00 480V ULTRA-CUT 100 XT ™ PLASMA CUTTING SYSTEM Operating Manual Revision: AE Issue Date: May 30, 2014 Manual No.: 0-5272 VictorThermalDynamics.
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! WARNINGS Read and understand this entire Manual and your employer’s safety practices before installing, operating, or servicing the equipment. While the information contained in this Manual represents the Manufacturer's best judgement, the Manufacturer assumes no liability for its use. Plasma Cutting Power Supply, Ultra-Cut 100 XT™ Operating Manual No. 0-5272 Published by: Victor Technologies, Inc, 82 Benning Street West Lebanon, New Hampshire, USA 03784 (603) 298-5711 www.thermal-dynamics.
TABLE OF CONTENTS SECTION 1: GENERAL INFORMATION............................................................................ 1-1 1.01 1.02 1.03 1.04 1.05 1.06 1.07 Notes, Cautions and Warnings......................................................................... 1-1 Important Safety Precautions.......................................................................... 1-1 Publications.....................................................................................................
TABLE OF CONTENTS SECTION 4: OPERATION.................................................................................... 4-1 4.01 4.02 4.03 4.04 4.05 4.06 4.07 4.08 Power Supply Control Panel............................................................................ 4-1 System Operation............................................................................................ 4-2 Gas Selection...................................................................................................
TABLE OF CONTENTS APPENDIX 7: CNC .......................................................................................... A-8 CNC functions................................................................................................................ A-8 CNC Input / Output Descriptions.................................................................................. A-10 Simplified CNC Circuit..................................................................................................
ULTRA-CUT 100 XT SECTION 1: GENERAL INFORMATION 1.01 Notes, Cautions and Warnings Throughout this manual, notes, cautions, and warnings are used to highlight important information. These highlights are categorized as follows: NOTE An operation, procedure, or background information which requires additional emphasis or is helpful in efficient operation of the system. CAUTION A procedure which, if not properly followed, may cause damage to the equipment.
ULTRA-CUT 100 XT • Extra care must be taken when the workplace is moist or damp. • Install and maintain equipment according to NEC code, refer to item 9 in Subsection 1.03, Publications. • Disconnect power source before performing any service or repairs. • Read and follow all the instructions in the Operating Manual. FIRE AND EXPLOSION PLASMA ARC RAYS Plasma Arc Rays can injure your eyes and burn your skin. The plasma arc process produces very bright ultra violet and infra red light.
ULTRA-CUT 100 XT 1.03 Publications Refer to the following standards or their latest revisions for more information: 1. OSHA, SAFETY AND HEALTH STANDARDS, 29CFR 1910, obtainable from the Superintendent of Documents, U.S. Government Printing Office, Washington, D.C. 20402 2. ANSI Standard Z49.1, SAFETY IN WELDING AND CUTTING, obtainable from the American Welding Society, 550 N.W. LeJeune Rd, Miami, FL 33126 3.
ULTRA-CUT 100 XT 1.04 Note, Attention et Avertissement FUMÉE et GAZ Dans ce manuel, les mots “note,” “attention,” et “avertissement” sont utilisés pour mettre en relief des informations à caractère important. Ces mises en relief sont classifiées comme suit : NOTE Toute opération, procédure ou renseignement général sur lequel il importe d’insister davantage ou qui contribue à l’efficacité de fonctionnement du système.
ULTRA-CUT 100 XT RAYONS D’ARC DE PLASMA CHOC ELECTRIQUE Les chocs électriques peuvent blesser ou même tuer. Le procédé au jet de plasma requiert et produit de l’énergie électrique haute tension. Cette énergie électrique peut produire des chocs graves, voire mortels, pour l’opérateur et les autres personnes sur le lieu de travail. • Ne touchez jamais une pièce “sous tension” ou “vive”; portez des gants et des vêtements secs. Isolez-vous de la pièce de travail ou des autres parties du circuit de soudage.
ULTRA-CUT 100 XT BRUIT Le bruit peut provoquer une perte permanente de l’ouïe. Les procédés de soudage à l’arc de plasma peuvent provoquer des niveaux sonores supérieurs aux limites normalement acceptables. Vous dú4ez vous protéger les oreilles contre les bruits forts afin d’éviter une perte permanente de l’ouïe. • Pour protéger votre ouïe contre les bruits forts, portez des tampons protecteurs et/ou des protections auriculaires.
ULTRA-CUT 100 XT 1.06 Documents De Reference Consultez les normes suivantes ou les révisions les plus récentes ayant été faites à celles-ci pour de plus amples renseignements : 1. OSHA, NORMES DE SÉCURITÉ DU TRAVAIL ET DE PROTECTION DE LA SANTÉ, 29CFR 1910, disponible auprès du Superintendent of Documents, U.S. Government Printing Office, Washington, D.C. 20402 2. Norme ANSI Z49.
ULTRA-CUT 100 XT 1.07 Statement of Warranty LIMITED WARRANTY: Victor Thermal Dynamics® Corporation (hereinafter “Thermal”) warrants that its products will be free of defects in workmanship or material.
ULTRA-CUT 100 XT SECTION 2: SPECIFICATIONS 2.01 General Description Of The System A typical Ultra-Cut XT™system configuration includes: • One Power Supply • Remote Arc Starter • Gas Control Module • Torch Valve Assembly • Precision Plasma Cutting Torch • Set Of Connecting Leads • Torch Spare Parts Kit The components are connected at installation. 2.02 Plasma Power Supply The power supply provides the necessary current for cutting operations.
ULTRA-CUT 100 XT 2.06 Specifications & Electrical Requirements Ultra-Cut 100 XT™ Specifications & Design Features 100 Amp System Max OCV (U0) 425 vdc Minimum Output Current 5 Amps Max Output Current 100 Amps Output Voltage 60 - 180 vdc Duty Cycle Rating 100% @ 100A, 200V, (20kW), Ambient Temperature for Duty Cycle Rating 104F° (40°C) Operating range 14°F to 122°F (-10°C to + 50°C) Power Factor 0.
