Tweco 200 Ultra-Cut(March 2013) Manuel d'utilisateur

Art# A-08586_ACPLASMA CUTTING SYSTEM& AUTOMATED GAS CONTROL200ULTRA-CUT™Operating ManualRev. AK Date: March 13, 2013 Manual # 0-5133Operating Fea

ULTRA-CUT 2001-2Manual 0-5133• Provide a fire watch when working in an area where fire hazardsmay exist.• Hydrogen gas may be formed and trapped under

Manual No. 0-5133 Ultra-Cut 200 6-2 Power Supply Parts ListULTRA-CUT 2006.02 System LayoutRefer to section 3.05 for ground connections and ground cabl

Manual No. 0-5133 Ultra-Cut 200 6-3 Power Supply Parts ListULTRA-CUT 2006.04 Leads and CablesGreen / Yellow #4 AWG (16 mm2)Green / Yellow 1/0 (50 mm2

Manual No. 0-5133 Ultra-Cut 200 6-4 Power Supply Parts ListULTRA-CUT 200Key Description Catalog #A,B,C,D,E Supply Lead Set, 4’ / 1.3 m (See Note 1) 4-

Manual No. 0-5133 Ultra-Cut 200 6-5 Power Supply Parts ListULTRA-CUT 200Key Description Catalog #C Hose, Coolant Supply, (only), 50’ / 15.2 m 9-4786C

Manual No. 0-5133 Ultra-Cut 200 6-6 Power Supply Parts ListULTRA-CUT 200Key Description Catalog #G Assembly, Torch Lead, 10’ / 3.05 m 4-3053G Assembly

Manual No. 0-5133 Ultra-Cut 200 6-7 Power Supply Parts ListULTRA-CUT 200Key Description Catalog #L Control Cable, Fiber Optic, 3’ / 1 m 9-4898L Contro

Manual No. 0-5133 Ultra-Cut 200 6-8 Power Supply Parts ListULTRA-CUT 200Key Description Catalog #Q Shield Gas Hose 10’ / 3.05 m 9-7277Q Shield Gas Ho

Manual No. 0-5133 Ultra-Cut 200 6-9 Power Supply Parts ListULTRA-CUT 200Key Description Catalog #T Water Shield 10’ / 3.05 m 9-6985T Water Shield 15

Manual No. 0-5133 Ultra-Cut 200 6-10 Power Supply Parts ListULTRA-CUT 2006.05 Power Supply External Replacement PartsItem # Qty Description Catalog #1

Manual No. 0-5133 Ultra-Cut 200 6-11 Power Supply Parts ListULTRA-CUT 2006.06 Power Supply Replacement Parts - Right SideItem # Qty Description

ULTRA-CUT 2001-3Manual 0-5133THAT HAVE HELD HAZARDOUS SUBSTANCES, obtainablefrom the American Welding Society, 550 N.W. LeJeune Rd,Miami, FL 3312615.

Manual No. 0-5133 Ultra-Cut 200 6-12 Power Supply Parts ListULTRA-CUT 2006.07 Power Supply Replacement Parts - Right SideItem # Qty Description Ref. D

Manual No. 0-5133 Ultra-Cut 200 6-13 Power Supply Parts ListULTRA-CUT 2006.08 Power Supply Replacement Parts - Right Side Item # Qty Description

Manual No. 0-5133 Ultra-Cut 200 6-14 Power Supply Parts ListULTRA-CUT 2006.09 Power Supply Replacement Parts - Front Panel Item # Qty Description

Manual No. 0-5133 Ultra-Cut 200 6-15 Power Supply Parts ListULTRA-CUT 2006.10 Power Supply Replacement Parts - Front Panel Item # Qty Description

Manual No. 0-5133 Ultra-Cut 200 6-16 Power Supply Parts ListULTRA-CUT 2006.11 Power Supply Replacement Parts - Right Side Item # Qty Description Ref

Manual No. 0-5133 Ultra-Cut 200 6-17 Power Supply Parts ListULTRA-CUT 2006.12 Power Supply Replacement Parts - Rear Panel Item # Qty Description

Manual No. 0-5133 Ultra-Cut 200 6-18 Power Supply Parts ListULTRA-CUT 2006.13 Power Supply Replacement Parts - Right Side Item # Qty Description

