Thermal Dynamics ULTRA-CUT 200 XT™ Operating Manual
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Thermal Dynamics ULTRA-CUT 200 XT™ Operating Manual

Plasma cutting system automated gas control
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480V
200
ULTRA-CUT 200 XT
™
PLASMA CUTTING SYSTEM
AUTOMATED GAS CONTROL
Operating
Manual
Revision: AG Issue Date: May 27, 2015
Manual No.: 0-5304
Thermal-Dynamics.com

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Summary of Contents for Thermal Dynamics ULTRA-CUT 200 XT™

  • Page 1 ® 480V ULTRA-CUT 200 XT ™ PLASMA CUTTING SYSTEM AUTOMATED GAS CONTROL Operating Manual Revision: AG Issue Date: May 27, 2015 Manual No.: 0-5304 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 Manufacturer assumes no liability for its use. Plasma Cutting Power Supply with Automated Gas Control, Ultra-Cut 200 XT ™ Operating Manual No. 0-5304 Published by: Thermal Dynamics Corporation. 2800 Airport Rd. Denton, Texas 76207 www.thermal-dynamics.com © Copyright 2013, 2014, 2015 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 ................... 4-1 4.03 TSC-3000 Navigation Functions ..............4-3 4.04 TSC-3000 Initial Setup ONLY ................4-4 4.05 TSC-3000 Selecting New Process ..............4-5 4.06 TSC-3000 Selecting Recently Used Process ...........
  • Page 9 TABLE OF CONTENTS APPENDIX 1: CNC - CONTROL MODULE PCB CONNECTIONS ........A-1 APPENDIX 2: SERIAL COMMUNICATIONS ............. A-2 A2.01 Cables and Switch Settings for 2 and 4 Wire ..........A-2 APPENDIX 3: CNC ..................A-4 CNC functions ....................... A-4 CNC Input / Output Descriptions ...................
  • Page 10 TABLE OF CONTENTS APPENDIX 24: SYSTEM SCHEMATIC 200A, 480V PG 2 ..........A-44 APPENDIX 25: ADVANCED TROUBLESHOOTING .............A-46 APPENDIX 26: SL100 INTERCONNECTION ............A-90 APPENDIX 27: HE 400 XT CONNECTION ..............A-92 APPENDIX 28: SL100 TORCH OPTION ..............A-93 APPENDIX 29: PUBLICATION HISTORY .............. A-100 INTERNATIONAL CONTACT INFORMATION ..........

  • Page 11: Section 1: Safety

    ULTRA-CUT 200 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 200 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. 2.
  • Page 13 ULTRA-CUT 200 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 200 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. CAUTION Means potential hazards which could result in personal injury or loss of life.
  • Page 15 ULTRA-CUT 200 XT This Page Intentionally Blank Manual 0-5304 SAFETY INSTRUCTIONS...

  • Page 16: Précautions De Sécurité - French Canadian

    ULTRA-CUT 200 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 200 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 200 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. Par conséquent : 1.
  • Page 19 ULTRA-CUT 200 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 200 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 l’équipement.

  • Page 21: Section 2: Specifications

    ULTRA-CUT 200 XT SECTION 2: SPECIFICATIONS 2.01 General Description Of The System A typical Ultra-Cut XT™system configuration includes: • One Power Supply • Remote Arc Starter • Gas Control - Digital manifold Control (DMC) • Gas Control - Digital Pressure Control (DPC) • Precision Plasma Cutting Torch • Set Of Connecting Leads • Torch Spare Parts Kit • Touch Screen Control (TSC), Optional • Heat Exchanger, Optional The components are connected at installation. 2.02 Plasma Power Supply The power supply provides the necessary current for cutting operations.

  • Page 22: Precision Plasma Cutting Torch

    ULTRA-CUT 200 XT 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 200 XT™ Specifications & Design Features Max OCV (U0) 425 vdc Minimum Output Current 5 Amps...

  • Page 23: Power Supply Dimensions

    ULTRA-CUT 200 XT 2.07 Power Supply Dimensions 47.77 inch 1213 mm 35.97 inch 200A 465 lb / 211 kg 914 mm 27.6 inch 701 mm Art # A-11980 Manual 0-5304 SPECIFICATIONS...

  • Page 24: Power Supply Rear Panel Features

    ULTRA-CUT 200 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 CB2 - 5A 120 VAC Arc Starter Connector AC Power Lamp...

  • Page 25: Gas Requirements

    ULTRA-CUT 200 XT 2.09 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 200 XT™ Power Supply: Gas Pressures, Flows, and Quality Requirements Quality Minimum Pressure Flow...

  • Page 26: Xt Torch Specifications

    ULTRA-CUT 200 XT 2.11 XT Torch Specifications A. Torch Dimensions Art # A-04897 End Cap 19.00" 2.25" 482.68 mm 57.15 mm Mounting Tube 2.0" 15.50" 50.8 mm 393.78 mm 6.30" 160.10 mm 2.39" 60.81 mm 3.54" 89.87 mm 2.74" 69.55 mm 1.57"...
  • Page 27 ULTRA-CUT 200 XT C. Torch Parts (Generic Parts Shown) Art # A-04741 Plasma Gas Shield Gas Distributor Distributor Shield Cap Electrode Shield Cup Cartridge D. Parts - In - Place (PIP) The torch is designed for use with a power supply which senses coolant return flow to confirm that torch parts are in place.
  • Page 28 ULTRA-CUT 200 XT This Page Intentionally Blank SPECIFICATIONS Manual 0-5304...

  • Page 29: 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 30: System Layout

    ULTRA-CUT 200 XT 3.02 System Layout Refer to section 3.04 for ground connections and ground cables. 175’ / 53.3 m Maximum Length 125’ / 38.1 m Maximum Length 100’ / 30.5 m Maximum Length Pilot Return Pilot Return Shield Negative Remote Coolant Supply Coolant Supply...

  • Page 31: Leads And Cables All Amperage

    ULTRA-CUT 200 XT 3.04 Leads and Cables All Amperage #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 Coolant Return Lead, Power Supply to Arc Starter E - Control Cable, Power Supply...

  • Page 32: Lift The Power Supply

    ULTRA-CUT 200 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 33: Connect Input Power And Ground Cables

    ULTRA-CUT 200 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 34: Connect Work Cable And Pilot And Negative Leads

    ULTRA-CUT 200 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. 2.

  • Page 35: 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 36 ULTRA-CUT 200 XT 4. The plasma power supply work cable (see NOTE) is connected to the cutting table at the single point “Star” ground. NOTE! Do Not connect the work cable directly to the ground rod. Do not coil up excess ground or power cables.
  • Page 37 ULTRA-CUT 200 XT 4. Assemble the transformer and power resistor in a metal box. Connect a 3 wire (w/gnd) power cord with ground wire attached to the metal box for safety. If a plastic box is used instead, connect the transformer core and the resistor mounts to the power cord ground wire.

