supply upper right side. Set switches on the CCM (Command-Control Module) per the illustrations. Switch settings and connection details are provided in the Appendix. Any changes made require a restart of the power supply.
  • Page 42 ULTRA-CUT 400 XT 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 43: Height Control Connections

    ULTRA-CUT 400 XT 3.13 Height Control Connections The terminal strip provides connections to negative Arc Volts (Torch or electrode), Tip Volts (Pilot) and Work. These are for a height control that requires connection to the full non-divided arc voltage. Also available on the terminal strip are 120VAC and 24 VAC.

  • Page 44: Gas Control Module Installation

    ULTRA-CUT 400 XT 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 45 ULTRA-CUT 400 XT 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...

  • Page 46: Fiber Optic Cable Installation

    ULTRA-CUT 400 XT 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. Pass enough of the cable into the Module to allow the cable to loop upward as shown.
  • Page 47 ULTRA-CUT 400 XT 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 48: Gas Control Module: Control, Input, And Output Connections

    ULTRA-CUT 400 XT 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 grounding.

  • Page 49: He400Xt Cooler

    ULTRA-CUT 400 XT 3.17 HE400XT COOLER Used in series with the existing cooling system of the Ultra-Cut XT™ series power supplies, the HE400XT Cooler provides addi- tional cooling when ambient temperatures exceed the units rated temperature. The HE400XT fan is thermally controlled to operate whenever the Ultra-Cut fan and pump is on and the coolant temperature is above a predetermined level.
  • Page 50 ULTRA-CUT 400 XT Included with the HE400XT are two 10’ hoses, supply (green) and return (red), that are to be connected to the matching colors on left side of the HE400XT and to the supply and return fittings on the rear of the Ultra-Cut XT power supply. Hoses to the RAS1000XT connect on the right side of the HE400XT.

  • Page 51: Install Remote Arc Starter

    ULTRA-CUT 400 XT 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 52 ULTRA-CUT 400 XT 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 53 ULTRA-CUT 400 XT Input Connections 1. Refer to the illustrations. Make the following input connections to the Arc Starter. • Coolant Supply and Return Hoses (from HE-400 Heat Exchanger). Hoses and connectors are color-coded; Red for Return, Green for Supply. Art # A-12061 Supply Return Coolant Supply and Return Hoses (from power supply) Art # A-12062...
  • Page 54 ULTRA-CUT 400 XT 2. Refer to illustration. Connect the Pilot wire and Negative cables using a star washer on each. NOTE! * Slave and Master refer to only those set ups using two power sup- plies in parrallel. Slave is not used in single system operations.
  • Page 55 ULTRA-CUT 400 XT Output Connections 1. Refer to the illustrations. Make the following output connections to the Arc Starter. Pilot Lead Coolant Return (Red) Coolant Supply (Green) Green Art # A-12065 Pilot Return Cable, Coolant Supply and Return Hoses (from Torch) 2.
  • Page 56 ULTRA-CUT 400 XT 3. 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 4. Use a clamp to secure the Torch Lead Shield braid brass ring to the port on the Remote Arc Starter as shown.
  • Page 57 ULTRA-CUT 400 XT Connect Control Cable 1. Connect the Remote Arc Starter cable to the Remote Arc Starter receptacle. J55 - GCM USER INPUT J15 - CNC HEIGHT CONTROL J54 - TSC /COMM J59 - RAS CB2 - 5A 120 VAC...

  • Page 58: Torch Valve Installation

    ULTRA-CUT 400 XT 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...
  • Page 59 ULTRA-CUT 400 XT 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. Exhaust Muffler Control Cable WMS™ Inlet...

  • Page 60: Connecting Torch

    ULTRA-CUT 400 XT 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...

  • Page 61: Install Consumable Torch Parts

    ULTRA-CUT 400 XT 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 continu- ing. If there are no leaks, shut off the gas supplies and continue with installation.
  • Page 62 ULTRA-CUT 400 XT 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. If any part of the O-ring protrudes from the cartridge, the parts are not seated properly.
  • Page 63 ULTRA-CUT 400 XT 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...

  • Page 64: Voltage Divider For Ihc Torch Height Control

    ULTRA-CUT 400 XT 3.22 Voltage Divider for iHC Torch Height Control For best plasma cutting performance it is necessary to maintain a constant height (standoff) above the metal while cutting. Cutting tables use a Torch Height Control (THC), also called a Z axis control, most of which use feedback from the arc voltage to control the height.
  • Page 65 ULTRA-CUT 400 XT Arc Voltage Connections. The XT plasma supplies provide a terminal strip, TB4, on the right side ahead of the CCM module for connections to Arc V- (Torch); Tip V (Pilot); Arc V + (Work). If the V-D board requires separate power, 24 VAC and 120 VAC is available on the terminal strip TB4.

  • Page 66: Complete The Installation

    3.23 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 67: Section 4: Operation

    ULTRA-CUT 400 XT SECTION 4: OPERATION 4.01 Power Supply Control Panel AC Indicator Gas Indicator Status Indicator Temp Indicator DC Indicator Art # A-11541_AB AC Power Lamp Indicates unit has passed the input power tests and AC power is being supplied to the inverter modules via the input contactor when the ON/OFF switch is in ON position.

  • Page 68: System Operation

    ULTRA-CUT 400 XT 4.02 System Operation This section contains operating information which is specific to the power supply. WARNING Review the safety precautions in Section 1. If the power supply cord has a plug or is not permanently connected to power, be sure the power to the outlet is disconnected when inserting the plug into the outlet.
  • Page 69 ULTRA-CUT 400 XT POWER Art # A-11542 3. Set Gas Pressure GCM 2010 a. Place Mode switch in SET PREFLOW mode. Adjust Preflow pressure as required for the cutting process. b. Set Mode Switch in SET PLASMA & SHIELD position. Adjust plasma and shield pressure regulators to correct pres- sure.