ULTRA-CUT 100 XT 2.07 Power Supply Dimensions 47.77 inch 1213 mm 35.97 inch 914 mm 100A 420 lb / 190 kg 27.
ULTRA-CUT 100 XT 2.08 Power Supply Rear Panel Features TSC/Comm Customer Optional Ports Circuit Breakers GCM Connector CNC Connector J55 - GCM USER INPUT Coolant Return C.C.M.
ULTRA-CUT 100 XT 2.09 Gas Requirements The customer will provide all gases and pressure regulators. Gases must be of high quality. Pressure regulators shall be double stage and installed within 3 meters from the Gas Console. Ultra-Cut 100 XT™ Power Supply: Gas Pressures, Flows, and Quality Requirements Gas Quality Minimum Pressure Flow O2 (Oxygen) 99.5% Purity (Liquid recommended) 120 psi 8.3 bar / 827 kPa 70 scfh (2000 l/h) N2 (Nitrogen) 99.
ULTRA-CUT 100 XT 2.11 XT Torch Specifications A. Torch Dimensions Art # A-04897 End Cap 19.00" 482.68 mm 2.25" 57.15 mm Mounting Tube 2.0" 50.8 mm 15.50" 393.78 mm 6.30" 160.10 mm 2.39" 60.81 mm 3.54" 89.87 mm 2.74" 69.55 mm 1.57" 39.96 mm 1.49" 37.8 mm B. Torch Leads Lengths Torch Lead Assembly Lengths ��� Feet Meters 10 3.05 15 4.6 25 7.6 50 15.2 75 22.9 100 30.
ULTRA-CUT 100 XT C. Torch Parts (Generic Parts Shown) Art # A-04741_AB Plasma Gas Distributor Shield Gas Distributor Tip Shield Cap Electrode Cartridge Shield Cup D. Parts - In - Place (PIP) The torch is designed for use with a power supply which senses coolant return flow to confirm that torch parts are in place. If coolant return flow to the power supply is absent or insufficient the power supply will not provide power to the torch.
ULTRA-CUT 100 XT This Page Intentionally Blank ��� SPECIFICATIONS Manual 0-5272
ULTRA-CUT 100 XT SECTION 3: INSTALLATION 3.01 Installation Requirements Electric Supply The electrical supply network, the gas and water supply system must meet local safety standards. This conformity shall be checked by qualified personnel. Ultra-Cut 100 XT™ Power Supply Input Power Input Current Suggested Sizes (See Note) Voltage Freq.
ULTRA-CUT 100 XT 3.02 System Layout Refer to section 3.04 for ground connections and ground cables. 175’ / 53.3 m Maximum Length 125’ / 38.1 m Maximum Length F1 Primary power CNC Ultra Cut XT Power Supply P 100’ / 30.
ULTRA-CUT 100 XT 3.03 Recommended Gas Supply Hose Item # Qty 1 Description Catalog # 3/8”Gray Synflex Hose. No fittings included. Catalog number per foot 9-3616 3.
ULTRA-CUT 100 XT 3.05 Lift the Power Supply WARNING Do not touch live electrical parts. Disconnect input power conductors from de-energized supply line before moving unit. FALLING EQUIPMENT can cause serious personal injury and equipment damage. Use a forklift, crane, or hoist to lift the unit off the shipping pallet as shown. Keep the power supply steady and vertical. Do not lift it any further than necessary to clear the shipping pallet. Ensure all panels and screws are secure prior to lifting.
ULTRA-CUT 100 XT 3.06 Connect Input Power and Ground Cables Connect Input Power and System Ground Cables 1. Remove the input power cover to the right of the coolant filter at the rear of the power supply. To do this remove the two screws then lift up and pull away. 2. Carefully cut back the outer sheath on the primary input power cable to expose the individual wires. Cut back the insulation on the individual wires. Route the cable upward through Input Power Port at the bottom of the panel.
ULTRA-CUT 100 XT 3.07 Connect Work Cable and Pilot and Negative Leads 1. Remove the output power cover to the left of the coolant filter at the rear of the power supply. To do this remove the two screws then lift up and pull away. 2. Route the ends of the work cable, pilot and negative/torch leads upward through the leads strain relief at the bottom edge of the left rear panel. 3. Refer to the illustration. Connect the leads as shown. Tighten securely. Do not overtighten.
ULTRA-CUT 100 XT 3.08 Ground Connections Star Ground on Cutting Table See Manufacturer Power Supply CNC Gas Control Module Primary location Torch Device Remote Arc Starter (RAS-1000) Cutting Machine / Gantry #4 AWG Ground (F) Cutting Table 1/0 Ground Cable (F1) Earth Ground Rod 1/0 Ground Cable Customer supplied Note: The gas control module can be mounted on top of the power supply. If it is, it should be grounded directly to the power supply with #4 AWG ground, (F).
ULTRA-CUT 100 XT NOTE Do Not connect the work cable directly to the ground rod. Do not coil up excess ground or power cables. Cut to proper length and reterminate as needed. 5. Make sure work cable and ground cables are properly connected. The work cable must have a solid connection to the cutting table. The work and ground connections must be free from rust, dirt, grease, oil and paint. If necessary grind or sand down to bare metal. Use lock washers to keep the connections tight.
ULTRA-CUT 100 XT Obtain a power resistor of either 1200 (1.2K) ohms, 15-25W min, if using a 120V secondary or 2200 (2.2K) ohms, 25 -30W for a 220V secondary. 4. Assemble the transformer and power resistor in a metal box. Connect a 3 wire (w/gnd) power cord with ground wire attached to the metal box for safety. If a plastic box is used instead, connect the transformer core and the resistor mounts to the power cord ground wire. There should be a fuse ¼ - ½ A, in series with the transformer primary.
ULTRA-CUT 100 XT 3.09 Connect Coolant Leads 1. Connect the color-coded coolant hoses to the coolant connections on the power supply rear panel. The supply line (out) is flagged green, the return line (in) is flagged red.
ULTRA-CUT 100 XT 3.10 Connect Cables for CNC, Remote Arc Starter, GCM and HE 400 1. Connect one end of each cable to the power supply. 2. Connect the other end of the CNC cable to the CNC device. 3. The CNC cable shield must be attached to ground at the CNC end.