Manual No. 0-5133 Ultra-Cut 200 6-19 Power Supply Parts ListULTRA-CUT 2006.14 Power Supply Replacement PartsItem # Qty Description Catalog #29 2 Inver

Manual No. 0-5133 Ultra-Cut 200 6-20 Power Supply Parts ListULTRA-CUT 2006.15 Power Supply Replacement Parts - Right Side Item # Qty Description

Manual No. 0-5133 Ultra-Cut 200 6-21 Power Supply Parts ListULTRA-CUT 2006.16 Power Supply Replacement Parts Item # Qty Description

ULTRA-CUT 2001-4Manual 0-5133• Montez et maintenez le matériel conformément au Code électriquenational des Etats-Unis. (Voir la page 5, article 9.)•

Manual No. 0-5133 Ultra-Cut 200 6-22 Power Supply Parts ListULTRA-CUT 2006.17 Power Supply Replacement Parts - Right Side Item # Qty Description

Manual No. 0-5133 Ultra-Cut 200 6-23 Power Supply Parts ListULTRA-CUT 2006.18 DFC-3000 Automated Gas Control System ReplacementComponantsItem # Qty De

Manual No. 0-5133 Ultra-Cut 200 6-24 Power Supply Parts ListULTRA-CUT 2006.19 DMC-3000 Gas Control Module Replacement PartsItem # Qty Description Cata

Manual No. 0-5133 Ultra-Cut 200 6-25 Power Supply Parts ListULTRA-CUT 2006.20 DPC-3000 Gas Control Module Replacement PartsItem # Qty Description Cata

Manual No. 0-5133 Ultra-Cut 200 6-26 Power Supply Parts ListULTRA-CUT 2006.21 TSC-3000 Touch Screen Control Remote and Internal ReplacementPartsItem #

Manual No. 0-5133 Ultra-Cut 200 6-27 Power Supply Parts ListULTRA-CUT 2006.22 Remote Arc Starter (RAS-1000) Replacement PartsItem # Qty Description Ca

Manual No. 0-5133 Ultra-Cut 200 6-28 Power Supply Parts ListULTRA-CUT 2006.23 Remote Arc Starter (RAS-1000) Replacement PartsItem # Qty Description Ca

Manual No. 0-5133 Ultra-Cut 200 6-29 Power Supply Parts ListULTRA-CUT 2006.24 Command & Control Module - Replacement PartsItem # Qty Descriptio

Manual No. 0-5133 Ultra-Cut 200 6-30 Power Supply Parts ListULTRA-CUT 200Intentionally Blank

Manual 0-5056 Ultra-Cut 200 7-1 TORCH INFORMATIONULTRA-CUT 200SECTION 7: TORCH MAINTENANCE7.01 Consumable Removal1. Use the removal tool to hold

ULTRA-CUT 2001-5Manual 0-51331.06 Documents De ReferenceConsultez les normes suivantes ou les révisions les plus récentes ayantété faites à celles-ci

TORCH INFORMATION 7-2 Manual 0-5056 Ultra-Cut 200ULTRA-CUT 2007.02 O-Ring LubricationLubricate all three O-Rings on the Cartridge Assembly and all th

Manual 0-5056 Ultra-Cut 200 7-3 TORCH INFORMATIONULTRA-CUT 2007.04 Torch Consumables InstallationArt # A-03887

TORCH INFORMATION 7-4 Manual 0-5056 Ultra-Cut 200ULTRA-CUT 2002, Remove the Removal Tool from the Cartridge and install the assembled Cartridge onto

Manual 0-5056 Ultra-Cut 200 7-5 TORCH INFORMATIONULTRA-CUT 200Amperage Plasma Gas Recommended Wear Depth

TORCH INFORMATION 7-6 Manual 0-5056 Ultra-Cut 200ULTRA-CUT 200This page is blank intentionally.

