Document Outline

• SECTION 1:GENERAL INFORMATION
  • 1.01 Notes, Cautions and Warnings
  • 1.02 Important Safety Precautions
  • 1.03 Publications
  • 1.04 Note, Attention et Avertissement
  • 1.05 Precautions De Securite Importantes
  • 1.06 Documents De Reference
  • 1.07 Declaration of Conformity
  • 1.08 Statement of Warranty
• SECTION 2: SPECIFICATIONS
  • 2.01 General Description Of The System
  • 2.02 Plasma Power Supply
  • 2.03 Remote Arc Starter
  • 2.04 Gas Control Module
  • 2.05 Precision Plasma Cutting Torch
  • 2.06 Specifications & Electrical Requirements
  • 2.07 Power Supply Dimensions
  • 2.08 Power Supply Rear Panel Features
  • 2.09 Gas Requirements
  • 2.10 Gas Applications
  • 2.11 XT Torch Specifications
• SECTION 3: INSTALLATION
  • 3.01 Installation Requirements
  • 3.02 System Layout 100 - 200 Amp
  • 3.03 System Layout 300 Amp
  • 3.04 System Layout 400 Amp
  • 3.05 Recommended Gas Supply Hose
  • 3.06 Leads and Cables All Amperage
  • 3.07 Lift the Power Supply
  • 3.08 Connect Input Power and Ground Cables
  • 3.09 Connect Work Cable and Pilot and Negative Leads
  • 3.10 Ground Connections
  • 3.11 Connect Coolant Leads
  • 3.12 Connect Cables for CNC, Remote Arc Starter, DMC-3000 and HE 400
  • 3.13 Handling and Installation of Fiber Optics
  • 3.14 Connect TSC-3000 Cable and DMC-3000 Fiber Optic Cable to CCM
  • 3.15 Set Switches on the Command - Control Module
  • 3.16 Height Control Connections
  • 3.17 HE400 COOLER
  • 3.18 DMC-3000 Gas Manifold Control Installation
  • 3.19 DPC-3000 Gas Pressure Control Installation
  • 3.20 Fiber Optic Cable Installation from CCM to DMC-3000.
  • 3.21 Fiber Optic Cable Installation From DMC-3000 to DPC-3000
  • 3.22 Install TSC-3000 Touch Screen Control
  • 3.23 Install Remote Arc Starter
  • 3.24 Connecting Torch
  • 3.25 Install Consumable Torch Parts
  • 3.26 Voltage Divider for iHC Torch Height Control
  • 3.27 Complete the Installation
• SECTION 4: OPERATION
  • 4.01 Power Supply Control Panel
  • 4.02 System Operation
  • 4.03 TSC-3000 Navigation Functions
  • 4.04 TSC-3000 Initial Setup ONLY
  • 4.05 TSC-3000 Selecting New Process
  • 4.06 TSC-3000 Selecting Recently Used Process
  • 4.07 TSC-3000 Creating a Custom Process
  • 4.08 Back up and Restoration of Custom Processes.
  • 4.09 Sequence of Operation
  • 4.10 Gas Selection
  • 4.11 CCM Status Codes
  • 4.12 DMC-3000 Status Codes
  • 4.13 DPC-3000 Status Codes
  • 4.14 Remote Arc Starter Trouble Shooting
• SECTION 5: MAINTENANCE
  • 5.01 General Maintenance
  • 5.02 External Coolant Filter Cleaning Procedure
  • 5.03 Coolant Replacement Procedure
• SECTION 6: REPLACEMENT ASSEMBLIES & PARTS
  • 6.01 Replacement Power Supply
  • 6.02 System Layout 100 - 200 Amp
  • 6.03 System Layout 300 Amp
  • 6.04 System Layout 400 Amp
  • 6.05 Recommended Gas Supply Hose
  • 6.06 Leads And Cables All Amperages
  • 6.07 Power Supply External Replacement Parts
  • 6.08 Power Supply Replacement Parts - Upper Right Side
  • 6.09 Power Supply Replacement Parts - Lower Right Side
  • 6.10 Power Supply Replacement Parts - Rear Panel
  • 6.11 Power Supply Replacement Parts - Left Side
  • 6.12 DFC-3000 Automated Gas Control System Replacement Components
  • 6.13 DMC-3000 Gas Control Module Replacement Parts
  • 6.14 DPC-3000 Gas Control Module Replacement Parts
  • 6.15 TSC-3000 Touch Screen Control Remote and Internal Replacement Parts
  • 6.16 Remote Arc Starter (RAS-1000 XT) Replacement Parts
