Tweco 400 Ultra-Cut XT Plasma Cutting System Manuel d'utilisateur

VictorThermalDynamics.com100 200 400300380VULTRA-CUT 100, 200, 300, 400 XT™ PLASMA CUTTING SYSTEM AUTOMATED GAS CONTROLOperating ManualRevision: AE

ULTRA-CUT 100 XT/200 XT/300 XT/400 XT 1-2 GENERAL INFORMATION Manual 0-5297 • Extracaremustbetakenwhentheworkplaceismoist or damp.• In

ULTRA-CUT 100 XT/200 XT/300 XT/400 XT 4-22 OPERATION Manual 0-5297 CCM Status CodeGroup 3 -- Gas Controller Status & P

ULTRA-CUT 100 XT/200 XT/300 XT/400 XTManual0-5297 OPERATION 4-23CCM Status CodeGroup 4 -- Torch Coolant SystemCode Message Remedy / Com

ULTRA-CUT 100 XT/200 XT/300 XT/400 XT 4-24 OPERATION Manual 0-5297 CCM Status CodeGroup 6 -- CCMCode Message Remedy / Comme

ULTRA-CUT 100 XT/200 XT/300 XT/400 XTManual0-5297 OPERATION 4-25StatusIndicatorsontheDMC&DPCmodulesasha2-partcode.Both

ULTRA-CUT 100 XT/200 XT/300 XT/400 XT 4-26 OPERATION Manual 0-5297 Group 5 - Shorted Solenoid Faults5-1 Sol 1 – H35 Plasm

ULTRA-CUT 100 XT/200 XT/300 XT/400 XTManual0-5297 OPERATION 4-27Group 3 - Inlet Pressure Faults3-1 Plasma Gas High (>145 PSI) Redu

ULTRA-CUT 100 XT/200 XT/300 XT/400 XT 4-28 OPERATION Manual 0-5297 Group 7 - Pilot Proportional Valve (V3)7-1 Valve open

ULTRA-CUT 100 XT/200 XT/300 XT/400 XTManual0-5297 OPERATION 4-294.14 Remote Arc Starter Trouble ShootingArc Starter Trouble ShootingSy

ULTRA-CUT 100 XT/200 XT/300 XT/400 XT 4-30 OPERATION Manual 0-5297 ThisPageIntentionallyBlank

ULTRA-CUT 100 XT/200 XT/300 XT/400 XTManual 0-5297 MAINTENANCE 5-1 SECTION 5: MAINTENANCE5.01 General MaintenancePerformthefollowingc

ULTRA-CUT 100 XT/200 XT/300 XT/400 XTManual 0-5297 GENERAL INFORMATION 1-3 6. ANSIStandardZ49.2,FIRE PREVENTION IN THE USE OF CUTTING AND

ULTRA-CUT 100 XT/200 XT/300 XT/400 XT 5-2 MAINTENANCE Manual 0-5297 5.03 Coolant Replacement ProcedureReplace coolant as f

ULTRA-CUT 100 XT/200 XT/300 XT/400 XTManual0-5297 PARTSLISTS 6-1SECTION6:REPLACEMENTASSEMBLIES&PARTS6.01 Replacement Power

ULTRA-CUT 100 XT/200 XT/300 XT/400 XT 6-2 PARTS LISTS Manual 0-5297 6.02 System Layout 100 - 200 AmpRefer to section 3.08 a

ULTRA-CUT 100 XT/200 XT/300 XT/400 XTManual0-5297 PARTSLISTS 6-36.04 System Layout 400 AmpRefer to section 3.08 and 3.10 for ground c

ULTRA-CUT 100 XT/200 XT/300 XT/400 XT 6-4 PARTS LISTS Manual 0-5297 6.06 Leads And Cables All AmperagesGreen / Yellow # 4

ULTRA-CUT 100 XT/200 XT/300 XT/400 XTManual0-5297 PARTSLISTS 6-5Ultra-Cut 100-200-300-400 XT Leads Key DescriptionLeads Length3 ft 1

ULTRA-CUT 100 XT/200 XT/300 XT/400 XT 6-6 PARTS LISTS Manual 0-5297 6.07 Power Supply External Replacement Parts Item #

ULTRA-CUT 100 XT/200 XT/300 XT/400 XTManual0-5297 PARTSLISTS 6-76.08 Power Supply Replacement Parts - Upper Right Side Item # Qty

ULTRA-CUT 100 XT/200 XT/300 XT/400 XT 6-8 PARTS LISTS Manual 0-5297 6.09 Power Supply Replacement Parts - Lower Right Side

ULTRA-CUT 100 XT/200 XT/300 XT/400 XTManual0-5297 PARTSLISTS 6-96.10 Power Supply Replacement Parts - Rear Panel Item # Qty Desc

ULTRA-CUT 100 XT/200 XT/300 XT/400 XT 1-4 GENERAL INFORMATION Manual 0-5297 • Utilisezunappareilrespiratoireà alimentationenairsil’aéra

ULTRA-CUT 100 XT/200 XT/300 XT/400 XT 6-10 PARTS LISTS Manual 0-5297 6.11 Power Supply Replacement Parts - Left Side Item

ULTRA-CUT 100 XT/200 XT/300 XT/400 XTManual0-5297 PARTSLISTS 6-116.12 DFC-3000 Automated Gas Control System Replacement Components I

ULTRA-CUT 100 XT/200 XT/300 XT/400 XT 6-12 PARTS LISTS Manual 0-5297 6.13 DMC-3000 Gas Control Module Replacement Parts It

ULTRA-CUT 100 XT/200 XT/300 XT/400 XTManual0-5297 PARTSLISTS 6-136.14 DPC-3000 Gas Control Module Replacement Parts Item # Qty Des