  • Page 70: Gas Selection

    ULTRA-CUT 400 XT 11. Shut off the system. a. Set the ON/OFF power switch on the front panel of the unit to OFF. WARNING AC power is still present inside the unit. • Fans and pump as well as all indicators turn off. • The display may show a fault code for a moment, this is a normal part of shutting off power and does not indicate a fault. b. Open (turn off) the main power disconnect. All power is now removed from the unit.
  • Page 71 ULTRA-CUT 400 XT 4. Nitrogen (N2) Plasma • Provides better cut quality on nonferrous materials such as stainless steel and aluminum. • Can be used in place of air plasma with air shield. • A good clean welding grade nitrogen should be used. • When used with a water mist secondary it produces superior cut speeds and cut quality on stainless steel and alumi- num. 5. H17 Plasma (17.5% Hydrogen / 32.5% Argon / 50% Nitrogen) • Recommended for 1/2 inch (12 mm) and thicker nonferrous materials. H17 is not normally used for thinner nonferrous materials because less expensive gases can achieve similar cut quality. • Alternative to H35 Plasma. Yields slightly higher cut speeds and similar cut quality. • When using H17, the gas should be supplied to the gas supply port marked “H35”.

  • Page 72: Gcm 2010 Gas Control Module Operation

    ULTRA-CUT 400 XT 4.04 GCM 2010 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...
  • Page 73 ULTRA-CUT 400 XT GCM 2010 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 & SHIELD...
  • Page 74 ULTRA-CUT 400 XT 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...
  • Page 75 ULTRA-CUT 400 XT 4. Current Control Adjusts the output current of the power supply. High Precision AMPERAGE SET-UP Plasma Cutting System O2 - AIR O2 - O2 ENABLE H35 -N SET PREFLOW F5 - N SET PLASMA & SHIELD AIR - AIR...

  • Page 76: Gcm 2010 First Time Operation Matching Gas Control To Lead Length

    ULTRA-CUT 400 XT 4.05 GCM 2010 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 DISABLE.
  • Page 77 ULTRA-CUT 400 XT NOTE! When switching gases between operations, allow enough purge time to clear the prior gas from the torch leads. CAUTION While nothing prevents the operator from switching gases during piloting or cutting it is not recommended to do so. If the operator switches gases during piloting or cutting, the power supply will finish the cut with the first gas chosen.
  • Page 78 ULTRA-CUT 400 XT 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: Power Supply Status Codes

    ULTRA-CUT 400 XT 4.07 Power Supply Status Codes NOTE! See the Appendix for Advanced Troubleshooting On start-up and during operation, the power supply control circuitry performs various tests. If the circuitry detects a condition requiring operator attention, the status display on the front panel shows a 3 digit number code preceded by either letter “E” (cur- rently active fault) or letter “L”...
  • Page 80 ULTRA-CUT 400 XT CCM Status Code Code Message Remedy / Comments Group 2 -- Plasma Power Supply Blown wall fuse, Blown unit fuse F1 or F2 or rear panel, Bad power cable connection; Missing AC Phase Defective System Bias PCB.
  • Page 81 ULTRA-CUT 400 XT CCM Status Code Code Message Remedy / Comments Inverter 3A Output Plasma work current high during cutting and attributed to Inverter Module 3 Section Current High A output high; If problem persists replace Inverter Module 3 Inverter 3B Output...
  • Page 82 ULTRA-CUT 400 XT CCM Status Code Code Message Remedy / Comments Inverter Input Voltage fault; voltage out of range or missing phase at AC Input of In- Inverter 1A Input Volt- verter Module 1 Section A; Poor AC Power Quality; Defective W1 contactor; Loose or...
  • Page 83 ULTRA-CUT 400 XT CCM Status Code Code Message Remedy / Comments Inverter Module 3 Section A is over temperature; Operating with side panels re- Inverter 3A Over Temp moved, Check for restricted air flow, clogged radiator; Defective fan; If problem persists replace inverter module.
  • Page 84 ULTRA-CUT 400 XT CCM Status Code Code Message Remedy / Comments Group 3 -- Gas Controller Status & Protocol Problem with fiber optic cable to GCM 2010; Dirt on fiber ends or in connectors; blow Gas control communication out with clean dry air. Fiber not locked into connector; Sharp bends in fiber cable;...
  • Page 85 ULTRA-CUT 400 XT No Group 5 (500) status codes with GCM 2010 system. CCM Status Code Code Message Remedy / Comments Group 6 -- CCM Analog Voltage Error Defective CCM, replace. ADC or DAC error Defective CCM, replace. Reserved No information available; Contact customer service Data Memory error Defective CCM, replace.
  • Page 86 ULTRA-CUT 400 XT CCM Status Code Code Message Remedy / Comments Group 7 -- Options 1 Torch isolation contactor W5 appears closed when expected to be Isolation Contactor Fault open. Contacts may fused or, W5 could be energized, 24 VAC on it's coil, when it should not be due to faulty Relay PCB.

  • Page 87: Remote Arc Starter Trouble Shooting

    ULTRA-CUT 400 XT 4.08 Remote Arc Starter Trouble Shooting Arc Starter Trouble Shooting Symptom Cause Check Remedy Pilot return wire not connected at torch head or broken in torch Visual inspection, continuity check Connect Wire or replace leads. lead Flush system,...
  • Page 88 ULTRA-CUT 400 XT This Page Intentionally Blank 4-22 OPERATION Manual 0-5275...

  • Page 89: Section 5: Maintenance

    ULTRA-CUT 400 XT 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. Check cooling fan; clean as needed.

  • Page 90: Coolant Replacement Procedure

    ULTRA-CUT 400 XT 5.03 Coolant Replacement Procedure Replace coolant as follows: 1. Disconnect the system from main input power. 2. Remove the two right side panels. 3. Locate the coupling in the coolant line that comes from the bottom of the coolant tank, #1 in the following illustration.

  • Page 91: Section 6: Replacement Assemblies & Parts

    ULTRA-CUT 400 XT SECTION 6: REPLACEMENT ASSEMBLIES & PARTS 6.01 Replacement Power Supply Complete Unit / Component Catalog Number Ultra-Cut 400 XT Power Supply, 480V +10 -15% 3-8120-2 ™ Ultra-Cut 400 XT Power Supply, 480V +10 -15% with SL100 interface 3-8120-2T ™...

  • Page 92: System Layout

    ULTRA-CUT 400 XT 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...