  • Page 38: Connect Coolant Leads

    ULTRA-CUT 200 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 USER INPUT J15 - CNC HEIGHT CONTROL...

  • Page 39: Connect Cables For Cnc, Remote Arc Starter, Dmc-3000 And He 400

    ULTRA-CUT 200 XT 3.10 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 at the CNC end. J55 To GCM J55 - GCM USER INPUT...

  • Page 40: Handling And Installation Of Fiber Optics

    ULTRA-CUT 200 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 41 ULTRA-CUT 200 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. Do not hook onto the fiber to pull on the cable. Art # A-09418 3.

  • Page 42: Correct Installation

    ULTRA-CUT 200 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 43 ULTRA-CUT 200 XT Unplugging the fiber optic connector. Do not pull on the fiber cable! 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_AB Manual 0-5304 INSTALLATION 3-15...

  • Page 44: Connect Dmc-3000 Fiber Optic Cable To Ccm

    ULTRA-CUT 200 XT 3.12 Connect DMC-3000 Fiber Optic Cable to CCM 1. Remove the bottom plastic plug in the CCM at the rear of the Power Supply. J55 - GCM USER INPUT J15 - CNC HEIGHT CONTROL TSC-3000 Cable J54 - TSC /COMM J59 - RAS CB2 - 5A 120 VAC CB3 - 5A 24 VAC...
  • Page 45 ULTRA-CUT 200 XT CAUTION Avoid kinking, twisting, or bunching the fiber optic cable. The cable can be damaged by being forced into tight-radius turns. 2. Remove outer thin nut from through hole protector at one end of Fiber Optic Cable (L) that connects between the CCM portion of the Power Supply and the DMC-3000.

  • Page 46: Set Switches On The Command - Control Module

    ULTRA-CUT 200 XT 3.13 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. CAUTION Printed circuit boards in the Command - Control Module are static - sensitive.
  • Page 47 ULTRA-CUT 200 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.) SW-11: Set “B”...

  • Page 48: Height Control Connections

    ULTRA-CUT 200 XT 2 - Wire and 4 - Wire settings When used with the TSC-3000 the plug should be in the 2 wire (2W) position shown below. For other CNC controls using 4 wire communication such as the XT iCNC, place the jumper in the 4W position. NOTE! Failure to set in the correct position will result in no communication with the device.

  • Page 49: Dmc-3000 Gas Manifold Control Installation

    ULTRA-CUT 200 XT NOTE! There are holes added in the rear panel for customer wiring. This, rather than the one in the CCM will be the preferred place for customer added wiring (and strain relief) for connections to height controls, etc.. 3.15 DMC-3000 Gas Manifold Control Installation The DMC-3000 Gas Control must be installed in a suitable location where it is easily accessible to the system operator.
  • Page 50 ULTRA-CUT 200 XT 2. Carefully remove the cover from the module noting the attached wire harness that connects to J1. Remove the wire harness and then set the cover to the side. Art # A-09140 3. Attach all hoses and cables to the front of the DMC-3000 except the Fiber Optic cable which will be covered a little later. Avoid turning any fittings already mounted in the unit by placing a wrench on it before tightening the hose fitting to it.
  • Page 51 ULTRA-CUT 200 XT 5. Connect Control cable from the Power Supply to J56 on the front of the DMC-3000 as shown below. The Fiber Optic cable will be covered a little later. Art # A-09142_AB 6. Install WMS Water Softener Kit in the line that feeds the inlet side of the DMC-3000. Mount the softener and bracket on the power supply where the provided 2’...

  • Page 52: Dpc-3000 Gas Pressure Control Installation

    ULTRA-CUT 200 XT 3.16 DPC-3000 Gas Pressure Control Installation The DPC-3000 Gas Control must be installed in a suitable location close to the Torch such as the gantry. The unit must be mounted to a flat horizontal surface. If the Module is mounted to any support subject to vibration or motion, the installer must fasten the module to the support securely.
  • Page 53 ULTRA-CUT 200 XT Preparation 1. Remove the screws securing the Cover Panel to the Module. Remove 2 Screws Loosen or remove 2 screws 2. Carefully remove the cover from the module noting the attached wire harness that connects to J4. Remove the wire harness and then set the cover to the side.
  • Page 54 ULTRA-CUT 200 XT 3. Attach all hoses and cables to the back of the DPC-3000 except the Fiber Optic cable which will be covered a little later. Avoid turning any fittings already mounted in the unit by placing a wrench on it before tightening the hose fitting to it. Do not connect Fiber Optic cable until later Art # A-09146_AB 4.

  • Page 55: Fiber Optic Cable Installation From Ccm To Dmc-3000

    ULTRA-CUT 200 XT 3.17 Fiber Optic Cable Installation from CCM to DMC-3000. CAUTION Avoid kinking, twisting, or bunching the fiber optic cable. The cable can be damaged by being forced into tight-radius turns. Review section 3.10 for proper handling and installation of fiber optic cable.
  • Page 56 ULTRA-CUT 200 XT 4. Secure the thin nut on the through hole protector so both nut faces are tight against the sheet metal inside and out. Art # A-09149_AB 5. Plug the Fiber Optic Cable into the PCB as shown below. Make sure the locking tabs are engaged. Fiber Optic Cable to/from CCM plugs in here Art # A-11999...

  • Page 57: Fiber Optic Cable Installation From Dmc-3000 To Dpc-3000

    ULTRA-CUT 200 XT 3.18 Fiber Optic Cable Installation From DMC-3000 to DPC-3000 1. Remove outer thin nuts from through hole protector at both ends of Fiber Optic Cable (L) that connects between the DCM-3000 and DPC-3000. CAUTION Avoid kinking, twisting, or bunching the fiber optic cable. The cable can be damaged by being forced into tight-radius turns.
  • Page 58 ULTRA-CUT 200 XT 4. Secure each of the thin nuts on the through hole protectors so both nut faces are tight against the sheet metal inside and out. 5. Plug the Fiber Optic Cable into the PCB as shown below for the DMC-3000. Make sure the locking tabs are engaged. Plug Fiber Optic cable to/from DPC-3000 here Art # A-09154 6.

  • Page 59: Install Tsc-3000 Touch Screen Control

    ULTRA-CUT 200 XT 3.19 Install TSC-3000 Touch Screen Control Mounting Dimensions TSC-3000 Profile TSC-3000 Top 1.11 in [28.2 mm] 2.35 in [59.69 mm] 6.99 in 5.58 in [177.5 mm] [141.7 mm] .25 in [6.35 mm] 10.83 in [275.0 mm] 11.80 in [299.7 mm] Art # A-09156 12.45 in...