ULTRA-CUT 100 XT/200 XT/300 XT/400 XT 6-14 PARTS LISTS Manual 0-5297 6.15 TSC-3000 Touch Screen Control Remote and Internal

ULTRA-CUT 100 XT/200 XT/300 XT/400 XTManual0-5297 PARTSLISTS 6-156.16 Remote Arc Starter (RAS-1000 XT) Replacement Parts Item # Qty

ULTRA-CUT 100 XT/200 XT/300 XT/400 XT 6-16 PARTS LISTS Manual 0-5297 6.17 HE 400 Heat Exchanger - Replacement Parts Item #

ULTRA-CUT 100 XT/200 XT/300 XT/400 XTManual 0-5297 TORCH INFORMATION 7-1 SECTION 7: TORCH MAINTENANCE7.01 Consumable Removal1. Usethe

ULTRA-CUT 100 XT/200 XT/300 XT/400 XT 7-2 TORCH INFORMATION Manual 0-5297 7.02 O-Ring LubricationLubricate all three O-Rings on

ULTRA-CUT 100 XT/200 XT/300 XT/400 XTManual 0-5297 TORCH INFORMATION 7-3 7.03 Parts WearReplacetheGasDistributorifitischarredorcrac

ULTRA-CUT 100 XT/200 XT/300 XT/400 XTManual 0-5297 GENERAL INFORMATION 1-5 • Maintenezvotrecasqueetvoslunettesdeprotectionenbonétat

ULTRA-CUT 100 XT/200 XT/300 XT/400 XT 7-4 TORCH INFORMATION Manual 0-5297 7.04 Torch Consumables InstallationArt # A-03887

ULTRA-CUT 100 XT/200 XT/300 XT/400 XTManual 0-5297 TORCH INFORMATION 7-5 CAUTIONThe cartridge assembly must cover the O-Ring on the torch he

ULTRA-CUT 100 XT/200 XT/300 XT/400 XT 7-6 TORCH INFORMATION Manual 0-5297 7.05 Coolant Leak Trouble-Shooting Neveroperatethe

ULTRA-CUT 100 XT/200 XT/300 XT/400 XTManual 0-5297 TORCH INFORMATION 7-7 Torch ElectrodesArt # A-09653Amperage Plasma GasRecommended Wear Dep

ULTRA-CUT 100 XT/200 XT/300 XT/400 XT 7-8 TORCH INFORMATION Manual 0-5297 ThisPageIntentionallyBlank

ULTRA-CUT 100 XT/200 XT/300 XT/400 XTManual 0-5297 APPENDIX A-1 APPENDIX 1: CNC - Control Module PCB ConnectionsArt # A-11512_AB12111098

ULTRA-CUT 100 XT/200 XT/300 XT/400 XT A-2 APPENDIX Manual 0-5297 APPENDIX 2: CNC CNC functionsCNCI/Ocircuitsprovideat

ULTRA-CUT 100 XT/200 XT/300 XT/400 XTManual 0-5297 APPENDIX A-3 Internal CNC connections. TB1, TB2 & TB3 on CCM module.Connectionsar

ULTRA-CUT 100 XT/200 XT/300 XT/400 XT A-4 APPENDIX Manual 0-5297 CNC Input / Output DescriptionsE-Stop input— Requires clos

ULTRA-CUT 100 XT/200 XT/300 XT/400 XTManual 0-5297 APPENDIX A-5 5 OK to Move2 –ProvidesasecondsetofN.O.contactsthatclosewhena

ULTRA-CUT 100 XT/200 XT/300 XT/400 XT 1-6 GENERAL INFORMATION Manual 0-5297 1.06 Documents De ReferenceConsultezlesnormessuivantesoulesrév

ULTRA-CUT 100 XT/200 XT/300 XT/400 XT A-6 APPENDIX Manual 0-5297 SimpliedCNCCircuitArt # A-11579Art # A-1157915 - K ey P

ULTRA-CUT 100 XT/200 XT/300 XT/400 XTManual 0-5297 APPENDIX A-7 Art # A-11579Art # A-1157915 - K ey Plug1234567891011121314151617181920J2

ULTRA-CUT 100 XT/200 XT/300 XT/400 XT A-8 APPENDIX Manual 0-5297 CNC ConnectionsStart Motion(OK-To-Move)Cutting Machine CNC

ULTRA-CUT 100 XT/200 XT/300 XT/400 XTManual 0-5297 APPENDIX A-9 APPENDIX 3: SERIAL COMMUNICATIONSA3.01 Cables and Switch Settings for 2

ULTRA-CUT 100 XT/200 XT/300 XT/400 XT A-10 APPENDIX Manual 0-5297 ForRS485itisrecommendedthatthecommunicationlines

ULTRA-CUT 100 XT/200 XT/300 XT/400 XTManual 0-5297 APPENDIX A-11 APPENDIX 4: DMC-3000 Control PCB LayoutJ1J9TP6J5J6SW2J8TP5J2TP3TP2TP4J3

ULTRA-CUT 100 XT/200 XT/300 XT/400 XT A-12 APPENDIX Manual 0-5297 APPENDIX 5: DPC-3000 Control PCB LayoutTP6J5J6SW2TP5TP3

ULTRA-CUT 100 XT/200 XT/300 XT/400 XTManual 0-5297 APPENDIX A-13 APPENDIX 6: DMC-3000 / DPC-3000 Power Supply PCB LayoutF2J2D7D6TP1TP6

ULTRA-CUT 100 XT/200 XT/300 XT/400 XT A-14 APPENDIX Manual 0-5297 APPENDIX 7: TSC-3000 PCB LayoutTP4TP1TP3J1J2J3TP2J4J5Ar