  • Page 93: Leads And Cables All Amperages

    ULTRA-CUT 400 XT 6.04 Leads And Cables All Amperages #8 AWG Cable Pilot Return, Power Supply to Arc Starter 3/0 AWG Cable (95 mm Negative Lead, Power Supply to Arc Starter Coolant Supply Lead, Green Green Power Supply to Arc Starter...
  • Page 94 ULTRA-CUT 400 XT REPLACEMENT PARTS Manual 0-5275...

  • Page 95: Power Supply External Replacement Parts

    ULTRA-CUT 400 XT 6.05 Power Supply External Replacement Parts Item # Description Catalog # Power and Leads Cable Cover 9-7346 Top Panel, 9-7300 Upper Side Covers 9-7301 Lower Left Side Panel 9-7304 Lower Right Side Panel (300A/400A) 9-7344 Lifting Eye...

  • Page 96: Power Supply Replacement Parts - Upper Right Side

    ULTRA-CUT 400 XT 6.06 Power Supply Replacement Parts - Upper Right Side Item # Description Ref. Des. Catalog # System Bias PCB 9-9253 Pilot PCB 9-9250 CCM Assembly 9-7335 Relays, Pump / Fan MC3 / MC2 9-7314 Relay, Inrush Control...

  • Page 97: Power Supply Replacement Parts - Lower Right Side

    ULTRA-CUT 400 XT 6.07 Power Supply Replacement Parts - Lower Right Side Item # Description Ref. Des. Catalog # Coolant Tank, Cap 8-5124 Coolant Tank 9-7306 Sensor, Coolant level 9-7307 Pump, Coolant, Assembly (with motor) 9-7309 Pump, Coolant, Assembly (no motor)

  • Page 98: Power Supply Replacement Parts - Rear Panel

    ULTRA-CUT 400 XT 6.08 Power Supply Replacement Parts - Rear Panel Item # Description Breaker Rating Circuit Rating Ref. Des. Catalog # Coolant Filter Assy 9-7320 Coolant Filter 9-7321 Fuse, 8A SB 500 VAC 9-7377 J55 - GCM USER INPUT...

  • Page 99: Power Supply Replacement Parts - Left Side

    ULTRA-CUT 400 XT 6.09 Power Supply Replacement Parts - Left Side Item # Description Ref. Des. Catalog # AC Suppresion PCB 9-9254 Main Contactor (2 total) W1, W2 9-7318 Inverter Module, Full 480 VAC (3 total) 9-7330 Art # A11990...

  • Page 100: Gas Control Module (Gcm-2010) Replacement Parts

    ULTRA-CUT 400 XT 6.10 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 101: Gas Control Module (Gcm-2010) Replacement Parts

    ULTRA-CUT 400 XT 6.11 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 102: Remote Arc Starter (Ras-1000 Xt) Replacement Parts

    ULTRA-CUT 400 XT 6.12 Remote Arc Starter (RAS-1000 XT) Replacement Parts Item # Description Catalog # Complete RAS 1000 XT Assembly 3-9130E Pilot Cap Assembly 9-9423 Electronic Ignition Module 9-7342 Toroidal Coil 9-7343 Art # A-12066 6-12 REPLACEMENT PARTS Manual 0-5275...

  • Page 103: He400Xt Heat Exchanger - Replacement Parts

    ULTRA-CUT 400 XT 6.13 HE400XT Heat Exchanger - Replacement Parts Item # Description Catalog # Assembly, HE400XT Heat Exchanger 9-9416 9-7348 Radiator 9-7349 Capacitor 9-1059 Thermal Switch 9-1448 Art # A-12672 Manual 0-5275 REPLACEMENT PARTS 6-13...

  • Page 104: Xtl Torch Valve Assembly External Replacement Parts

    ULTRA-CUT 400 XT 6.14 XTL Torch Valve Assembly External Replacement Parts NOTE! The XTL Torch Valve Assembly requires Firmware versions 3.2 or higher for the C.C.M. and 3.1 or higher for the GCM 2010. It also requires the resetting of DIP switches in the C.C.M..

  • Page 105: Xtl Torch Valve Assembly Internal Replacement Parts

    ULTRA-CUT 400 XT 6.15 XTL Torch Valve Assembly Internal Replacement Parts NOTE! The XTL Torch Valve Assembly requires Firmware versions 3.2 or higher for the C.C.M. and 3.1 or higher for the GCM 2010. It also requires the resetting of DIP switches in the C.C.M..
  • Page 106 ULTRA-CUT 400 XT This Page Intentionally Blank 6-16 REPLACEMENT PARTS Manual 0-5275...

  • Page 107: Torch Maintenance

    ULTRA-CUT 400 XT 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...

  • Page 108: O-Ring Lubrication

    Cat. No. 9-3025 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. TORCH INFORMATION Manual 0-5275...

  • Page 109: Parts Wear

    ULTRA-CUT 400 XT 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...

  • Page 110: Torch Consumables Installation

    ULTRA-CUT 400 XT 7.04 Torch Consumables Installation Art # A-03887 1. Install the consumables as follows: 1: Stack Parts 2: Press Cartridge onto Stacked Parts Electrode Plasma Gas Distributor Upper O-Ring on Tip No Gaps Between Parts Shield Gas Cartridge Covers...
  • Page 111 ULTRA-CUT 400 XT CAUTION The cartridge assembly must cover the O-Ring on the torch head. Do not force the cartridge if it will not tighten fully. Remove the cartridge assembly and gently clean the threads on the torch head with a wire brush. Apply oxygen-compatible lubricant (supplied with the torch) to the threads.

  • Page 112: Coolant Leak Trouble-Shooting

    ULTRA-CUT 400 XT 7.05 Coolant Leak Trouble-Shooting Never operate the system if coolant leaks from the torch. A steady drip indicates that torch parts are damaged or installed im- properly. Operating the system in this condition can damage the torch head. Refer to the following chart for guidance on coolant leakage from the torch head.
  • Page 113 ULTRA-CUT 400 XT 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 0.04 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 114 ULTRA-CUT 400 XT This Page Intentionally Blank TORCH INFORMATION Manual 0-5275...

