100 AUTO-CUT. Operating Manual PLASMA CUTTING SYSTEM. Rev. AD.01 Date: March 28, 2007 Manual # Operating Features: Art # A-04821

Transcription

1 00 AUTO-CUT PLASMA CUTTING SYSTEM Art # A-0482 Operating Manual Rev. AD.0 Date: March 28, 2007 Manual # Operating Features:

2 WE APPRECIATE YOUR BUSINESS! Congratulations on your new Thermal Dynamics product. We are proud to have you as our customer and will strive to provide you with the best service and reliability in the industry. This product is backed by our extensive warranty and world-wide service network. To locate your nearest distributor or service agency call , or visit us on the web at This Operating Manual has been designed to instruct you on the correct use and operation of your Thermal Dynamics product. Your satisfaction with this product and its safe operation is our ultimate concern. Therefore please take the time to read the entire manual, especially the Safety Precautions. They will help you to avoid potential hazards that may exist when working with this product. YOU ARE IN GOOD COMPANY! The Brand of Choice for Contractors and Fabricators Worldwide. Thermal Dynamics is a Global Brand of manual and automation Plasma Cutting Products for Thermadyne Industries Inc. We distinguish ourselves from our competition through marketleading, dependable products that have stood the test of time. We pride ourselves on technical innovation, competitive prices, excellent delivery, superior customer service and technical support, together with excellence in sales and marketing expertise. Above all, we are committed to developing technologically advanced products to achieve a safer working environment within the welding industry.

3 WARNINGS Read and understand this entire Manual and your employer s safety practices before installing, operating, or servicing the equipment. While the information contained in this Manual represents the Manufacturer's best judgement, the Manufacturer assumes no liability for its use. Plasma Cutting Power Supply, Auto-Cut 00 Operating Manual No Published by: Thermadyne Corporation 82 Benning Street West Lebanon, New Hampshire, USA (603) Copyright 2005,2006,2007 by Thermadyne Corporation All rights reserved. Reproduction of this work, in whole or in part, without written permission of the publisher is prohibited. The publisher does not assume and hereby disclaims any liability to any party for any loss or damage caused by any error or omission in this Manual, whether such error results from negligence, accident, or any other cause. Printed in the United States of America Publication Date: March 28, 2007 Record the following information for Warranty purposes: Where Purchased: Purchase Date: Power Supply Serial #: Torch Serial #:

4 This page intentionally blank

5 Table of Contents SECTION : GENERAL INFORMATION Notes, Cautions and Warnings Important Safety Precautions Publications Declaration of Conformity Statement of Warranty SECTION 2: SPECIFICATIONS General Description Of The System Plasma Power Supply Gas Control Module / Arc Starter Plasma Cutting Torch System Component Layout Power Supply Specifications & Electrical Requirements Power Supply Dimensions Power Supply Rear Panel Features Gas Requirements Gas Applications XTTM-30 Torch Specifications SECTION 3: INSTALLATION A. Installation Requirements B. Cables and Leads Identification C. Position the Power Supply D. Set Command-Control Module Switches E. Check / Adjust Input Voltage Configuration F. Remove the Connections Cover G. Connect Work Cable H. Connect Input Power and System Ground Cables I. Ground Connections J. Connect Gas Supply Lines SECTION 4: OPERATION Power Supply Indicators Control Console Features Operating Set-up Cut Quality System Operation SECTION 5: MAINTENANCE Coolant Filter Cleaning Procedure Water Filter Cleaning Procedure Coolant Replacement Procedure Arc Starter Service Arc Starter Spark Gap Adjustment

6 Table of Contents Section 6: Replacement Assemblies & Parts Leads and Cables Optional Gas Supply Leads Power Supply External Replacement Parts Power Supply Replacement Parts - Right Side Power Supply Replacement Parts - Right Side Power Supply Replacement Parts - Right Side Power Supply Replacement Parts - Front Panel Power Supply Replacement Parts - Front Panel Power Supply Replacement Parts - Right Side Power Supply Replacement Parts - Rear Panel Power Supply Replacement Parts - Right Side Power Supply Replacement Parts Power Supply Replacement Parts - Right Side Power Supply Replacement Parts Power Supply Replacement Parts - Right Side Power Supply Replacement Parts - Right Side Arc Starter & Gas Control Module (GCM-000) Replacement Parts Command & Control Module Type - Replacement Parts Command & Control Module Type 2 - Replacement Parts SECTION 7: Torch Maintenance A. Consumable Removal B. O-Ring Lubrication C. Parts Wear D. Torch Consumables Installation E. Coolant Leak Trouble-Shooting Appendix : Control Cable Pinouts... A- Appendix 2: Control Cable Pinouts... A-2 Appendix 3: Command-Control PC Board Layout (A)... A-3 Appendix 4: Command-Control PC Board Layout (B)... A-4 Appendix 5: CNC - Control Module Board PCB Connections... A-6 CNC functions... A-7 CNC Input / Output Descriptions... A-8 Simplified CNC Circuit.... A-9 Appendix 6: Schematic, V, Chopper Pilot w/ Diode... A-0 Appendix 7: Schematic, V, Chopper Pilot w/o Diode... A-2 Appendix 8: Schematic, V, Resistor Pilot... A-4

7 Table of Contents Appendix 9: Schematic, CCC 400V, Chopper Pilot w/ Diode... A-6 Appendix 0: Schematic, CE 400V, Chopper Pilot w/ Diode... A-8 Appendix : Schematic, CE 400V, Resistor Pilot... A-20 Appendix 2: Schematic, CSA 600V, Chopper Pilot... A-22 Appendix 3: Arc Starter / Gas Control Module Schematic... A-24 APPENDIX 4: PUBLICATION HISTORY... A-26 Global Customer Service Contact Information... A-2

8 Table of Contents

9 .0 Notes, Cautions and Warnings SECTION : GENERAL INFORMATION Throughout this manual, notes, cautions, and warnings are used to highlight important information. These highlights are categorized as follows: NOTE An operation, procedure, or background information which requires additional emphasis or is helpful in efficient operation of the system. CAUTION A procedure which, if not properly followed, may cause damage to the equipment. WARNING A procedure which, if not properly followed, may cause injury to the operator or others in the operating area..02 Important Safety Precautions WARNINGS OPERATION AND MAINTENANCE OF PLASMA ARC EQUIPMENT CAN BE DANGEROUS AND HAZ- ARDOUS TO YOUR HEALTH. Plasma arc cutting produces intense electric and magnetic emissions that may interfere with the proper function of cardiac pacemakers, hearing aids, or other electronic health equipment. Persons who work near plasma arc cutting applications should consult their medical health professional and the manufacturer of the health equipment to determine whether a hazard exists. To prevent possible injury, read, understand and follow all warnings, safety precautions and instructions before using the equipment. Call or your local distributor if you have any questions. GASES AND FUMES Gases and fumes produced during the plasma cutting process can be dangerous and hazardous to your health. Keep all fumes and gases from the breathing area. Keep your head out of the welding fume plume. Use an air-supplied respirator if ventilation is not adequate to remove all fumes and gases. The kinds of fumes and gases from the plasma arc depend on the kind of metal being used, coatings on the metal, and the different processes. You must be very careful when cutting or welding any metals which may contain one or more of the following: Antimony Chromium Mercury Beryllium Arsenic Cobalt Nickel Lead Barium Copper Selenium Silver Cadmium Manganese Vanadium Manual GENERAL INFORMATION

10 Always read the Material Safety Data Sheets (MSDS) that should be supplied with the material you are using. These MSDSs will give you the information regarding the kind and amount of fumes and gases that may be dangerous to your health. For information on how to test for fumes and gases in your workplace, refer to item in Subsection.03, Publications in this manual. Use special equipment, such as water or down draft cutting tables, to capture fumes and gases. Do not use the plasma torch in an area where combustible or explosive gases or materials are located. Phosgene, a toxic gas, is generated from the vapors of chlorinated solvents and cleansers. Remove all sources of these vapors. This product, when used for welding or cutting, produces fumes or gases which contain chemicals known to the State of California to cause birth defects and, in some cases, cancer. (California Health & Safety Code Sec et seq.) ELECTRIC SHOCK Electric Shock can injure or kill. The plasma arc process uses and produces high voltage electrical energy. This electric energy can cause severe or fatal shock to the operator or others in the workplace. Never touch any parts that are electrically live or hot. Wear dry gloves and clothing. Insulate yourself from the work piece or other parts of the welding circuit. Repair or replace all worn or damaged parts. Extra care must be taken when the workplace is moist or damp. Install and maintain equipment according to NEC code, refer to item 9 in Subsection.03, Publications. Disconnect power source before performing any service or repairs. Read and follow all the instructions in the Operating Manual. FIRE AND EXPLOSION Fire and explosion can be caused by hot slag, sparks, or the plasma arc. Be sure there is no combustible or flammable material in the workplace. Any material that cannot be removed must be protected. Ventilate all flammable or explosive vapors from the workplace. Do not cut or weld on containers that may have held combustibles. Provide a fire watch when working in an area where fire hazards may exist. Hydrogen gas may be formed and trapped under aluminum workpieces when they are cut underwater or while using a water table. DO NOT cut aluminum alloys underwater or on a water table unless the hydrogen gas can be eliminated or dissipated. Trapped hydrogen gas that is ignited will cause an explosion. NOISE Noise can cause permanent hearing loss. Plasma arc processes can cause noise levels to exceed safe limits. You must protect your ears from loud noise to prevent permanent loss of hearing. To protect your hearing from loud noise, wear protective ear plugs and/or ear muffs. Protect others in the workplace. Noise levels should be measured to be sure the decibels (sound) do not exceed safe levels. For information on how to test for noise, see item in Subsection.03, Publications, in this manual. GENERAL INFORMATION -2 Manual