ULTRA-CUT 100 XT/200 XT/300 XT/400 XTManual 0-5297 APPENDIX A-15 ThisPageIntentionallyBlank

ULTRA-CUT 100 XT/200 XT/300 XT/400 XTManual 0-5297 GENERAL INFORMATION 1-7 Signature   JulianChow  Full Name  V.P.AsiaPaci

ULTRA-CUT 100 XT/200 XT/300 XT/400 XT A-16 APPENDIX Manual 0-5297 APPENDIX 8: CCM CPU PCB Layout= Test Point= Test PointAr

ULTRA-CUT 100 XT/200 XT/300 XT/400 XTManual 0-5297 APPENDIX A-17 CCM CPU PCB Test PointsTP1 GNDTP2ISO+5.0VTP3+24VTP4+3.3VTP5 ISO GN

ULTRA-CUT 100 XT/200 XT/300 XT/400 XT A-18 APPENDIX Manual 0-5297 APPENDIX 9: CCM I/O PCB Layout= Test Point= Test PointAr

ULTRA-CUT 100 XT/200 XT/300 XT/400 XTManual 0-5297 APPENDIX A-19 CCM I/O PCB Test PointsTP1 GNDTP2/COOLANTFANSONTP3/TORCHPUMPONTP4

ULTRA-CUT 100 XT/200 XT/300 XT/400 XT A-20 APPENDIX Manual 0-5297 APPENDIX 10: Pilot PCB LayoutArt # A-11677= Test Point=

ULTRA-CUT 100 XT/200 XT/300 XT/400 XTManual 0-5297 APPENDIX A-21 Pilot PCB Test PointsTP1 GNDTP2 PILOT GATETP3+5VTP4TIPLED ReferenceD2

ULTRA-CUT 100 XT/200 XT/300 XT/400 XT A-22 APPENDIX Manual 0-5297 APPENDIX 11: Relay and Interface PCB Layout= Test Point=

ULTRA-CUT 100 XT/200 XT/300 XT/400 XTManual 0-5297 APPENDIX A-23 Relay and Interface PCB Test PointsTP1 GNDTP2 -15VTP3+5VDCTP4+12VTP5+

ULTRA-CUT 100 XT/200 XT/300 XT/400 XT A-24 APPENDIX Manual 0-5297 APPENDIX 12: Display PCB Layout= Test Point= Test PointA

ULTRA-CUT 100 XT/200 XT/300 XT/400 XTManual 0-5297 APPENDIX A-25 Display PCB Test PointsTP1 GNDTP2+5VDCTP3+24VDC

ULTRA-CUT 100 XT/200 XT/300 XT/400 XT 1-8 GENERAL INFORMATION Manual 0-5297 Classication:TheequipmentdescribedinthismanualisClass A and

ULTRA-CUT 100 XT/200 XT/300 XT/400 XT A-26 APPENDIX Manual 0-5297 APPENDIX 13: System Bias PCB Layout= Test Point= Test Po

ULTRA-CUT 100 XT/200 XT/300 XT/400 XTManual 0-5297 APPENDIX A-27 System Bias PCB Test PointsTP1 GNDTP224VDCTP3 DC INPUT POSITIVETP4Vcc1

ULTRA-CUT 100 XT/200 XT/300 XT/400 XT A-28 APPENDIX Manual 0-5297 APPENDIX 14: Main Inverter Bottom PCB Layout= Test Point

ULTRA-CUT 100 XT/200 XT/300 XT/400 XTManual 0-5297 APPENDIX A-29 Main Inverter Bottom PCB Test PointsTP1 GNDTP2 GATE 2ATP3 GATE 1ATP4G

ULTRA-CUT 100 XT/200 XT/300 XT/400 XT A-30 APPENDIX Manual 0-5297 APPENDIX 15: Main Inverter Top PCB Layout= Test Point= T

ULTRA-CUT 100 XT/200 XT/300 XT/400 XTManual 0-5297 APPENDIX A-31 Main Inverter Top PCB Test PointsTP1 GNDTP2 GATE 2ATP3 GATE 1ATP4GATE

ULTRA-CUT 100 XT/200 XT/300 XT/400 XT A-32 APPENDIX Manual 0-5297 APPENDIX 16: Control and Fault PCB Layout= Test Point= T

ULTRA-CUT 100 XT/200 XT/300 XT/400 XTManual 0-5297 APPENDIX A-33 Control and Fault PCB Test PointsTP1 GNDTP22 +12VDCTP23 +5VDCTP24 G

ULTRA-CUT 100 XT/200 XT/300 XT/400 XT A-34 APPENDIX Manual 0-5297 APPENDIX 17: Cap Bias Bottom PCB LayoutArt # A-11685

ULTRA-CUT 100 XT/200 XT/300 XT/400 XTManual 0-5297 APPENDIX A-35 APPENDIX 18: Cap Bias Top PCB LayoutArt # A-11686

ULTRA-CUT 100 XT/200 XT/300 XT/400 XTManual 0-5297 GENERAL INFORMATION 1-9 1.08 Statement of WarrantyLIMITED WARRANTY: Victor Thermal Dynami

ULTRA-CUT 100 XT/200 XT/300 XT/400 XT A-36 APPENDIX Manual 0-5297 APPENDIX 19: Suppressor PCB LayoutArt # A-11684

ULTRA-CUT 100 XT/200 XT/300 XT/400 XTManual 0-5297 APPENDIX A-37 Appendix 20: COOLING DIAGRAMArt # A-12268HS1 TempSensorFlow SwitchBubbl

ULTRA-CUT 100 XT/200 XT/300 XT/400 XT A-38 APPENDIX Manual 0-5297 APPENDIX 21: Remote Arc Starter SchematicArt # A-12071_A

