Tweco 100 Ultra-Cut Plasma Cutting System with Automated Gas Control User Manual

Operating manual, Ultra-cut 100 xt, Plasma cutting system automated gas control

VictorThermalDynamics.com

100

480V

ULTRA-CUT 100 XT

™

PLASMA CUTTING SYSTEM

AUTOMATED GAS CONTROL

Operating

Manual

Revision: AD Issue Date: January 16, 2014

Manual No.: 0-5303

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
- 3.03 Recommended Gas Supply Hose
- 3.04 Leads and Cables All Amperage
- 3.05 Lift the Power Supply
- 3.06 Connect Input Power and Ground Cables
- 3.07 Connect Work Cable and Pilot and Negative Leads
- 3.08 Ground Connections
- 3.09 Connect Coolant Leads
- 3.10 Connect Cables for CNC, Remote Arc Starter, DMC-3000 and HE 400
- 3.11 Handling and Installation of Fiber Optics
- 3.12 Connect TSC-3000 Cable and DMC-3000 Fiber Optic Cable to CCM
- 3.13 Set Switches on the Command - Control Module
- 3.14 Height Control Connections
- 3.15 DMC-3000 Gas Manifold Control Installation
- 3.16 DPC-3000 Gas Pressure Control Installation
- 3.17 Fiber Optic Cable Installation from CCM to DMC-3000.
- 3.18 Fiber Optic Cable Installation From DMC-3000 to DPC-3000
- 3.19 Install TSC-3000 Touch Screen Control
- 3.20 Install Remote Arc Starter
- 3.21 Connecting Torch
- 3.22 Install Consumable Torch Parts
- 3.23 Voltage Divider for iHC Torch Height Control
- 3.24 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
- 6.03 Recommended Gas Supply Hose
- 6.04 Leads And Cables All Amperages
- 6.05 Power Supply External Replacement Parts
- 6.06 Power Supply Replacement Parts - Upper Right Side
- 6.07 Power Supply Replacement Parts - Lower Right Side
- 6.08 Power Supply Replacement Parts - Rear Panel
- 6.09 Power Supply Replacement Parts - Left Side
- 6.10 DFC-3000 Automated Gas Control System Replacement Components
- 6.11 DMC-3000 Gas Control Module Replacement Parts
- 6.12 DPC-3000 Gas Control Module Replacement Parts
- 6.13 TSC-3000 Touch Screen Control Remote and Internal Replacement Parts
- 6.14 Remote Arc Starter (RAS-1000) Replacement Parts
- 6.15 Optional 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: DMC-3000 Control PCB Layout
APPENDIX 4: DPC-3000 Control PCB Layout
APPENDIX 5: DMC-3000 / DPC-3000 Power Supply PCB Layout
APPENDIX 6: TSC-3000 PCB Layout
APPENDIX 7: CCM CPU PCB Layout
APPENDIX 8: CCM I/O PCB Layout
APPENDIX 9: Pilot PCB Layout
APPENDIX 10: Relay and Interface PCB Layout
APPENDIX 11: Display PCB Layout
APPENDIX 12: System Bias PCB Layout
APPENDIX 13: Main Inverter Bottom PCB Layout
APPENDIX 14: Main Inverter Top PCB Layout
APPENDIX 15: Control and Fault PCB Layout
APPENDIX 16: Cap Bias Bottom PCB Layout
APPENDIX 17: Cap Bias Top PCB Layout
APPENDIX 18: Suppressor PCB Layout
Appendix 19: COOLING DIAGRAM
APPENDIX 20: Remote Arc Starter Schematic
APPENDIX 21: Schematic, DFC-3000 Auto Gas Box System
APPENDIX 22: System Schematic 100A, 480V PG 1
APPENDIX 23: System Schematic 100A, 480V PG 2
Appendix 18: Advanced Troubleshooting
APPENDIX 24: PUBLICATION HISTORY