11 PLASMA ARC RAYS Plasma Arc Rays can injure your eyes and burn your skin. The plasma arc process produces very bright ultra violet and infra red light. These arc rays will damage your eyes and burn your skin if you are not properly protected. To protect your eyes, always wear a welding helmet or shield. Also always wear safety glasses with side shields, goggles or other protective eye wear. Wear welding gloves and suitable clothing to protect your skin from the arc rays and sparks. Keep helmet and safety glasses in good condition. Replace lenses when cracked, chipped or dirty. Protect others in the work area from the arc rays. Use protective booths, screens or shields. Use the shade of lens as suggested in the following per ANSI/ASC Z49.: Minimum Protective Suggested Arc Current Shade No. Shade No. Less Than 300* * * 0 4 * These values apply where the actual arc is clearly seen. Experience has shown that lighter filters may be used when the arc is hidden by the workpiece..03 Publications Refer to the following standards or their latest revisions for more information:. OSHA, SAFETY AND HEALTH STANDARDS, 29CFR 90, obtainable from the Superintendent of Documents, U.S. Government Printing Office, Washington, D.C ANSI Standard Z49., SAFETY IN WELDING AND CUTTING, obtainable from the American Welding Society, 550 N.W. LeJeune Rd, Miami, FL NIOSH, SAFETY AND HEALTH IN ARC WELDING AND GAS WELDING AND CUTTING, obtainable from the Superintendent of Documents, U.S. Government Printing Office, Washington, D.C ANSI Standard Z87., SAFE PRACTICES FOR OCCUPATION AND EDUCATIONAL EYE AND FACE PROTEC- TION, obtainable from American National Standards Institute, 430 Broadway, New York, NY ANSI Standard Z4., STANDARD FOR MEN S SAFETY-TOE FOOTWEAR, obtainable from the American National Standards Institute, 430 Broadway, New York, NY ANSI Standard Z49.2, FIRE PREVENTION IN THE USE OF CUTTING AND WELDING PROCESSES, obtainable from American National Standards Institute, 430 Broadway, New York, NY AWS Standard A6.0, WELDING AND CUTTING CONTAINERS WHICH HAVE HELD COMBUSTIBLES, obtainable from American Welding Society, 550 N.W. LeJeune Rd, Miami, FL NFPA Standard 5, OXYGEN-FUEL GAS SYSTEMS FOR WELDING, CUTTING AND ALLIED PROCESSES, obtainable from the National Fire Protection Association, Batterymarch Park, Quincy, MA NFPA Standard 70, NATIONAL ELECTRICAL CODE, obtainable from the National Fire Protection Association, Batterymarch Park, Quincy, MA NFPA Standard 5B, CUTTING AND WELDING PROCESSES, obtainable from the National Fire Protection Association, Batterymarch Park, Quincy, MA CGA Pamphlet P-, SAFE HANDLING OF COMPRESSED GASES IN CYLINDERS, obtainable from the Compressed Gas Association, 235 Jefferson Davis Highway, Suite 50, Arlington, VA CSA Standard W7.2, CODE FOR SAFETY IN WELDING AND CUTTING, obtainable from the Canadian Standards Association, Standards Sales, 78 Rexdale Boulevard, Rexdale, Ontario, Canada M9W R3 Manual GENERAL INFORMATION

12 3. NWSA booklet, WELDING SAFETY BIBLIOGRAPHY obtainable from the National Welding Supply Association, 900 Arch Street, Philadelphia, PA American Welding Society Standard AWSF4., RECOMMENDED SAFE PRACTICES FOR THE PREPARATION FOR WELDING AND CUTTING OF CONTAINERS AND PIPING THAT HAVE HELD HAZARDOUS SUBSTANCES, obtainable from the American Welding Society, 550 N.W. LeJeune Rd, Miami, FL ANSI Standard Z88.2, PRACTICE FOR RESPIRATORY PROTECTION, obtainable from American National Standards Institute, 430 Broadway, New York, NY 008 GENERAL INFORMATION -4 Manual

13 .04 Declaration of Conformity Manufacturer: Thermal Dynamics Corporation Address: 82 Benning Street West Lebanon, New Hampshire USA The equipment described in this manual conforms to all applicable aspects and regulations of the Low Voltage Directive (European Council Directive 73/23/EEC as amended by Council Directive 93/68/EEC) and to the National legislation for the enforcement of this Directive. The equipment described in this manual conforms to all applicable aspects and regulations of the "EMC Directive" (European Council Directive 89/336/EEC) and to the National legislation for the enforcement of this Directive. Serial numbers are unique with each individual piece of equipment and details description, parts used to manufacture a unit and date of manufacture. National Standard and Technical Specifications The product is designed and manufactured to a number of standards and technical requirements. Among them are: * CSA (Canadian Standards Association) standard C22.2 number 60 for Arc welding equipment. * UL (Underwriters Laboratory) rating 94VO flammability testing for all printed-circuit boards used. * ISO/IEC (BS 638-PT0) (EN ) (EN5092) (EN50078) applicable to plasma cutting equipment and associated accessories. * CENELEC EN5099 EMC Product Standard for Arc Welding Equipment * For environments with increased hazard of electrical shock, Power Supplies bearing the S mark conform to EN5092 when used in conjunction with hand torches with exposed tips, if equipped with properly installed standoff guides. * Extensive product design verification is conducted at the manufacturing facility as part of the routine design and manufacturing process. This is to ensure the product is safe, when used according to instructions in this manual and related industry standards, and performs as specified. Rigorous testing is incorporated into the manufacturing process to ensure the manufactured product meets or exceeds all design specifications. Thermal Dynamics has been manufacturing products for more than 30 years, and will continue to achieve excellence in our area of manufacture. Manufacturers responsible representative: Steve Ward Operations Director Thermadyne Europe Europa Building Chorley N Industrial Park Chorley, Lancashire, England PR6 7BX Manual GENERAL INFORMATION

14 .05 Statement of Warranty LIMITED WARRANTY: Thermal Dynamics Corporation (hereinafter Thermal ) warrants that its products will be free of defects in workmanship or material. Should any failure to conform to this warranty appear within the time period applicable to the Thermal products as stated below, Thermal shall, upon notification thereof and substantiation that the product has been stored, installed, operated, and maintained in accordance with Thermal s specifications, instructions, recommendations and recognized standard industry practice, and not subject to misuse, repair, neglect, alteration, or accident, correct such defects by suitable repair or replacement, at Thermal s sole option, of any components or parts of the product determined by Thermal to be defective. THIS WARRANTY IS EXCLUSIVE AND IS IN LIEU OF ANY WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. LIMITATION OF LIABILITY: Thermal shall not under any circumstances be liable for special or consequential damages, such as, but not limited to, damage or loss of purchased or replacement goods, or claims of customers of distributor (hereinafter Purchaser ) for service interruption. The remedies of the Purchaser set forth herein are exclusive and the liability of Thermal with respect to any contract, or anything done in connection therewith such as the performance or breach thereof, or from the manufacture, sale, delivery, resale, or use of any goods covered by or furnished by Thermal whether arising out of contract, negligence, strict tort, or under any warranty, or otherwise, shall not, except as expressly provided herein, exceed the price of the goods upon which such liability is based. THIS WARRANTY BECOMES INVALID IF REPLACEMENT PARTS OR ACCESSORIES ARE USED WHICH MAY IMPAIR THE SAFETY OR PERFORMANCE OF ANY THERMAL PRODUCT. THIS WARRANTY IS INVALID IF THE PRODUCT IS SOLD BY NON-AUTHORIZED PERSONS. The limited warranty periods for this product shall be: A maximum of three (3) years from date of sale to an authorized distributor and a maximum of two (2) years from date of sale by such distributor to the Purchaser, and with further limitations on such two (2) year period (see chart below). Parts Labor AutoCut and UltraCut Power Supplies and Components 2 Years Year Torch And Leads XT TM -300/XT TM -30 Torch (Excluding Consumable Parts) Year Year Repair/Replacement Parts 90 Days 90 Days Warranty repairs or replacement claims under this limited warranty must be submitted by an authorized Thermal Dynamics repair facility within thirty (30) days of the repair. No transportation costs of any kind will be paid under this warranty. Transportation charges to send products to an authorized warranty repair facility shall be the responsibility of the customer. All returned goods shall be at the customer s risk and expense. This warranty supersedes all previous Thermal warranties. Effective August 9, 2005 GENERAL INFORMATION -6 Manual