Manual 0-5133 A-1 APPENDIXULTRA-CUT 200APPENDIX 1: Remote Arc Starter Schematic5544332211D DC CB BA ANEG (from PS)120 VAC120 VAC RETCHASSIS GNDPILO

APPENDIX A-2 Manual 0-5133ULTRA-CUT 200APPENDIX 2: DMC-3000 PCB LayoutJ1J9TP6J5J6SW2J8TP5J2TP3TP2TP4J3J4SW1TP7TP1Art # A-09188_ABLEDD1D-17LEDD_E1D_E

Manual 0-5133 A-3 APPENDIXULTRA-CUT 200APPENDIX 3: DPC-3000 PCB LayoutTP6J5J6SW2TP5TP3TP2TP4SW1TP8TP1Art # A-09189_ABJ1J2J3J4J9J8TP7TP9TP10TP11J10D

APPENDIX A-4 Manual 0-5133ULTRA-CUT 200APPENDIX 4: TSC-3000 PCB LayoutTP4TP1TP3J1J2J3TP2J4J5Art # A-09190_ABD1D11D13D14D15

Manual 0-5133 A-5 APPENDIXULTRA-CUT 200APPENDIX 5: CCM Input / Output PCB LayoutArt # A-09187_ABTP7TP6J1SW6SW12J36TB1TB2J4J9TP11J5J6J7 SW11TP9J8TP12

ULTRA-CUT 2001-6Manual 0-51331.07 Declaration of ConformityManufacturer: Thermal Dynamics CorporationAddress: 82 Benning StreetWest Lebanon, New Hamps

APPENDIX A-6 Manual 0-5133ULTRA-CUT 200APPENDIX 6: CCM CPU PCB LayoutTP11TP2TP1TP3TP4TP5TP6TP7TP8J2J3J1TP9TP10TP13TP12TP14TP15SwitchesONON121SW3121

Manual 0-5133 A-7 APPENDIXULTRA-CUT 200Art # A-04900_ACTB1-1 E-Stop (Com)TB1-2 E-StopTB1-3 OK 2 Contacts 24V MaxTB1-4 Stop LatchedTB1-5 S

APPENDIX A-8 Manual 0-5133ULTRA-CUT 200APPENDIX 7: CNCA7.01 CNC functionsCNC I/O circuits provide at least 1000V galvanic isolation from the plasma p

Manual 0-5133 A-9 APPENDIXULTRA-CUT 200Function ConnectionOK to Move (Contacts or DC Volts) TB2-10(-); TB2-12(+)Plasma Marking Remote Select TB3-1: T

APPENDIX A-10 Manual 0-5133ULTRA-CUT 2005 +10V @ 10ma. For Remote CC Pot – Previously CCM versions if one wanted to use a potentiometer for the Remo

Manual 0-5133 A-11 APPENDIXULTRA-CUT 200A7.04 CNC Connections.A-07632Start Motion(OK-To-Move)Cutting Machine CNC CablePower SupplyShieldJ151349678131

APPENDIX A-12 Manual 0-5133ULTRA-CUT 200APPENDIX 8: SERIAL COMMUNICATIONSA8.01 Cables and Switch Settings for 2 and 4 WireThe CCM communicates with

Manual 0-5133 A-13 APPENDIXULTRA-CUT 200Recommend using the 4 wire when possible as it is easier to troubleshoot if there is a problem. Note that CCM

APPENDIX A-14 Manual 0-5133ULTRA-CUT 200APPENDIX 9: Schematic, 230-460V, Chopper Pilot1122334455ABCDEF-15VINPUT_NG+5VGND+15V+15V+15VMISSING_PHASE/ 23

Manual 0-5133 A-15 APPENDIXULTRA-CUT 200667788991010ABCDEFN2P1+12V-12VSIGNALCOMMONI_sensePIref_GGNDWP_enaGND_CTEMP_CGNDWIsense_W-15Vw+15Vw+15Vw-15VwI

ULTRA-CUT 2001-7Manual 0-51331.08 Statement of WarrantyLIMITED WARRANTY: Thermal Dynamics® Corporation (hereinafter “Thermal”) warrants that its prod

APPENDIX A-16 Manual 0-5133ULTRA-CUT 200APPENDIX9: Schematic, 230-460V, Chopper Pilot Cont.1122334455ABCDEF460AC120 @ 1AAC13V @ 2A/PUMP+15V+15V460/FA

Manual 0-5133 A-17 APPENDIXULTRA-CUT 200667788991010ABCDEFPLASMA ENABLEPRESS OK (GCM 1000)24VAC24 VAC RETPLASMA ENABLE+15V/ AC/ TEMP/ STATUS/ DC/ GAS

