Tweco 400 Ultra-Cut(October 2014) - Manual (Page 5)

TABLE OF CONTENTS
SECTION 4: OPERATION ................................................................................... 4-1
4.01 Power Supply Control Panel ........................................................................... 4-1
4.02 System Operation ........................................................................................... 4-2
4.03 Gas Selection .................................................................................................. 4-4
4.04 GCM 2010 Gas Control Module Operation ...................................................... 4-6
4.05 GCM 2010 First Time Operation Matching Gas Control to Lead Length ........ 4-10
4.06 GCM 2010 Sequence Of Operation ............................................................... 4-10
4.07 Power Supply Status Codes .......................................................................... 4-13
4.08 Remote Arc Starter Trouble Shooting ........................................................... 4-20
SECTION 5: MAINTENANCE ............................................................................... 5-1
5.01 General Maintenance ...................................................................................... 5-1
5.02 External Coolant Filter Cleaning Procedure ..................................................... 5-1
5.03 Coolant Replacement Procedure ..................................................................... 5-2
SECTION 6: REPLACEMENT ASSEMBLIES & PARTS ................................................. 6-1
6.01 Replacement Power Supply ............................................................................ 6-1
6.02 System Layout 100 - 200 Amp ....................................................................... 6-2
6.03 System Layout 300 Amp ................................................................................. 6-2
6.04 System Layout 400 Amp ................................................................................. 6-3
6.05 Recommended Gas Supply Hose .................................................................... 6-3
6.06 Leads And Cables All Amperages .................................................................... 6-4
6.07 Power Supply External Replacement Parts .................................................... 6-6
6.08 Power Supply Replacement Parts - Upper Right Side ..................................... 6-7
6.09 Power Supply Replacement Parts - Lower Right Side ................................... 6-8
6.10 Power Supply Replacement Parts - Rear Panel .............................................. 6-9
6.11 Power Supply Replacement Parts - Left Side ................................................ 6-10
6.12 Gas Control Module (GCM-2010) Replacement Parts ................................... 6-11
6.13 Gas Control Module (GCM-2010) Replacement Parts ................................... 6-12
6.14 Remote Arc Starter (RAS-1000 XT) Replacement Parts ............................... 6-13
6.15 HE400XT Heat Exchanger - Replacement Parts ............................................ 6-14
SECTION 7: TORCH MAINTENANCE ................................................................... 7-1
7.01 Consumable Removal ..................................................................................... 7-1
7.02 O-Ring Lubrication ......................................................................................... 7-2
7.03 Parts Wear ...................................................................................................... 7-2
7.04 Torch Consumables Installation ...................................................................... 7-3
7.05 Coolant Leak Trouble-Shooting ...................................................................... 7-5
APPENDIX 1: REMOTE ARC STARTER SCHEMATIC ................................................... A-1
APPENDIX 2: GAS CONTROL AND TORCH VALVE SCHEMATIC ..................................... A-2
APPENDIX 3: GAS CONTROL MODULE PLUMBING DIAGRAM ....................................... A-4
APPENDIX 4: GAS CONTROL MODULE PCB LAYOUT ................................................. A-5
APPENDIX 5: GAS CONTROL DISPLAY MODULE PCB LAYOUT ..................................... A-6
APPENDIX 6: CNC - CONTROL MODULE PCB CONNECTIONS ....................................... A-7