15 SECTION 2: SPECIFICATIONS General Description Of The System A typical Auto-Cut 00 plasma cutting system includes: One Power Supply Arc Starter / Gas Control Module (Mounted on Power Supply) General Purpose Plasma Cutting Torch Set Of Connecting Leads Torch Spare Parts Kit The components are connected at installation. Plasma Power Supply The power supply provides the necessary current for cutting operations, and monitors system performance. The power supply also cools and circulates the liquid coolant for the torch and leads. Gas Control Module / Arc Starter This module mounts to the top of the power supply. This module enables the operator to select gas, set pressures and flows and set cutting current. Plasma Cutting Torch The torch delivers the controlled current to the work through the main arc, causing the metal to be cut. System Component Layout Pilot Return Negative Coolant Supply Coolant Return Control Cable Arc Starter / Gas Control Module (GCM-000) Auto-Cut Power Supply Control Cable Maximum Length 00 / 30.5 m Ground Cable Torch Lead Set, Shielded - Coolant Supply w/ Negative - Coolant Return - Pilot Return - Plasma Gas - Shield Gas CNC CNC Cable Primary power Positioning Tube Torch Ground Cables Work Cable Work Art # A-0723 Manual No SPECIFICATIONS

16 Power Supply Specifications & Electrical Requirements SPECIFICATIONS & DESIGN FEATURES Max OCV (U0) 380 vdc Max Output Current 00 Amps Output Voltage 60 vdc Duty Cycle Rating 60V (6kW) Operating range 4 F to 22 F (-0 C to + 50 C) Power Factor 00 ADC Output Cooling Forced Air (Class F) Auto-Cut 00 Power Supply Input Power Input Current Suggested Sizes (See Note) Voltage Freq. 3-Ph 3-Ph Fuse (Amps) Wire (AWG) (Volts) (Hz) (kva) (Amps) 3-Ph 3-Ph / # / # #6 400 (CE) # / #8 Line Voltages with Suggested Circuit Protection and Wire Sizes Based on National Electric Code and Canadian Electrical Code Extra Hard Usage Type SO, SOW, SOO, SOOW, ST, STW, STO, STOW, STOO, STOOW CAUTION Fuse and wire sizes are for reference only. The installation must conform to national and local codes for the type and method of wire being used. Manual No SPECIFICATIONS

17 Power Supply Dimensions 27 inch 680 mm 4.25 inch 050 mm inch 238 mm 27.5 inch 700 mm 33 inch 840 mm inch 960 mm 397 lb / 80 kg Art # A Manual No SPECIFICATIONS

18 Power Supply Rear Panel Features Gas Control Connector Arc Starter Connector Pilot (Pos) Terminal Torch (Neg) Terminal Torch Leads Port Input Power Terminals AC Power Lamp Gas Entry Ports Circuit Breaker Panel Gas Control Connector Ground Terminals CNC Connection Work Cable Terminal Terminal Cover Arc Starter Connector RETURN SUPPLY Terminal Cover Support Panel Coolant Connections Coolant Filter Coolant Tank Leads Bracket Art # A Manual No SPECIFICATIONS

19 Gas Requirements The customer will provide all gases and pressure regulators. Gases must be of high quality. Pressure regulators shall be equipped with stainless-steel diaphragms and installed as close as possible to the Gas Console. NOTE: The chart includes gases which may not be used in all applications. Auto-Cut 200 BASIC Power Supply: Gas Pressures, Flows, and Quality Requirements Gas Quality Minimum Pressure Flow O 2 (Oxygen) 99.5% Purity (Liquid recommended) 20 psi 8.3 bar / 827 kpa 200 scfh (5700 l/h) N 2 (Nitrogen) 99.5% Purity (Liquid recommended) <000 ppm O 2, <32 ppm H 2 O) 20 psi 8.3 bar / 827 kpa 300 scfh (8496 l/h) Compressed Air Clean, Dry, Free of Oil (see Note ) 90 psi 6.2 bar / 62 kpa 400 scfh (327 l/h) H35 (Argon-Hydrogen) H35 = 35% Hydrogen, 65% Argon % Purity (gas recommended) 20 psi 8.3 bar / 827 kpa 200 scfh (5664 l/h) H 2 O (Water) See Note 2 50 psi (3.5 bar) 0 gph (38 lph) Note : The air source must be adequately filtered to remove all oil or grease. Oil or grease contamination from compressed or bottled air can cause fires in conjunction with oxygen. For filtering, a coalescing filter able to filter to 0.0 microns should be placed as close as possible to the gas inlets on the Gas Control Module. Note 2: The tap water source does not need to be deionized, but in water systems with extremely high mineral content a water softener is recommended. Tap water with high levels of particulate matter must be filtered. Gas Applications MATERIAL OPERATION 55 A CUT 00 A CUT MILD STEEL STAINLESS STEEL ALUMINUM GAS TYPE GAS TYPE GAS TYPE PLASMA SHIELD PLASMA SHIELD PLASMA SHIELD O2 O2 Air Air Air Air O2 Air N2 H20 N2 H20 O2 Air H35 N2 H35 N2 N2 H20 N2 H20 Manual No SPECIFICATIONS

20 XT TM -30 Torch Specifications A. Torch Dimensions Art # A End Cap 9.00" mm 2.25" 57.5 mm Mounting Tube 5.50" mm 2.0" 50.8 mm Torch Body 6.30" 60.0 mm 3.54" mm 2.39" 60.8 mm 2.74" mm.57" mm.49" 37.8 mm Manual No SPECIFICATIONS

21 B. Torch Leads Lengths Gas Lead Assemblies Length Feet Meters C. Torch Parts (Generic Parts Shown) Art # A-0474 Shield Gas Distributor Plasma Gas Distributor Shield Cup Shield Cap Tip Electrode Cartridge D. Parts - In - Place (PIP) The torch is designed for use with a power supply which senses coolant return flow to confirm that torch parts are in place. If coolant return flow to the power supply is absent or insufficient the power supply will not provide power to the torch. Coolant leakage from the torch also indicates that torch parts are absent or installed improperly. E. Type Cooling Combination of gas stream through torch and liquid cooling. Manual No SPECIFICATIONS

22 F. XT TM -30 Torch Data (with AutoCut TM 00 Power Supply) XT TM -30 Torch Ratings (when used with Auto-Cut 00 Power Supply) Ambient Temperature 04 F 40 C Duty Cycle 00 Amps Maximum Current 00 Amps Voltage (V peak ) 500V Arc Striking Voltage 0kV Current Up to 00 Amps, DC, Straight Polarity (See Note) XT TM -30 Torch Gas Specifications Plasma Gases: Compressed Air, Oxygen, Nitrogen, H35 Shield Gases: Compressed Air, Oxygen, Nitrogen, Water Operating Pressure 25 psi ± 0 psi 8.6 bar ± 0.7 bar Maximum Input Pressure 35 psi / 9.3 bar Gas flow scfh Power Supply used with: Auto-Cut 00 Manual No SPECIFICATIONS

23 A. Installation Requirements. Electric Supply SECTION 3: INSTALLATION The electrical supply network, the gas and water supply system must meet local safety standards. This conformity shall be checked by qualified personnel. Auto-Cut 00 Power Supply Input Power Input Current Suggested Sizes (See Note) Voltage Freq. 3-Ph 3-Ph Fuse (Amps) Wire (AWG) (Volts) (Hz) (kva) (Amps) 3-Ph 3-Ph / # / # #6 400 (CE) # / #8 Line Voltages with Suggested Circuit Protection and Wire Sizes Based on National Electric Code and Canadian Electrical Code Extra Hard Usage Type SO, SOW, SOO, SOOW, ST, STW, STO, STOW, STOO, STOOW CAUTION Fuse and wire sizes are for reference only. The installation must conform to national and local codes for the type and method of wire being used. 2. Gas Supply The customer must supply all gases and pressure regulators. Gases must be of high quality. Pressure regulators must be double-stage and installed as close as possible to the gas console. Contaminated gas can cause one or more of the following problems: Reduced cutting speed Poor cut quality Poor cutting precision Reduced consumables life. Oil or grease contamination from compressed or bottled air can cause fires in conjunction with oxygen. Cooling System Requirements Coolant must be added to the system on installation. The amount required varies with torch leads length. Thermal Dynamics recommends the use of its coolants and (for low temperatures). Coolant Capabilities Cat. Number and Mixture Mixture Protects To 'Extra-Cool TM ' 25 / 75 0 F / -2 C 'Ultra-Cool TM ' 50 / F / -33 C 'Extreme Cool TM ' Concentrate* -65 F / -5 C * For mixing with D-I Cool TM Manual No INSTALLATION

24 B. Cables and Leads Identification F Pilot Return Negative Coolant Supply Coolant Return Control Cable F CNC CNC Cable A B C D E P Arc Starter / Gas Control Module (GCM-000) Auto-Cut Power Supply Control Cable K Q Ground Cable Primary power G: Torch Lead Set, Shielded - Coolant Supply w/ Negative - Coolant Return - Pilot Return - Plasma Gas - Shield Gas Positioning Tube Torch Ground Cables Work Cable O Work Art # A Manual No INSTALLATION

25 A #8 AWG Cable Pilot Return, Power Supply to Arc Starter B # AWG Cable Negative Lead, Power Supply to Arc Starter C D Green Red Green Red Coolant Leads, Power Supply to Arc Starter E 4 Control Cable, Power Supply to Arc Starter F F Green / Yellow #0 AWG Green / Yellow /0 (50 mm ) 2 Ground Cable Ground Cable, Arc Starter To Earth Ground G Torch Lead Set K 37 Control Cable, Power Supply to Gas Control Module O /0 (50 mm ) Cable 2 Work Cable P CNC Cable (4 Wire) 4 /.3 m Q #4 AWG Ground Cable, Gas Control Module to Power Supply. Factory Installed. Art # A-0703 Manual No INSTALLATION