APPENDIX A-18 Manual 0-5133ULTRA-CUT 200APPENDIX 10: Schematic, CCC 400V, w/ Chopper Pilot1122334455ABCDEF-15VINPUT_NG+5VGND+15V+15V+15VMISSING_PHASE

Manual 0-5133 A-19 APPENDIXULTRA-CUT 200667788991010ABCDEFN2P1+12V-12VSIGNALCOMMONI_sensePIref_GGNDWP_enaGND_CTEMP_CGNDWIsense_W-15Vw+15Vw+15Vw-15VwI

APPENDIX A-20 Manual 0-5133ULTRA-CUT 200APPENDIX 10: Schematic, CCC 400V, w/ Chopper PilotCont.1122334455ABCDEF400AC120V @ 1AAC13V @ 2A/PUMP+15V+15V

Manual 0-5133 A-21 APPENDIXULTRA-CUT 200667788991010ABCDEFPLASMA ENABLEPRESS OK (GCM 1000)24VAC24 VAC RETPLASMA ENABLE+15V/ AC/ TEMP/ STATUS/ DC/ GAS

APPENDIX A-22 Manual 0-5133ULTRA-CUT 200APPENDIX 11: Schematic, CE 400V, Chopper Pilot1122334455ABCDEF-15VINPUT_NG+5VGND+15V+15V+15VMISSING_PHASE/ 20

Manual 0-5133 A-23 APPENDIXULTRA-CUT 200667788991010ABCDEFN2P1+12V-12VSIGNALCOMMONI_sensePIref_GGNDWP_enaGND_CTEMP_CGNDWIsense_W-15Vw+15Vw+15Vw-15VwI

APPENDIX A-24 Manual 0-5133ULTRA-CUT 200APPENDIX 11: Schematic, CE 400V, Chopper Pilot Cont.1122334455ABCDEF400AC120 @ 1AAC13V @ 2A/PUMP+15V+15V400/F

Manual 0-5133 A-25 APPENDIXULTRA-CUT 200667788991010ABCDEFPLASMA ENABLEPRESS OK (GCM 1000)24VAC24 VAC RETPLASMA ENABLE+15V/ AC/ TEMP/ STATUS/ DC/ GAS

ULTRA-CUT 2001-8Manual 0-5133

APPENDIX A-26 Manual 0-5133ULTRA-CUT 200APPENDIX 12: Schematic, CSA 600V, Chopper Pilot1122334455ABCDEF-15VINPUT_NG+5VGND+15V+15V+15VMISSING_PHASE/ 2

Manual 0-5133 A-27 APPENDIXULTRA-CUT 200667788991010ABCDEF+12V-12VSIGNALCOMMONI_sensePIref_GGNDWP_enaGND_CTEMP_CGNDWIsense_W-15Vw+15Vw+15Vw-15VwIsens

APPENDIX A-28 Manual 0-5133ULTRA-CUT 200APPENDIX 12: Schematic, CSA 600V, Chopper Pilot Cont.1122334455ABCDEF600AC120V @ 1AAC13V @ 2A/PUMP+15V+15V60

Manual 0-5133 A-29 APPENDIXULTRA-CUT 200667788991010ABCDEFPLASMA ENABLEPRESS OK (GCM 1000)24VAC24 VAC RETPLASMA ENABLE+15V/ AC/ TEMP/ STATUS/ DC/ GAS

APPENDIX A-30 Manual 0-5133ULTRA-CUT 200APPENDIX 13: Schematic, DFC-3000 Auto Gas Box System112233ABCD(S15T)(S14B)(S14T)(S13T)(S12B)(S12T)(S11T)(S10B

Manual 0-5133 A-31 APPENDIXULTRA-CUT 200Art # A-09197445566ABCDBLKPURPLEORANGEBLKPURPLEORANGEBLKPURPLEORANGEBLKPURPLEORANGEBLKPURPLEBLKPURPLEORANGEBL

APPENDIX A-32 Manual 0-5133ULTRA-CUT 200APPENDIX 14: PUBLICATION HISTORYCover DateCover DateCover DateCover DateCover DateRevRevRevRevRevChange(s)Ch