ULTRA-CUT 100 XT 3.11 Handling and Installation of Fiber Optics General Information This kit is for proper handling and installation of Fiber Optic Cables used in Thermal Dynamics Ultra-Cut® and Auto-Cut O2® automated gas boxes and Gas Control Modules. Fiber Optic cable is used in place of wire because it offers far superior immunity to electrical noise but it is more delicate and requires careful handling. With fiber optics, electrical signals are converted to light with a transmitter LED.
ULTRA-CUT 100 XT Avoid the following: 1. If you need to pull the cable through a power track do not fold the fiber back on itself making a sharp bend where it exits the hose. Art # A-09417 2. Don’t hook onto the fiber to pull on the cable. Art # A-09418 3.
ULTRA-CUT 100 XT Hose not secured in the Strain Relief Art # A-09677_AB Correct installation: Correct way to pull the cable is to use a snake or a wire or another cable and attach it securely to the hose behind the strain relief. Then secure the fiber connector to the pulling device leaving some slack in the fiber. Keep the protective end covers on the fiber until you are ready to connect it to the PCB in the CCM or gas control.
ULTRA-CUT 100 XT 3.12 Set Switches on the Command - Control Module Remove the power supply upper right side. Set switches on the CCM (Command-Control Module) per the illustrations. Switch settings and connection details are provided in the Appendix. Any changes made require a restart of the power supply. CAUTION Printed circuit boards in the Command - Control Module are static - sensitive. Discharge any built-up static charges in your body or surroundings before touching the printed circuit boards.
ULTRA-CUT 100 XT CAUTION Printed circuit boards in the Command - Control Module are static - sensitive. Discharge any built-up static charges in your body or surroundings before touching the printed circuit boards. SW11 SW6 SW12 SW13 SW-6: OK-to-Move: Contact closure, 120VAC @ 1A (Factory default setting) or DC Volts (16-18vdc@ up to 100 ma.) SW-11: Set “B” position, (up) for default SW-11: Set “A” position (down) for remote analog current control. SW-8-2 must be set to “ON”.
ULTRA-CUT 100 XT 3.13 Height Control Connections The terminal strip provides connections to negative Arc Volts (Torch or electrode), Tip Volts (Pilot) and Work. These are for a height control that requires connection to the full non-divided arc voltage. Also available on the terminal strip are 120VAC and 24 VAC. The allowable current draw is 100ma @ 120VAC and 1Amp @ 24 VAC. Art # A-11900 TB4 1 2 24 VAC @ 1A 3 4 5 6 7 120 VAC Work @ 100 ma.
ULTRA-CUT 100 XT 3.14 Gas Control Module Installation The Gas Control Module must be installed in a suitable location where it is easily accessible to the system operator. The unit must be mounted to a flat horizontal surface. If the Module is mounted to a gantry or to any other support subject to vibration or motion, the installer must fasten the module to the support securely. The Module should be located as far away as possible from the Arc Starter due to electromagnetic interference.
ULTRA-CUT 100 XT Preparation 1. Remove the screws securing the Cover Panel to the Module. 2. Carefully remove the cover from the module noting the attached ground wire. Remove the ground wire if needed.
ULTRA-CUT 100 XT 3.15 Fiber Optic Cable Installation 1. Install the through-hole protector for the fiber-optic cable in the hole in connection panel on the back of the Module. 2. Pass the fiber-optic cable connector through the hole in connection panel on the back of the Module. Pass enough of the cable into the Module to allow the cable to loop upward as shown. CAUTION Avoid kinking, twisting, or bunching the fiber optic cable. The cable can be damaged by being forced into tightradius turns.
ULTRA-CUT 100 XT 3. Insert the fiber-optic cable connector into the receptacle on the vertically-mounted circuit board as shown. Cable must snap into place. Circuit Board Fiber Optic Cable Art # A-04773 4. Tighten the through-hole protector for the fiber-optic cable using hand tools. 5. Reinstall the Cover Panel making sure the ground wire is attached.
ULTRA-CUT 100 XT 3.16 Gas Control Module: Control, Input, and Output Connections 1. Make all other connections to the rear of the Module. The connections are labeled. The Module must be grounded; the grounding terminal is marked Use #10 AWG (European 6 mm2) (or thicker) wire for grounding. Keep the ground wire as short as possible. 2. Position the Module on a flat, horizontal, mounting surface. 3. Ensure that the Flowmeters are plumb. 4. Secure the Module to the mounting surface. 5.
ULTRA-CUT 100 XT 3.17 Optional HE400 COOLER Used in series with the existing cooling system of the Ultra-Cut XT™ series power supplies, the optional HE400 Cooler provides additional cooling when ambient temperatures exceed the units rated temperature.. The HE400 fan is thermally controlled to operate whenever the Ultra-Cut fan and pump is on and the coolant temperature is above a predetermined level. It may come on anytime while the main pump is operating.
ULTRA-CUT 100 XT NOTE Ensure the four coolant lines described below are connected and leak free before connecting power to J71. Match the colors of the hoses to the front panel label. Supply lines are green and return lines are red. Facing the unit as shown below, the left connections go to the Ultra-Cut XT™ power supply, the right connections go to the RAS1000 arc starter.
ULTRA-CUT 100 XT 3.18 Install Remote Arc Starter Site Location Select a clean, dry location with good ventilation and adequate working space around all components. Review the safety precautions in the front of this manual to be sure that the location meets all safety requirements. Interconnecting cables and hoses attach to the Arc Starter. There must be adequate space around the Arc Starter for these connections without excessive kinking or bending. Mounting Dimensions NOTE Height not shown is 7.
ULTRA-CUT 100 XT 2. Remove the Cover Panel from the Arc Starter. Upper screws (2 per side) Cover Ground Wire Lower screws (2 per side) Art # A-12059 Cover Removal 3. Position the Arc Starter on a flat, horizontal mounting surface. 4. Use pre-drilled holes in at least two of the feet on the bottom of the Arc Starter to secure the Arc Starter to the mounting surface.