  • Page 115: Appendix 1: Remote Arc Starter Schematic

    ULTRA-CUT 400 XT APPENDIX 1: Remote Arc Starter Schematic Jumper in cable to ID Arc Starter IGNITION UNIT SIG 4.5 is connected. PLASMA 1000 XT POWER SUPPLY J59-RAS Chassis gnd 115 Vac 115 Vac RET (99) 120 VAC 120 VAC RET...

  • Page 116: Appendix 2: Gas Control And Torch Valve Schematic

    ULTRA-CUT 400 XT 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 117 <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 118: Appendix 3: Gas Control Module Plumbing Diagram

    ULTRA-CUT 400 XT 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 &...

  • Page 119: Appendix 4: Gas Control Module Pcb Layout

    ULTRA-CUT 400 XT APPENDIX 4: Gas Control Module PCB Layout TP10 TP11 TP12 TP15 TP13 Art # A-07621 TP19 TP18 TP16 TP14 Manual 0-5275 APPENDIX...

  • Page 120: Appendix 5: Gas Control Display Module Pcb Layout

    ULTRA-CUT 400 XT APPENDIX 5: Gas Control Display Module PCB Layout 19X2220 REV LCD INTERFACE C 2005 Art # A-06904 APPENDIX Manual 0-5275...

  • Page 121: Appendix 6: Cnc - Control Module Pcb Connections

    ULTRA-CUT 400 XT APPENDIX 6: CNC - Control Module PCB Connections (LV) OK To Move 2 High +10V Analog Current Control Wiper / Input Low (-) Divided Arc Volts Output Start/Stop Input Stop (NC) (LV) OK To Move 2 CNC Plasma Enable...

  • Page 122: Appendix 7: Cnc

    ULTRA-CUT 400 XT APPENDIX 7: 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, TB2 & TB3 are common to each other.
  • Page 123 ULTRA-CUT 400 XT Internal CNC connections. TB1, TB2 & TB3 on CCM module. Connections are provided on the CCM module TB1, TB2 & TB3 terminal blocks including most of the rear panel functions plus some additional features. All these signals are isolated from the plasma power supply but signals marked (comm.) and (-) are common to each other.

  • Page 124: Cnc Input / Output Descriptions

    ULTRA-CUT 400 XT 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 125 ULTRA-CUT 400 XT Pilot On output – Relay contacts rated 1A @ 120 VAC / 28 VDC. Contacts close when pilot on. Can be wired parallel with Ok to Move contacts to start machine motion when pilot established. Used when starting over holes. Starting over holes requires setting SW8-1 ON (up) on the CPU PCB for extended pilot time.

  • Page 126: Simplified Cnc Circuit

    ULTRA-CUT 400 XT Simplified CNC Circuit Ult racut X T Simplified CNC OK TO MOV E SELECT 18 V D C or Con tacts SW6A D C VO LT S +18VDC OK2 (cont act) C ONTA CT S +10V (CC Pot Hi )
  • Page 127 ULTRA-CUT 400 XT J54 - Rem ote HM I & CN C CO M M (100) 1 - 24 V AC (101) 2 - 24 V AC Re t (102) 3- Jumper to 24 V AC Harness to Relay PCB...

  • Page 128: Cnc Connections

    ULTRA-CUT 400 XT CNC Connections Cutting Machine CNC Cable Power Supply START/STOP ..Source, 16 VDC, 10 ma..Divided Arc V (-) ..Divided Arc V (+) ..Pre Flow ON (+) ..Pre Flow ON (-) ..Corner Current Reduction (+)

  • Page 129: Cnc Cable Color Code

    ULTRA-CUT 400 XT CNC Cable Color Code TABLE 1: CABLE ITEM#4 COLOR CODE TABLE COLOR SIGNAL DESCRIPTION LOCATION WHITE/BLUE START CNC (+) WHITE/VIOLET START CNC (-) WHITE/BROWN/VIOLET DIV ARC (-) WHITE/BROWN DIV ARC(+) YELLOW PREFLOW ON (+) GREEN COMM 1K...

  • Page 130: Appendix 8: Ccm Cpu Pcb Layout

    ULTRA-CUT 400 XT APPENDIX 8: CCM CPU PCB Layout = Test Point Art # A-11675_AB A-16 APPENDIX Manual 0-5275...
  • Page 131 ULTRA-CUT 400 XT CCM CPU PCB Test Points TP1 GND TP2 ISO +5.0V TP3 +24V TP4 +3.3V TP5 ISO GND TP6 +5.0V TP7 TOTAL DEMAND 3.3V=400A TP9 /WR TP10 TP11 CPU TEMP SENSE TP12 +3.3VA TP13 -15VDAC TP14 TP15 +15VDAC...

  • Page 132: Appendix 9: Ccm I/O Pcb Layout

    ULTRA-CUT 400 XT APPENDIX 9: CCM I/O PCB Layout = Test Point A-18 APPENDIX Manual 0-5275...
  • Page 133 ULTRA-CUT 400 XT CCM I/O PCB J Connectors Test Points J21 BASIC CNC J22 EXTENDED CNC TP1 GND J23 RELAY - INTERFACE BOARD TP2 /COOLANT FANS ON J24 ARC / TIP VOLTS TP3 /TORCH PUMP ON J25 TEST TP4 LOW COOLANT FLOW (SW)

  • Page 134: Appendix 10: Pilot Pcb Layout

    ULTRA-CUT 400 XT APPENDIX 10: Pilot PCB Layout = Test Point Art # A-11677 A-20 APPENDIX Manual 0-5275...
  • Page 135 ULTRA-CUT 400 XT Pilot PCB Test Points TP1 GND TP2 PILOT GATE TP3 +5V TP4 TIP LED Reference Green PILOT ENABLE Green +5V Manual 0-5275 APPENDIX A-21...

  • Page 136: Appendix 11: Relay And Interface Pcb Layout

    ULTRA-CUT 400 XT APPENDIX 11: Relay and Interface PCB Layout = Test Point Art # A-11678_AB A-22 APPENDIX Manual 0-5275...
  • Page 137 ULTRA-CUT 400 XT Relay and Interface PCB Test Points TP1 GND TP2 -15V TP3 +5VDC TP4 +12V TP5 +24V TP6 +15V TP7 +5VDC LED Reference Green 1 TORCH GAS ON Green PILOT ENABLE Green PILOT CURRENT DETECTED D12 Green WORK CURRENT DETECTED...

