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

Manual 0-5275 REPLACEMENT PARTS 6-15

6.15 XTL Torch Valve Assembly Internal Replacement Parts

NOTE!

The XTL Torch Valve Assembly requires Firmware versions 3.2 or higher for the C.C.M. and 3.1

or higher for the GCM 2010. It also requires the resetting of DIP switches in the C.C.M..

Item # Qty Description Catalog #

1 1 Exhaust Mufﬂer 9-3321

2 2 Solenoid 9-3319

3 3 Solenoid 9-9392

Art # A-07651

SOL18

SOL19

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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