ULTRA-CUT 100 XT Input Connections 1. Refer to the illustrations. Make the following input connections to the Arc Starter. • Coolant Supply and Return Hoses (from HE-400 Heat Exchanger). Hoses and connectors are colorcoded; Red for Return, Green for Supply.
ULTRA-CUT 100 XT 2. Refer to illustration. Connect the Pilot wire and Negative cables using a star washer on each. NOTE * Slave and Master refer to only those set ups using two power supplies in parrallel. Slave is not used in single system operations.
ULTRA-CUT 100 XT Output Connections 1. Refer to the illustrations. Make the following output connections to the Arc Starter.
ULTRA-CUT 100 XT 2. Reinstall the Arc Starter Cover. Ensure that the ground wire is not crimped between the cover and the base. Upper screws (2 per side) Cover Ground Wire Lower screws (2 per side) Art # A-12059 3. The Arc Starter must be grounded; the grounding terminal is marked grounding details. .
ULTRA-CUT 100 XT 4. Use a clamp to secure the Torch Lead Shield braid brass ring to the port on the Remote Arc Starter as shown.
ULTRA-CUT 100 XT Connect Control Cable 1. Connect the Remote Arc Starter cable to the Remote Arc Starter receptacle.
ULTRA-CUT 100 XT 3.19 Torch Valve Installation General Information This assembly mounts as close as possible to the torch head. It accepts preflow, plasma, and shield gases from the Gas Control Module and supplies these gases to the Torch. Mounting 113.03 mm 4.450” 6.63 mm .261” Dia. 36.83 mm 1.450” Art # A-07648 1. Mount the Valve Kit as close as possible to the Torch.
ULTRA-CUT 100 XT 3. Connect the gas supply lines and the control cable connector from the Gas Control Module to the Valve Kit as shown. Hold the check valves stationary while attaching the gas lines. Exhaust Muffler Control Cable WMS™ Inlet Shield Gas Inlet Preflow Gas Inlet Plasma Gas Inlet Art # A-07646 CAUTION Hold all fittings stationary while attaching hoses or leaks can be created. Side pressure can break the check valves or weaken their connection to the torch valve assembly.
ULTRA-CUT 100 XT 3. Remove and discard the protective end caps from the Mounting Tube. 4. Install the O-ring in the groove at the upper end of the Mounting Tube. 5. Install the Mounting Tube as follows: a. Position the Mounting Tube at the end of the leads assemblies as shown. b. Slide the Mounting Tube upward onto the leads assemblies. c. Press the upper end of the Mounting Tube into the lower end of the Torch Leads End Cap.
ULTRA-CUT 100 XT 3.21 Install Consumable Torch Parts Install the consumable parts as follows to ensure proper operation. These steps will help ensure that parts are seated correctly. WARNINGS Do not install consumables into the Cartridge while the Cartridge is attached to the Torch Head. Keep foreign materials out of the consumables and Cartridge. Handle all parts carefully to avoid damage, which may affect torch performance. Art # A-03887 1.
ULTRA-CUT 100 XT 6. Take the cartridge tool off the cartridge. Fit the cartridge assembly onto the torch head. The Speed Lok ring should click into place and the cartridge assembly should touch the large O-ring on the torch body. Torch Head Torch Head O-Ring 0.063 - 0.083" (1.6 - 2.1 mm) Protrusion Art # A-08300_AB Installing Assembled Cartridge Onto Torch Head 7. Slide the ohmic clip over the shield cup if using ohmic torch height sensing. 8.
ULTRA-CUT 100 XT 30 - 100 Amp Parts Assembly 1: Stack Parts 2: Press Cartridge onto Stacked Parts Electrode Plasma Gas Distributor O-Ring on Tip No Gaps Between Parts Tip Shield Gas Distributor Cartridge Covers O-Ring on Torch Tip Shield Cap 3: Thread Shield Cup onto Cartridge 4: Check Shield Cap Protrusion Shield Cup Shield Cap Shield Cap Protrudes 0.063-0.083" (1.6 - 2.1 mm) Art # A-04873 Installing Assembled Cartridge Onto Torch Head 3.
ULTRA-CUT 100 XT Install the V-D Board. 1. Locate the V-D Board which should be with the iCNC. 2. Inside the Power Supply, locate and remove the mounting panel’s 2 screws and panel. 3. Install the V-D board standoffs and the V-D Board from the XT iCNC then reattach the panel with the 2 screws, securing the V-D board in place. If using another V-D Board, follow the instructions provided mounting it in this same location.
ULTRA-CUT 100 XT J55 - GCM USER INPUT Ohmic clip cable port J15 - CNC HEIGHT CONTROL V-D Board connection J54 - TSC /COMM J59 - RAS CB2 - 5A 120 VAC CB3 - 5A 24 VAC J70 - HE CB4 - 5A 120 VAC F1 - 8A SB 230 VAC F2 - 8A SB 230 VAC Art # A-12080 Arc Voltage Connections. The XT plasma supplies provide a terminal strip, TB4, on the right side ahead of the CCM module for connections to Arc V- (Torch); Tip V (Pilot); Arc V + (Work).
ULTRA-CUT 100 XT 3.23 Complete the Installation 1. Remove the cap from the coolant tank. Fill the coolant tank to the level shown, with Thermal Dynamics coolant. The coolant level is visible through the translucent coolant tank. The amount of coolant required varies with torch leads length. Coolant Capabilities Cat.
ULTRA-CUT 100 XT 2. After the complete system has been installed, check that the coolant has been pumped through the system as follows (see NOTE): NOTE Depending on the length of the torch leads, the system may require more coolant after turning the system ON for the first time. a. Place the ON/OFF Switch to ON. b. After about 4 minutes the system may shut down if the leads are not full of coolant. c. Place the ON/OFF switch to OFF. Add more coolant if needed d.