ULTRA-CUT 100 XT/200 XT/300 XT/400 XTManual 0-5297 APPENDIX A-39 ThisPageIntentionallyBlank

ULTRA-CUT 100 XT/200 XT/300 XT/400 XT A-40 APPENDIX Manual 0-5297 APPENDIX 22: Schematic, DFC-3000 Auto Gas Box SystemArt #

ULTRA-CUT 100 XT/200 XT/300 XT/400 XTManual 0-5297 APPENDIX A-41 Art # A-09197_ACArt # A-09197_AB112233445566AABBC CD DBLKPURPLEORANGEBLK

ULTRA-CUT 100 XT/200 XT/300 XT/400 XT A-42 APPENDIX Manual 0-5297 APPENDIX 23: System Schematic 100A, 380-415V PG 111223344

ULTRA-CUT 100 XT/200 XT/300 XT/400 XTManual0-5297 APPENDIX A-431122334455667788991010FFEEDDCCBBAARevRevisionByDateRevRevisionByDate042X

ULTRA-CUT 100 XT/200 XT/300 XT/400 XT A-44 APPENDIX Manual 0-5297 APPENDIX 24: System Schematic 100A, 380-415V PG 211223344

ULTRA-CUT 100 XT/200 XT/300 XT/400 XTManual0-5297 APPENDIX A-451122334455667788991010FFEEDDCCBBAARevRevisionByDateRevRevisionByDate042X

ULTRA-CUT 100 XT/200 XT/300 XT/400 XT 1-10 GENERAL INFORMATION Manual 0-5297 This Page Intentionally Blank

ULTRA-CUT 100 XT/200 XT/300 XT/400 XT A-46 APPENDIX Manual 0-5297 APPENDIX 25: System Schematic 200A, 380-415V PG 111223344

ULTRA-CUT 100 XT/200 XT/300 XT/400 XTManual0-5297 APPENDIX A-471122334455667788991010FFEEDDCCBBAARevRevisionByDateRevRevisionByDate042X

ULTRA-CUT 100 XT/200 XT/300 XT/400 XT A-48 APPENDIX Manual 0-5297 APPENDIX 26: System Schematic 200A, 380-415V PG 211223344

ULTRA-CUT 100 XT/200 XT/300 XT/400 XTManual0-5297 APPENDIX A-491122334455667788991010FFEEDDCCBBAARevRevisionByDateRevRevisionByDate042X

ULTRA-CUT 100 XT/200 XT/300 XT/400 XT A-50 APPENDIX Manual 0-5297 APPENDIX 27: System Schematic 300A, 380-415V PG 111223344

ULTRA-CUT 100 XT/200 XT/300 XT/400 XTManual 0-5297 APPENDIX A-51 1122334455667788991010FFEEDDCCBBAARevRevisionByDateRevRevisionByDate042X

ULTRA-CUT 100 XT/200 XT/300 XT/400 XT A-52 APPENDIX Manual 0-5297 APPENDIX 28: System Schematic 300A, 380-415V PG 211223344

ULTRA-CUT 100 XT/200 XT/300 XT/400 XTManual 0-5297 APPENDIX A-53 1122334455667788991010FFEEDDCCBBAARevRevisionByDateRevRevisionByDate042X

ULTRA-CUT 100 XT/200 XT/300 XT/400 XT A-54 APPENDIX Manual 0-5297 APPENDIX 29: System Schematic 400A, 380-415V PG 111223344

ULTRA-CUT 100 XT/200 XT/300 XT/400 XTManual 0-5297 APPENDIX A-55 1122334455667788991010FFEEDDCCBBAARevRevisionByDateRevRevisionByDate042X

ULTRA-CUT 100 XT/200 XT/300 XT/400 XTManual 0-5297 SPECIFICATIONS 2-1 SECTION 2: SPECIFICATIONS2.01 General Description Of The SystemAt

ULTRA-CUT 100 XT/200 XT/300 XT/400 XT A-56 APPENDIX Manual 0-5297 APPENDIX 30: System Schematic 400A, 380-415V PG 211223344

ULTRA-CUT 100 XT/200 XT/300 XT/400 XTManual 0-5297 APPENDIX A-57 1122334455667788991010FFEEDDCCBBAARevRevisionByDateRevRevisionByDate042X

ULTRA-CUT 100 XT/200 XT/300 XT/400 XT A-58 APPENDIX Manual 0-5297 Appendix 31: ADVANCED TROUBLESHOOTINGSystem OverviewThe

ULTRA-CUT 100 XT/200 XT/300 XT/400 XTManual 0-5297 APPENDIX A-59 willonlyhaveribboncablesinJ31&J32;a200AwillhaveJ31-J33

ULTRA-CUT 100 XT/200 XT/300 XT/400 XT A-60 APPENDIX Manual 0-5297 The AC Suppression PCB has capacitors and other transient

ULTRA-CUT 100 XT/200 XT/300 XT/400 XTManual0-5297 APPENDIX A-61Status codes.ThecodesforthepowersupplyaredisplayedontheDisplay

ULTRA-CUT 100 XT/200 XT/300 XT/400 XT A-62 APPENDIX Manual 0-5297 Power Supply Status CodesGroup 1, Process Codes101 Plasm

ULTRA-CUT 100 XT/200 XT/300 XT/400 XTManual0-5297 APPENDIX A-63IfaTSC3000isnotconnectedorunitisanAuto-Cut,K7ontheRelayP

ULTRA-CUT 100 XT/200 XT/300 XT/400 XT A-64 APPENDIX Manual 0-5297 102 Pilot Ignition FailureCode102isactivatedwhenthe