  • Page 60: Optional He400Xt Cooler

    ULTRA-CUT 200 XT 3.20 Optional HE400XT COOLER Used in series with the existing cooling system of the Ultra-Cut XT™ series power supplies, the optional HE400XT Cooler provides additional 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 61 ULTRA-CUT 200 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 62: Install Remote Arc Starter

    ULTRA-CUT 200 XT 3.21 Install Remote Arc Starter Site Location Select a clean, dry location with good ventilation and adequate working space around all components. Review the safety precautions in the front of this manual to be sure that the location meets all safety requirements. Interconnecting cables and hoses attach to the Arc Starter.
  • Page 63 ULTRA-CUT 200 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. 1.
  • Page 64 ULTRA-CUT 200 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 Coolant Return (Red) Green Coolant Supply (Green)
  • Page 65 ULTRA-CUT 200 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 supplies in parrallel. Slave is not used in single system operations. *Negative (Slave) Pilot *Negative (Master)
  • Page 66 ULTRA-CUT 200 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 67 ULTRA-CUT 200 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. Art # A-04759 Torch Leads Shield Shield Clamp...
  • Page 68 ULTRA-CUT 200 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 CB3 - 5A 24 VAC J70 - HE CB4 - 5A 120 VAC...

  • Page 69: Connecting Torch

    ULTRA-CUT 200 XT 3.22 Connecting Torch Connect the Torch as follows: Coolant Supply, Coolant Return, and Pilot Leads Leads Cover Torch Leads End Cap Shield Gas (Right Hand Thread) Groove for O-Ring Pilot Lead O-Ring Mounting Tube To Torch Valve Plasma Gas (Left Hand Thread) Coolant Supply...
  • Page 70 ULTRA-CUT 200 XT CAUTION The gas and coolant leads include compression fittings. Do not use sealant on these con- nections. 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. 7.

  • Page 71: Install Consumable Torch Parts

    ULTRA-CUT 200 XT 3.23 Install Consumable Torch Parts Install the consumable parts as follows to ensure proper operation. These steps will help ensure that parts are seated correctly. WARNINGS Do not install consumables into the Cartridge while the Cartridge is attached to the Torch Head. Keep foreign materials out of the consumables and Cartridge.
  • Page 72 ULTRA-CUT 200 XT 7. Slide the ohmic clip over the shield cup if using ohmic torch height sensing. 8. Connect the wire lead from the height finder to the ohmic clip if using ohmic torch height sensing. Ohmic Clip Art # A-03393_AB NOTE! Ohmic height sensing is not recommended with water shield.

  • Page 73: Voltage Divider For Ihc Torch Height Control

    ULTRA-CUT 200 XT 3.24 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 74: Control Cable

    ULTRA-CUT 200 XT Control Cable. The iHC board can be supplied with a wire harness and connector (shown in previous image), to be installed in the rear panel hole labeled “Height Control” . The connector mates with a cable from the iHC. For other height control V-D boards a strain relief can be installed in this hole for those cables.

  • Page 75: Complete The Installation

    3.25 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 76 ULTRA-CUT 200 XT This Page Intentionally Blank 3-48 INSTALLATION Manual 0-5304...

  • Page 77: Section 4: Operation

    ULTRA-CUT 200 XT SECTION 4: OPERATION 4.01 Power Supply Control Panel Status Indicator AC Indicator Gas 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 78 ULTRA-CUT 200 XT NOTE! Prior to starting the system determine the process to be used. The process is determined by the type and thickness of the metal to be cut. Select and install the required consumables, connect the required gasses to the system. 1.

  • Page 79: Tsc-3000 Navigation Functions

    ULTRA-CUT 200 XT 4.03 TSC-3000 Navigation Functions PAGE HEADER Art # A-09158 SAMPLE SAMPLE SELECTION NAVIGATION MOVES CURSOR /SELECTION UP AND DOWN ON THE PAGE OR SCROLLS TEXT IN DIALOG BOX WINDOW System Status : IDLE BACK BUTTON REVERSES TO THE PREVIOUS PAGE OK /NEXT BUTTON : INCREMENTS DECREMENTS THE...

  • Page 80: Tsc-3000 Initial Setup Only

    ULTRA-CUT 200 XT 4.04 TSC-3000 Initial Setup ONLY Initial steps required before First operation only. Note 400 Amp system requires a Height Controller with Elevation Height (EH) feature. ENTER/CHANGE PASSWORD HOME When power is turned on TSC 3000 goes to the Home screen.

  • Page 81: Tsc-3000 Selecting New Process

    ULTRA-CUT 200 XT 4.05 TSC-3000 Selecting New Process Select new standard process by material; thickness; amperage (1) or enter process # using pop-up number pad (2). SELECT MATERIAL, THICKNESS HOME Material – Scroll to select, Thic kness – Scroll to select, A ccept &...

  • Page 82: Tsc-3000 Selecting Recently Used Process

    ULTRA-CUT 200 XT 4.06 TSC-3000 Selecting Recently Used Process Home screen shows some of the most recently used processes with the last one used highlighted. Select the highlighted process by pressing the Green arrow or scroll with up/down arrows to select another recent process then press the green arrow. HOME TORCH CONSUMABLES TORCH CONSUMABLES...

  • Page 83: Tsc-3000 Creating A Custom Process

    ULTRA-CUT 200 XT 4.07 TSC-3000 Creating a Custom Process Considerable effort has been made to define the best parameters for each cutting and marking process. However for various rea- sons, variations in material composition, variations in cutting table performance, user preferences, etc. you may desire to modify one or more processes.
  • Page 84 ULTRA-CUT 200 XT HOME CUSTOM PROCESS SETUP Customize Recent Cut. Highlight the process closest to what you want to use then press CUSTOM CUTS button. Select NEW CUT then MATERIAL & THICKNESS. TORCH CONSUMABLES LIST SELECT MATERIAL/THICKNESS Select value to change using UP/DN arrows.

  • Page 85: Back Up And Restoration Of Custom Processes

    ULTRA-CUT 200 XT 4.08 Back up and Restoration of Custom Processes Users can create their own custom cut processes. These can be lost by accidentally deleting them on the TDC 3000 or they can be over written when updating programs. They can also be lost if the DSC 3000 should be replaced. We recommend you back up your custom processes every time a new one is created.
  • Page 86 ULTRA-CUT 200 XT Restoring Custom Processes: During file backup (see previous process) a folder and sub folders called “TD” were placed on your flash drive. You should copy this folder with its subfolders to some secure place. Making more than one copy is advised. If the need arises to restore from this backup, place the entire TD folder in the root directory (not in another folder) on a USB flash drive and plug it into the USB port on the TDC 3000.