  • Page 138: Appendix 12: Display Pcb Layout

    ULTRA-CUT 400 XT APPENDIX 12: Display PCB Layout = Test Point Art # A-11679 A-24 APPENDIX Manual 0-5275...
  • Page 139 ULTRA-CUT 400 XT Display PCB Test Points TP1 GND TP2 +5VDC TP3 +24VDC Manual 0-5275 APPENDIX A-25...

  • Page 140: Appendix 13: System Bias Pcb Layout

    ULTRA-CUT 400 XT APPENDIX 13: System Bias PCB Layout = Test Point Art # A-11680 A-26 APPENDIX Manual 0-5275...
  • Page 141 ULTRA-CUT 400 XT System Bias PCB Test Points TP1 GND TP2 24VDC TP3 DC INPUT POSITIVE TP4 Vcc1 TP5 Vcc2 TP6 GATE TP7 PRIMARY GND TP8 +12V PRIMARY TP9 P_ISOL_GND TP10 DC SENSE POSITIVE LED Reference MISSING PHASE AC V HIGH...

  • Page 142: Appendix 14: Main Inverter Bottom Pcb Layout

    ULTRA-CUT 400 XT APPENDIX 14: Main Inverter Bottom PCB Layout = Test Point A-28 APPENDIX Manual 0-5275...
  • Page 143 ULTRA-CUT 400 XT Main Inverter Bottom PCB Test Points TP1 GND TP2 GATE 2A TP3 GATE 1A TP4 GATE 3A TP5 GATE 4A TP6 GATE 2B TP7 GATE 1B TP8 GATE 4B TP9 GATE 3B TP10 +12VP TP11 +12VDC TP12...

  • Page 144: Appendix 15: Main Inverter Top Pcb Layout

    ULTRA-CUT 400 XT APPENDIX 15: Main Inverter Top PCB Layout = Test Point A-30 APPENDIX Manual 0-5275...
  • Page 145 ULTRA-CUT 400 XT Main Inverter Top PCB Test Points TP1 GND TP2 GATE 2A TP3 GATE 1A TP4 GATE 3A TP5 GATE 4A TP6 GATE 2B TP7 GATE 1B TP8 GATE 4B TP9 GATE 3B TP10 +12VP TP11 +12VDC TP12...

  • Page 146: Appendix 16: Control And Fault Pcb Layout

    ULTRA-CUT 400 XT APPENDIX 16: Control and Fault PCB Layout = Test Point Art # A11683_AB A-32 APPENDIX Manual 0-5275...
  • Page 147 ULTRA-CUT 400 XT Control and Fault PCB Test Points TP1 GND TP22 +12VDC TP23 +5VDC TP24 GATE 1+ TP25 A_OUT1 TP26 B_OUT1 TP27 GATE 1- TP28 I_SNS1 TP29 GATE 2+ TP30 I_DMD1 0.5V-6.7V TP31 GATE 2- TP32 -12VDC TP33 START 2...

  • Page 148: Appendix 17: Cap Bias Bottom Pcb Layout

    ULTRA-CUT 400 XT APPENDIX 17: Cap Bias Bottom PCB Layout Art # A-11685_AB A-34 APPENDIX Manual 0-5275...

  • Page 149: Appendix 18: Cap Bias Top Pcb Layout

    ULTRA-CUT 400 XT APPENDIX 18: Cap Bias Top PCB Layout Art # A-11686_AB Manual 0-5275 APPENDIX A-35...

  • Page 150: Appendix 19: Suppressor Pcb Layout

    ULTRA-CUT 400 XT APPENDIX 19: Suppressor PCB Layout Art # A-11684_AB A-36 APPENDIX Manual 0-5275...

  • Page 151: Appendix 20: Cooling Diagram

    ULTRA-CUT 400 XT APPENDIX 20: COOLING DIAGRAM Manual 0-5275 APPENDIX A-37...

  • Page 152: Appendix 21: System Schematic 400A, 480V

    ULTRA-CUT 400 XT APPENDIX 21: System Schematic 400A, 480V PG 1 INVERTER MODULE (IM) #3 (top) IM #3 Section B (upper) AC INPUT J105B J104B J103B 019X502700 J105A AC INPUT IM #3 Section A (lower) J104A J103A 019X502000 INVERTER MODULE (IM) #2 (middle)
  • Page 153 ULTRA-CUT 400 XT TO CCM CPU PCB J36 (Sht 2, C3) J100 -- 30 CKT RIBBON TORCH (49F) (49) ELECTRODE (-) (51F) PILOT BOARD LED'S TEST POINTS TORCH TP1 GND WORK (+) (49) To TB4-7 TP2 PILOT GATE D2 PILOT ENABLE...

  • Page 154: Appendix 22: System Schematic 400A, 480V

    ULTRA-CUT 400 XT APPENDIX 22: System Schematic 400A, 480V PG 2 AMBIENT J12 = Mini-Fit Jr COOLANT 400 VAC -- Single 18 AWG in pins 1 & 4 (90) 480 VAC -- Single 18 AWG in pins 1 & 8...
  • Page 155 ULTRA-CUT 400 XT TO PILOT PCB J70 - HE (70) 230 VAC to HE 400 (70) Fan Control 230 VAC _ SW (D2) 230 VAC Ret 230 VAC _ SW _ RET (D2) (96) ARC_SUPPRESSOR Pump Motor Control J59 - RAS...