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THE AMERICASDenton, TX USAU.S. Customer CarePh: 1-800-426-1888 (tollfree)Fax: 1-800-535-0557 (tollfree)International Customer CarePh: 1-940-381-1212F

Manual No. 0-5133 Ultra-Cut 200 2-1 SPECIFICATIONSSECTION 2: SPECIFICATIONS2.01 General Description Of The SystemA typical Ultra-Cut® 200 system confi

Manual No. 0-5133 Ultra-Cut 200 2-2 SPECIFICATIONS2.06 Specifications & Electrical RequirementsMaximum OCV (U0) 380 vdcMaximum Output Current 200

Manual No. 0-5133 Ultra-Cut 200 2-3 SPECIFICATIONS2.07 System Component LayoutRefer to section 3.11 for ground connections and ground cables.Primary p

WE APPRECIATE YOUR BUSINESS!Congratulations on your new Thermal Dynamics product. We areproud to have you as our customer and will strive to provide y

Manual No. 0-5133 Ultra-Cut 200 2-4 SPECIFICATIONS2.08 Power Supply DimensionsArt # A-0718237.75 inch 960 mm27.5 inch 700 mm33 inch 840 mm27 inch 680

Manual No. 0-5133 Ultra-Cut 200 2-5 SPECIFICATIONS2.09 Power Supply Rear Panel FeaturesTerminal Cover Support PanelCoolant TankCoolant FilterCoolant C

Manual No. 0-5133 Ultra-Cut 200 2-6 SPECIFICATIONS2.10 Gas RequirementsThe customer will provide all gases and pressure regulators. Gases must be of

Manual No. 0-5133 Ultra-Cut 200 2-7 SPECIFICATIONS2.12 XTTM-300 Torch SpecificationsA. Torch Dimensions2.25"57.15 mm2.0"50.8 mm2.39"60.

Manual No. 0-5133 Ultra-Cut 200 2-8 SPECIFICATIONSB. Torch Leads LengthsFeet Meters10 3.0515 4.625 7.635 10.650 15.275 22.8100 30.4125 38.2150 45.7175

Manual No. 0-5133 Ultra-Cut 200 2-9 SPECIFICATIONSF. XTTM-300 Torch Data (with Ultra-CutTM 200 Power Supply)AmbientTemperature104° F40° CDuty Cycle 10

Manual No. 0-5133 Ultra-Cut 200 2-10 SPECIFICATIONSThis Page Intentionally Blank

Manual No. 0-5133 3-1 INSTALLATIONULTRA-CUT 200SECTION 3: INSTALLATION3.01 Installation RequirementsElectric SupplyThe electrical supply network, the

INSTALLATION 3-2 Manual No. 0-5133ULTRA-CUT 2003.02 System LayoutRefer to section 3.05 for ground connections and ground cables.Cooling System Require

Manual No. 0-5133 3-3 INSTALLATIONULTRA-CUT 2003.03 Cables & Leads IdentificationGreen / Yellow #4 AWG (16 mm2)Green / Yellow 1/0 (50 mm2)AGreenR

! WARNINGSRead and understand this entire Manual and your employer’s safety practices beforeinstalling, operating, or servicing the equipment.While t

INSTALLATION 3-4 Manual No. 0-5133ULTRA-CUT 2003.04 Lift the Power SupplyWARNINGSDo not touch live electrical parts.Disconnect input power conductors

Manual No. 0-5133 3-5 INSTALLATIONULTRA-CUT 2003.05 Remove the Connections CoverThe primary power cable must be supplied by the end user and connected

INSTALLATION 3-6 Manual No. 0-5133ULTRA-CUT 200Check / Adjust Input Voltage Configuration for 208/230 and 460V Systems1. The 208/230 and 460 V power s

Manual No. 0-5133 3-7 INSTALLATIONULTRA-CUT 200Connect Input Power and System Ground Cables1. Carefully cut back the outer sheath on the primary input

INSTALLATION 3-8 Manual No. 0-5133ULTRA-CUT 2003.06 Connect Work Cable and Pilot and Negative Leads1. Pass the ends of the work cable and pilot and ne

Manual No. 0-5133 3-9 INSTALLATIONULTRA-CUT 2003.07 Ground Connections0 - 10 ft (0 - 3 m) Ideal20 ft (6 m) Maximum1/0Ground CablePower Supply‘Star’Gro