  • Page 87: Sequence Of Operation

    ULTRA-CUT 200 XT Art # A-09237 3. Now put the flash drive with the renamed file back into the TSC 3000 and perform the file restore. 4. Go back to the Home screen. You will find your new file name (John Doe’s) and the old name with the same file number [20392].
  • Page 88 ULTRA-CUT 200 XT d) The coolant pump starts and the Gas indicator blinks, and the display shows E304, while the cutting gasses are purged. Purge time varies with the torch lead length and the cutting process. See section 4.04 for setting lead length. When the gas purge ends the E304 goes away but the gas LED may continue blinking if the coolant flow hasn’t been satisfied.
  • Page 89 ULTRA-CUT 200 XT 8. Once purge is complete you are ready to start cutting. a) If marking is desired press button “Go to Marking”. The screen will show recommended CNC/THC setting. Green arrow takes you back to the Cut Monitor set up for Marking. b) To return to cutting on the Cut Monitor press button “Got to Cutting”.

  • Page 90: Gas Selection

    ULTRA-CUT 200 XT 4.10 Gas Selection A. Plasma Gases 1. Air Plasma • Most often used on ferrous or carbon base materials for good quality at faster cutting speeds. • Air plasma is normally used with air shield. • Only clean, dry air is recommended for use as plasma gas. Any oil or moisture in the air supply will substantially reduce torch parts life. • Provides satisfactory results on nonferrous materials. 2. Argon/Hydrogen (H35) Plasma • Recommended for use on 3/4 in (19 mm) and thicker stainless steel. Recommended for 1/2 inch (12 mm) and thicker nonferrous materials. Ar/H2 is not normally used for thinner nonferrous materials because less expensive gases can achieve similar cut quality.

  • Page 91: Ccm Status Codes

    ULTRA-CUT 200 XT 3. Water Shield • Normally used with nitrogen. • Provides very smooth cut surface. • Reduces smoke and heat input to the workpiece. • Effective when used with N2 up to 2 inch (50mm) maximum material thickness. • Tap water provides low operating expense. Operational Suggestions 1. Wait four minutes before setting the ON/OFF switch to OFF after operation. This allows the cooling fans to run to dissipate operating heat from the power supply.
  • Page 92 ULTRA-CUT 200 XT CCM Status Code Group 1 -- Plasma Process Code Message Remedy / Comments Plasma Enable Off ; Disable activated on TSC3000 or GCM 2010 or external Plasma Disabled SW disabled (CNC); CCM TB1-1&2 jumper missing; 40 circuit ribbon cable from Relay PCB to CCM disconnected or defective;...
  • Page 93 ULTRA-CUT 200 XT CCM Status Code Group 2 -- Plasma Power Supply Code Message Remedy / Comments Work Current Too Work lead current detected greater than 16% above process setting. Possible defec- High tive HCT1 Work lead current sensor or Relay PCB; Defective CCM. Work current detected more than 16% below process setting.
  • Page 94 ULTRA-CUT 200 XT CCM Status Code Group 2 -- Plasma Power Supply Code Message Remedy / Comments Inverter 3A Incompat- Unsupported Inverter Revision; Ribbon cable CCM J35 to Inverter Module 3 Section ible Revision A damaged; CCM code version incompatible with Inverter revision or model Inverter 3B Incompat- Unsupported Inverter Revision;...
  • Page 95 ULTRA-CUT 200 XT CCM Status Code Group 2 -- Plasma Power Supply Code Message Remedy / Comments Inverter Input Voltage fault; voltage out of range or missing phase at AC Input of In- Inverter 3A Input Volt- verter Module 3 Section A; Poor AC Power Quality; Defective W2 contactor; Loose or age Error open connection between input terminals and W2 contactor or contactor and input of Inverter Section;...
  • Page 96 ULTRA-CUT 200 XT CCM Status Code Group 2 -- Plasma Power Supply Code Message Remedy / Comments Inverter circuitry is over temperature likely cause is ambient greater than 40 deg Inverter 2B Over Temp C; Reduce power supply cutting Duty Cycle; Reduce ambient air temperature; Add Ambient auxiliary cooler.
  • Page 97 ULTRA-CUT 200 XT CCM Status Code Group 3 -- Gas Controller Status & Protocol Message Code Remedy / Comments Verify Firmware revision for compatibility with GCM 2010 or DMC and DPC; Gas Control command fault Electromagnetic interference with Arc Starter; inspect grounding; bonding; and isolation 310 * DPC fault...
  • Page 98 ULTRA-CUT 200 XT CCM Status Code CCM-Group-5 Gas Controller Communication Port Code Message Remedy / Comments CANBUS Acknowledge Fault CCM to DMC Fiber-optic Control cable not connected, not properly connected or cable defective. DMC power supply or Control PCB defective. Defective CCM, replace. CANBUS Off Dirt on fiber ends or in connectors;...

  • Page 99: Dmc-3000 Status Codes

    ULTRA-CUT 200 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 100 ULTRA-CUT 200 XT DMC Status Code Key Group 1 - DMC Code Message Cause/Remedy Plasma Disabled Enable Plasma; Defective DMC Power Supply (E-Stop relay) 24 VDC fault Check /replace DMC power supply fuse (F2); Replace DMC Power Supply; Replace DMC control PCB 5 VDC fault Check /replace DMC power supply;...

  • Page 101: Dpc-3000 Status Codes

    ULTRA-CUT 200 XT Group 5 - Shorted Solenoid Faults Sol 1 – H35 Plasma Replace solenoid; Shorted wire harness; Defective DMC Control PCB Sol 2 – Oxygen Plasma Replace solenoid; Shorted wire harness; Defective DMC Control PCB Sol 3 – Air Plasma Replace solenoid;...
  • Page 102 ULTRA-CUT 200 XT Group 3 - Inlet Pressure Faults Plasma Gas High (>145 PSI) Reduce pressure from gas supply; defective pressure sensor (PS4). Pilot Gas High (>145 PSI) Reduce pressure from gas supply; defective pressure sensor (PS3). Shield Gas High (>145 PSI) Reduce pressure from gas supply;...
  • Page 103 ULTRA-CUT 200 XT Group 8 - Shield Gas Proportional Valve (V1) Valve open Check for open connection; Replace valve. DPC inlet Supply pressure Raise plasma inlet pressure; check for DMC valve not open; restriction in gas supply/hoses. Outlet pressure too low Valve full open but pressure still too low.

  • Page 104: Remote Arc Starter Trouble Shooting

    ULTRA-CUT 200 XT 4.14 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, Coolant has become conductive Use conductivity meter replace coolant.

  • Page 105: Section 5: Maintenance

    ULTRA-CUT 200 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. Weekly Check O-Rings in Torch and Cartridge Monthly...

  • Page 106: Coolant Replacement Procedure

    ULTRA-CUT 200 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. Disconnect the coolant line at this fitting and drain the coolant into a disposable container of sufficient size.

  • Page 107: Section 6: Replacement Assemblies & Parts

    ULTRA-CUT 200 XT SECTION 6: REPLACEMENT ASSEMBLIES & PARTS 6.01 Replacement Power Supply Complete Unit / Component Catalog Number Ultra-Cut 200 XT Power Supply, 480V +10 -15% 3-8119-2 ™ Ultra-Cut 200 XT Power Supply, 480V +10 -15% with SL100 interface 3-8119-2T ™...