ULTRA-CUT 100 XT SECTION 4: OPERATION 4.01 Power Supply Control Panel A/ Gas Indicator AC Indicator Temp Indicator Status Indicator DC Indicator A/ Art # A-11541_AB AC Power Lamp Indicates unit has passed the input power tests and AC power is being supplied to the inverter modules via the input contactor when the ON/OFF switch is in ON position. TEMP Lamp: Normally OFF. Lamp will come ON when the internal temperature sensors detect temperatures above normal limits.
ULTRA-CUT 100 XT 4.02 System Operation This section contains operating information which is specific to the power supply. WARNING Review the safety precautions in Section 1. If the power supply cord has a plug or is not permanently connected to power, be sure the power to the outlet is disconnected when inserting the plug into the outlet. Disconnect primary power at the source before assembling or disassembling power supply, torch parts, or torch and leads assemblies, or adding coolant.
ULTRA-CUT 100 XT POWER I ON OFF O OFF O OFF O O OFF Art # A-11542 3. Set Gas Pressure GCM 2010 a. Place Mode switch in SET PREFLOW mode. Adjust Preflow pressure as required for the cutting process. b. Set Mode Switch in SET PLASMA & SHIELD position. Adjust plasma and shield pressure regulators to correct pressure. c. Set plasma and shield ( if process calls for setting shield flow) flow meters to correct flow. d. Return Mode Switch to RUN position. 4. Set cutting current. a.
ULTRA-CUT 100 XT 11. Shut off the system. a. Set the ON/OFF power switch on the front panel of the unit to OFF. WARNING AC power is still present inside the unit. • Fans and pump as well as all indicators turn off. • The display may show a fault code for a moment, this is a normal part of shutting off power and does not indicate a fault. b. Open (turn off) the main power disconnect. All power is now removed from the unit. • Rear panel AC indicator turns OFF. Operational Suggestions 1.
ULTRA-CUT 100 XT 4. Nitrogen (N2) Plasma • Provides better cut quality on nonferrous materials such as stainless steel and aluminum. • Can be used in place of air plasma with air shield. • A good clean welding grade nitrogen should be used. • When used with a water mist secondary it produces superior cut speeds and cut quality on stainless steel and aluminum. 5. H17 Plasma (17.5% Hydrogen / 32.5% Argon / 50% Nitrogen) • Recommended for 1/2 inch (12 mm) and thicker nonferrous materials.
ULTRA-CUT 100 XT 4.04 GCM 2010 Gas Control Module Operation Functional Overview The Gas Control Module provides all Plasma and Secondary gas selection and control instrumentation. There are various controls and indicators used to set gas pressures and flows.
ULTRA-CUT 100 XT GCM 2010 Gas Control Module: Controls & Indicators 1. MODE Selection Switch RUN SET PREFLOW SET PLASMA & SHIELD TEST MODE O2 - AIR O2 - O2 H35 -N2 F5 - N2 AIR - AIR N 2 - H2 O N2 - N2 RUN SET PREFLOW SET PLASMA & SHIELD TEST GAS MODE PREFLOW ENABLE DISABLE High Precision Plasma Cutting System PLASMA POWER SUPPLY SHIELD PLASMA 9 9 GCM H2O MIST PRESSURE GAS 2010 FLOW Art # A-04765_AB • Normally in the RUN position during torch operation.
ULTRA-CUT 100 XT 2. GAS Selection Switch Selects combinations of plasma and shield gases. O2 - AIR O2 - O2 H35 -N2 F5 - N2 AIR - AIR N2 - H2O N2 - N2 GAS O2 - AIR O2 - O2 H35 -N2 F5 - N2 AIR - AIR N2 - H2O N2 - N2 RUN SET PREFLOW SET PLASMA & SHIELD TEST GAS MODE PREFLOW ENABLE 9 2010 PLASMA POWER SUPPLY SHIELD PLASMA 9 GCM DISABLE High Precision Plasma Cutting System H2O MIST PRESSURE GAS FLOW Art # A-04766_AB 3.
ULTRA-CUT 100 XT 4. Current Control Adjusts the output current of the power supply. High Precision Plasma Cutting System RUN SET PREFLOW SET PLASMA & SHIELD TEST GAS MODE PREFLOW O2 - AIR O2 - O2 H35 -N2 F5 - N2 AIR - AIR N2 - H2O N2 - N2 ENABLE High Precision Plasma Cutting System PLASMA DISABLE AMPERAGE SET-UP PLASMA POWER SUPPLY SHIELD 9 9 GCM AMPERAGE SET-UP H2O MIST PRESSURE GAS 2010 FLOW Art # A-04767_AC 5.
ULTRA-CUT 100 XT 4.05 GCM 2010 First Time Operation Matching Gas Control to Lead Length For initial operation of GCM2010 with software version 2.1 or later. 1. Before applying AC power set the Power Supply ENABLE/DISABLE switch on the gas control module to DISABLE. 2. Set Gas Selection switch to the correct position for cutting process being used. 3. Turn on AC power and set Power Supply ENABLE/DISABLE switch to ENABLE.
ULTRA-CUT 100 XT 6. Place the MODE switch to the RUN position. 7. Set the Plasma Power Supply Enable / Disableswitch (on the Gas Control Module) to Enable. The Module performs purges of 15 seconds, 11 seconds, and another 11 seconds. This removes water from the torch parts. NOTE When switching gases between operations, allow enough purge time to clear the prior gas from the torch leads.
ULTRA-CUT 100 XT Direction of Cut The plasma gas stream swirls as it leaves the torch to maintain a smooth column of gas. This swirl effect results in one side of a cut being more square than the other. Viewed along the direction of travel, the right side of the cut is more square than the left.
ULTRA-CUT 100 XT 4.07 Power Supply Status Codes NOTE See the Appendix for Advanced Troubleshooting On start-up and during operation, the power supply control circuitry performs various tests. If the circuitry detects a condition requiring operator attention, the status display on the front panel shows a 3 digit number code preceded by either letter “E” (currently active fault) or letter “L” (last or latched fault) meaning a fault occurred stopping the process but is not currently active.
ULTRA-CUT 100 XT CCM Status Code Code Message Remedy / Comments Group 2 -- Plasma Power Supply ���� 201 Missing AC Phase Blown wall fuse, Blown unit fuse F1 or F2 or rear panel, Bad power cable connection; Defective System Bias PCB.