  • 6.17 HE 400 Heat Exchanger - Replacement Parts
• SECTION 7: TORCH MAINTENANCE
  • 7.01 Consumable Removal
  • 7.02 O-Ring Lubrication
  • 7.03 Parts Wear
  • 7.04 Torch Consumables Installation
  • 7.05 Coolant Leak Trouble-Shooting
• APPENDIX 1: CNC - Control Module PCB Connections
• APPENDIX 2: CNC
  • CNC functions
  • CNC Input / Output Descriptions
  • Simplified CNC Circuit
  • CNC Connections
• APPENDIX 3: SERIAL COMMUNICATIONS
  • A3.01 Cables and Switch Settings for 2 and 4 Wire
• APPENDIX 4: DMC-3000 Control PCB Layout
• APPENDIX 5: DPC-3000 Control PCB Layout
• APPENDIX 6: DMC-3000 / DPC-3000 Power Supply PCB Layout
• APPENDIX 7: TSC-3000 PCB Layout
• APPENDIX 8: CCM CPU PCB Layout
• APPENDIX 9: CCM I/O PCB Layout
• APPENDIX 10: Pilot PCB Layout
• APPENDIX 11: Relay and Interface PCB Layout
• APPENDIX 12: Display PCB Layout
• APPENDIX 13: System Bias PCB Layout
• APPENDIX 14: Main Inverter Bottom PCB Layout
• APPENDIX 15: Main Inverter Top PCB Layout
• APPENDIX 16: Control and Fault PCB Layout
• APPENDIX 17: Cap Bias Bottom PCB Layout
• APPENDIX 18: Cap Bias Top PCB Layout
• APPENDIX 19: Suppressor PCB Layout
• Appendix 20: COOLING DIAGRAM
• APPENDIX 21: Remote Arc Starter Schematic
• APPENDIX 22: Schematic, DFC-3000 Auto Gas Box System
• APPENDIX 23: System Schematic 100A, 380-415V PG 1
• APPENDIX 24: System Schematic 100A, 380-415V PG 2
• APPENDIX 25: System Schematic 200A, 380-415V PG 1
• APPENDIX 26: System Schematic 200A, 380-415V PG 2
• APPENDIX 27: System Schematic 300A, 380-415V PG 1
• APPENDIX 28: System Schematic 300A, 380-415V PG 2
• APPENDIX 29: System Schematic 400A, 380-415V PG 1
• APPENDIX 30: System Schematic 400A, 380-415V PG 2
• Appendix 31: ADVANCED TROUBLESHOOTING
• APPENDIX 32: PUBLICATION HISTORY
• 0-5297-TOC.pdf
  • SECTION 1:GENERAL INFORMATION
    • 1.01 Notes, Cautions and Warnings
    • 1.02 Important Safety Precautions
    • 1.03 Publications
    • 1.04 Note, Attention et Avertissement
    • 1.05 Precautions De Securite Importantes
    • 1.06 Documents De Reference
    • 1.07 Declaration of Conformity
    • 1.08 Statement of Warranty
  • SECTION 2: SPECIFICATIONS
    • 2.01 General Description Of The System
    • 2.02 Plasma Power Supply
    • 2.03 Remote Arc Starter
    • 2.04 Gas Control Module
    • 2.05 Precision Plasma Cutting Torch
    • 2.06 Specifications & Electrical Requirements
    • 2.07 Power Supply Dimensions
    • 2.08 Power Supply Rear Panel Features
    • 2.09 Gas Requirements
    • 2.10 Gas Applications
    • 2.11 XT Torch Specifications
  • SECTION 3: INSTALLATION
    • 3.01 Installation Requirements
    • 3.02 System Layout 100 - 200 Amp
    • 3.03 System Layout 300 Amp
    • 3.04 System Layout 400 Amp
    • 3.05 Recommended Gas Supply Hose
    • 3.06 Leads and Cables All Amperage
    • 3.07 Lift the Power Supply
    • 3.08 Connect Input Power and Ground Cables
    • 3.09 Connect Work Cable and Pilot and Negative Leads
    • 3.10 Ground Connections
    • 3.11 Connect Coolant Leads
    • 3.12 Connect Cables for CNC, Remote Arc Starter, DMC-3000 and HE 400
    • 3.13 Handling and Installation of Fiber Optics
    • 3.14 Connect TSC-3000 Cable and DMC-3000 Fiber Optic Cable to CCM
    • 3.15 Set Switches on the Command - Control Module
    • 3.16 Height Control Connections
    • 3.17 HE400 COOLER
    • 3.18 DMC-3000 Gas Manifold Control Installation
    • 3.19 DPC-3000 Gas Pressure Control Installation
    • 3.20 Fiber Optic Cable Installation from CCM to DMC-3000.