ULTRA-CUT 100 XT/200 XT/300 XT/400 XTManual0-5297 APPENDIX A-65Arc starter without Spark Gap (Ultra-Cut)1. CheckforpowertotheRAS

WE APPRECIATE YOUR BUSINESS!Congratulations on your new Victor Thermal Dynamics product. We are proud to have you as our customer and will strive to p

ULTRA-CUT 100 XT/200 XT/300 XT/400 XT 2-2 SPECIFICATIONS Manual 0-5297 2.06 Specications&ElectricalRequirements100

ULTRA-CUT 100 XT/200 XT/300 XT/400 XT A-66 APPENDIX Manual 0-5297 signal to the CCM. On the Relay board D11 LED “Pilot Cur

ULTRA-CUT 100 XT/200 XT/300 XT/400 XTManual0-5297 APPENDIX A-67c. If120VACispresentatJ8duringtheignitiontimegobackandper

ULTRA-CUT 100 XT/200 XT/300 XT/400 XT A-68 APPENDIX Manual 0-5297 • DefectiveInvertermoduleputsoutlesscurrentthani

ULTRA-CUT 100 XT/200 XT/300 XT/400 XTManual0-5297 APPENDIX A-69• Torchtoofarfromwork.• Cutcurrentsettoolowfortorchpartsbe

ULTRA-CUT 100 XT/200 XT/300 XT/400 XT A-70 APPENDIX Manual 0-5297 Thefaultresultingina108codeismeasuredwhilecutti

ULTRA-CUT 100 XT/200 XT/300 XT/400 XTManual 0-5297 APPENDIX A-71 • InverterovertemperaturelightsLEDD14ontheInverterControland

ULTRA-CUT 100 XT/200 XT/300 XT/400 XT A-72 APPENDIX Manual 0-5297 3. IfthevoltageatJ27-3&4ishigherthan10-14V

ULTRA-CUT 100 XT/200 XT/300 XT/400 XTManual 0-5297 APPENDIX A-73 • Theworkcurrentsensor,HCT1,receivespower,+15VDCand-15VDCfrom

ULTRA-CUT 100 XT/200 XT/300 XT/400 XT A-74 APPENDIX Manual 0-5297 wasthecause.Doublecheckbymeasuringpin8&9a

ULTRA-CUT 100 XT/200 XT/300 XT/400 XTManual 0-5297 APPENDIX A-75 • CCMPossiblecauseforworkcurrenttolow.• Alltheaboveplusasho

ULTRA-CUT 100 XT/200 XT/300 XT/400 XTManual 0-5297 SPECIFICATIONS 2-3 Ultra-Cut 100 XT™ Power SupplyInput Power Input Current Suggested S

ULTRA-CUT 100 XT/200 XT/300 XT/400 XT A-76 APPENDIX Manual 0-5297 c. Swap both ends of the ribbon cable with one next to i

ULTRA-CUT 100 XT/200 XT/300 XT/400 XTManual 0-5297 APPENDIX A-77 • Wrongvoltageinverter(veryunlikelybuteasytocheck).• SystemBi

ULTRA-CUT 100 XT/200 XT/300 XT/400 XT A-78 APPENDIX Manual 0-5297 a. Swaptheribboncablesoftheinvertersection1Aand

ULTRA-CUT 100 XT/200 XT/300 XT/400 XTManual 0-5297 APPENDIX A-79 ThevoltagethattriggersanACVoltageHighfaultisabove550Vfor480

ULTRA-CUT 100 XT/200 XT/300 XT/400 XT A-80 APPENDIX Manual 0-5297 2. VoltagecanbeOKwhennotcuttingorcuttingatlowe

ULTRA-CUT 100 XT/200 XT/300 XT/400 XTManual 0-5297 APPENDIX A-81 • Oneormoreofthelocalbiassupplies(+/-12VDC)failedoroutofsp

ULTRA-CUT 100 XT/200 XT/300 XT/400 XT A-82 APPENDIX Manual 0-5297 Possible causes:• Ambientistoohigh.• Coolingfan(s)

ULTRA-CUT 100 XT/200 XT/300 XT/400 XTManual 0-5297 APPENDIX A-83 Troubleshooting:1. Checkthattheinputpowercablesareconnectedtot

ULTRA-CUT 100 XT/200 XT/300 XT/400 XT A-84 APPENDIX Manual 0-5297 Group 3 codes relate to the GAS Controls Status and Commu

ULTRA-CUT 100 XT/200 XT/300 XT/400 XTManual 0-5297 APPENDIX A-85 This is the normal code when the gas control is conducting a purge at st

ULTRA-CUT 100 XT/200 XT/300 XT/400 XT 2-4 SPECIFICATIONS Manual 0-5297 2.07 Power Supply DimensionsArt # A-11487_AB35.97 i

ULTRA-CUT 100 XT/200 XT/300 XT/400 XT A-86 APPENDIX Manual 0-5297 Fromthebypassvalveinmostsystemscoolantisplumbed

ULTRA-CUT 100 XT/200 XT/300 XT/400 XTManual 0-5297 APPENDIX A-87 Possiblecausesforlowow:• Coolantlterclogged.• Flowbypassvalv

ULTRA-CUT 100 XT/200 XT/300 XT/400 XT A-88 APPENDIX Manual 0-5297 Troubleshooting:1. Checkforairblowingoutoftheunit

ULTRA-CUT 100 XT/200 XT/300 XT/400 XTManual 0-5297 APPENDIX A-89 mayhavetobeadded.Onasystemthathasbeenrunbeforeitnormally

ULTRA-CUT 100 XT/200 XT/300 XT/400 XT A-90 APPENDIX Manual 0-5297 c.IfD27isnoton,measureontheCCMI/Oboardbetween