ULTRA-CUT 100 XT CCM Status Code Code Message Remedy / Comments 223 Inverter 3B Output Current High Plasma work current high during cutting and attributed to Inverter Module 3 Section B output high; If problem persists replace Inverter Module 3 224 Inverter 1 Not Found Inverter Module 1 Section A required for Piloting; Bad ribbon cable connection to CCM J31 to Inverter Module 1 Section A.
ULTRA-CUT 100 XT CCM Status Code Code ���� Message Remedy / Comments 242 Inverter Input Voltage fault; voltage out of range or missing phase at AC Input of InInverter 1B Input Volt- verter Module 1 Section B; Poor AC Power Quality; Defective W1 contactor; Loose or age Error open connection between input terminals and W1 contactor or contactor and input of Inverter Section; Defective Inverter module 243 Inverter Input Voltage fault; voltage out of range or missing phase at AC Input of InInverter 2A
ULTRA-CUT 100 XT CCM Status Code Code Message Remedy / Comments 258 Inverter Module 3 Section B is over temperature; Operating with side panels reInverter 3B Over Temp moved, Check for restricted air flow, clogged radiator; Defective fan; If problem persists replace inverter module. 259 Inverter circuitry is over temperature likely cause is ambient greater than 40 deg Inverter 1A Over Temp C; Reduce power supply cutting Duty Cycle; Reduce ambient air temperature; Add Ambient auxiliary cooler.
ULTRA-CUT 100 XT CCM Status Code Code Message Remedy / Comments Group 3 -- Gas Controller Status & Protocol 301 Gas control communication Problem with fiber optic cable to GCM 2010; Dirt on fiber ends or in connectors; blow out with clean dry air.
ULTRA-CUT 100 XT CCM Status Code Code Message Remedy / Comments Group 6 -- CCM 601 Analog Voltage Error Defective CCM, replace. 602 ADC or DAC error Defective CCM, replace. 603 Reserved No information available; Contact customer service 604 Data Memory error Defective CCM, replace. 605 Program memory fault Defective CCM, replace. 606 +5V Logic supply low Defective CCM, replace.
ULTRA-CUT 100 XT 4.08 Remote Arc Starter Trouble Shooting Arc Starter Trouble Shooting Symptom Cause Visual inspection, continuity check Connect Wire or replace leads. Coolant has become conductive Use conductivity meter Flush system, replace coolant. Use capacitance meter Reconnect or replace. Negative supply cable not connected correctly Visual inspection Reconnect Pilot return wire not connected or loose in arcstarter. Visual inspection Connect Wire.
ULTRA-CUT 100 XT SECTION 5: MAINTENANCE 5.01 General Maintenance Perform the following checks periodically to ensure proper system performance. Power Supply Maintenance Schedule Daily Check coolant level; add coolant as needed. Check gas hose connections and pressures. UC-AC Maintenance schedule Monthly Check cooling fan and radiator; clean as needed. Check gas hoses for cracks, leaks, or abrasion. Replace as needed. Check all electrical connections for cracks or abrasion. Replace as needed.
ULTRA-CUT 100 XT 5.03 Coolant Replacement Procedure Replace coolant as follows: 1. Disconnect the system from main input power. 2. Remove the two right side panels. 3. Locate the coupling in the coolant line that comes from the bottom of the coolant tank, #1 in the following illustration. Disconnect the coolant line at this fitting and drain the coolant into a disposable container of sufficient size. Remember you will be draining more than the contents of the coolant reservoir. 4.
ULTRA-CUT 100 XT SECTION 6: REPLACEMENT ASSEMBLIES & PARTS 6.01 Replacement Power Supply Complete Unit / Component Catalog Number Ultra-Cut 100 XT™ Power Supply, 480V +10 -15% 3-8116-2 Gas Control Module (GCM-2010) with XTL Torch Valve Assembly 3-9131 Gas Control Module (GCM-2010) Only 7-4000 Original Torch Valve Assembly Repair Part Only 4-3049 XTL Torch Valve Assembly Only 4-3054 (Requires GCM 2010 Firmware version 3.
ULTRA-CUT 100 XT 6.02 System Layout Refer to section 3.05 for ground connections and ground cables. 175’ / 53.3 m Maximum Length 125’ / 38.1 m Maximum Length F1 Primary power CNC Ultra Cut XT Power Supply Pilot Return A Negative B Coolant Supply C Coolant Return D Control Cable F1 Fiber Optic Cable P 100’ / 30.
ULTRA-CUT 100 XT 6.
ULTRA-CUT 100 XT Ultra-Cut 100 XT Leads 10 ft 3.05 m 4-3029 15 ft 4.5 m 9-7359 9-4791 9-4783 9-4766 9-4784 9-7360 9-9426 9-4767 9-4785 9-4768 9-4786 9-7361 9-4792 4-3031 50 ft 15.2 m 9-4769 9-4787 9-7362 9-4793 4-3032 75 ft 22.8 m 9-4770 9-4788 9-7363 9-4794 4-3033 100 ft 30.5 m 9-4922 9-7364 9-4796 4-3034 125 ft 38.1 m Leads Length 4-3028 9-4790 9-4782 9-4765 9-4944 9-4930 150 ft 45.7 m 4 ft 1.
ULTRA-CUT 100 XT 6.
ULTRA-CUT 100 XT 6.06 Power Supply Replacement Parts - Upper Right Side Item # Qty Description 1 1 System Bias PCB 9-9253 2 1 Pilot PCB Assembly 3 1 CCM Assembly 9-7335 4 1 Relays, Pump / Fan 5 1 Relay, Inrush Control 6 1 Relay, Inrush 7 1 Resistor, Inrush 8 1 Display PCB 9 1 Auxiliary Transformer T1 9-7315 10 1 On/Off Switch Breaker CB1 9-7316 11 1 Ref. Des.
ULTRA-CUT 100 XT 6.07 Power Supply Replacement Parts - Lower Right Side Item # Qty Description Ref. Des.