  • Page 156: Appendix 23: Advanced Troubleshooting

    ULTRA-CUT 400 XT APPENDIX 23: ADVANCED TROUBLESHOOTING System Overview The Auto-Cut 200 & 300 XT, PAK200i & Ultra-Cut 100, 200, 300 & 400 XT power supplies include one, two or three inverter modules (IM). Each IM may have either 1 or 2 inverter sections designated A or B sections.
  • Page 157 ULTRA-CUT 400 XT to the inverter sections 1A through 3B. The ribbon cables are labeled on the inverter ends as INV with the number and section (INV 1A, INV 1B, etc.). A 100A unit will only have ribbon cables in J31 & J32; a 200A will have J31-J33 filled with the others empty.
  • Page 158 ULTRA-CUT 400 XT 2nd INVERTER SECTION (INV 1 B) PILOT SW (IGBT) 1st INVERTER SECTION (INV 1 A) WORK Art # 12301 The AC Suppression PCB has capacitors and other transient suppression components to protect the system from transients on the AC lines. It also provides power for the neon AC present indicators which illuminate when AC power is connected even when the ON-OFF switch, CB1, is off.
  • Page 159 ULTRA-CUT 400 XT Ultra-Cut XTs have standard consumables for cutting currents lower than those used for Auto-Cut XT, 15A vs. 55A as well as marking at lower currents. To improve operation at these lower currents an additional output inductor, L1, is added in series with the 1st inverter section (IM#1A).
  • Page 160 ULTRA-CUT 400 XT Troubleshooting (General) In many cases where the cause may be listed as a cable or wire disconnected but also includes loose or broken. All Ribbon cables have an extra receptacle near one end for measuring signals on the cable.
  • Page 161 ULTRA-CUT 400 XT Power Supply Status Codes Group 1, Process Codes Plasma Enable Is Disabled Code 101 is activated by either an open circuit between TB1-1 & 2 on CCM I/O PCB or Plasma Enable switched off on the GCM 2010 or on the TSC 3000. TB1-1 & 2 comes from the factory with a jumper installed. An in- staller may remove the jumper and connect a separate Plasma Enable switch or use the Plasma Enable wires included in the 37 pin CNC cable used with the Ultra-Cut XT &...
  • Page 162 ULTRA-CUT 400 XT Plasma Enable from Gas Control or TSC 3000 If the External or CNC Plasma Enable is satisfied, D2 is on, a relay K7 on the CCM I/O PCB energizes supply- ing +15V to another relay K1 on the I/O board. An active low signal, /Plasma Enable-HMI, comes from TSC 3000 Plasma Enable switch via the Relay PCB or if TSC 3000 is not installed the signal originates on the Relay PCB.
  • Page 163 ULTRA-CUT 400 XT GCM 2010 PLASMA ENABLE / E-STOP SIMPLIFIED CIRCUIT XT PLASMA SUPPLY RELAY BOARD AC24V GCM1 GCM 2010 GAS CONTROL AC24V Ret - GCM1 CONTROL GCM 2010 CONTROL BOARD CABLE CCM I/O BOARD (103) (56) (112) (58) (110)
  • Page 164 ULTRA-CUT 400 XT Arc starter with Spark Gap (Auto-Cut) No spark at spark gap 1. Check that spark gap is set for 0.062” +/- 0.002”. If gap is too high there may not be enough voltage from T1 to fire the gap.
  • Page 165 ULTRA-CUT 400 XT 2. If 120 VAC is not present go to step 3. a. If 120 VAC is present and still no spark, the Ignition Module may be bad. 3. 120 VAC to the remote Arc Starter comes from J59-7 & 9 on the power supply rear panel and connects to J58-7 &...
  • Page 166 ULTRA-CUT 400 XT Reasons why RAS Control relay would not close: 6. Pilot current flowing. There actually is pilot current flowing somewhere. Unlikely as it would normally set the 208 fault but we have to rule it out. a. Disconnect J41 on the Pilot board, if HF still doesn’t fire and the Relay board Pilot LED, D11, is still on, it’s due to a fault in the detection circuits.
  • Page 167 ULTRA-CUT 400 XT 2. Test pilot IGBT operation. D2 on shows the pilot is enabled but you don’t know if the pilot switch (IGBT transistor) actually closes the circuit. To test attach a jumper, 18 AWG or larger as follows: a.
  • Page 168 ULTRA-CUT 400 XT Transfer Lost Arc transferred to metal for at least 50 ms. then went out. Causes for 104 code: • Cut demand set much lower than recommended for torch parts, i.e. 100A consumables in torch but cut current set for 30 or 50A (or zero). Current may be too low to keep arc on.
  • Page 169 ULTRA-CUT 400 XT Visible Pilot: • First the obvious, make sure the work lead is connected both to the work and the power supply. Also make sure the work itself is making good electrical contact with cutting table. If rusty or painted metal, you may need to clean a spot and attach the work lead directly to the metal.
  • Page 170 ULTRA-CUT 400 XT Causes for 108 code: • Gas Flow/pressure too low for consumable parts being used. o If gas source pressure is not well regulated it is possible pressure may be OK at times and drop too low at other times such as during a cut.
  • Page 171 ULTRA-CUT 400 XT INV FLT (D1, INV FLT LED, red, on the Inverter Control and Fault board) Several things can cause Inv Flt (Inverter Fault). Inverter fault is indicated by an LED, D1 on the Inverter Con- trol and Fault board. Inverter Fault, when it occurs, is latched on. The latch is reset next time the inverter is enabled unless it is still active in which case it is immediately latched again.
  • Page 172 ULTRA-CUT 400 XT E201: • Phase missing from the wall fuse box, blown fuse. • F1 or F2, 8A 500V slow blow fuses blown. • CB1 one phase open. • System Bias board defective. • I/O board defective. Troubleshooting: 1. System Bias board has a red LED, D3, that lights if it detects a missing phase. If D3 is on, check J60 for all 3 phases.
  • Page 173 ULTRA-CUT 400 XT Not used. Reserved codes from the earlier product. Unexpected Current in the Work Lead. HCT1, a Hall Effect current sensor on the positive (work buss bar) measures the work lead current. Inverter section 1A is enabled during preflow time but there should be no current in the work lead before the pilot is ignited and before the arc is transferred to the work.
  • Page 174 ULTRA-CUT 400 XT Unexpected current in Pilot Circuit The Pilot board includes a current sensor to measure the pilot current. There should not be any pilot current until the inverters and the pilot board are enabled and the arc starter has fired to ignite the pilot. Pilot current or the signal indicating pilot current should not be present until the arc starter has fired.
  • Page 175 ULTRA-CUT 400 XT Not used. Reserved codes from the earlier product. 210–211 Output current, measured by the work lead current sensor, is too high (210) or too low (211). These are warnings and do not shut down the process but may explain poor cut quality or poor parts life.
  • Page 176 ULTRA-CUT 400 XT 2. If the report is current too low (which included no current) check the connections. 3. The ribbon cable for the first inverter section (IM#1A) must connect to that section only but if there are 2 additional sections, unit is 200A or greater, swap the ribbon cable going into those sections.
  • Page 177 ULTRA-CUT 400 XT At power on, the System Bias board measures the incoming voltage, determines what input voltage range it fall into and sends that range information to the CCM. Before Appling power to the inverters by turning on the input contactors, the CCM checks that each connected inverter is of the correct voltage matching that of the System Bias board.
  • Page 178 ULTRA-CUT 400 XT Troubleshooting: 1. Check that all cables are connected, latches locked down, at both the inverter and CCM ends. 2. If this fault occurs it’s most likely on a 100A unit which only has one section (1B) in addition to the 1A sec- tion.