    • 3.21 Fiber Optic Cable Installation From DMC-3000 to DPC-3000
    • 3.22 Install TSC-3000 Touch Screen Control
    • 3.23 Install Remote Arc Starter
    • 3.24 Connecting Torch
    • 3.25 Install Consumable Torch Parts
    • 3.26 Voltage Divider for iHC Torch Height Control
    • 3.27 Complete the Installation
  • SECTION 4: OPERATION
    • 4.01 Power Supply Control Panel
    • 4.02 System Operation
    • 4.03 TSC-3000 Navigation Functions
    • 4.04 TSC-3000 Initial Setup ONLY
    • 4.05 TSC-3000 Selecting New Process
    • 4.06 TSC-3000 Selecting Recently Used Process
    • 4.07 TSC-3000 Creating a Custom Process
    • 4.08 Back up and Restoration of Custom Processes.
    • 4.09 Sequence of Operation
    • 4.10 Gas Selection
    • 4.11 CCM Status Codes
    • 4.12 DMC-3000 Status Codes
    • 4.13 DPC-3000 Status Codes
    • 4.14 Remote Arc Starter Trouble Shooting
  • SECTION 5: MAINTENANCE
    • 5.01 General Maintenance
    • 5.02 External Coolant Filter Cleaning Procedure
    • 5.03 Coolant Replacement Procedure
  • SECTION 6: REPLACEMENT ASSEMBLIES & PARTS
    • 6.01 Replacement Power Supply
    • 6.02 System Layout 100 - 200 Amp
    • 6.03 System Layout 300 Amp
    • 6.04 System Layout 400 Amp
    • 6.05 Recommended Gas Supply Hose
    • 6.06 Leads And Cables All Amperages
    • 6.07 Power Supply External Replacement Parts
    • 6.08 Power Supply Replacement Parts - Upper Right Side
    • 6.09 Power Supply Replacement Parts - Lower Right Side
    • 6.10 Power Supply Replacement Parts - Rear Panel
    • 6.11 Power Supply Replacement Parts - Left Side
    • 6.12 DFC-3000 Automated Gas Control System Replacement Components
    • 6.13 DMC-3000 Gas Control Module Replacement Parts
    • 6.14 DPC-3000 Gas Control Module Replacement Parts
    • 6.15 TSC-3000 Touch Screen Control Remote and Internal Replacement Parts
    • 6.16 Remote Arc Starter (RAS-1000 XT) Replacement Parts
    • 6.17 HE 400 Heat Exchanger - Replacement Parts
  • SECTION 7: TORCH MAINTENANCE
    • 7.01 Consumable Removal
    • 7.02 O-Ring Lubrication
    • 7.03 Parts Wear
    • 7.04 Torch Consumables Installation
    • 7.05 Coolant Leak Trouble-Shooting
  • APPENDIX 1: CNC - Control Module PCB Connections
  • APPENDIX 2: CNC
    • CNC functions
    • CNC Input / Output Descriptions
    • Simplified CNC Circuit
    • CNC Connections
  • APPENDIX 3: SERIAL COMMUNICATIONS
    • A3.01 Cables and Switch Settings for 2 and 4 Wire
  • APPENDIX 4: DMC-3000 Control PCB Layout
  • APPENDIX 5: DPC-3000 Control PCB Layout
  • APPENDIX 6: DMC-3000 / DPC-3000 Power Supply PCB Layout
  • APPENDIX 7: TSC-3000 PCB Layout
  • APPENDIX 8: CCM CPU PCB Layout
  • APPENDIX 9: CCM I/O PCB Layout
  • APPENDIX 10: Pilot PCB Layout
  • APPENDIX 11: Relay and Interface PCB Layout
  • APPENDIX 12: Display PCB Layout
  • APPENDIX 13: System Bias PCB Layout
  • APPENDIX 14: Main Inverter Bottom PCB Layout
  • APPENDIX 15: Main Inverter Top PCB Layout
  • APPENDIX 16: Control and Fault PCB Layout
  • APPENDIX 17: Cap Bias Bottom PCB Layout
  • APPENDIX 18: Cap Bias Top PCB Layout
  • APPENDIX 19: Suppressor PCB Layout
  • Appendix 20: COOLING DIAGRAM
  • APPENDIX 21: Remote Arc Starter Schematic
  • APPENDIX 22: Schematic, DFC-3000 Auto Gas Box System
  • APPENDIX 23: System Schematic 100A, 380-415V PG 1
  • APPENDIX 24: System Schematic 100A, 380-415V PG 2
  • APPENDIX 25: System Schematic 200A, 380-415V PG 1
  • APPENDIX 26: System Schematic 200A, 380-415V PG 2
  • APPENDIX 27: System Schematic 300A, 380-415V PG 1
  • APPENDIX 28: System Schematic 300A, 380-415V PG 2
  • APPENDIX 29: System Schematic 400A, 380-415V PG 1
  • APPENDIX 30: System Schematic 400A, 380-415V PG 2
  • Appendix 31: ADVANCED TROUBLESHOOTING
  • APPENDIX 32: PUBLICATION HISTORY