Tweco 400 Ultra-Cut(May 2014) User Manual

Operating manual, Plasma cutting system automated gas control

VictorThermalDynamics.com

100 200

400

300

400V

ULTRA-CUT 100,

200, 300, 400 XT

™

PLASMA CUTTING SYSTEM

AUTOMATED GAS CONTROL

Operating

Manual

Revision: AE Issue Date: May 12, 2014

Manual No.: 0-5302

This manual is related to the following products:

300 Ultra-Cut(May 2014) 200 Ultra-Cut(May 2014) 100 Ultra-Cut(May 2014)

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 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: Remote Arc Starter Schematic
APPENDIX 2: Gas Control and Torch Valve Schematic
APPENDIX 3: Gas Control Module Plumbing Diagram
APPENDIX 4: Gas Control Module PCB Layout
APPENDIX 5: Gas Control Display Module PCB Layout
APPENDIX 6: CNC - Control Module PCB Connections
APPENDIX 7: CNC
- CNC functions
- CNC Input / Output Descriptions
- Simplified CNC Circuit
- CNC Connections
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: System Schematic 100A, 380-415V PG 1
APPENDIX 22: System Schematic 100A, 380-415V PG 2
APPENDIX 23: System Schematic 200A, 380-415V PG 1
APPENDIX 24: System Schematic 200A, 380-415V PG 2
APPENDIX 25: System Schematic 300A, 380-415V PG 1
APPENDIX 26: System Schematic 300A, 380-415V PG 2
APPENDIX 27: System Schematic 400A, 380-415V PG 1
APPENDIX 28: System Schematic 400A, 380-415V PG 2
Appendix 29: Advanced Troubleshooting
APPENDIX 30: Publication History
0-5302-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: Remote Arc Starter Schematic
- APPENDIX 2: Gas Control and Torch Valve Schematic
- APPENDIX 3: Gas Control Module Plumbing Diagram
- APPENDIX 4: Gas Control Module PCB Layout
- APPENDIX 5: Gas Control Display Module PCB Layout
- APPENDIX 6: CNC - Control Module PCB Connections
- APPENDIX 7: CNC
  - CNC functions
  - CNC Input / Output Descriptions
  - Simplified CNC Circuit
  - CNC Connections
- 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: System Schematic 100A, 380-415V PG 1
- APPENDIX 22: System Schematic 100A, 380-415V PG 2
- APPENDIX 23: System Schematic 200A, 380-415V PG 1
- APPENDIX 24: System Schematic 200A, 380-415V PG 2
- APPENDIX 25: System Schematic 300A, 380-415V PG 1
- APPENDIX 26: System Schematic 300A, 380-415V PG 2
- APPENDIX 27: System Schematic 400A, 380-415V PG 1
- APPENDIX 28: System Schematic 400A, 380-415V PG 2
- Appendix 29: Advanced Troubleshooting
- APPENDIX 30: Publication History