  • Page 179 ULTRA-CUT 400 XT If the fault is E239 that means it is currently active, that is, currently detected as being too high. If it’s L239 that means the voltage too high previously but it is not too high now. Applying START will clear the fault unless it becomes active again.
  • Page 180 ULTRA-CUT 400 XT Troubleshooting: 1. If the fault is L240, applying START will clear the fault unless it becomes active again. An occasional problem may be due to incoming voltage dips or sags (voltage drops lasting from ½ cycle to as much as a minute).
  • Page 181 ULTRA-CUT 400 XT 247-252 Inverter Fault Once the input contactors close applying voltage to the inverters several tests are performed. The Inverter Fault signal latches on so even if the cause has gone away you can see that there was a fault as indicated by red LED D1, INV FLT on the inverter Control &...
  • Page 182 ULTRA-CUT 400 XT 259-264 Inverter Over Temperature due to high Ambient. The CCM measures the ambient temperature where the cooling air enters the louvers on the left side of the front panel. If an inverter goes over temperature and we have determined that the ambient exceeds 40 deg C we will get one or more of the high ambient codes, 252-264.
  • Page 183 ULTRA-CUT 400 XT 265-270 Inverter No Input Power There are several digital signals on the ribbon cables between the inverter sections and the CCM that involve some level of voltage. These include AC_INPUT_FLT\, INVERTER _FLT\, OVERTEMP_FLT\ and POWER_ PRESENT. Normally all of these should be high. Before power is applied to the inverter modules the CCM has already performed a continuity check to see if that section is in place and it’s ribbon cable connected (code...
  • Page 184 ULTRA-CUT 400 XT Troubleshooting: 1. First recycle power to see if the fault is still there. It may now show up as one of the 225-230 codes which will indicate which inverter. 2. Determine when the code shows up. If it is EMI it may not happen every time but if, when it happens, it is always at the beginning of piloting, it may be EMI interference.
  • Page 185 ULTRA-CUT 400 XT In the GCM 2010 Gas Control, on the main PCB, measure between test points TP1 (ground) and TP18 (shield) and TP19 (plasma) to measure the output of the pressure sensors. Voltage should be between 2.6V to 3.5V for 100-135 PSI.
  • Page 186 ULTRA-CUT 400 XT GCM 2010 Status Codes GCM 2000 has an LED on the front panel which blinks various codes. GCM 2010 has LCD display which displays many of the Status messages. However, there are a few relating to communications that aren’t clear.
  • Page 187 ULTRA-CUT 400 XT 3. If there was continuity at J7 plug it back in and measure voltage on pin 9 of the 40 pin ribbon cable (Relay board J4 to CCM J23). Common is TP1 on either the Relay or the I/O board.
  • Page 188 ULTRA-CUT 400 XT Coolant overheated. TS1 is a linear negative temperature coefficient (NTC) resistor sensor attached to the brass fitting at the exit of the bypass valve. Here we determine the coolant being supplied to the torch is below the required temperature which is currently 75 deg C (167F).
  • Page 189 ULTRA-CUT 400 XT 3. Check for 230 VAC at either of the fan connectors, J72 & J73. It may also be measured at the rear panel con- nector J70 for the HE400XT fan. a. If the fans are not getting 230 VAC, measure for 24 VAC on the coil of MC2. If present and the relay contacts aren’t closed the relay is defective.
  • Page 190 ULTRA-CUT 400 XT Some consumables use an extension on the coolant tube. A missing extension will not allow the check valve to open. Internal Check Valve Fingers Coolant Tube Extension Art # 12312 No Power to the Pump Motor The pump motor is powered by 230 VAC controlled by the MC3 control relay. During the 4 minutes after turning on power, before the 404 fault code is displayed, measure for 230 VAC at the motor connector J16 pin 1 to pin 3.
  • Page 191 ULTRA-CUT 400 XT Turn the on the unit. You will have 4 minutes to perform the test/adjustment before the system times out with a coolant flow fault. If that happens recycling the power gives you another 4 minutes. 1. The pressure on the gauge should be close to 173 (170-175) PSI. If it is the pump and the bypass are OK.
  • Page 192 ULTRA-CUT 400 XT Coolant Overheated due to High Ambient As described in the section for codes 259-264 the CCM measures the ambient temperature using sensor TS2 and, like with the inverters, if the coolant is over temperature we first check the ambient and if it is above 40 deg C we attribute the cause of the coolant over temperature to high ambient and of course the solution is to lower the ambient or reduce the duty cycle.
  • Page 193 ULTRA-CUT 400 XT d. Excessive electrical interference. While the fiber is immune to EMI it can bother circuits at either end. Check that all the grounding connections are connected per the manual and are clean and tight. Check the resistance of the ground rod (with all wires disconnected from it). It may have increased due to dryer weather conditions.
  • Page 194 ULTRA-CUT 400 XT Group 6 codes relate to the CCM and program updates. One exception is 619 which is a coolant flow switch FS1 fault. 601-611 Various CCM CPU board internal faults. For most of these faults try recycling the power but if the problem returns only thing to do is replace the CCM.
  • Page 195 ULTRA-CUT 400 XT 615-617 No Update File for CCM, DPC or DMC found Program files for the CCM, DMC & DPC may be updated through the plasma supply’s USB port. The GCM2010 is updated by other means. For a unit with GCM 2010 the CCM may still be updated using the USB. Program update files are in the format Cx_x_0.S (CCM);...
  • Page 196 ULTRA-CUT 400 XT When the 1Torch trigger is pressed an interlock circuit first determines if the 1Torch consumables are in place and making proper contact as required to start a pilot. 1. -15V (J85-3) is applied to the 1Torch electrode via K201 NC contacts and returns from the tip on J85-1 where measurement is taken by U13A on the Relay Board.
  • Page 197 ULTRA-CUT 400 XT No Fault Codes showing. Some problems may not result in fault codes such as: 1. Failure to respond to the 1Torch Trigger. To operate the 1Torch trigger the automation torch must be in idle state, not preflow, post-flowing, etc. When the XT automation torch is idle K200 in the 1Torch module should be energized connecting the torch trigger through to the Relay Board and CCM.
  • Page 198 ULTRA-CUT 400 XT Isolation Contactor (W5) Fault. This fault occurs if one or more of W5 contacts are closed when they should not be. Either because W5 is ener- gized when it shouldn’t be due to a faulty circuit board or the contact(s) is physically stuck.
  • Page 199 ULTRA-CUT 400 XT b. If D35 is off remove J85 from the Relay Board and measure for minus 12-15 VDC on pin 3 of J85 PCB header. If not there the Relay Board is defective. If voltage is present plug J85 back in and measure pin 3 again.
  • Page 200 ULTRA-CUT 400 XT Pressure Fault Normal 1Torch operating pressure is 70-85 PSI. However minimum pressure to satisfy the pressure switch is 35 PSI. When the 1Torch trigger is pressed and the tests to determine that the consumables are in place (702) and detection circuit is working (703) then the gas solenoid SOL4 is turned on.
  • Page 201 ULTRA-CUT 400 XT This Page Intentionally Blank Manual 0-5275 APPENDIX A-87...

