Name: Thermal Dynamics 200 ULTRA-CUT
Brand: Thermal Dynamics
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Manual 0-5056 A-38 APPENDIX

APPENDIX 15: PUBLICATION HISTORY

Cover Date Rev Change(s)

Jan. 7, 2008 AA First issue

Jan. 14, 2008 AB Added flow meter replacement parts per ECOB704.

Jan. 28, 2008 AC Per ECOB738 updated GCM plumbing diagram in Appendix.

Feb. 5, 2008 AD Per ECOB646 added input terminal strip information to sections 3 and 6.

Table of Contents5
General Information9
- Notes, Cautions and Warnings9
- Important Safety Precautions9
- Publications11
- Declaration of Conformity13
- Statement of Warranty14
Section 2: Specifications15
- General Description of the System15
- Plasma Power Supply15
- Remote Arc Starter15
- Gas Control Module15
- Precision Plasma Cutting Torch15
- Specifications & Electrical Requirements16
- System Component Layout16
- Power Supply Dimensions17
- Power Supply Rear Panel Features18
- Gas Requirements19
- Gas Applications19
- XTTM-300 Torch Specifications22
Section 3: Installation23
- Installation Requirements23
- System Layout24
- Cables & Leads Identification25
- Lift the Power Supply26
- Remove the Connections Cover27
- Ground Connections32
- Connect Work Cable and Pilot and Negative Leads34
- Connect Coolant Leads35
- Connect Control Cables for CNC, Remote Arc Starter, and GCM36
- Connect Fiber Optic Cable (Type 2 Internal Control Module)37
- Set Switches on the Command - Control Module (Type 2 Module)38
- Height Control Connections40
- Gas Control Module Installation41
- Fiber Optic Cable Installation43
- Gas Control Module: Control, Input, and Output Connections45
- Install Remote Arc Starter46
- Original & XTL Torch Valve Installation55
- Connecting Torch57
- Install Consumable Torch Parts59
- Complete the Installation63
Section 4: Operation65
- Power Supply Control Panel65
- Start-Up Sequence66
- Gas Control Module Operation67
- Gas Control Module: Controls & Indicators68
- Sequence of Operation71
- Nitride Build-Up72
- Gas Selection73
- Power Supply Status Codes74
- Remote Arc Starter: Service Chart78
- Remote Arc Starter: Spark Gap Adjustment79
Section 5: Maintenance81
- Periodic Checks81
- External Coolant Filter Cleaning Procedure81
- Internal Coolant Filter Cleaning Procedure82
- Coolant Replacement Procedure82
Section 6: Replacement Assemblies & Parts83
- Main Component / System Replacement83
- System Layout84
- Leads and Cables85
- Recommended Gas Supply Hose85
- Power Supply External Replacement Parts90
- Power Supply Replacement Parts - Right Side91
- Power Supply Replacement Parts - Right Side92
- Power Supply Replacement Parts - Right Side93
- Power Supply Replacement Parts - Front Panel94
- Power Supply Replacement Parts - Front Panel95
- Power Supply Replacement Parts - Right Side96
- Power Supply Replacement Parts - Rear Panel97
- Power Supply Replacement Parts - Right Side98
- Power Supply Replacement Parts99
- Power Supply Replacement Parts - Right Side100
- Power Supply Replacement Parts101
- Power Supply Replacement Parts - Right Side102
- Gas Control Module (GCM-2010) Replacement Parts103
- Gas Control Module (GCM-2010) Replacement Parts104
- Remote Arc Starter (RAS-1000) Replacement Parts105
- Remote Arc Starter (RAS-1000) Replacement Parts106
- Command & Control Module Type 2 - Replacement Parts107
- XTL Torch Valve Assembly External Replacement Parts108
- XTL Torch Valve Assembly Internal Replacement Parts109
Section 7: Torch Maintenance111
- Consumable Removal111
- O-Ring Lubrication112
- Parts Wear112
- Torch Consumables Installation113
- Coolant Leak Trouble-Shooting115
APPENDIX 1: Remote Arc Starter Schematic117
APPENDIX 2: Gas Control and Torch Valve Schematic118
APPENDIX 3: Gas Control Module120
APPENDIX 4: Gas Control Module PCB Layout121
APPENDIX 5: Gas Control Display Interface PCB Layout122
APPENDIX 6: CCM CPU PCB Layout123
APPENDIX 7: CCM Input / Output PCB Layout124
APPENDIX 8: CNC - Control Module PCB Connections125
- CNC Functions126
- CNC Input / Output Descriptions127
- Simplified CNC Circuit128
APPENDIX 9: Schematic: 230/460V Unit W/ Chopper Pilot W/ Diode130
APPENDIX 9: Schematic: 230/460V Unit W/ Chopper Pilot W/ Diode Continued132
APPENDIX 10: Schematic: 230/460V Unit W/ Resistor Pilot134
APPENDIX 10: Schematic: 230/460V Unit W/ Resistor Pilot Continued136
APPENDIX 11: Schematic: CCC 400V Unit W/ Chopper Pilot138
APPENDIX 11: Schematic: CCC 400V Unit W/ Chopper Pilot Continued140
APPENDIX 12: Schematic: CE 400V Unit W/ Chopper Pilot142
APPENDIX 12: Schematic: CE 400V Unit W/ Chopper Pilot Continued144
APPENDIX 13: Schematic: CE 400V Unit W/ Resistor Pilot146
APPENDIX 13: Schematic: CE 400V Unit W/ Resistor Pilot Continued148
APPENDIX 14: Schematic: CSA 600V Unit W/ Chopper Pilot150
APPENDIX 14: Schematic: CSA 600V Unit W/ Chopper Pilot Continued152
Appendix 15: Publication History154
- Global Customer Service Contact Information155

Brand	Thermal Dynamics
Model	200 ULTRA-CUT
Category	Welding System
Language	English

Thermal Dynamics 200 ULTRA-CUT User Manual

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