Thermal Dynamics ULTRA-CUT 400 XT User Manual

Name: Thermal Dynamics ULTRA-CUT 400 XT
Brand: Thermal Dynamics
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214 pages

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ULTRA-CUT 400 XT

™

PLASMA CUTTING SYSTEM

Operating

Manual

Revision: AH Issue Date: May 27, 2015 Manual No.: 0-5275

480V

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 Torch21
- Specifications & Electrical Requirements21
- Power Supply Dimensions22
- Power Supply Rear Panel Features23
- Gas Requirements24
- Gas Applications24
- XT Torch Specifications25
Section 3: Installation27
- Installation Requirements27
- System Layout28
- Recommended Gas Supply Hose29
- Leads and Cables All Amperage29
- Lift the Power Supply30
- Connect Input Power and Ground Cables31
- Connect Work Cable and Pilot and Negative Leads32
- Ground Connections33
- Connect Coolant Leads36
- Connect Cables for CNC, Remote Arc Starter, GCM and HE 40037
- Handling and Installation of Fiber Optics38
- Correct Installation40
- Set Switches on the Command - Control Module41
- Height Control Connections43
- Gas Control Module Installation44
- Fiber Optic Cable Installation46
- Gas Control Module: Control, Input, and Output Connections48
- He400Xt Cooler49
- Install Remote Arc Starter51
- Torch Valve Installation58
- Connecting Torch60
- Install Consumable Torch Parts61
- Voltage Divider for Ihc Torch Height Control64
- Complete the Installation66
Section 4: Operation67
- Power Supply Control Panel67
- System Operation68
- Gas Selection70
- GCM 2010 Gas Control Module Operation72
- GCM 2010 First Time Operation Matching Gas Control to Lead Length76
- GCM 2010 Sequence of Operation76
- Power Supply Status Codes79
- Remote Arc Starter Trouble Shooting87
Section 5: Maintenance89
- General Maintenance89
- External Coolant Filter Cleaning Procedure89
- Coolant Replacement Procedure90
Section 6: Replacement Assemblies & Parts91
- Replacement Power Supply91
- System Layout92
- Recommended Gas Supply Hose92
- Leads and Cables All Amperages93
- Power Supply External Replacement Parts95
- Power Supply Replacement Parts - Upper Right Side96
- Power Supply Replacement Parts - Lower Right Side97
- Power Supply Replacement Parts - Rear Panel98
- Power Supply Replacement Parts - Left Side99
- Gas Control Module (GCM-2010) Replacement Parts100
- Gas Control Module (GCM-2010) Replacement Parts101
- Remote Arc Starter (RAS-1000 XT) Replacement Parts102
- HE400XT Heat Exchanger - Replacement Parts103
- XTL Torch Valve Assembly External Replacement Parts104
- XTL Torch Valve Assembly Internal Replacement Parts105
Torch Maintenance107
- Consumable Removal107
- Section 7: Torch Maintenance107
- O-Ring Lubrication108
- Parts Wear109
- Torch Consumables Installation110
- Coolant Leak Trouble-Shooting112
APPENDIX 1: Remote Arc Starter Schematic115
APPENDIX 2: Gas Control and Torch Valve Schematic116
APPENDIX 3: Gas Control Module Plumbing Diagram118
APPENDIX 4: Gas Control Module PCB Layout119
APPENDIX 5: Gas Control Display Module PCB Layout120
APPENDIX 6: CNC - Control Module PCB Connections121
Appendix 7: Cnc122
- CNC Functions122
- CNC Input / Output Descriptions124
- Simplified CNC Circuit126
- CNC Connections128
- CNC Cable Color Code129
APPENDIX 8: CCM CPU PCB Layout130
APPENDIX 9: CCM I/O PCB Layout132
APPENDIX 10: Pilot PCB Layout134
APPENDIX 11: Relay and Interface PCB Layout136
APPENDIX 12: Display PCB Layout138
APPENDIX 13: System Bias PCB Layout140
APPENDIX 14: Main Inverter Bottom PCB Layout142
APPENDIX 15: Main Inverter Top PCB Layout144
APPENDIX 16: Control and Fault PCB Layout146
APPENDIX 17: Cap Bias Bottom PCB Layout148
APPENDIX 18: Cap Bias Top PCB Layout149
APPENDIX 19: Suppressor PCB Layout150
Appendix 20: Cooling Diagram151
APPENDIX 21: System Schematic 400A, 480V152
APPENDIX 22: System Schematic 400A, 480V154
Appendix 23: Advanced Troubleshooting156
Appendix 24: Sl100 Interconnection202
Appendix 25: He 400 Xt Connection204
APPENDIX 26: SL100 Torch Option205
- Replacement Parts210
Appendix 27: Publication History212

Brand	Thermal Dynamics
Model	ULTRA-CUT 400 XT
Category	Welding System
Language	English

Thermal Dynamics ULTRA-CUT 400 XT User Manual

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