  • Page 108: Leads And Cables All Amperages

    ULTRA-CUT 200 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 Coolant Return Lead, Power Supply to Arc Starter E - Control Cable, Power Supply...
  • Page 109 ULTRA-CUT 200 XT Manual 0-5304 REPLACEMENT PARTS...

  • Page 110: Power Supply External Replacement Parts

    ULTRA-CUT 200 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 100A/200A Panel 9-7302 Lifting Eye 9-9373 Art # A-11968 REPLACEMENT PARTS...

  • Page 111: Power Supply Replacement Parts - Upper Right Side

    ULTRA-CUT 200 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 9-7336 Relay, Inrush 9-7337...

  • Page 112: Power Supply Replacement Parts - Lower Right Side

    ULTRA-CUT 200 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) 9-7423 Motor, Pump (motor only) 9-7424...

  • Page 113: Power Supply Replacement Parts - Rear Panel

    ULTRA-CUT 200 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 J15 - CNC HEIGHT CONTROL J54 - TSC /COMM...

  • Page 114: Power Supply Replacement Parts - Left Side

    ULTRA-CUT 200 XT 6.09 Power Supply Replacement Parts - Left Side Item # Description Ref. Des. Catalog # AC Suppresion PCB 9-9254 Main Contactor 9-7318 Inverter Module, Partial 480 VAC 9-7331 Inverter Module, Full 480 VAC 9-7330 Art # A-11983 REPLACEMENT PARTS Manual 0-5304...

  • Page 115: Dfc-3000 Automated Gas Control System Replacement Components

    ULTRA-CUT 200 XT 6.10 DFC-3000 Automated Gas Control System Replacement Components Item # Description Catalog # Assy, DMC-3000, Demo 9-9491D Assy, DPC-3000, Demo 9-9443D Assy, TSC-3000, Remote, Demo 9-9490D Art # A-09135_AC Manual 0-5304 REPLACEMENT PARTS...

  • Page 116: Dmc-3000 Gas Control Module Replacement Parts

    ULTRA-CUT 200 XT 6.11 DMC-3000 Gas Control Module Replacement Parts Item # Description Catalog # DMC-3000 assembly 9-9491D Solenoid 9-8264 Manifold subassembly (includes 15 of item 2) 9-7546 SMPS PCB 9-8263 Control PCB 9-7291 Not shown: WMS Water Softener Kit (includes the following items) 9-1068 WMS Replacement Filter Cartridge 9-1069...

  • Page 117: Dpc-3000 Gas Control Module Replacement Parts

    ULTRA-CUT 200 XT 6.12 DPC-3000 Gas Control Module Replacement Parts Item # Description Catalog # Assy, DPC-3000, Demo 9-9443D DPC-PCB 9-8262 SMPS PCB 9-8263 Shield Gas P Valve 9-8267 Sensor, Pressure, 1/8mnpt (six total) 9-8269 Solenoid 9-8264 Plasma Lo and Pre-Flow P Valve 9-8268 DPC Manifold Fully Assembled 9-7658...

  • Page 118: Tsc-3000 Touch Screen Control Remote And Internal Replacement Parts

    ULTRA-CUT 200 XT 6.13 TSC-3000 Touch Screen Control Remote and Internal Replacement Parts Item # Description Catalog # Assy, TSC-3000, Remote, Demo 9-9490D Touch Panel Computer 9-7543 Switch, Rocker SPST 9-1042 Ribbon Cable HMI to Interface PCB 9-7547 USB Panel Mount Extension 9-7545 6-12 REPLACEMENT PARTS...

  • Page 119: Remote Arc Starter (Ras-1000) Replacement Parts

    ULTRA-CUT 200 XT 6.14 Remote Arc Starter (RAS-1000) 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 Manual 0-5304 REPLACEMENT PARTS 6-13...

  • Page 120: Optional He400Xt Heat Exchanger - Replacement Parts

    ULTRA-CUT 200 XT 6.15 Optional 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 6-14 REPLACEMENT PARTS Manual 0-5304...

  • Page 121: Torch Maintenance

    ULTRA-CUT 200 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 Shield Cup 2.

  • Page 122: 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 123: Torch Consumables Installation

    ULTRA-CUT 200 XT 7.04 Torch Consumables Installation WARNINGS Do not install consumables into the Cartridge while the Cartridge is attached to the Torch Head. Keep foreign materials out of the consumables and Cartridge. Handle all parts carefully to avoid damage, which may affect torch performance.
  • Page 124 ULTRA-CUT 200 XT 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 125: Coolant Leak Trouble-Shooting

    ULTRA-CUT 200 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 126 ULTRA-CUT 200 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 TORCH INFORMATION Manual 0-5304...

  • Page 127: Appendix 1: Cnc - Control Module Pcb Connections

    ULTRA-CUT 200 XT APPENDIX 1: 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 OK To Move Pilot On Output (Contacts)

  • Page 128: Appendix 2: Serial Communications

    ULTRA-CUT 200 XT APPENDIX 2: SERIAL COMMUNICATIONS A2.01 Cables and Switch Settings for 2 and 4 Wire The CCM communicates with the TSC 3000 (touch screen HMI panel) using RS 485 (2 wire, half duplex). When a CNC controller is used in place of the TSC the CCM can be reconfigured for RS 422 (4 wire, half duplex) if sup- ported by the CNC.
  • Page 129 ULTRA-CUT 200 XT Line termination: RS 485 and RS 422 are both “multi-drop protocols, that is there can be multiple devices on the same line. We do not currently support more than one CCM. Until we do line termination should always be ON. For RS 485 it is recommended that the communication lines be terminated at each end with the line’s characteristic impedance.

  • Page 130: Appendix 3: Cnc

    ULTRA-CUT 200 XT APPENDIX 3: 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 131 ULTRA-CUT 200 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 132: Cnc Input / Output Descriptions

    ULTRA-CUT 200 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 133 ULTRA-CUT 200 XT Plasma Marking Select (Remote) – Plasma Marking, available only with DFC 3000, may be activated with a con- tact closure between TB3-1 & TB3-2 if SW8-4, DIP switch on the CPU board (smaller of the 2 CCM boards), is also on.

  • Page 134: Simplified Cnc Circuit

    ULTRA-CUT 200 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 ) CC Pot W iper CC Pot L ow Di v A rc V (+)
  • Page 135 ULTRA-CUT 200 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 (109) 5-H M I Pl asma Enabl e SW (108)

  • Page 136: Cnc Connections

    ULTRA-CUT 200 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 (+) Corner Current Reduction (-) OK-To-Move Relay...

  • Page 137: Cnc Cable Color Code

    ULTRA-CUT 200 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 WHITE/BLACK/BROWN PREFLOW ON (-) WHITE/BROWN/BLUE...

  • Page 138: Appendix 4: Dmc-3000 Control Pcb Layout

    ULTRA-CUT 200 XT APPENDIX 4: DMC-3000 Control PCB Layout D-17 D_E1 D_E15 Art # A-09188_AB A-12 APPENDIX Manual 0-5304...

