Name: Thermal Dynamics ULTRA-CUT 200 XT™
Brand: Thermal Dynamics
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ULTRA-CUT 200 XT

Manual 0-5304 APPENDIX A-17

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 /RD

TP11 CPU TEMP SENSE

TP12 +3.3VA

TP13 -15VDAC

TP14 PC2

TP15 +15VDAC

TP16 CLKO

TP18 OSC_CLOCK

LED Reference

D2 Red RXD

D3 Red TXD

D4 Red Fiber Out 2

D7 Red Fiber Out 1

D11 Green Future Use

D17 Green Future Use

Default Chapter4
- User Responsibility4
- Table of Contents7
Section 1: Safety11
- Safety Precautions - ENGLISH11
- Précautions de Sécurité - FRENCH CANADIAN16
Section 2: Specifications21
- General Description of the System21
- Plasma Power Supply21
- Remote Arc Starter21
- Gas Control Module21
- Precision Plasma Cutting Torch22
- Specifications & Electrical Requirements22
- Power Supply Dimensions23
- Power Supply Rear Panel Features24
- Gas Requirements25
- Gas Applications25
- XT Torch Specifications26
Section 3: Installation29
- Installation Requirements29
- System Layout30
- Recommended Gas Supply Hose30
- Leads and Cables All Amperage31
- Lift the Power Supply32
- Connect Input Power and Ground Cables33
- Connect Work Cable and Pilot and Negative Leads34
- Ground Connections35
- Connect Coolant Leads38
- Connect Cables for CNC, Remote Arc Starter, DMC-3000 and HE 40039
- Handling and Installation of Fiber Optics40
- Correct Installation42
- Connect DMC-3000 Fiber Optic Cable to CCM44
- Set Switches on the Command - Control Module46
- Height Control Connections48
- DMC-3000 Gas Manifold Control Installation49
- DPC-3000 Gas Pressure Control Installation52
- Fiber Optic Cable Installation from CCM to DMC-300055
- Fiber Optic Cable Installation from DMC-3000 to DPC-300057
- Install TSC-3000 Touch Screen Control59
- Optional HE400XT COOLER60
- Install Remote Arc Starter62
- Connecting Torch69
- Install Consumable Torch Parts71
- Voltage Divider for Ihc Torch Height Control73
- Control Cable74
- Complete the Installation75
Section 4: Operation77
- Power Supply Control Panel77
- System Operation77
- TSC-3000 Navigation Functions79
- TSC-3000 Initial Setup ONLY80
- TSC-3000 Selecting New Process81
- TSC-3000 Selecting Recently Used Process82
- TSC-3000 Creating a Custom Process83
- Back up and Restoration of Custom Processes85
- Sequence of Operation87
- Gas Selection90
- CCM Status Codes91
- DMC-3000 Status Codes99
- DPC-3000 Status Codes101
- Remote Arc Starter Trouble Shooting104
Section 5: Maintenance105
- General Maintenance105
- External Coolant Filter Cleaning Procedure105
- Coolant Replacement Procedure106
Section 6: Replacement Assemblies & Parts107
- Replacement Power Supply107
- System Layout107
- Recommended Gas Supply Hose107
- Leads and Cables All Amperages108
- Power Supply External Replacement Parts110
- Power Supply Replacement Parts - Upper Right Side111
- Power Supply Replacement Parts - Lower Right Side112
- Power Supply Replacement Parts - Rear Panel113
- Power Supply Replacement Parts - Left Side114
- Dfc-3000 Automated Gas Control System Replacement Components115
- DMC-3000 Gas Control Module Replacement Parts116
- DPC-3000 Gas Control Module Replacement Parts117
- TSC-3000 Touch Screen Control Remote and Internal Replacement Parts118
- Remote Arc Starter (RAS-1000) Replacement Parts119
- Optional HE400XT Heat Exchanger - Replacement Parts120
Torch Maintenance121
- Consumable Removal121
- O-Ring Lubrication122
- Parts Wear122
- Torch Consumables Installation123
- Coolant Leak Trouble-Shooting125
Appendix 1: Cnc - Control Module Pcb Connections127
Appendix 2: Serial Communications128
- A2.01 Cables and Switch Settings for 2 and 4 Wire128
Appendix 3: Cnc130
- CNC Functions130
- CNC Input / Output Descriptions132
- Simplified CNC Circuit134
- CNC Connections136
- CNC Cable Color Code137
Appendix 4: DMC-3000 Control Pcb Layout138
Appendix 5: Dpc-3000 Control Pcb Layout139
Appendix 6: DMC-3000 / Dpc-3000 Power Supply Pcb Layout140
Appendix 7: Tsc-3000 Pcb Layout141
Appendix 8: CCM Cpu Pcb Layout142
Appendix 9: CCM I/O Pcb Layout144
Appendix 10: Pilot Pcb Layout146
Appendix 11: Relay and Interface Pcb Layout148
Appendix 12: Display Pcb Layout150
Appendix 13: System Bias Pcb Layout152
Appendix 14: Main Inverter Bottom Pcb Layout154
Appendix 15: Main Inverter Top Pcb Layout156
Appendix 16: Control and Fault Pcb Layout158
Appendix 17: Cap Bias Bottom Pcb Layout160
Appendix 18: Cap Bias Top Pcb Layout161
Appendix 19: Suppressor Pcb Layout162
Appendix 20: Cooling Diagram163
Appendix 21: Remote Arc Starter Schematic164
Appendix 22: Schematic, Dfc-3000 Auto Gas Box System166
Appendix 23: System Schematic 200A, 480V168
Appendix 24: System Schematic 200A, 480V170
Appendix 25: Advanced Troubleshooting172
Appendix 26: Sl100 Interconnection216
Appendix 27: He 400 Xt Connection218
Appendix 28: Sl100 Torch Option219
- Replacement Parts224
Appendix 29: Publication History226

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

Thermal Dynamics ULTRA-CUT 200 XT™ User Manual

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