Thermal Dynamics ULTRA-CUT 100 User Manual

144 pages

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300

Operating Manual

PLASMA CUTTING SYSTEM

ULTRA-CUT

™

Rev. AG.01 Date: July 10, 2007 Manual # 0-4819

Operating Features:

Art # A-04816

Table of Contents5
General Information9
- 1.01 Notes, Cautions and Warnings9
- 1.02 Important Safety Precautions9
- 1.03 Publications11
- 1.04 Declaration of Conformity13
- 1.05 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 Specifications20
Section 3: Installation23
- Installation Requirements23
- Cooling System Requirements23
- System Layout24
- Cables & Leads Identification25
- Lift the Power Supply26
- E -1. Set Switches on the Command - Control Module (Type 1 Module)27
- E -2. Set Switches on the Command - Control Module (Type 2 Module)29
- Remove the Connections Cover31
- Connect Work Cable and Pilot and Negative Leads32
- Check / Adjust Input Voltage Configuration33
- Connect Input Power and System Ground Cables34
- Ground Connections35
- Connect Coolant Leads37
- Connect Control Cables for CNC, Remote Arc Starter, and GCM38
- Gas Control Module Installation41
- Fiber Optic Cable Installation42
- Gas Control Module: Control, Input, and Output Connections45
- Install Remote Arc Starter46
- Original & XTL Torch Valve Installation55
- Connecting Torch56
- Install Consumable Torch Parts58
- Complete the Installation62
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 Selection74
- Power Supply Status Codes75
- Remote Arc Starter: Service Chart78
- Remote Arc Starter: Spark Gap Adjustment79
Section 5: Maintenance81
- External Coolant Filter Cleaning Procedure81
- Internal Coolant Filter Cleaning Procedure82
- Coolant Replacement Procedure82
Section 6: Replacement Assemblies & Parts83
- System Layout84
- Leads and Cables85
- Optional Gas Supply Leads90
- Power Supply External Replacement Parts91
- Power Supply Replacement Parts - Right Side92
- Power Supply Replacement Parts - Right Side94
- Power Supply Replacement Parts - Front Panel95
- Power Supply Replacement Parts - Right Side97
- Power Supply Replacement Parts - Rear Panel98
- Power Supply Replacement Parts - Right Side99
- Power Supply Replacement Parts100
- Power Supply Replacement Parts - Right Side101
- Power Supply Replacement Parts102
- Power Supply Replacement Parts - Right Side103
- Power Supply Replacement Parts - Right Side104
- Gas Control Module (GCM-2010) Replacement Parts105
- Remote Arc Starter (RAS-1000) Replacement Parts107
- Command & Control Module Type 1- Replacement Parts109
- Command & Control Module Type 2 - Replacement Parts110
- Torch Valve Assembly Replacement Parts111
- XTL Torch Valve Assembly External Replacement Parts112
- XTL Torch Valve Assembly Internal Replacement Parts113
Section 7: Torch Maintenance115
- Consumable Removal115
- O-Ring Lubrication116
- Parts Wear116
- Torch Consumables Installation117
- Coolant Leak Trouble-Shooting119
APPENDIX 1: Remote Arc Starter Schematic121
APPENDIX 2: Gas Control and Torch Valve Schematic122
APPENDIX 3: Gas Control Module124
APPENDIX 4: Gas Control Module PCB Layout125
APPENDIX 5: Gas Control Display Module PCB Layout126
APPENDIX 6: CCM CPU PCB Layout127
APPENDIX 7: CCM Input-Output PCB Layout128
APPENDIX 8: CNC - Control Module PCB Connections129
- CNC Functions130
- CNC Input / Output Descriptions131
- Simplified CNC Circuit132
APPENDIX 9: Schematic, 230-460V Power Supply134
APPENDIX 10: Schematic, CCC 400V Power Supply136
APPENDIX 11: Schematic, CE 400V Power Supply138
APPENDIX 12: Schematic, CSA 600V Power Supply140
APPENDIX 13: Publication History142
- Global Customer Service Contact Information143

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Thermal Dynamics ULTRA-CUT 100 Specifications

General

Open Circuit Voltage (OCV)	300V
Input Voltage	208-480V
Output Current	100A
Rated Output Voltage	140V
Cutting Capacity (Mild Steel)	1" (25 mm)
Severance Capacity (Mild Steel)	1-1/4" (32 mm)
Gas Type	Air, Nitrogen, Oxygen
Duty Cycle	60% @ 100 A
Weight	79 lbs (36 kg)
Dimensions (H x W x D)	15" x 12" x 25" (381 x 305 x 635 mm)