ULTRA-CUT 100 XT 6.08 Power Supply Replacement Parts - Rear Panel Item # Qty Description Breaker Rating Circuit Rating Ref. Des.
ULTRA-CUT 100 XT 6.09 Power Supply Replacement Parts - Left Side Item # Qty 1 2 3 1 1 1 Description Ref. Des.
ULTRA-CUT 100 XT 6.10 Gas Control Module (GCM-2010) Replacement Parts Item # Qty 1 2 3 4 5 6 7 8 9 10 11 12 13 14 6 1 1 1 1 1 1 1 1 1 3 1 1 2 7W Solenoid for O2 use Gas Selection Manifold Assembly Check Valve, 1/4 NPT .
ULTRA-CUT 100 XT 6.
ULTRA-CUT 100 XT 6.
ULTRA-CUT 100 XT 6.
ULTRA-CUT 100 XT This Page Intentionally Blank ���� PARTS LISTS Manual 0-5272
ULTRA-CUT 100 XT SECTION 7: TORCH MAINTENANCE 7.01 Consumable Removal 1. Use the removal tool to hold the Shield Cup & Cartridge Assembly stationary. Turn the Shield Cup to remove it from the Cartridge Assembly. Cartridge Tool Assembled Cartridge Art # A-04344_AB Shield Cup 2. Take the Removal Tool off the back of the Cartridge Assembly Use the removal tool to push the consumable parts out of the Cartridge.
ULTRA-CUT 100 XT 7.02 O-Ring Lubrication Lubricate all three O-Rings on the Cartridge Assembly and all three O-Rings on the Torch Head periodically with O-Ring Lubricant supplied. Remove the snap ring on the cartridge assembly and slide the locking ring downward for access to the O-Ring under the locking ring. Inner O-Ring (Cat. No. 9-3030) Location (Under Locking Ring) O-Rings Torch Head Cat. No. 9-9041 O-Ring, Cat. No. 9-3029 O-Ring, Cat. No. 9-3028 Cat. No. 9-3027 Cartridge Assembly Cat. No.
ULTRA-CUT 100 XT 7.04 Torch Consumables Installation WARNINGS Do not install consumables into the Cartridge while the Cartridge is attached to the Torch Head. Keep foreign materials out of the consumables and Cartridge. Handle all parts carefully to avoid damage, which may affect torch performance. Art # A-03887 1.
ULTRA-CUT 100 XT CAUTION The cartridge assembly must cover the O-Ring on the torch head. Do not force the cartridge if it will not tighten fully. Remove the cartridge assembly and gently clean the threads on the torch head with a wire brush. Apply oxygen-compatible lubricant (supplied with the torch) to the threads. Torch Head Torch Head O-Ring 0.063 - 0.083" (1.6 - 2.1 mm) Protrusion Art # A-07202 Installing Assembled Cartridge Onto Torch Head 3.
ULTRA-CUT 100 XT 7.05 Coolant Leak Trouble-Shooting Never operate the system if coolant leaks from the torch. A steady drip indicates that torch parts are damaged or installed improperly. Operating the system in this condition can damage the torch head. Refer to the following chart for guidance on coolant leakage from the torch head.
ULTRA-CUT 100 XT Torch Electrodes Art # A-09653 Amperage 30 50 70 100 ��� Plasma Gas Recommended Wear Depth for Electrode Replacement Inch mm O2 0.04 1 Air 0.04 1 N2 0.04 1 O2 0.04 1 Air 0.08 2 N2 0.04 1 O2 0.04 1 Air 0.08 2 N2 0.04 1 O2 0.04 1 H35 0.08 2 N2 0.
ULTRA-CUT 100 XT APPENDIX 1: Remote Arc Starter Schematic 2 Jumper in cable to ID Arc Starter is connected. A PLASMA POWER SUPPLY J59-RAS 1 2 3 4 5 6 7 8 9 10 11 12 13 14 GND 3 4 RAS 1000 XT 5 6 A IGNITION UNIT SIG 4.5 J58 Chassis gnd 120 VAC 120 VAC RET 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 115 Vac GND 115 Vac RET Ho Hb (99) (98) (49) (52) Torch Shield NEG NEG 0.047 uf CGND PU 100K 0.047 uf GND B RAS Capacitor PCB Brass Ring NEG B 0.
ULTRA-CUT 100 XT APPENDIX 2: Gas Control and Torch Valve Schematic 5 4 ULTRACUT SW2 GAS D SW3 MODE O2 - AIR O2 - O2 H35 - N2 F5 - N2 AIR - AIR N2 - H2O N2 - N2 1 2 3 4 5 6 7 A GCM 2010 GAS CONTROL A 1 2 3 4 RUN SET PREFLOW SET CUTFLOW TEST (10) To CCM (13) (3) (4) (5) (6) (7) (8) (9) (14) PLASMA ENABLE SW6 2 SW7 SHIELD FLOW / PRESSURE2 1 DISABLE (50) J5 3 1 ENABLE (51) 3 3 4 (55) 24 VAC RET 120 VAC 120 VAC RET Shield 5 4 3 2 1 9 8 10 7 6 5 4 3 2 D25 GREEN
ULTRA-CUT 100 XT 3 2 LCD Display Assembly 19X2220 D LCD DISPLAY ENCODER w/SW 15 16 1 2 3 4 5 6 7 8 9 10 11 12 13 14 INTERFACE BOARD PS1 Plasma Outlet Pressure 34 34 33 32 32 31 30 30 29 28 28 27 26 26 25 24 24 23 22 22 21 20 20 19 18 18 17 16 16 15 14 14 9 12 12 13 10 10 7 8 11 6 5 4 8 3 1 2 6 2 4 4 3 2 1 JP1 33 31 29 27 25 23 21 19 17 15 13 11 9 1 7 3 5 1 2 3 4 5 6 J8 4 (62) (63) (64) (65) (66) (67) { 34 DUAL RIBBON HEADER ENCODER
ULTRA-CUT 100 XT APPENDIX 3: Gas Control Module Plumbing Diagram New Plasma Inlet Pressure Sensor SOL5 SOL11 F5 H35 TVA & XTL -TVA Atmosphere SOL4 PLASMA SOL19 SOL18 SOL1 SOL2 Pressure Sensor SOL3 SOL14 PLASMA SOL6 PREFLOW AIR SOL15 SOL16 N2 SHIELD SOL7 O2 SOL12 SOL8 SOL9 SOL 18 & 19 in XTL -TVA only. SOL10 SOL13 SHIELD GAS MANIFOLD New Shield Inlet Pressure Sensor H 2O SO L17 SOL 18 & 19 normally open. Operate in parallel with normally closed SOL 14 & 15.