  • Page 202: Appendix 24: Sl100 Interconnection

    ULTRA-CUT 400 XT APPENDIX 24: SL100 INTERCONNECTION Interconnection to XT Power Supply (Simpli ed) Harness I/O PCB +24 VDC 500uH Relay PCB (simpli ed) connector to Relay +15 VDC / Start 1 Torch 500uH / Gas Sol ON 1 Torch...
  • Page 203 ULTRA-CUT 400 XT Optional 1 Torch Module XT 1 TORCH MODULE (201) (201) 1 Torch Contactor ON (24VAC) +24VDC (202) (202) (202) Relay under control of (203) (203) / Main Torch Idle (203) D200 CCM isolates torch Start (204) (204)

  • Page 204: Appendix 25: He 400 Xt Connection

    ULTRA-CUT 400 XT APPENDIX 25: HE 400 XT CONNECTION FAN ASSEMBLY FAN1 (6A) 130F Art # A-12793 Revision Date Victor Technologies Headquarters ECO-B2687 8/20/2014 16052 Swingley Ridge Road, Suite 300 St Louis, Missouri 63017 USA Date Printed Date Revised 12/16/2014...

  • Page 205: Appendix 26: Sl100 Torch Option

    Torch Connections If necessary, connect the torch to the Power Supply. Connect only the Thermal Dynamics model SL100 Manual Torch to this power supply. Maximum torch leads length is 100 feet / 30.5 m, including extensions.
  • Page 206 ULTRA-CUT 400 XT Torch Parts Selection The output of the power supply is fixed at 100 Amps. Torch is assembled with 100 Amp parts from the factory. Refer to the SL100 torch manual for details. Drag cutting with 1Torch. For best consumable life, drag cutting should use the special Drag Shield Cap or the Shield Cup Standoff guide...
  • Page 207 ULTRA-CUT 400 XT Connecting Air Supply to Unit The SL100 torch option needs a separate air supply from that of the XT power supply. The connection is the same for compressed air or high pressure cylinders. Refer to the following two subsections if an optional air line filter is to be installed.
  • Page 208 ULTRA-CUT 400 XT Check Air Quality Air must be free of oil and moisture. To test the quality of air: 1. Pull trigger momentarily to initiate gas/air flow. 2. Place a welding filter lens in front of the torch and turn ON the air. Do not start an arc! Any oil or moisture in the air will be visible on the lens.
  • Page 209 ULTRA-CUT 400 XT Installing Optional Single - Stage Air Filter An optional filter kit is recommended for improved filtering with compressed air, to keep moisture and debris out of the torch. 1. Attach the Single - Stage Filter Hose to the Inlet Port.

  • Page 210: Replacement Parts

    ULTRA-CUT 400 XT Replacement parts Art # A-12762 Description BOM ID Qty Name Description BOM ID Qty Name 9-7379 Contactor 8-6800 Pressure Gauge 9-6319 Solenoid Assy 9-9509 Regulator 9-1044 Pressure Switch 9-7380 Relay A-96 APPENDIX Manual 0-5275...
  • Page 211 ULTRA-CUT 400 XT Description Catalog # Single - Stage Filter Kit (includes Filter & Hose) 7-7507 Replacement Filter Body 9-7740 Replacement Filter Hose (not shown) 9-7742 Replacement Filter Element 9-7741 Housing Filter Element (Cat. No. 9-7741) Spring O-ring (Cat. No. 9-7743)

  • Page 212: Appendix 27: Publication History

    Section 3 updated cable hose art all per ECOB2694. May 27, 2015 AH Change branding back to Thermal Dynamics. Add Read Me Pages. New Safety section, New safety icons throughout. Update HE-400 art section 3. Add note to grounding art A-11875.
  • Page 214 Fax: +86 21-64483032 Singapore Sales Office Ph: +65 6832-8066 Fax: +65 6763-5812 U.S. Customer Care: 866-279-2628 / 800-535-0557 Canada Customer Care: 905-827-4515 / 800-588-1714 • International Customer Care: 940-381-1212 / 940-483-8178 © 2015 Thermal Dynamics Corp. thermal-dynamics.com Printed in U.S.A.

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