ULTRA-CUT 100 XT/200 XT/300 XT/400 XTManual 0-5297 APPENDIX A-91 • Thepumpiswornout(maybethecasewithanolderunit).Coolant

ULTRA-CUT 100 XT/200 XT/300 XT/400 XT A-92 APPENDIX Manual 0-5297 Troubleshooting:1. GCM1000XT(alsocalledaBasicGasC

ULTRA-CUT 100 XT/200 XT/300 XT/400 XTManual 0-5297 APPENDIX A-93 Theblackendofthebercableisinsertedintothetransmitterwhichi

ULTRA-CUT 100 XT/200 XT/300 XT/400 XT A-94 APPENDIX Manual 0-5297 613 USB Log File Creation FaultWhenupdatingtheCCM,DM

ULTRA-CUT 100 XT/200 XT/300 XT/400 XTManual 0-5297 APPENDIX A-95 CNC Cable Color CodeTABLE 1: CABLE ITEM#4 COLOR CODE TABLEPIN LOCATION

ULTRA-CUT 100 XT/200 XT/300 XT/400 XTManual 0-5297 SPECIFICATIONS 2-5 2.08 Power Supply Rear Panel FeaturesUSER INPUTHEIGHT CONTROLF1 -

ULTRA-CUT 100 XT/200 XT/300 XT/400 XT A-96 APPENDIX Manual 0-5297 APPENDIX 32: PUBLICATION HISTORYCover Date Rev Change(

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© 2012 Victor Technologies International, Inc. www.victortechnologies.com Printed in USATHE AMERICASDenton, TX USAU.S. Customer CarePh

ULTRA-CUT 100 XT/200 XT/300 XT/400 XT 2-6 SPECIFICATIONS Manual 0-5297 2.09 GasRequirementsThecustomerwillprovideall

ULTRA-CUT 100 XT/200 XT/300 XT/400 XTManual 0-5297 SPECIFICATIONS 2-7 Ultra-Cut 300 XT™ Power Supply: Gas Pressures, Flows, and Quality

ULTRA-CUT 100 XT/200 XT/300 XT/400 XT 2-8 SPECIFICATIONS Manual 0-5297 2.10 Gas ApplicationsMATERIAL MILD STEEL STAINLESS

ULTRA-CUT 100 XT/200 XT/300 XT/400 XTManual 0-5297 SPECIFICATIONS 2-9 2.11 XTTorchSpecicationsA. Torch Dimensions.5”12.7 mm2.4”61 m

ULTRA-CUT 100 XT/200 XT/300 XT/400 XT 2-10 SPECIFICATIONS Manual 0-5297 B. Torch Leads LengthsTorch Lead AssembliesLengthF

ULTRA-CUT 100 XT/200 XT/300 XT/400 XTManual 0-5297 INSTALLATION 3-1 SECTION 3: INSTALLATION3.01 InstallationRequirementsElectric Supply

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

ULTRA-CUT 100 XT/200 XT/300 XT/400 XT 3-2 INSTALLATION Manual 0-5297 Gas SupplyThe customer must supply all gases and press

ULTRA-CUT 100 XT/200 XT/300 XT/400 XTManual 0-5297 INSTALLATION 3-3 3.03 System Layout 300 AmpRefer to section 3.08 and 3.10 for ground c

ULTRA-CUT 100 XT/200 XT/300 XT/400 XT 3-4 INSTALLATION Manual 0-5297 3.04 System Layout 400 AmpRefer to section 3.08 and 3

ULTRA-CUT 100 XT/200 XT/300 XT/400 XTManual 0-5297 INSTALLATION 3-5 3.06 Leads and Cables All AmperageGreen / Yellow # 4 AWGGreen / Yell

ULTRA-CUT 100 XT/200 XT/300 XT/400 XT 3-6 INSTALLATION Manual 0-5297 3.07 Lift the Power SupplyWARNINGDo not touch live el

ULTRA-CUT 100 XT/200 XT/300 XT/400 XTManual 0-5297 INSTALLATION 3-7 3.08 Connect Input Power and Ground CablesConnect Input Power and Sys

ULTRA-CUT 100 XT/200 XT/300 XT/400 XT 3-8 INSTALLATION Manual 0-5297 3.09 Connect Work Cable and Pilot and Negative Leads1

ULTRA-CUT 100 XT/200 XT/300 XT/400 XTManual 0-5297 INSTALLATION 3-9 A. Electromagnetic Interference (EMI)Pilot arc starting generates a c

ULTRA-CUT 100 XT/200 XT/300 XT/400 XT 3-10 INSTALLATION Manual 0-5297 Creating An Earth Ground1. Tocreateasolid,lowre

ULTRA-CUT 100 XT/200 XT/300 XT/400 XTManual 0-5297 INSTALLATION 3-11 3.11 Connect Coolant Leads1. Connect the color-coded coolant hoses

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ULTRA-CUT 100 XT/200 XT/300 XT/400 XT 3-12 INSTALLATION Manual 0-5297 3.12 Connect Cables for CNC, Remote Arc Starter, DMC

ULTRA-CUT 100 XT/200 XT/300 XT/400 XTManual 0-5297 INSTALLATION 3-13 3.13 Handling and Installation of Fiber OpticsGeneral InformationThi

ULTRA-CUT 100 XT/200 XT/300 XT/400 XT 3-14 INSTALLATION Manual 0-5297 Avoid the following:1. Ifyouneedtopullthecable

ULTRA-CUT 100 XT/200 XT/300 XT/400 XTManual 0-5297 INSTALLATION 3-15 Correct installation:Correctwaytopullthecableistouseasnake

ULTRA-CUT 100 XT/200 XT/300 XT/400 XT 3-16 INSTALLATION Manual 0-5297 Unplugging the fiber optic connector. Do not pull

ULTRA-CUT 100 XT/200 XT/300 XT/400 XTManual 0-5297 INSTALLATION 3-17 3.14 Connect TSC-3000 Cable and DMC-3000 Fiber Optic Cable to CCM1.