INSTALLATION 3-10 Manual No. 0-5133ULTRA-CUT 2003. The cutting machine frame is then connected to the “Star” point using 1/0 AWG (European 50 mm2) or

Manual No. 0-5133 3-11 INSTALLATIONULTRA-CUT 200This test assumes the 115 or 230 VAC source neutral is connected to the utility earth ground.Art # A-0

INSTALLATION 3-12 Manual No. 0-5133ULTRA-CUT 2003.08 Connect Coolant Leads1. Connect the color-coded coolant hoses to the coolant connections on the p

Manual No. 0-5133 3-13 INSTALLATIONULTRA-CUT 2003.09 Connect Control Cables for CNC, Remote Arc Starter, and DMC-30001. Connect one end of each cable

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INSTALLATION 3-14 Manual No. 0-5133ULTRA-CUT 2003.10 Connect TSC-3000 Cable and DMC-3000 Fiber Optic Cable toCCM1. Remove the plastic plug in the CCM

Manual No. 0-5133 3-15 INSTALLATIONULTRA-CUT 2003. Feed the Fiber Optic Cable plug and wires through the hole where the plastic plug was removed label

INSTALLATION 3-16 Manual No. 0-5133ULTRA-CUT 2003.11 Set Switches on the Command - Control ModuleCompare the command - control module to the illustrat

Manual No. 0-5133 3-17 INSTALLATIONULTRA-CUT 200 CAUTIONPrinted circuit boards in the Command - Control Module are static - sensitive. Discharge an

INSTALLATION 3-18 Manual No. 0-5133ULTRA-CUT 2003.12 Height Control ConnectionsThe terminal strip has Arc Volts (-) connection to power supply negativ

Manual No. 0-5133 3-19 INSTALLATIONULTRA-CUT 200Mounting Dimensions5.00 in[127.0 mm]7.08 in[179.8 mm] 12.18 in[309.4 mm]11.44 in[290.6 mm].30 in[7.62

INSTALLATION 3-20 Manual No. 0-5133ULTRA-CUT 2002. Carefully remove the cover from the module noting the attached wire harness that connects to J1. R

Manual No. 0-5133 3-21 INSTALLATIONULTRA-CUT 200NOTEAll gas fittings are 1/4” and the air fitting is 3/8”.4. Connect the ground cable to rear of DMC-3

INSTALLATION 3-22 Manual No. 0-5133ULTRA-CUT 2003.14 DPC-3000 Gas Pressure Control InstallationThe DPC-3000 Gas Control must be installed in a suitabl

Manual No. 0-5133 3-23 INSTALLATIONULTRA-CUT 200Preparation1. Remove the screws securing the Cover Panel to the Module.Loosen or remove 2 screwsRemove

TABLE OF CONTENTSSECTION 1:GENERAL INFORMATION ... 1-11.0

INSTALLATION 3-24 Manual No. 0-5133ULTRA-CUT 2003. Attach all hoses and cables to the back of the DPC-3000 except the Fiber Optic cable which will be

Manual No. 0-5133 3-25 INSTALLATIONULTRA-CUT 2003.15 Fiber Optic Cable Installation from CCM to DMC-3000.1. Remove outer thin nut from through hole pr

INSTALLATION 3-26 Manual No. 0-5133ULTRA-CUT 2004. Secure the thin nut on the through hole protector so both nut faces are tight against the sheet met

Manual No. 0-5133 3-27 INSTALLATIONULTRA-CUT 200Art # A-09151After

INSTALLATION 3-28 Manual No. 0-5133ULTRA-CUT 2003.16 Fiber Optic Cable Installation From DMC-3000 to DPC-30001. Remove outer thin nuts from through ho

Manual No. 0-5133 3-29 INSTALLATIONULTRA-CUT 2004. Secure each of the thin nuts on the through hole protectors so both nut faces are tight against the

INSTALLATION 3-30 Manual No. 0-5133ULTRA-CUT 2003.17 Install TSC-3000 Touch Screen ControlMounting Dimensions6.99 in[177.5 mm]TSC-3000 Profile5.58 in[

Manual No. 0-5133 3-31 INSTALLATIONULTRA-CUT 2003.18 Install Remote Arc StarterSite LocationSelect a clean, dry location with good ventilation and ade

INSTALLATION 3-32 Manual No. 0-5133ULTRA-CUT 200InstallationThe Remote Arc Starter must be installed in a suitable location near the torch head. If t

Manual No. 0-5133 3-33 INSTALLATIONULTRA-CUT 2004. Use pre-drilled holes in at least two of the feet on the bottom of the Arc Starter to secure the Ar

TABLE OF CONTENTS (continued)SECTION 4: OPERATION ...