  • Page 139: Appendix 5: Dpc-3000 Control Pcb Layout

    ULTRA-CUT 200 XT APPENDIX 5: DPC-3000 Control PCB Layout TP11 TP10 Art # A-09189_AB Manual 0-5304 APPENDIX A-13...

  • Page 140: Appendix 6: Dmc-3000 / Dpc-3000 Power Supply Pcb Layout

    ULTRA-CUT 200 XT APPENDIX 6: DMC-3000 / DPC-3000 Power Supply PCB Layout Art # A-09597 A-14 APPENDIX Manual 0-5304...

  • Page 141: Appendix 7: Tsc-3000 Pcb Layout

    ULTRA-CUT 200 XT APPENDIX 7: TSC-3000 PCB Layout D14 D15 Art # A-09190_AB Manual 0-5304 APPENDIX A-15...

  • Page 142: Appendix 8: Ccm Cpu Pcb Layout

    ULTRA-CUT 200 XT APPENDIX 8: CCM CPU PCB Layout = Test Point Art # A-11675_AB A-16 APPENDIX Manual 0-5304...
  • Page 143 ULTRA-CUT 200 XT CCM CPU PCB Test Points ISO +5.0V +24V +3.3V ISO GND +5.0V TOTAL DEMAND 3.3V=400A TP10 TP11 CPU TEMP SENSE TP12 +3.3VA TP13 -15VDAC TP14 TP15 +15VDAC TP16 CLKO TP18 OSC_CLOCK LED Reference Fiber Out 2 Fiber Out 1 Green Future Use Green Future Use Manual 0-5304...

  • Page 144: Appendix 9: Ccm I/O Pcb Layout

    ULTRA-CUT 200 XT APPENDIX 9: CCM I/O PCB Layout = Test Point A-18 APPENDIX Manual 0-5304...
  • Page 145 ULTRA-CUT 200 XT CCM I/O PCB J Connectors Test Points BASIC CNC EXTENDED CNC RELAY - INTERFACE BOARD /COOLANT FANS ON ARC / TIP VOLTS /TORCH PUMP ON TEST LOW COOLANT FLOW (SW) GAS BOX COOLANT FLOW SIGNAL (PULSE) TO CPU +15V ISOLATED TO CPU -15V ISOLATED...

  • Page 146: Appendix 10: Pilot Pcb Layout

    ULTRA-CUT 200 XT APPENDIX 10: Pilot PCB Layout = Test Point Art # A-11677 A-20 APPENDIX Manual 0-5304...
  • Page 147 ULTRA-CUT 200 XT Pilot PCB Test Points PILOT GATE LED Reference Green PILOT ENABLE Green +5V Manual 0-5304 APPENDIX A-21...

  • Page 148: Appendix 11: Relay And Interface Pcb Layout

    ULTRA-CUT 200 XT APPENDIX 11: Relay and Interface PCB Layout = Test Point Art # A-11678_AB A-22 APPENDIX Manual 0-5304...
  • Page 149 ULTRA-CUT 200 XT Relay and Interface PCB Test Points -15V +5VDC +12V +24V +15V +5VDC LED Reference Green 1 TORCH GAS ON Green PILOT ENABLE Green PILOT CURRENT DETECTED Green WORK CURRENT DETECTED Green CONTACTORS ON Green RF ON Green FANS ON Green PLASMA ENABLED Green 1 TORCH ON Green TORCH COOLANT ON...

  • Page 150: Appendix 12: Display Pcb Layout

    ULTRA-CUT 200 XT APPENDIX 12: Display PCB Layout = Test Point Art # A-11679 A-24 APPENDIX Manual 0-5304...
  • Page 151 ULTRA-CUT 200 XT Display PCB Test Points +5VDC +24VDC Manual 0-5304 APPENDIX A-25...

  • Page 152: Appendix 13: System Bias Pcb Layout

    ULTRA-CUT 200 XT APPENDIX 13: System Bias PCB Layout = Test Point Art # A-11680 A-26 APPENDIX Manual 0-5304...
  • Page 153 ULTRA-CUT 200 XT System Bias PCB Test Points 24VDC DC INPUT POSITIVE Vcc1 Vcc2 GATE PRIMARY GND +12V PRIMARY P_ISOL_GND TP10 DC SENSE POSITIVE LED Reference MISSING PHASE AC V HIGH AC V LOW Green VAC_IDA Green +12V PRIMARY Green VAC_IDB Green 24VDC Green TRANSFORMER ON Manual 0-5304...

  • Page 154: Appendix 14: Main Inverter Bottom Pcb Layout

    ULTRA-CUT 200 XT APPENDIX 14: Main Inverter Bottom PCB Layout = Test Point A-28 APPENDIX Manual 0-5304...
  • Page 155 ULTRA-CUT 200 XT Main Inverter Bottom PCB Test Points GATE 2A GATE 1A GATE 3A GATE 4A GATE 2B GATE 1B GATE 4B GATE 3B TP10 +12VP TP11 +12VDC TP12 THERMISTOR SIDE A TP13 THERMISTOR SIDE B TP14 +5VDC TP15 PGND LED Reference CAP IMBALANCE...

  • Page 156: Appendix 15: Main Inverter Top Pcb Layout

    ULTRA-CUT 200 XT APPENDIX 15: Main Inverter Top PCB Layout = Test Point A-30 APPENDIX Manual 0-5304...
  • Page 157 ULTRA-CUT 200 XT Main Inverter Top PCB Test Points GATE 2A GATE 1A GATE 3A GATE 4A GATE 2B GATE 1B GATE 4B GATE 3B TP10 +12VP TP11 +12VDC TP12 THERMISTOR SIDE A TP13 THERMISTOR SIDE B TP14 +5VDC TP15 PGND LED Reference CAP IMBALANCE...

  • Page 158: Appendix 16: Control And Fault Pcb Layout

    ULTRA-CUT 200 XT APPENDIX 16: Control and Fault PCB Layout = Test Point Art # A11683_AB A-32 APPENDIX Manual 0-5304...
  • Page 159 ULTRA-CUT 200 XT Control and Fault PCB Test Points 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 TP34 SHDN TP35 ENABLE...

  • Page 160: Appendix 17: Cap Bias Bottom Pcb Layout

    ULTRA-CUT 200 XT APPENDIX 17: Cap Bias Bottom PCB Layout Art # A-11685_AB A-34 APPENDIX Manual 0-5304...

  • Page 161: Appendix 18: Cap Bias Top Pcb Layout

    ULTRA-CUT 200 XT APPENDIX 18: Cap Bias Top PCB Layout Art # A-11686_AB Manual 0-5304 APPENDIX A-35...

  • Page 162: Appendix 19: Suppressor Pcb Layout

    ULTRA-CUT 200 XT APPENDIX 19: Suppressor PCB Layout Art # A-11684_AB A-36 APPENDIX Manual 0-5304...