26 C. Position the Power Supply WARNINGS Do not touch live electrical parts. Disconnect input power conductors from de-energized supply line before moving unit. FALLING EQUIPMENT can cause serious personal injury and equipment damage. Use all four lifting eyes when using lifting straps to lift the power supply. Use a forklift, crane, or hoist to lift the unit off the shipping pallet as shown. Keep the power supply steady and vertical. Do not lift it any further than necessary to clear the shipping pallet. Art # A Set the power supply on a solid, level surface. The installer may fasten the power supply to the floor or a supporting fixture with hardware passing through the horizontal parts of the power supply feet. Manual No INSTALLATION

27 D. Set Command-Control Module Switches CAUTION There are two types of command-control module. Refer to the illustration to determine the type installed.. Set Switches for Type Command-Control Module Remove the power supply right side. Set switches on the CCM (Command-Control Module) per the illustrations. Switch settings and connection details are provided in the Appendix. CAUTION Printed circuit boards in the Command - Control Module are static - sensitive. Discharge any built-up static charges in your body or surroundings before touching the printed circuit boards. Future Use O N SW SW3 SW4 SW5 SW O N SW--: Auto Pilot Restart. = ON = Auto Pilot Function enabled. = OFF = Auto Pilot Function disabled (Factory default setting). SW--2: Pilot Delay 2 = OFF, 3 = OFF, 4 = OFF: 0 Seconds (Factory default setting). SW--3: Pilot Delay 2 = ON, 3 = OFF, 4 = OFF: 0. Seconds SW--4: Pilot Delay 2 = OFF, 3 = ON, 4 = OFF: 0.2 Seconds 2 = ON, 3 = ON, 4 = OFF: 0.4 Seconds 2 = OFF, 3 = OFF, 4 = ON: 0.8 Seconds 2 = ON, 3 = OFF, 4 = ON:.0 Seconds 2 = OFF, 3 = ON, 4 = ON:.5 Seconds 2 = ON, 3 = ON, 4 = ON: 2.0 Seconds SW-3: Gas Preflow Time = OFF, 2 = OFF: 2 Seconds (Factory default setting). = ON, 2 = OFF: 4 Seconds = OFF, 2 = ON: 6 Seconds = ON, 2 = ON: 8 Seconds SW-4: Postflow Time = OFF, 2 = OFF: 0 Seconds (Factory default setting). = ON, 2 = OFF: 20 Seconds = OFF, 2 = ON: 5 Seconds = ON, 2 = ON: 0 Seconds (Disabled) SW-5-: Tip Saver = OFF = Disabled (Factory default setting). = ON = Enabled SW-5-2: Off Plate 2 = OFF = Disabled (Factory default setting). 2 = ON = Enabled SW 8-: Pilot Time = OFF = Short (85 ms.) (Factory default setting). = ON = Long (3 s.) SW 8-2: Remote Current = ON (Remote Analog Current Control) SW8-3, SW 8-4: Reserved for Factory use. Art # A Active only when SW-- is set to ON. Manual No INSTALLATION

28 CAUTION Printed circuit boards in the Command - Control Module are static - sensitive. Discharge any built-up static charges in your body or surroundings before touching the printed circuit boards. SW SW6 SW2 SW3 SW-6: OK-to-Move: Contact closure, A (Factory default setting) or DC Volts (6-8vdc@ upt to 00 ma.) SW-: Analog Current Control. B = from Basic Gas Control (Factory default setting) or A = from CNC. Position A requires that SW-8-2 be ON. SW-2-/2/3/4: Divided Arc signal All = OFF = 50: (Factory default setting) = ON = 6.6: 2 = ON = 30: Only on at a time. 3 = ON = 40: 4 = Not used. SW3: Reserved for Factory Use. Art # A NOTE Standoff Control SC- requires Switch 2- set to ON. Manual No INSTALLATION

29 2. Set Switches for Type 2 Command-Control Module CAUTION There are two types of command-control module. Refer to the illustration to determine the type installed. Remove the power supply right side. Set switches on the CCM (Command-Control Module) per the illustrations. Switch settings and connection details are provided in the Appendix. CAUTION Printed circuit boards in the Command - Control Module are static - sensitive. Discharge any built-up static charges in your body or surroundings before touching the printed circuit boards. Future Use O N SW SW3 SW4 SW5 SW O N SW--: Auto Pilot Restart. = ON = Auto Pilot Function enabled. = OFF = Auto Pilot Function disabled (Factory default setting). SW--2: Pilot Delay 2 = OFF, 3 = OFF, 4 = OFF: 0 Seconds (Factory default setting). SW--3: Pilot Delay 2 = ON, 3 = OFF, 4 = OFF: 0. Seconds SW--4: Pilot Delay 2 = OFF, 3 = ON, 4 = OFF: 0.2 Seconds 2 = ON, 3 = ON, 4 = OFF: 0.4 Seconds 2 = OFF, 3 = OFF, 4 = ON: 0.8 Seconds 2 = ON, 3 = OFF, 4 = ON:.0 Seconds 2 = OFF, 3 = ON, 4 = ON:.5 Seconds 2 = ON, 3 = ON, 4 = ON: 2.0 Seconds SW-3: Gas Preflow Time = Off, 2 = OFF: 2 seconds = ON, 2 = OFF: 4 seconds = OFF, 2 = ON: 6 seconds = ON, 2 = ON: 8 seconds SW-4: Postflow Time SW-5-: Tip Saver = OFF, 2 = OFF: 0 Seconds (Factory default setting). = ON, 2 = OFF: 20 Seconds = OFF, 2 = ON: 5 Seconds = ON, 2 = ON: 0 Seconds = OFF = Disabled (Factory default setting). = ON = Enabled SW-5-2: Off Plate 2 = OFF = Disabled (Factory default setting). 2 = ON = Enabled SW 8-: Pilot Time = OFF = Short (85 ms.) (Factory default setting). = ON = Long (3 s.) SW 8-2: Remote Current = ON (Remote Analog Current Control) SW8-3, SW 8-4: Reserved for Factory use. Active only when SW-- is set to O N. Art # A Manual No INSTALLATION

30 CAUTION Printed circuit boards in the Command - Control Module are static - sensitive. Discharge any built-up static charges in your body or surroundings before touching the printed circuit boards. SW SW6 SW2 No external connection cover SW3 SW-6: OK-to-Move: Contact closure, A (Factory default setting) or DC Volts (6-8vdc@ up to 00 ma.) SW-: Analog Current Control. B = from Gas Control (Factory default setting) or A = from CNC. Position A requires that SW-8-2 be ON. SW-2-/2/3/4: Divided Arc signal All = OFF = 50: (Factory default setting) = ON = 6.6: 2 = ON = 30: Only on at a time. 3 = ON = 40: 4 = Not used. SW3-, SW3-2: Reserved for Factory Use. Art # A NOTE Standoff Control SC- requires Switch 2- set to ON. Manual No INSTALLATION

31 E. Check / Adjust Input Voltage Configuration. The power supply includes a voltage configuration board which must be positioned to match the primary input voltage. Remove the power supply left side panel and locate the voltage configuration board. The input voltage configuration is shown at the top of the board. 2. If necessary, disconnect the jumper from the top-right corner of the board, remove the board and re-install with the correct input voltage shown at the top of the board. Reconnect the jumper to the top-right corner of the board. 3. Re-install the power supply side panel.. Disconnect jumper 208/230V / 460V Input Voltage Board (Shown in 460V Position) 2. Remove bolts. 3. Invert board. 4. Re-install board. 5. Connect jumper. Art # A Manual No INSTALLATION

32 F. Remove the Connections Cover The primary power cable must be supplied by the end user and connected to the power supply. Refer to local and national electrical codes for suggested cable and fuse sizes. Remove the connections cover on the rear of the Power Supply. Use caution when removing the panel; there is a ground wire connected to the inside of the panel. Do not disconnect this wire. Connection Panel Connections Cover (Removed) Art # A Manual No INSTALLATION

33 G. Connect Work Cable. Pass the end of the work cable upward through the bracket at the bottom edge of the rear panel, and through the opening in the connections cover support panel. 2. Refer to the illustration. Connect the lead as shown. Tighten securely. Do not overtighten. WARNINGS Ensure that lead attachment hardware is properly sized. Excess length may cause damage if hardware contacts other parts of the system. The clear connections cover must remain in place. Connections Cover Connection Panel Work Cable AC INPUT L L2 L3 PILOT WORK TORCH Work Lead Connections Cover Support Panel Work Lead Connection Detail Leads Bracket To Cutting Table Art # A Manual No INSTALLATION

34 H. Connect Input Power and System Ground Cables. Carefully cut back the outer sheath on the primary input power cable to expose the individual cords. Cut back the insulation on the individual cords. Route the cable upward through the bracket at the bottom edge of the power supply rear panel and through the connections cover support panel on the rear of the power supply. 2. Install ring tongue terminals on the individual cords. Fasten the terminals to the individual cords securely. 3. Connect the individual cords as shown. Connect the power cable ground cord to the ground terminal block. Tighten the hardware securely. Do not overtighten. WARNING The clear connections cover must remain in place. 4. Pass a system ground cable through the bracket at the bottom edge of the power supply rear panel and through the same opening in the connections cover support panel as the input power cable. Connect the cable to the ground terminal block on the power supply rear panel. Refer to the Ground Connections Section for full details and procedures on proper system grounding. Clear Connections Cover Ground Terminal Block Connection Panel PILOT WORK TORCH AC INPUT L L2 L3 L L2 L3 System Ground Cable Input power cable ground Connections Cover Support Panel System Ground Cable Input power cable Leads Bracket Art # A Re-install the connections cover on the power supply. Snug the hardware securely by hand. Do not overtighten. Manual No INSTALLATION