INSTALLATION 3-34 Manual No. 0-5133ULTRA-CUT 200Coolant Return (Red) Coolant Supply (Green) Art # A-09628GreenRedArt # A-09629Negative Cable from powe

Manual No. 0-5133 3-35 INSTALLATIONULTRA-CUT 200Art # A-09630Pilot Return Cablefrom Power supplyPILOT Return Cable (from Power Supply rear panel)Art #

INSTALLATION 3-36 Manual No. 0-5133ULTRA-CUT 200Output Connections1. Refer to the illustrations. Make the following output connections to the Arc Sta

Manual No. 0-5133 3-37 INSTALLATIONULTRA-CUT 200Art # A-09633Some items are removed for clarity.Coolant Supply Fitting(Tagged with Green)Coolant Retur

INSTALLATION 3-38 Manual No. 0-5133ULTRA-CUT 200The Arc Starter must be grounded; the grounding terminal is marked . Refer to the previous section

Manual No. 0-5133 3-39 INSTALLATIONULTRA-CUT 200Connect Control Cable1. Connect the Remote Arc Starter cable to the Remote Arc Starter receptacle.Art

INSTALLATION 3-40 Manual No. 0-5133ULTRA-CUT 2003.19 Connecting TorchConnect the Torch as follows:Art # A-09198Pilot Lead ConnectorTorch Head Assembly

Manual No. 0-5133 3-41 INSTALLATIONULTRA-CUT 2006. Connect the gas and coolant leads to the Torch Head.a. Coolant supply and return connections to the

INSTALLATION 3-42 Manual No. 0-5133ULTRA-CUT 2001. Check the appropriate cut chart for the right combination of parts for the cutting application.2. S

Manual No. 0-5133 3-43 INSTALLATIONULTRA-CUT 20055 - 100 Amp Parts AssemblyCartridge Covers O-Ring on Torch TipShield Cap Protrudes 0.063-0.083"

TABLE OF CONTENTS (continued)SECTION 7: TORCH MAINTENANCE ... 7-1

INSTALLATION 3-44 Manual No. 0-5133ULTRA-CUT 2007. Connect the wire lead from the height finder to the ohmic clip if using ohmic torch heightsensing.O

Manual No. 0-5133 3-45 INSTALLATIONULTRA-CUT 2003.21 Complete the Installation1. Remove the cap from the coolant tank. Fill the coolant tank to the

INSTALLATION 3-46 Manual No. 0-5133ULTRA-CUT 2002. After the complete system has been installed, check that the coolant has been pumped through thesys

Manual No. 0-5133 4-1 OPERATIONULTRA-CUT 200SECTION 4: OPERATION4.01 Power Supply Control PanelArt # A-04862AC IndicatorTemp IndicatorGas IndicatorDC

OPERATION 4-2 Manual No. 0-5133ULTRA-CUT 2004.02 Start-Up Sequence1. Connect system to primary input power.2. Turn ON/OFF switch to ON (up) position.

Manual No. 0-5133 4-3 OPERATIONULTRA-CUT 2004.04 TSC-3000 Initial Setup ONLYInitial steps required before First operation only. Note 400 Amp system re

OPERATION 4-4 Manual No. 0-5133ULTRA-CUT 2004.05 TSC-3000 Selecting New ProcessArt # A -09160Select process by # (2) or by name (3). If by name, first

Manual No. 0-5133 4-5 OPERATIONULTRA-CUT 2004.06 TSC-3000 Selecting Recently Used ProcessArt # A-09161HOME1TORCH CONSUMABLESCheck that you have the co

OPERATION 4-6 Manual No. 0-5133ULTRA-CUT 2004.07 TSC-3000 Creating a Custom ProcessConsiderable effort has been made to define the best parameters for

Manual No. 0-5133 4-7 OPERATIONULTRA-CUT 200Art # A -09162Customize Recent Cut. Highlight the process closest to what you want to use then press CU

NOTESection 8, Torch operation, is provided separately.