  • Page 163: Appendix 20: Cooling Diagram

    ULTRA-CUT 200 XT APPENDIX 20: COOLING DIAGRAM Manual 0-5304 APPENDIX A-37...

  • Page 164: Appendix 21: Remote Arc Starter Schematic

    ULTRA-CUT 200 XT APPENDIX 21: 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 (98) (49) (52)
  • Page 165 ULTRA-CUT 200 XT This Page Intentionally Blank Manual 0-5304 APPENDIX A-39...

  • Page 166: Appendix 22: Schematic, Dfc-3000 Auto Gas Box System

    ULTRA-CUT 200 XT APPENDIX 22: Schematic, DFC-3000 Auto Gas Box System DMC3000 - MANIFOLD CONTROLLER ASSEMBLY 19X2367 755x000 ULTRACUT POWER SUPPLY CONTROL CABLE (JMP) PLASMA ENABLE + Power Supply PCB (19X2384) LEDS 120VAC DMC PLASMA ENABLE - See list by DPC 3000 Power Supply 120VAC DMC RET (2a) 19X2384...
  • Page 167 Scale Supersedes Supersedes Supersedes CONDUCTOR FOR EACH ASSEMBLY TO STAR GND. Information Proprietary to THERMAL DYNAMICS CORPORATION. Information Proprietary to THERMAL DYNAMICS CORPORATION. Information Proprietary to THERMAL DYNAMICS CORPORATION. 2: KEEP GROUNDS AS SHORT AS POSSIBLE. Friday, December 08, 2006...

  • Page 168: Appendix 23: System Schematic 200A, 480V

    ULTRA-CUT 200 XT APPENDIX 23: System Schematic 200A, 480V PG 1 INVERTER MODULE (IM) #2 half module (middle position) J105A AC INPUT (23) IM #2 Section A (lower) J100 -- 30 CKT RIBBON J104A (24) J103A (25) 019X502000 INVERTER MODULE (IM) #1 (bottom) J105B IM #1 Section B (upper) AC INPUT...
  • Page 169 ULTRA-CUT 200 XT TORCH (49) PILOT BOARD LED'S TEST POINTS (49) TORCH TP1 GND To TB4-7 TP2 PILOT GATE D2 PILOT ENABLE TP3 +5V D11 +5V PILOT ELECTRODE To TB4-6 PILOT PCB J58A (52) R3 & R4 J41 (J87) J58C CHASSIS GND (50) CHASSIS GND...

  • Page 170: Appendix 24: System Schematic 200A, 480V

    ULTRA-CUT 200 XT APPENDIX 24: System Schematic 200A, 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 & 8 230 VAC -- 18 AWG wires in pins 1,5,2,6 (89) COOLANT LEVEL...
  • Page 171 ULTRA-CUT 200 XT TO PILOT PCB J70 - HE Sht 1, B8) (70) 230 VAC to HE 400 (70) Fan Control 230 VAC _ SW (D2) 230 VAC Ret 230 VAC _ SW _ RET (D2) ARC_SUPPRESSOR Pump Motor Control J59 - RAS CHASSIS GND (96)