35 WARNING Dangerous high voltage is present when the power supply is connected to input power. Do not connect input power or operate the power supply unless the connections cover is fastened in place. I. Ground Connections A. Electromagnetic Interference (EMI) Pilot arc starting generates a certain amount of electromagnetic interference (EMI), commonly called RF noise. This RF noise may interfere with other electronic equipment such as CNC controllers, remote controls, height controllers, etc. To minimize RF interference, follow these grounding procedures when installing mechanized systems: B. Grounding. The preferred grounding arrangement is a single point or Star ground. The single point, usually on the cutting table, is connected with /0 AWG (European 50 mm 2 ) or larger wire to a good earth ground (measuring leass than 3 ohms; an ideal ground measures ohm or less. Refer to paragraph C, Creating An Earth Ground. The ground rod must be placed as close as possible to the cutting table, ideally less than 0 ft (3.0 m), but no more than 20 ft (6. m) from the cutting table. NOTE All ground wires should be as short as possible. Long wires will have increased resistance to RF frequencies. Smaller diameter wire has increased resistance to RF frequencies, so using a larger diameter wire is better. 2. Grounding for components mounted on the cutting table (CNC controllers, height controllers, plasma remote controls, etc.) should follow the manufacturer s recommendations for wire size, type, and connection point locations. For Thermal Dynamics components (except Arc Starter and Gas Control Module) it is recommended to use a minimum of 0 AWG (European 6 mm 2 ) wire or flat copper braid with cross section equal to or greater than 0 AWG connected to the cutting table frame. The Remote Arc Starter uses /0 earth ground wire and the Gas Control Module should use minimum # 4 AWG wire. The connection point must be to clean bare metal; rust and paint make poor connections. For all components, wires larger than the recommended minimum can be used and may improve noise protection. 3. The cutting machine frame is then connected to the Star point using /0 AWG (European 50 mm 2 ) or larger wire. 4. The plasma power supply work cable (see NOTE) is connected to the cutting table at the single point Star ground. NOTE Do Not connect the work cable directly to the ground rod. 5. Make sure work cable and ground cables are properly connected. The work cable must have a solid connection to the cutting table. The work and ground connections must be free from rust, dirt, grease, oil and paint. If necessary grind or sand down to bare metal. Use lock washers to keep the connections tight. Using electrical joint compound to prevent corrosion is also recommended. Manual No INSTALLATION

36 6. The plasma power supply chassis is connected to the power distribution system ground as required by electrical codes. If the plasma supply is close to the cutting table (see NOTE) a second ground rod is not usually needed, in fact it could be detrimental as it can set up ground loop currents that cause interference. When the plasma power supply is far away from the ground rod and interference is experienced, it may help to install a second earth ground rod next to the plasma power supply. The plasma power supply chassis would then be connected to this ground rod. NOTE It is recommended that the Plasma Power Supply be within ft (6. 9. m) of the cutting table, if possible. 7. The plasma control cable should be shielded with the shield connected only at the cutting machine end. Connecting the shield at both ends will allow ground loop currents which may cause more interference than with no shield at all. C. Creating An Earth Ground. To create a solid, low resistance, earth ground, drive a /2 in (2 mm) or greater diameter copper clad ground rod at least 6-8 ft ( m) into the earth so that the rod contacts moist soil over most of its length. Depending on location, a greater depth may be required to obtain a low resistance ground (see NOTE). Ground rods, typically 0 ft (3.0 m) long, may be welded end to end for greater lengths. Locate the rod as close as possible to the work table. Install a ground wire, /0 AWG (European 50 mm2) or greater, between the ground rod and the star ground point on the cutting table. NOTE Ideally, a properly installed ground rod will have a resistance of three ohms or less. To test for a proper earth ground, refer to the following diagram. Ideally, the reading on the multimeter should be 3 VAC for 5VAC line, or.5 VAC for 230 VAC line. CAUTION Remove all other connections from the ground rod during this test. This test assumes the 5 or 230 VAC source neutral is connected to the utility earth ground. NEUTRAL Earth Grounded NEUTRAL PROBE HOT HOT PROBE WARNING Use extreme caution. This test uses live voltage. 00W Incandescent light bulb* * Can replace light bulb with a 00w resistor. Use 00 ohm for 5VAC. Use 500 ohm for 230VAC Ground Rod with other connections removed VAC On 5V AC Line: 3VAC = 3 ohms VAC = ohm On 230V AC Line:.5VAC = 3 ohms 0.5VAC = ohm Art # A Ground Testing Manual No INSTALLATION

37 2. Increasing the ground rod length beyond ft (6. 9. m) does not generally increase the effectiveness of the ground rod. A larger diameter rod which has more surface area may help. Sometimes keeping the soil around the ground rod moist by continuously running a small amount of water into it will work. Adding salt to the soil by soaking it in salt water may also reduce its resistance. When these methods are used, periodic checking of the ground resistance is required to make sure the ground is still good. D. Routing Of Torch Leads. To minimize RF interference, position torch leads as far as possible from any CNC components, drive motors, control cables, or primary power lines. If cables have to pass over torch leads, do so at an angle. Do not run the plasma control or other control cables in parallel with the torch leads in power tracts. J. Connect Gas Supply Lines. Connect the gas supply lines to the appropriate input ports as shown. Plasma Gas - In Water - In Shield Gas - In RETURN SUPPLY RETURN SUPPLY Art # A Manual No INSTALLATION

38 K. Connect CNC Cable. Connect one end of the CNC cable to the power supply receptacle marked CNC. 2. Connect the other end of the cable to the CNC device. 3. The CNC cable shield must be attached to ground. To CNC RETURN SUPPLY RETURN SUPPLY Art # A Manual No INSTALLATION

39 Note The CNC Cable shield must be grounded. See Illustration for further CNC cable wiring details. Cutting Machine CNC Cable Power Supply J5 * () ( 2) 2 * NC START/STOP ( 3) ( 4) Source, 6 VDC, 0 ma. ( 5) 5... Divided Arc V (-) ( 6) 6... Divided Arc V (+) ( 7) 7... Arc V (-) through 00K *** 8 ( 9) 9... Arc V (+) through 00K *** ( 0) 0... Remote Analog Current Control (-) Start Motion (OK-To-Move) ( )... ( 2) { 2 3 * ( 4) 4 ** Shield Remote Analog Current Control (+) OK-To-Move Relay DCV (-) Contact or DCV (+) 20 VAC ( 5-8 or 28 VDC) up to 00 ma.) * Power Supply Gnd not used for CNC cable Do not connect wire # to anything. A ** Cable Shield drain wire must be connected to ground at cutting machine. *** Used only for special Torch Height Control Manual No INSTALLATION

40 L. Connect Torch Leads to the Gas Control Module / Arc Starter. Remove the top cover from the Gas Control Module / Arc Starter. 2. Pass the torch leads and coolant leads through the torch leads port on the back of the module. Ensure that the leads outer jacket slides into the port. CAUTION Use protective gloves when handling the leads. Do not kink or bend the leads. 3. Inside the module, slide the leads clamp over the leads. 4. Connect the leads to the module in the sequence shown. Coolant leads and connectors are color-tagged; red for coolant return, green for coolant supply. Shield gas and plasma gas connections are left- and right- hand threaded and will not interchange. Torch Leads: Coolant Supply & Return Plasma Gas Shield Gas Inner Leads Shield Outer Leads Shield 2 Clamp * (Clamp type may vary) Inner Shield Lead Connection Detail CAUTION: Keep two terminals arranged as shown. Art # A Manual No INSTALLATION

41 Coolant Return Connection (Tagged Red) Coolant Supply Connection (Tagged Green) Plasma Gas Connection Shield Gas Connection Torch Leads Art # A Fold the end of the leads outer jacket back over the connection ring inside the module. Slide the leads clamp over the jacket and fasten the clamp and jacket to the connection ring. Re-install the module top cover. Manual No INSTALLATION

42 5 Clamp Inner Shield Connection Art # A Manual No INSTALLATION

43 M. Torch Head Installation and Connection Install the Torch as follows:. Install the torch mounting block on the cutting table (gantry). Fasten the block in place. 2. Leave the end cap in place on the torch leads. Remove and discard the protective end caps from the Mounting Tube. 3. Install the O-ring in the groove at the upper end of the mounting tube. Slide the torch mounting tube onto the leads far enough to expose the fittings on the ends of the leads. 4. Connect the Torch Head to the torch leads. Follow the sequence shown. Do not let the leads twist. End Cap Shown to illustrate assembly order only; parts must remain secured tightly. O-Ring Insulating Paper Pilot Lead Plasma Lead Torch Leads Plasma Lead Connector Positioning Tube O-Ring 2 Coolant Return Check Valve and Connector Shield ('Secondary') Gas Connector Insulating Paper Coolant Supply Connector Positioning Tube Detail Threaded Holes Art # A Drain Holes Manual No INSTALLATION