ULTRA-CUT 100 XT/200 XT/300 XT/400 XT 3-18 INSTALLATION Manual 0-5297 5. PlugtheFiberOpticCableintothePCBasshown

ULTRA-CUT 100 XT/200 XT/300 XT/400 XTManual 0-5297 INSTALLATION 3-19 3.15 Set Switches on the Command - Control ModuleRemovethepowersu

ULTRA-CUT 100 XT/200 XT/300 XT/400 XT 3-20 INSTALLATION Manual 0-5297 CAUTIONPrinted circuit boards in the Command - Con

ULTRA-CUT 100 XT/200 XT/300 XT/400 XTManual 0-5297 INSTALLATION 3-21 2 - Wire and 4 - Wire settingsWhenusedwiththeTSC-3000theplugsh

TABLE OF CONTENTSSECTION 1: GENERAL INFORMATION ... 1-11.01 Notes, Cautions a

ULTRA-CUT 100 XT/200 XT/300 XT/400 XT 3-22 INSTALLATION Manual 0-5297 NOTEThere are holes added in the rear panel for custo

ULTRA-CUT 100 XT/200 XT/300 XT/400 XTManual 0-5297 INSTALLATION 3-23 Match the colors of the hoses to the front panel label. Supply lines

ULTRA-CUT 100 XT/200 XT/300 XT/400 XT 3-24 INSTALLATION Manual 0-5297 3.18 DMC-3000 Gas Manifold Control InstallationThe D

ULTRA-CUT 100 XT/200 XT/300 XT/400 XTManual 0-5297 INSTALLATION 3-25 Preparation1. RemovethescrewssecuringtheCoverPaneltotheModu

ULTRA-CUT 100 XT/200 XT/300 XT/400 XT 3-26 INSTALLATION Manual 0-5297 3. AttachallhosesandcablestothefrontoftheD

ULTRA-CUT 100 XT/200 XT/300 XT/400 XTManual 0-5297 INSTALLATION 3-27 6. InstallWMSWaterSoftenerKitinthelinethatfeedstheinlets

ULTRA-CUT 100 XT/200 XT/300 XT/400 XT 3-28 INSTALLATION Manual 0-5297 3.19 DPC-3000 Gas Pressure Control InstallationThe D

ULTRA-CUT 100 XT/200 XT/300 XT/400 XTManual 0-5297 INSTALLATION 3-29 Preparation1. RemovethescrewssecuringtheCoverPaneltotheModu

ULTRA-CUT 100 XT/200 XT/300 XT/400 XT 3-30 INSTALLATION Manual 0-5297 3. AttachallhosesandcablestothebackoftheDP

ULTRA-CUT 100 XT/200 XT/300 XT/400 XTManual 0-5297 INSTALLATION 3-31 3.20 Fiber Optic Cable Installation from CCM to DMC-3000. CAUTIONAv

TABLE OF CONTENTS3.25 Install Consumable Torch Parts ... 3-443.26 Voltage Divider f

ULTRA-CUT 100 XT/200 XT/300 XT/400 XT 3-32 INSTALLATION Manual 0-5297 4. Securethethinnutonthethroughholeprotector

ULTRA-CUT 100 XT/200 XT/300 XT/400 XTManual 0-5297 INSTALLATION 3-33 3.21 Fiber Optic Cable Installation From DMC-3000 to DPC-30001. Rem

ULTRA-CUT 100 XT/200 XT/300 XT/400 XT 3-34 INSTALLATION Manual 0-5297 4. Secureeachofthethinnutsonthethroughhole

ULTRA-CUT 100 XT/200 XT/300 XT/400 XTManual 0-5297 INSTALLATION 3-35 3.22 Install TSC-3000 Touch Screen ControlMounting Dimensions6.99 in

ULTRA-CUT 100 XT/200 XT/300 XT/400 XT 3-36 INSTALLATION Manual 0-5297 3.23 Install Remote Arc StarterSite LocationSelecta

ULTRA-CUT 100 XT/200 XT/300 XT/400 XTManual 0-5297 INSTALLATION 3-37 2. RemovetheCoverPanelfromtheArcStarter.Art # A-12059Lower s

ULTRA-CUT 100 XT/200 XT/300 XT/400 XT 3-38 INSTALLATION Manual 0-5297 Input Connections1. Refertotheillustrations.Mak

ULTRA-CUT 100 XT/200 XT/300 XT/400 XTManual 0-5297 INSTALLATION 3-39 2. Refertoillustration.ConnectthePilotwireandNegativecables

ULTRA-CUT 100 XT/200 XT/300 XT/400 XT 3-40 INSTALLATION Manual 0-5297 Output Connections1. Refertotheillustrations.Ma

ULTRA-CUT 100 XT/200 XT/300 XT/400 XTManual0-5297 INSTALLATION 3-413. TheArcStartermustbegrounded;thegroundingterminalismarke

TABLE OF CONTENTSAPPENDIX 1: CNC - CONTROL MODULE PCB CONNECTIONS ... A-1APPENDIX 2: CNC ...

