Tweco 100 Ultra-Cut(March 2013) User Manual

100 ultra-cut, Operating manual, Plasma cutting system w/automated gas control

Table of contents

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 System Component Layout
2.08 Power Supply Dimensions
2.09 Power Supply Rear Panel Features
2.10 Gas Requirements
2.11 Gas Applications
2.12 XTTM-300 Torch Specifications
SECTION 3: INSTALLATION
3.01 Installation Requirements
3.02 System Layout
3.03 Cables & Leads Identification
3.04 Lift the Power Supply
3.05 Remove the Connections Cover
3.06 Connect Work Cable and Pilot and Negative Leads
3.07 Ground Connections
3.08 Connect Coolant Leads
3.09 Connect Control Cables for CNC, Remote Arc Starter, and DMC-3000
3.10 Connect TSC-3000 Cable and DMC-3000 Fiber Optic Cable to CCM
3.11 Set Switches on the Command - Control Module
3.12 Height Control Connections
3.13 DMC-3000 Gas Manifold Control Installation
3.14 DPC-3000 Gas Pressure Control Installation
3.15 Fiber Optic Cable Installation from CCM to DMC-3000.
3.16 Fiber Optic Cable Installation From DMC-3000 to DPC-3000
3.17 Install TSC-3000 Touch Screen Control
3.18 Install Remote Arc Starter
3.19 Connecting Torch
3.20 Install Consumable Torch Parts
3.21 Complete the Installation
SECTION 4: OPERATION
4.01 Power Supply Control Panel
4.02 Start-Up Sequence
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 Power Supply Status Codes
4.12 DMC-3000 Status Codes
4.13 DPC-3000 Status Codes
SECTION 5: MAINTENANCE
5.01 General Maintenance
5.02 External Coolant Filter Cleaning Procedure
5.03 Internal Coolant Filter Cleaning Procedure
5.04 Coolant Replacement Procedure
5.05 Remote Arc Starter: Service Chart
5.06 Remote Arc Starter: Spark Gap Adjustment
SECTION 6: REPLACEMENT ASSEMBLIES & PARTS
6.01 Main Component / System Replacement
6.02 System Layout
6.03 Recommended Gas Supply Hose
6.04 Leads and Cables
6.05 Power Supply External Replacement Parts
6.06 Power Supply Replacement Parts - Right Side
6.07 Power Supply Replacement Parts - Right Side
6.08 Power Supply Replacement Parts - Right Side
6.09 Power Supply Replacement Parts - Front Panel
6.10 Power Supply Replacement Parts - Front Panel
6.11 Power Supply Replacement Parts - Right Side
6.12 Power Supply Replacement Parts - Rear Panel
6.13 Power Supply Replacement Parts - Right Side
6.14 Power Supply Replacement Parts
6.15 Power Supply Replacement Parts - Right Side
6.16 Power Supply Replacement Parts
6.17 Power Supply Replacement Parts - Right Side
6.18 DFC-3000 Automated Gas Control System Replacement Componants
6.19 DMC-3000 Gas Control Module Replacement Parts
6.20 DPC-3000 Gas Control Module Replacement Parts
6.21 TSC-3000 Touch Screen Control Remote and Internal Replacement Parts
6.22 Remote Arc Starter (RAS-1000) Replacement Parts
6.23 Remote Arc Starter (RAS-1000) Replacement Parts
6.24 Command & Control Module For Auto Gas Control - 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: Remote Arc Starter Schematic
APPENDIX 2: DMC-3000 PCB Layout
APPENDIX 3: DPC-3000 PCB Layout
APPENDIX 4: TSC-3000 PCB Layout
APPENDIX 5: CCM Input / Output PCB Layout
APPENDIX 6: CCM CPU PCB Layout
APPENDIX 7: CNC
A7.01 CNC functions
A7.02 CNC Input / Output Descriptions
A7.03 Simplified CNC Circuit.
A7.04 CNC Connections.
APPENDIX 8: SERIAL COMMUNICATIONS
A8.01 Cables and Switch Settings for 2 and 4 Wire
APPENDIX 9: Schematic, 230-460V, Chopper Pilot
APPENDIX 9: Schematic, 230-460V, Chopper Pilot Cont.
APPENDIX 10: Schematic, CCC 400V, w/ Chopper Pilot
APPENDIX 10: Schematic, CCC 400V, w/ Chopper Pilot Cont.
APPENDIX 11: Schematic, CE 400V, Chopper Pilot
APPENDIX 11: Schematic, CE 400V, Chopper Pilot Cont.
APPENDIX 12: Schematic, CSA 600V, Chopper Pilot
APPENDIX 12: Schematic, CSA 600V, Chopper Pilot Cont.
APPENDIX 13: Schematic, DFC-3000 Auto Gas Box System
APPENDIX 14: PUBLICATION HISTORY