44 5. Slide the positioning tube down to the torch head. Hold the torch head stationary. Rotate the positioning tube onto the torch head. Pull the leads back as needed to ensure a proper fit through the Mounting Tube. Do not let the torch leads twist. CAUTION Ensure that the leads do not twist within the mounting tube. Leads must lie as shown in the installation sketch. 6. The lower end of the Mounting Tube includes four threaded holes. Install an Allen set screw from the hardware kit in any of the threaded holes to secure the Torch Head Assembly to the Mounting Tube. 7. Fasten the positioning tube into the mounting block. Slide the leads end cap down onto the torch positioning tube. Ensure that the end cap engages the O-ring at the top of the positioning tube. 8. Install the shield cup, and cartridge assembly (including consumables) onto the torch head. Manual No INSTALLATION

45 N. Install Consumable Torch Parts. Refer to the Torch Speed Charts to select the correct parts for the application. The application will determine which torch parts must be used. Refer to the speed charts for the proper torch parts to install for a selected application. CAUTION Do not interchange parts. Make sure both the tip and electrode in the torch correspond with the plasma and shield gas in use for the application. 2. Install the consumable parts as follows to ensure proper operation. These steps will help ensure that parts are seated correctly. 3. Stack the consumable parts together. 4. Insert the stack of consumable parts into the cartridge. Ensure that the large O-ring on the torch tip fits completely into the cartridge. If any part of the O-ring protrudes from the cartridge, the parts are not seated properly. : Stack Parts 2: Press Cartridge onto Stacked Parts Electrode Plasma Gas Distributor Tip O-Ring on Tip No Gaps Between Parts Shield Gas Distributor Shield Cap Cartridge Covers O-Ring on Torch Tip 3: Thread Shield Cup onto Cartridge 4: Check Shield Cap Protrusion Shield Cup Shield Cap Shield Cap Protrudes " (.6-2. mm) Art # A Manual No INSTALLATION

46 5. Use the removal tool to hold the cartridge assembly, while turning the shield cup onto the cartridge assembly. When this group is fully assembled, the shield should protrude from the front of the shield cup 0.063" to 0.083" (.6-2. mm). Without this protrusion the shield cup is not properly tightened onto the cartridge assembly. Removal Tool Assembled Cartridge Art # A Shield Cup Installing Shield Cup Onto Cartridge 6. Take the removal tool off the cartridge. Fit the cartridge assembly onto the torch head. The cartridge should seal to the large O-ring on the torch body as shown. If the cartridge does not seal on the O-ring, the cartridge is not fully tightened. CAUTION Do not force the cartridge if it will not fully tighten. Remove the cartridge and gently clean the threads on the torch head body with a wire brush. Apply oxygen-compatible lubricant (supplied with the torch) to the threads. Torch Head Assembled Cartridge Art # A Installing Assembled Cartridge Onto Torch Head Manual No INSTALLATION

47 7. Confirm proper parts assembly as shown. Torch Head Torch Head O-Ring " (.6-2. mm) Protrusion Art # A Slide the ohmic clip over the shield cup if using ohmic torch height sensing. NOTE Ohmic height sensing is not recommended with water shield. Water on the plate interferes electrically with the ohmic sensing circuit. Ohmic Clip A Connect the wire lead from the height finder to the ohmic clip if using ohmic torch height sensing. Manual No INSTALLATION

48 O. Complete the Installation. Remove the cap, deioinizer basket, and deionizer bag from the coolant tank. Fill the coolant tank to the level shown, with Thermal Dynamics coolant. The coolant level is visible through the translucent coolant tank. The amount of coolant required varies with torch leads length. 2. Remove the deionizer bag from its its shipping bag. Insert the basket into the top of the coolant tank. Drop the deionizer bag into the basket. Replace the cap on the tank. Coolant Capabilities Cat. Number and Mixture Mixture Protects To 'Extra-Cool TM ' 25 / 75 0 F / -2 C 'Ultra-Cool TM ' 50 / F / -33 C 'Extreme Cool TM ' Concentrate* -65 F / -5 C * For mixing with D-I Cool TM COOLANT RETURN SUPPLY RETURN SUPPLY Fill Range Coolant Tank Art # A Manual No INSTALLATION

49 2. After the complete system has been installed, check that the coolant has been pumped through the system as follows (see NOTE): NOTE Depending on the length of the torch leads, the system may require more coolant after turning the system ON for the first time. a. Place the ON/OFF Switch to ON. The power supply will start to circulate coolant throughout the system. b. After about 30 seconds the system may shut down if the leads are not full of coolant. c. Place the ON/OFF switch to OFF. d. After 0 seconds place the ON/OFF switch to ON again. e. Repeat steps b through d until the system no longer shuts down. Depending on the length of the torch leads this sequence may need to be done three to five times. f. After the system stays operational allow the pump to operate for ten minutes to properly purge any air from the coolant lines before using the system. 3. Re-fill the reservoir and re-install the filler cap. NOTE Circuitry in the power supply will generate a Low coolant message if the coolant level is too low. Manual No INSTALLATION

50 Manual No INSTALLATION

51 Power Supply Indicators SECTION 4: OPERATION AC Indicator Gas Indicator Status Indicator Temp Indicator DC Indicator Art # A-0483 AC Power Lamp Indicates AC power is being supplied to the system when the ON/OFF switch is in ON position. When switch is first set to ON, the lamp will blink, indicating gas purge at power on. TEMP Lamp: Normally OFF. Lamp will come ON when the internal temperature sensors detect temperatures above normal limits. Let the unit cool before continuing operation. GAS Lamp: Normally ON. Indicates adequate gas pressure for operation in the system DC Lamp: Indicates the power supply is generating output DC voltage. Message Center: Show system status. The number of flashes indicates the status. Refer to the Status Code Section for details. On power supply start-up, the indicator flashes to show the operating software revision level. Manual No OPERATION

52 Control Console Features Art # A RUN SET PLASMA SHIELD SHIELD GAS Plasma Gas Pressure Gauge CUT OUT A H2O MIST Shield Gas Pressure Gauge Run / Set Selector RUN Amperage Selector GCM 000 CUT OUT SET PLASMA SHIELD SHIELD GAS H2O MIST A H2O MIST Shield Selector Plasma Gas Pressure Control Knob Shield Gas Pressure Control Knob Water Mist (Shield) Flow Meter and Control Knob Run / Set Selector: Use SET position to adjust plasma and shield pressures and flows. Once these are set, switch to RUN position for operation. Plasma and Shield Gas Pressure Control Knobs: Adjust plasma and shield gas pressures. Turn knobs to set desired levels. Plasma and Shield Gas Pressure Gauges: Display plasma and shield gas pressures. Shield Selector: Selects shield fluid, gas or H 2 O Mist (water). Water Shield Mist (H 2 O) Flowmeter and Control Knob: Controls flow rate of shield water supply. Amperage Selector: Continuously adjustable up to 00 Amps. Manual No OPERATION

53 Operating Set-up Follow this set-up procedure each time the system is operated: WARNING Disconnect primary power at the source before assembling or disassembling power supply, torch parts, torch and leads assemblies or adding coolant. A. Coolant Level Inspection Check the coolant level in the coolant tank at the rear of the unit. If the tank is below 3/4 full, add coolant. B. Deionizer Bag Inspection Check the deionizer bag in the tank basket. If the bag is a yellowish brown (straw) color, replace the bag. C. Torch Parts Selection Check the torch for proper assembly. Install proper torch parts for the application per the Torch section of the manual.. D. Input Power Check the power source for proper input voltage. Make sure that Power Supply is set for the proper voltage. Close main disconnect switch or plug unit in to supply primary power to the system. E. Work Cable Connection Check for a solid and clean work cable connection to the workpiece or cutting table. The connection area must be free from paint and rust. F. Torch Connection Check that the torch is properly connected. G. Gas Supplies Connect desired plasma and shield gases. Make sure gas sources meet requirements. Check connections and turn gas supply on. Select the desired shield gas as follows:. If gas shield is desired, set shield selector switch to GAS position. 2. If Water Mist shield is desired, set shield mode selector switch to H 2 O MIST position. Water must be connected to the control console at the shield water connection. Tap water should only be used for shield gas. NOTES If tap water pressure is over 00 psi (6.9 bar) there must be a Water Regulator (Catalog No. 8-68) installed between the water source and the Power Supply. Manual No OPERATION

54 H. Plasma Gas Purge Move the Power Supply ON/OFF switch to the ON position. An automatic gas purge will remove any condensation that may have accumulated in the torch and leads while the system was shut down. After the purge is complete, if the RUN/SET switch is in SET position, gases will flow. I. Amperage Selection Select the desired current output amperage. J. Pressure and Flow Settings. Refer to the Torch manual for pressure and flow details according to the material being cut. Move the RUN/SET switch to SET position. (Gas will flow through the torch). Set gas pressures and flows as follows: 2. To set the Plasma Gas pressure: a. Pull out the knob on the Plasma Gas pressure control knob. c. Turn the knob to adjust gas pressure. d. Push the knob back in to lock the pressure setting. 3. To set the Shield Gas pressure: Set the Shield Mode Selector switch to the GAS or H 2 O MIST position. For Gas Shield: a. Pull out the Shield Gas Pressure Control Knob. c. Turn the knob to adjust gas pressure. d. Push the knob back in to lock the pressure setting. For H 2 O MIST Shield: a. Turn the Water Mist Control Knob to adjust pressure. b. Push the knob back in to lock the pressure setting. NOTE Unless the installation includes gas selection equipment between the gas supplies and the control console, switching between gases requires disconnecting the gas supply line(s) from the control console rear panel and connecting the appropriate input gases. Water input can remain connected permanently because the shield selector switch disables and enables the flow of water for H 2 O Mist shield. 4. Place the RUN/SET switch to the RUN position. Manual No OPERATION

