Name: Thermal Dynamics ULTRA-CUT 100
Brand: Thermal Dynamics
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Manual No. 0-4819 3-16 INSTALLATION

L. Connect Control Cables for CNC, Remote Arc Starter, and GCM

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 of the cable. Do not ground to the

Plasma Power Supply.

RETURN

SUPPLY

Art # A-04802

To CNC

To Remote Arc Starter

To Gas Control Module

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

Brand	Thermal Dynamics
Model	ULTRA-CUT 100
Category	Welding System
Language	English

Thermal Dynamics ULTRA-CUT 100 User Manual

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