OPERATION 4-8 Manual No. 0-5133ULTRA-CUT 2004.08 Back up and Restoration of Custom Processes.Users can create their own custom cut processes. These c

Manual No. 0-5133 4-9 OPERATIONULTRA-CUT 200Restoring Custom Processes:During file backup (see previous process) a folder and sub folders called “TD”

OPERATION 4-10 Manual No. 0-5133ULTRA-CUT 200Renaming Custom FilesYou cannot rename the files while on the TSC 3000 but once you backup a file on the

Manual No. 0-5133 4-11 OPERATIONULTRA-CUT 2004.09 Sequence of OperationUltracut with DFC 3000 using TSC 3000The purpose of this section is to explain

OPERATION 4-12 Manual No. 0-5133ULTRA-CUT 2003. Turn on 3 phase power at the main disconnect (Plasma Enable on TSC 3000 Disabled).a) AC indicator on f

Manual No. 0-5133 4-13 OPERATIONULTRA-CUT 20010. Changing torch consumables:Following a consumables change or inspection the system will initiate a pu

OPERATION 4-14 Manual No. 0-5133ULTRA-CUT 2004.10 Gas SelectionA. Plasma Gases1. Air Plasma• Most often used on ferrous or carbon base materials for g

Manual No. 0-5133 4-15 OPERATIONULTRA-CUT 200B. Shield Gases1. Compressed Air Shield• Air shield is normally used when operating with air plasma and o

OPERATION 4-16 Manual No. 0-5133ULTRA-CUT 2004.11 Power Supply Status CodesOn start-up and during operation, the power supply control circuitry perfor

Manual No. 0-5133 4-17 OPERATIONULTRA-CUT 200Code Message Remedy / Comments2-1 Missing AC Phase Blown fuse, Broken or loose connection on power cable2

ULTRA-CUT 2001-1Manual 0-5133SECTION 1:GENERAL INFORMATION1.01 Notes, Cautions and WarningsThroughout this manual, notes, cautions, and warnings are u

OPERATION 4-18 Manual No. 0-5133ULTRA-CUT 200Code Message Remedy / Comments4-1 Coolant Level low Check coolant level, add as needed.4-2Low coolant fl

Manual No. 0-5133 4-19 OPERATIONULTRA-CUT 2004.12 DMC-3000 Status CodesStatus Code indicators:1. At power up, RED & GREEN indicators flash program

OPERATION 4-20 Manual No. 0-5133ULTRA-CUT 200Code Message Cause/Remedy1-1 Plasma Disabled Enable Plasma; Defective DMC Power Supply (E-Stop relay)1-2

Manual No. 0-5133 4-21 OPERATIONULTRA-CUT 2004.13 DPC-3000 Status CodesCode Message Cause/Remedy1-1 Plasma DisabledEnable Plasma; DMC Power Supply inp

OPERATION 4-22 Manual No. 0-5133ULTRA-CUT 200Code Message Cause/Remedy6-1 Valve open Check for open connection; Replace valve.6-2DPC inlet Supply pres

Manual No. 0-5133 Ultra-Cut 200 5-1 MAINTENANCEULTRA-CUT 200SECTION 5: MAINTENANCE5.01 Periodic ChecksPerform the following checks periodically to ens

Manual No. 0-5133 Ultra-Cut 200 5-2 MAINTENANCEULTRA-CUT 2005.03 Internal Coolant Filter Cleaning ProcedureThe in-line filter screen should be cleaned

Manual No. 0-5133 Ultra-Cut 200 5-3 MAINTENANCEULTRA-CUT 2005.05 Remote Arc Starter: Service ChartSymptom Cause Check RemedyCoolant has become conduc

Manual No. 0-5133 Ultra-Cut 200 5-4 MAINTENANCEULTRA-CUT 2005.06 Remote Arc Starter: SparkGap AdjustmentArt # A-048570.063" ± 0.002"1.6 ± 0

Manual No. 0-5133 Ultra-Cut 200 6-1 Power Supply Parts ListULTRA-CUT 200SECTION 6: REPLACEMENT ASSEMBLIES & PARTS6.01 Main Component / System Rep