55 Cut Quality Cut quality requirements differ depending on application. For instance, nitride build-up and bevel angle may be major factors when the surface will be welded after cutting. Dross-free cutting is important when finish cut quality is desired to avoid a secondary cleaning operation. Cut quality will vary on different materials and thicknesses. Left Side Cut Angle Right Side Cut Angle Top Spatter Kerf Width Cut Surface Bevel Angle Top Edge Rounding A-0052 Dross Build-Up Cut Surface Drag Lines A Cut Surface The condition (smooth or rough) of the face of the cut. Bevel Angle The angle between the surface of the cut edge and a plane perpendicular to the surface of the plate. A perfectly perpendicular cut would result in a 0 bevel angle. Top-Edge Rounding Rounding on the top edge of a cut due to wearing from the initial contact of the plasma arc on the workpiece. Dross Build-up and Top Spatter Dross is molten material which is not blown out of the cut area and re-solidifies on the plate. Top spatter is dross which accumulates on the top surface of the workpiece. Excessive dross may require secondary cleanup operations after cutting. Kerf Width The width of material removed during the cut. Nitride Build-up Nitride deposits which may remain on the cut edge of the carbon steel when nitrogen is present in the plasma gas stream. Nitride buildups may create difficulties if the steel is welded after the cutting process. Manual No OPERATION

56 Direction of Cut The plasma gas stream swirls as it leaves the torch to maintain a smooth column of gas. This swirl effect results in one side of a cut being more square than the other. Viewed along the direction of travel, the right side of the cut is more square than the left. Left Side Cut Angle Right Side Cut Angle Clockwise Scrap Counter- Clockwise Scrap Workpiece A-0052 Art # A-0482 Swirl Effect on Side Characteristics Of Cut To make a square - edged cut along an inside diameter of a circle, the torch should move counterclockwise around the circle. To keep the square edge along an outside diameter cut, the torch should travel in a clockwise direction. Underwater Cutting Cutting on a water table either underwater or with the water touching the plate or with a water muffler system is not recommended. If a water table is used the water level must be a minimum of 4 inches from the bottom of the plate. Failure to follow this recommendation could result in poor cut quality and short consumable parts life. Ohmic Sensing Ohmic height sensing is not recommended with water shield. Water on the plate interferes electrically with the ohmic sensing circuit. Manual No OPERATION

57 System Operation This section contains operating information which is specific to the power supply. WARNINGS Frequently review the safety precautions in Section. Disconnect primary power at the source before assembling or disassembling power supply, torch parts, or torch and leads assemblies, or adding coolant. It is not enough to simply move the ON/OFF switch on the unit to OFF position when cutting operations have been completed. Always open the power supply disconnect switch five minutes after the last cut is made.. Connect system to primary input power. 2. Turn ON/OFF switch to ON (up) position. AC Lamp turns ON. Fan and coolant pump turn on. There is a start-up purge of gas through the system. I POWER OFF O ON O OFF Art # A Check the AC lamp. If lamp is ON, AC input power is present in the power supply. Circuitry in the power supply monitors the status of various conditions. If the circuitry detects a situation requiring operator attention, the status lamp on the control panel flashes a 2-part code to indicate a code group and then a particular condition within the group. After 4 seconds, the sequence repeats. Example: Lamp flashes 4 times; the condition is in group 4. After a.2 second delay, the lamp blinks 3 times; the status code is 4-3. After a 4-second delay, the lamp repeats the sequence until the condition is corrected. Some conditions can be active indefinitely, while others are momentary. The power supply latches momentary conditions; some momentary errors can shut down the system. The lamp may show multiple conditions in sequence; it is important to recognize all possible conditions that may be displayed. The Error Code section provides explanations of status codes. Manual No OPERATION

58 4. Place RUN/SET switch to SET mode. a. Gases flow to set pressures. 5. Place RUN/SET switch to RUN mode. a. Gas flow stops. 6. Protect eyes and start torch. a. Gas pre-flows starts. 7. After gas pre-flow: a. Power supply enabled. DC lamp turns ON. 8. Pilot arc is established. 9. Move Torch within transfer distance of workpiece. a. Main arc transfers to the workpiece. Pilot arc shuts off. 0. Complete cutting operation.. Stop the torch. a. Main arc stops. 2. Gas will flows briefly ( post-flow ). a. Gas solenoid closes; gas flow stops: 3. Set the ON/OFF power switch on the front panel of the unit to OFF. a. AC Power lamp turns OFF. b. Fan and pump turn OFF. 4. Place the main power disconnect to open. a. Main AC power is removed from the system. Manual No OPERATION

59 Operational Suggestions. Wait five minutes before setting the ON/OFF switch to OFF after operation. This allows the cooling fan to run to dissipate operating heat from the power supply. 2. For maximum parts life, do not operate the pilot arc any longer than necessary. 3. Use care in handling torch leads and protect them from damage. 4. When using water as the shield note the following: Use clean drinking quality tap water to help prevent particulate build-up within the system water shield plumbing. Particulate contamination and bulid-up can cause reduced consumable parts life and premature torch failure. A cartridge type particulate water filter may help achieve optimum cutting performance. Manual No OPERATION

60 Note These codes are for systems with Firmware versions 2.4 or later. If your system s Firmware is a prior version, contact your distributor for updates. Error Code Error Remedy / Comments - External E-Stop Activated or Check and correct. Plasma Enable Switch OFF -2 Pilot Ignition Failure Pilot does not start > 5 seconds. -3 Pilot Out Pilot shut off without shutoff signal. -4 Loss of Transfer Arc transferred (>50 ms) then shut off without signal. -5 Off the Plate Torch moved past edge of metal (0nly with Off Plate enabled and Auto Pilot Restart disabled.) -6 Transfer Timeout (Failure to transfer in allowed time) Fault Code Key Must transfer from pilot to cutting arc in 85 ms. (Sw 8- off) or 3 sec (SW 8- on). -7 Tip Saver (If enabled; active during ramping and cutting. Possible double arc. -8 Shorted Torch Electrode to tip voltage <50v w/ inverter on. 2- Missing Phase of 3 input AC phases missing. 2-2 Input voltage out of tolerance Test and correct. 2-3 Power Supply Overheated Inverter module or pilot module overheated. 2-4 Power Supply Not ready 2-5 DC Output Low < 60 vdc. 2-6 AC Input over Current Fault Turn off power to reset. 2-7 Unwanted Current Possible shorted torch. Current in pilot lead or work lead before pilot arc starts. 2-8 Unwanted Pilot Current Signal Current in pilot circuit before starting pilot. 2-9 Unwanted Transfer Current in work lead before starting pilot. Manual No OPERATION

61 Error Code Error Gas Control Conn Fault - 3- Connection missing or lost 3-3 Plasma Pressure Low Coolant Level Low 4- (before arc start) Low or Missing Coolant Flow (> 5 seconds when arc off, or 4-2 ASAP when flow <0.35 gal/min during active arc, or when flow is gal/min Coolant Overheated (over 58 F [70 C]) Cooling System Not Ready. Pump has run >30 sec w/o reaching minimum flow requirement. Low Coolant Warning (during cut) Fault Code Key Remedy / Comments Check coolant level in tank, add as needed. Check coolant level in tank, add as needed. Coolant temperature must drop by 9 F (5 C) to clear overtemp condition Recycle power or cycle plasma enable / E-Stop. Warning does not stop cut. Stop cut, shut off input power, add coolant to tank. 6- CCM Analog Voltage Error Contact Thermal Dynamics. 6-2 CCM Analog to Digital Coverter Contact Thermal Dynamics. 6-3 Coolant Flow Circuit Error Contact Thermal Dynamics. 6-4 CCM Data Memory Error Contact Thermal Dynamics. Manual No OPERATION

62 This page intentionally blank

63 SECTION 5: MAINTENANCE Perform the following checks periodically to ensure proper system performance. Power Supply Maintenance Schedule Daily Check coolant level; add coolant as needed. Check gas hose connections and pressures. Check cooling fan; clean as needed. Monthly Check cooling fan and radiator; clean as needed. Check gas hoses for cracks, leaks, or abrasion. Replace as needed. Check all electrical connections for cracks or abrasion. Replace as needed. Clean water filter (if using H 2 O Mist) Six Months Replace coolant filter. Clean coolant tank. Vacuum out any dust buildup inside power supply. Coolant Filter Cleaning Procedure Periodic cleaning of the coolant filter ensures maximum coolant flow efficiency. Poor coolant flow causes inefficient torch parts cooling with consequent faster consumable wear. Clean the coolant filter as follows:. Disconnect system from main input power. 2. Unscrew and remove the filter bowl by hand. Be sure to keep the O-ring. 3. Remove and clean the filter. Re-install the bowl, tightening it by hand. Be sure the O-ring is in place. 4. Turn the system on and check for leaks. Manual No MAINTENANCE

64 Water Filter Cleaning Procedure NOTE This procedure is only required in installations using water as a shield. Clean the filter as follows:. Disconnect system from main input power. 2. Unscrew and remove the filter bowl by hand. Be sure to keep the gasket. 3. Remove and clean the filter. Re-install the bowl, tightening it by hand. Be sure the gasket is in place. 4. Turn the system on and check for leaks. Water Filter Assembly Water Filter Screen Gasket Cup Art # A Manual No MAINTENANCE