ULTRA-CUT 100 XT/200 XT/300 XT/400 XT 3-42 INSTALLATION Manual 0-5297 Connect Control Cable 1. Connect the Remote Arc St

ULTRA-CUT 100 XT/200 XT/300 XT/400 XTManual0-5297 INSTALLATION 3-433.24 Connecting TorchConnect the Torch as follows:Art # A-09198Pilot

ULTRA-CUT 100 XT/200 XT/300 XT/400 XT 3-44 INSTALLATION Manual 0-5297 CAUTIONThe gas and coolant leads include compression

ULTRA-CUT 100 XT/200 XT/300 XT/400 XTManual0-5297 INSTALLATION 3-454. Insertthestackofconsumablepartsintothecartridge.Ensure

ULTRA-CUT 100 XT/200 XT/300 XT/400 XT 3-46 INSTALLATION Manual 0-5297 30 - 100 Amp Parts AssemblyCartridge Covers O-Ring on

ULTRA-CUT 100 XT/200 XT/300 XT/400 XTManual0-5297 INSTALLATION 3-473.26 Voltage Divider for iHC Torch Height ControlForbestplasmacut

ULTRA-CUT 100 XT/200 XT/300 XT/400 XT 3-48 INSTALLATION Manual 0-5297 Control Cable. TheiHCboardcanbesuppliedwitha

ULTRA-CUT 100 XT/200 XT/300 XT/400 XTManual0-5297 INSTALLATION 3-493.27 Complete the Installation1. Removethecapfromthecoolantta

ULTRA-CUT 100 XT/200 XT/300 XT/400 XT 3-50 INSTALLATION Manual 0-5297 2. Afterthecompletesystemhasbeeninstalled,che

ULTRA-CUT 100 XT/200 XT/300 XT/400 XTManual0-5297 OPERATION 4-1SECTION 4: OPERATION4.01 Power Supply Control PanelArt # A-11541_ABAC I

TABLE OF CONTENTSAPPENDIX 24: SYSTEM SCHEMATIC 100A, 380-415V PG 2 ...A-44APPENDIX 25: SYSTEM SCHEMATIC 200A, 380

ULTRA-CUT 100 XT/200 XT/300 XT/400 XT 4-2 OPERATION Manual 0-5297 NOTEPrior to starting the system determine the process to

ULTRA-CUT 100 XT/200 XT/300 XT/400 XTManual0-5297 OPERATION 4-34.03 TSC-3000 Navigation FunctionsSAMPLESAMPLESystem Status: IDLE- +DIS

ULTRA-CUT 100 XT/200 XT/300 XT/400 XT 4-4 OPERATION Manual 0-5297 4.04 TSC-3000 Initial Setup ONLYInitial steps required b

ULTRA-CUT 100 XT/200 XT/300 XT/400 XTManual0-5297 OPERATION 4-54.05 TSC-3000 Selecting New Process Art # A -09160Select process by # (

ULTRA-CUT 100 XT/200 XT/300 XT/400 XT 4-6 OPERATION Manual 0-5297 4.06 TSC-3000 Selecting Recently Used ProcessArt # A-091

ULTRA-CUT 100 XT/200 XT/300 XT/400 XTManual0-5297 OPERATION 4-74.07 TSC-3000 Creating a Custom ProcessConsiderableefforthasbeenmad

ULTRA-CUT 100 XT/200 XT/300 XT/400 XT 4-8 OPERATION Manual 0-5297 Art # A -09162Customize eet Cut iit teoess

ULTRA-CUT 100 XT/200 XT/300 XT/400 XTManual0-5297 OPERATION 4-94.08 Back up and Restoration of Custom ProcessesUsers can create their

ULTRA-CUT 100 XT/200 XT/300 XT/400 XT 4-10 OPERATION Manual 0-5297 Restoring Custom Processes:Duringlebackup(seeprevio

ULTRA-CUT 100 XT/200 XT/300 XT/400 XTManual0-5297 OPERATION 4-11Renaming Custom FilesYoucannotrenametheleswhileontheTSC3000b

ULTRA-CUT 100 XT/200 XT/300 XT/400 XTManual 0-5297 GENERAL INFORMATION 1-1 SECTION 1: GENERAL INFORMATION1.01 Notes, Cautions and WarningsThr

ULTRA-CUT 100 XT/200 XT/300 XT/400 XT 4-12 OPERATION Manual 0-5297 4.09 SequenceofOperationUltracut with DFC 3000 using

ULTRA-CUT 100 XT/200 XT/300 XT/400 XTManual0-5297 OPERATION 4-13g) Followingthermwareversionindication,whileCCMestablishescom

ULTRA-CUT 100 XT/200 XT/300 XT/400 XT 4-14 OPERATION Manual 0-5297 10. Changing torch consumables:Followingaconsumablesc

ULTRA-CUT 100 XT/200 XT/300 XT/400 XTManual0-5297 OPERATION 4-154.10 Gas SelectionA. Plasma Gases1. Air Plasma• Mostoftenusedon

ULTRA-CUT 100 XT/200 XT/300 XT/400 XT 4-16 OPERATION Manual 0-5297 B. Shield Gases1. Compressed Air Shield• Airshieldi

ULTRA-CUT 100 XT/200 XT/300 XT/400 XTManual0-5297 OPERATION 4-174.11 CCM Status CodesNOTESee the Appendix for Advanced Troubleshooting

ULTRA-CUT 100 XT/200 XT/300 XT/400 XT 4-18 OPERATION Manual 0-5297 CCM Status CodeGroup 2 -- Plasma Power SupplyCode Messa

ULTRA-CUT 100 XT/200 XT/300 XT/400 XTManual0-5297 OPERATION 4-19222Inverter 3A Output Current HighPlasma work current high during cutti

ULTRA-CUT 100 XT/200 XT/300 XT/400 XT 4-20 OPERATION Manual 0-5297 242Inverter 1B Input Volt-age ErrorInverter Input Voltag

ULTRA-CUT 100 XT/200 XT/300 XT/400 XTManual0-5297 OPERATION 4-21259Inverter 1A Over Temp AmbientInverter circuitry is over temperature