  • Page 172: Appendix 25: Advanced Troubleshooting

    ULTRA-CUT 200 XT APPENDIX 25: 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 173 ULTRA-CUT 200 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 174 ULTRA-CUT 200 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 175 ULTRA-CUT 200 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). Optional 1Torch module Starting early in 2015 all the Auto-Cut 300 XT and Ultra-Cut XT models may be ordered from the factory with an optional module allowing connecting an SL100 “1Torch”...
  • Page 176 ULTRA-CUT 200 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. A number of the measurements will require probing of some small connectors or measuring signal on ribbon cables.
  • Page 177 ULTRA-CUT 200 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 178 ULTRA-CUT 200 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 179 ULTRA-CUT 200 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) (57) PLASMA ENABLE GREEN...
  • Page 180 ULTRA-CUT 200 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. 2.
  • Page 181 ULTRA-CUT 200 XT Either Arc Starter 5. /RAS ON signal not on. CCM sends active low signal “ /RAS ON” over the 40 pin ribbon cable on pin 16 to the Relay & Interface board. On the relay board RAS Control relay (K2) closes (RF ON LED, D23 on) sending 120 VAC to J8-3 with return on J8-11.
  • Page 182 ULTRA-CUT 200 XT 8. If “ /RAS ON” signal is low on pin 16 of the 40 pin ribbon cable, relative to TP1 on the CCM I/O board, during the ignition time then we need to determine if the Relay board is defective. If /RAS ON signal is not low the CCM or the 40 pin ribbon cable may be defective.
  • Page 183 ULTRA-CUT 200 XT Lost Pilot Code 103 occurs when Pilot has ignited as sensed by the pilot current sensor on the Pilot board , but went out on its own while CNC Start is still active before the pilot timeout (85 ms. or 3 sec.). Possible causes: •...
  • Page 184 ULTRA-CUT 200 XT Not Used. This is one of the reserved codes from the earlier product. Pilot Timeout, no Transfer Pilot time is limited to either 0.085 seconds (85 ms.) with CCM SW8-1 off (default for pierce starting) or 3 seconds with SW8-1 on (used for cutting over holes, expanded metal, etc.).
  • Page 185 ULTRA-CUT 200 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. o A leak of the preflow/plasma gas after the pressure/flow control (GCM 2010, DPC, GCM 1000 XT) can reduce the pressure/flow to the torch because some if it is bypassing the torch, while seeming to have enough pressure/flow at the gas control.
  • Page 186 ULTRA-CUT 200 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 187 ULTRA-CUT 200 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 188 ULTRA-CUT 200 XT 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 189 ULTRA-CUT 200 XT Unwanted current signal due to defective sensor or defective circuit boards will most likely be present as soon as the power up sequence completes and will be indicated as an active fault, E208. An actual short allowing real current to flow in the pilot circuit will not occur until the inverter and pilot board are enabled near the end of preflow.
  • Page 190 ULTRA-CUT 200 XT 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. Individual inverter sections have their own current sensors and the work lead has a current sensor whose signal should equal the sum of the individual inverter sections.
  • Page 191 ULTRA-CUT 200 XT Troubleshooting: 1. If it reports the current of an individual inverter section is too high, the problem is the inverter. 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 192 ULTRA-CUT 200 XT 231-236 Inverter VAC Mismatch. Different inverter modules are manufactured for 480VAC, 380-415VAC & 208-230VAC operation voltages. There is a key, called inverter ID, read through the inverter’s ribbon cable, to identify which voltage range the inverter is designed for. The unit itself is wired differently for the different input voltages and part of that includes a jumper at J61 on the System Bias board that indicates to the System Bias board what voltage the unit is wired to accept.
  • Page 193 ULTRA-CUT 200 XT Too Few Inverters Found There must be a minimum of 2 inverter sections present to operate. We know the ribbon cable for inverter sec- tion 1A is connected or else we would have code 224. During the power up sequence, before power is connected to the inverters, the CCM does a continuity test through the ribbon cable to see if an inverter is connected.
  • Page 194 ULTRA-CUT 200 XT AC Voltage High Voltage OK -- At power up the System Bias board measures the input voltage and determined if it is within the range of voltage set by the J16 jumper. See section 231-236 Inverter VAC Mismatch Troubleshooting step 1.a for details of the jumper.
  • Page 195 ULTRA-CUT 200 XT AC Voltage Low Refer to the first paragraph for code 239 for explanation of what should happen when the input voltage is correct. Voltage Low -- If the System Bias board determines AC voltage is too low it lights a red LED, D14, ACV LOW, and sets the signal “AC V LOW b”...
  • Page 196 ULTRA-CUT 200 XT 241-246 Inverter Section Input Voltage Error. The System Bias board checks for input voltage high, low or missing a phase from the power coming in from the power cord. It is unlikely but not impossible that a problem with the incoming power could result in 241-246 codes.
  • Page 197 ULTRA-CUT 200 XT Possible causes: • Cooling fan(s) not operating. • Disrupted air flow. • Defective inverter module. • Inverter Ribbon cable bad connection. • Defective CCM. Originally 100 and 200A units had 2 smaller fans while 300 & 400A used a single larger fan along with a larger radiator.
  • Page 198 ULTRA-CUT 200 XT 4. To test TS2 remove J2 from the Relay board and measure the resistance between pins 4 & 6 of the J2 harness connector. The resistance varies from about 33K ohms at 0 degrees C to about 12K ohms at 20C to 5.3K ohms at 40C.
  • Page 199 ULTRA-CUT 200 XT 4. The inverter section may be defective with a bad bias supply. Swap the inverter end of the ribbon cable with one next to it. a. If it now reports a different code, that of the inverter that was swapped with, then the original section is bad.
  • Page 200 ULTRA-CUT 200 XT Gas Control communications reply fault Communication has been established but Gas Control did not reply to a request from the CCM in the time al- lowed. Likely cause is Fiber-optic problems (see code 501) or if problem persists defective Gas Control main PCB. Gas Pressure fault Gas pressure faults only show up when you try to start the torch, not during purging or setting flows .
  • Page 201 ULTRA-CUT 200 XT Gas Control Communication reply fault. Relay doesn’t match what was requested. Possible firmware incompatibility. Consult factory for latest firm- ware update. Possible electromagnetic interference from the Arc Starter; inspect grounding; bonding; and isolation. 310-313 DFC 3000 Auto Gas Faults. These different codes displayed on the power simply indicate one of the Auto Gas modules (DPC for codes 310 or 311;...
  • Page 202 ULTRA-CUT 200 XT Troubleshooting: 1. Confirm visually that the level switch float is below the coolant, if not add more coolant to the tank. 2. Check J7 on the Relay board. a. If properly connected remove J7 and check continuity between pins 2 and 4 (pins 2 & 3 of J71 on the switch itself).
  • Page 203 ULTRA-CUT 200 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 204 ULTRA-CUT 200 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 205 ULTRA-CUT 200 XT Damaged Coolant Tube Coolant tube includes a check valve at its upper end. When cartridge with consumables is not installed the spring loaded coolant tube is fully extended closing the check valve preventing coolant from leaking out. When consumables are in place they push the tube inward, opening the check valve, allowing coolant to flow.
  • Page 206 ULTRA-CUT 200 XT This test measures the “dead head” or blocked flow pressure at the rear panel coolant supply fitting. Perform this test only after the coolant system is fully primed, that is after the coolant is circulated throughout the system and is mostly free of bubbles.
  • Page 207 ULTRA-CUT 200 XT Coolant Flow Low Warning This code is a warning, it does not prevent cutting but if it persists the cause should be investigated. Ultra-Cut XT units, in addition to a coolant flow switch, include a turbine flow sensor FL1, referred to in the plumbing diagram as a “bubble sensor”, with a pulse output that accurately measures coolant flow and in addition can detect the presence of gas bubbles in the coolant.
  • Page 208 ULTRA-CUT 200 XT 3. GCM 2010. 4. CANBUS / Fiber-optic communication errors can be difficult to troubleshoot, especially when they are intermittent. See “Test the Fiber” below. Things to look for are: a. The connectors not locked in place at either end of the fiber. b.
  • Page 209 ULTRA-CUT 200 XT Reserved for future use. Should not get this but if it happens may be due to EMI. Contact customer service. Group 6 codes relate to the CCM and program updates. One exception is 619 which is a coolant flow switch FS1 fault.
  • Page 210 ULTRA-CUT 200 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 211 ULTRA-CUT 200 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 212 ULTRA-CUT 200 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 213 ULTRA-CUT 200 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. 1.
  • Page 214 ULTRA-CUT 200 XT Contact Start Consumable Fault. As explained above, a circuit on the Relay Board applies -15VDC to the electrode and expects to see that voltage on the tip insuring the electrode, start cartridge and tip are in place and making electrical contact. 1.
  • Page 215 ULTRA-CUT 200 XT ii. Remove power. Remove J11 from the Relay Board. On the J11 harness connector measure for resis- tance of 400-800 ohms between pins 8 & 9. Do not use the meters diode scale. If resistance is less than 400 ohms reverse your leads, you may be measuring the diode D202.

  • Page 216: Appendix 26: Sl100 Interconnection

    ULTRA-CUT 200 XT APPENDIX 26: 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 / Main torch Idle 1 Torch (201) / Press OK 1 Torch...
  • Page 217 ULTRA-CUT 200 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) / 1 Torch START wires (for noise) when (205)

  • Page 218: Appendix 27: He 400 Xt Connection

    ULTRA-CUT 200 XT APPENDIX 27: 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 11/25/2014 Drawn Date...

  • Page 219: Appendix 28: 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 220 ULTRA-CUT 200 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 which does not allow tip to work contact, and allows cutting with the full 100A With the standard standoff 100A tip, if it comes in contact with the work the current is reduced to 40A to prevent damage to the tip.
  • Page 221 ULTRA-CUT 200 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 222 ULTRA-CUT 200 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 223 ULTRA-CUT 200 XT Inlet Port Regulator/Filter Assembly Hose Clamp 1/4 NPT to 1/4" Gas Supply (6mm) Fitting Hose Art # A-12760 Single Stage Air Filter Attachment Manual 0-5304 APPENDIX A-97...

  • Page 224: Replacement Parts

    ULTRA-CUT 200 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-98 APPENDIX Manual 0-5304...
  • Page 225 ULTRA-CUT 200 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) Assembled Filter Cover Barbed...

  • Page 226: Appendix 29: Publication History

    Section 3 updated cable hose art all per ECOB2694. May 27, 2015 AG 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 228 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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