65 Coolant Replacement Procedure Replace coolant as follows:. Disconnect the system from main input power. At the bottom of the coolant tank, disconnect the coolant line fitting and collect coolant in a disposable container. 2. Connect the system to main input power and turn it on to allow the pump to empty the tank,. The pump will run approximately for 20 seconds before the flow switch causes an interlock. This procedure may be repeated a few times until the tank is completely empty. 3. Connect the coolant line fitting and fill the tank with fresh coolant until the right level is reached. COOLANT RETURN SUPPLY RETURN SUPPLY Fill Range Coolant Tank Art # A Turn system on, let it run for a few minutes and check coolant level, refill if necessary. Manual No MAINTENANCE

66 Arc Starter Service Symptom Cause Check Remedy Coolant has become conductiveuse conductivity meter Flush system, replace coolant. Pilot return wire not connected Visual inspection Connect Wire. Spark gap set too close Check with feeler gauge Set to 0.063" ±0.002" High Frequency cap (C4) possibly open Use capacitance meter Reconnect or replace. Broken or missing ferrites Visual inspection Replace. No Pilot ignition: Spark in Arc Starter but no ignition No Pilot ignition: No Spark in Arc Starter No cooling or insufficient cooling: Leaks coolant Short across in inductor (L) Visual inspection Remove short; increase coil gaps. Spark gap bus caps (C, C2, C3) Capacitance meter Replace. broken or defective Negative supply not connected correctly Visual inspection Reconnect. Spark gap set too large Check with feeler gauge Set to 0.063" ±0.002" Faulty transformer Resistance measurement Replace. No 20V supply Check input voltage at EMI filter Make connections; replace harness. No/ loose connection to spark gap Visual inspection Reconnect. Faulty EMI filter Voltage/ Resistor measurement Replace. Loose fitting(s) Visual inspection Tighten fittings. Failure to braze joints (L) Visual inspection Replace HF Coil. Damaged or punctured coolant line(s). No cooling or Supply & return hose reversed insufficient cooling: No Coolant Flow Blockage in coil or supply/return hoses Erratic System Behavior (EMI Interference) Shield Drain / Torch lead inner shield connector missing or loose. Missing or loose ground connection Cap C5 not connected, open or loose Arc Starter Service Chart Visual inspection Visual Inspection of color-coded connections Loosen fitting slightly and check for coolant flow Visual inspection of lead attachment to Arc Starter Visual inspection of ground wire to Arc Starter Visual inspection / capacitor measurement Replace coolant line(s). Match coolant connection colors to arc starter fitting colors. Flush system. Reconnect / tighten lead connectors. Make or tighten connections to good ground. Replace PCB. Manual No MAINTENANCE

67 Arc Starter Spark Gap Adjustment. Shut off input power. Remove the top console cover. 2. Adjust the spark gap as shown. Re-install the top cover " ± 0.002".6 ± 0.05 mm Art # A Manual No MAINTENANCE

68 This page is blank intentionally. Manual No MAINTENANCE

69 Section 6: Replacement Assemblies & Parts Complete Unit / Component Catalog Numbers Catalog Number AutoCut 00 Power Supply, 208/230 V 3-9- AutoCut 00 Power Supply, 208/ V 3-9- AutoCut 00 Power Supply, 460 V AutoCut 00 Power Supply, 400 V AutoCut 00 Power Supply, 400 V (CE) OPTIONAL EQUIPMENT: Wheel Kit Manual No Parts List

70 Leads and Cables F Pilot Return Negative Coolant Supply Coolant Return Control Cable F CNC CNC Cable A B C D E P Arc Starter / Gas Control Module (GCM-000) Auto-Cut Power Supply Control Cable K Q Ground Cable Primary power G: Torch Lead Set, Shielded - Coolant Supply w/ Negative - Coolant Return - Pilot Return - Plasma Gas - Shield Gas Positioning Tube Torch Ground Cables Work Cable O Work Art # A Key Leads Catalog Numbers; Auto-Cut 00 Power Supply, XT-30 Torch Leads Length 3 ft m Description A,B,C,D,E Supply Lead Set A Pilot Return Cable (only) (4 ft /.2 m) B Negative Cable (only) C Hose, Coolant Supply (only) D Hose, Coolant Return (only) ft 3.05 m 5 ft 4.5 m 25 ft 7.6 m 35 ft 0.6 m 50 ft 5.2 m 75 ft 22.8 m 00 ft 30.5 m 25 ft 38. m Control Cable (only), Power Supply E to Arc Starter (4 ft /.2 m) F Ground Wire (only), Power Supply to Ground Ground Cable, Gas Control Module F to Earth G Torch Lead Assembly Control Cable, Power Supply K to Gas Control Module O Work Cable Control Cable, CNC P to Power Supply Q Ground Cable, Gas Control Module to Power Supply (factory installed) NOTE : Supply lead set includes Pilot Return Cable, Negative Cable, Coolant Supply & Return Hoses, and Control Cable. Manual No Parts List

71 A #8 AWG Cable Pilot Return, Power Supply to Arc Starter B # AWG Cable Negative Lead, Power Supply to Arc Starter C D Green Red Green Red Coolant Leads, Power Supply to Arc Starter E 4 Control Cable, Power Supply to Arc Starter F F Green / Yellow #0 AWG Green / Yellow /0 (50 mm ) 2 Ground Cable Ground Cable, Arc Starter To Earth Ground G Torch Lead Set K 37 Control Cable, Power Supply to Gas Control Module O /0 (50 mm ) Cable 2 Work Cable P CNC Cable (4 Wire) 4 /.3 m Q #4 AWG Ground Cable, Gas Control Module to Power Supply. Factory Installed. Art # A-0703 Manual No Parts List

72 Optional Gas Supply Leads HOSE ASSEMBLIES Length (Feet) 0' 5' 25' 35' 50' 75' 00' Length (Meters) Inert B (RH) /4" O2 B (RH) JIC Inert B (RH) 3/8" Inert B (LH) JIC SYNFLEX HOSE FITTINGS ID CATALOG# NUT NUT NIPPLE NUT NUT NIPPLE JIC CLAMP per foot Inert B (LH) Inert B (RH) Inert FUEL B (LH) O2 B (RH) /4" /8" N/A N/A N/A N/A /2" N/A N/A ADAPTER FITTINGS Catalog # Inert B (RH) /4" NPT Inert B (LH) O2 B (RH) /4" Barb Manual No Parts List

73 Power Supply External Replacement Parts Item # Qty Description Catalog # Power Supply Front Panel Power Supply Rear Panel Power Supply Top Panel Power Supply Right Side Power Supply Left Side Louver Panel Power Supply Connections Cover Lifting Eye Touch-Up Paint (Not Shown) Art # A-0493 Manual No Parts List

74 Power Supply Replacement Parts - Right Side Item # Qty Description Ref. Des. Catalog # Heat Exchanger Fan FAN Radiator Manual No Parts List

75 Power Supply Replacement Parts - Right Side Item # Qty Description Ref. Des. Catalog # 3 Resistor R PCB PCB Sensor HCT Manual No Parts List

76 Power Supply Replacement Parts - Right Side Item # Qty Description Ref. Des. Catalog # 5 Sensor HCT Contactor MC Manual No Parts List

77 Power Supply Replacement Parts - Front Panel Item # Qty Description Ref. Des. Catalog # 7 Main Power Switch CP Manual No Parts List

78 Power Supply Replacement Parts - Front Panel Item # Qty Description Ref. Des. Catalog # PCB, LED PCB Manual No Parts List

79 Power Supply Replacement Parts - Right Side Item # Qty Description Ref. Des. Catalog # 9 Resistor R Resistor R Resistor R Chopper Module Manual No Parts List

80 Power Supply Replacement Parts - Rear Panel Item # Qty Description Ref. Des. Catalog # 2 Circuit Breaker CP Circuit Breaker CP Circuit Breaker CP Circuit Breaker CP Circuit Breaker CP Circuit Breaker CP Circuit Breaker CP Coolant Tank Tank Cap CIRCUIT BREAKERS CP2 2 J55 RAS 20V 5A CP3 3 G C M CCM 24V3 5A CP4 4 GCM 24V 0A CP5 Tank Cap COOLANT RETURN SUPPLY J5 C N C J59 R A S GCM 20V2 5A GCM 5V2 5A PUMP 200V 5A FAN 24V 5A CP6 CP7 CP8 Art # A-0607 Coolant Tank Art # A Manual No Parts List

81 Power Supply Replacement Parts - Right Side Item # Qty Description Ref. Des. Catalog # 23 Transformer T Manual No Parts List

82 Power Supply Replacement Parts Item # Qty Description Catalog # 29 Inverter Module 208/230V D Inverter Module 400V CE and 400V Non CE D Inverter Module 600V D Art # A Manual No Parts List

83 Power Supply Replacement Parts - Right Side Item # Qty Description Ref. Des. Catalog # 30 Sensor (Thermistor) TH Manual No Parts List

84 Power Supply Replacement Parts Item # Qty Description Ref. Des. Catalog # 3 PC Board PCB Resistor R Magnetic Contactor MC PC Board PCB Manual No Parts List

85 Power Supply Replacement Parts - Right Side Item # Qty Description Ref. Des. Catalog # 8 Rectifier (Diode) D PC Board PCB Transformer T PC Board PCB Manual No Parts List