ULTRA-CUT 100 XT APPENDIX 4: Gas Control Module PCB Layout F10 F12 F8 J1 F17 F9 F11 F15 F16 F7 J13 J13 F13 F14 J3 F19 F18 TP4 J12 F5 F3 F1 TP3 TP2 F2 F4 F6 TP7 F20 J5 JP1 TP8 TP5 TP10 TP9 TP6 TP1 TP11 Art # A-07621 J6 Manual 0-5272 TP12 J7 J11 TP13 TP15 TP14 APPENDIX TP16 TP19 J8 J10 TP18 A-5
ULTRA-CUT 100 XT APPENDIX 5: Gas Control Display Module PCB Layout J1 D15 R1 R2 R22 R21 19X2220 REV LCD INTERFACE TDC C 2005 R23 72 69 R24 C1 D11 D13 D12 D26 D10 D9 C2 D25 D20 + D24 D8 D7 D23 D6 D22 J1 D19 D3 D16 D14 D2 D5 D4 D18 D1 34 33 D21 2 1 D17 70 R3 R4 R5 R6 R7 R8 R9 R10 R11 R20 R19 R18 R17 R16 R15 R14 R13 R12 AB 1 16 68 Art # A-06904 ��� APPENDIX Manual 0-5272
ULTRA-CUT 100 XT APPENDIX 6: CNC - Control Module PCB Connections TB1 (LV) OK To Move 2 High +10V 10K Analog Current Control Wiper / Input Low (-) Divided Arc Volts Output Start/Stop Input 12 11 10 9 (+) 8 (-) 7 (+) 6 (-) 5 Stop (NC) 4 (LV) OK To Move 2 3 (+) 2 (-) 1 CNC Plasma Enable TB2 OK To Move (+) SW6 DC 12 11 10 9 Pilot On Output (Contacts) Preflow On Hold Start 8 7 6 5 (+) 4 (-) 3 (+) 2 Art # A-11512_AB (-) 1 TB3 Spare #2 Output Normally Open Contacts 12 Spare #2 Output Normal
ULTRA-CUT 100 XT APPENDIX 7: CNC CNC functions CNC I/O circuits provide at least 1000V galvanic isolation from the plasma power supply. While the CNC circuits are isolated from the power supply, many of the signal returns on J15 and TB1, TB2 & TB3 are common to each other. J15 pins 1, 4, 5, 10, 17, and TB1-1, 5, 7, 9, and TB2-1 & 3 are all common. J15 pin 12 and TB2-10 are also connected to the others when SW6 (OK to Move select) is set for voltage.
ULTRA-CUT 100 XT Internal CNC connections. TB1, TB2 & TB3 on CCM module. Connections are provided on the CCM module TB1, TB2 & TB3 terminal blocks including most of the rear panel functions plus some additional features. All these signals are isolated from the plasma power supply but signals marked (comm.) and (-) are common to each other. Users are expected to install their own CNC cable to these connections. Knockout hole is provided in rear panel of CCM module.
ULTRA-CUT 100 XT CNC Input / Output Descriptions E-Stop input— Requires closed connection rated for 35ma. @ 20VDC for unit to operate. Factory installed jumper between TB1-1&2 must be removing when connecting user supplied E-Stop circuit. 4 Start/Stop input—Switch (momentary or sustained) rating 35ma. @ 20 VDC Start / Stop circuit configurations. Momentary Start / Stop (Latched) is only available at TB1.
ULTRA-CUT 100 XT OK to Move2 – Provides a second set of N.O. contacts that close when arc transfer is detected. Contacts are rated for maximum of 24 VAC/DC @ 1A. Simplified CNC Circuit. 5 +10V @ 10ma. For Remote CC Pot – Previously CCM versions if one wanted to use a potentiometer for the Remote Analog Current Control (CC) input an external 10 V supply was required for Pot High.. Now an isolated (from main plasma circuits) 10V supply is provided. Recommended value of the pot is 5K or 10K. 5 TB1 Ext.
ULTRA-CUT 100 XT Simplified CNC Circuit.
ULTRA-CUT 100 XT J54 - Rem ote HM I & CN C CO M M (100) (101) (102) Harness to Relay PCB (109) (108) (115) Harness to CPU PCB 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 G ND SPA RE #1a (142) (116) (117) (118) (119) (120) (133) (134) (137) (139) (138) (143) J22 C hassi s (140) (141) (136) (135) (132) (153) (133) (134) (135) (136) (137) (138) (139) (140) (141) (142) (143) (144) (145) (144) (145) (146) (147) (148) (149) (150) (151) (146) (147) (148) (149) (150) (151) (152) (154) (155) (132)
ULTRA-CUT 100 XT CNC Connections. Cutting Machine CNC Cable Power Supply J15 START/STOP 1 2 3 4 5 6 7 8 9 10 11 (9) (10) (11) Start Motion (OK-To-Move) { (12) * NC .......... Source, 16 VDC, 10 ma. ... Divided Arc V (-) .......... Divided Arc V (+) .......... Pre Flow ON (+) .......... Pre Flow ON (-) .......... ... Corner Current Reduction (+) Corner Current Reduction (-) 12 13 * (14) 14 (16) 15 16 (17) DC (+) * (1) ( 2) (3) (4) ( 5) (6) ( 7) SW6 .......... /Hold Start(+) ........
ULTRA-CUT 100 XT This Page Intentionally Blank Manual 0-5272 APPENDIX A-15
ULTRA-CUT 100 XT Appendix 8: CCM CPU PCB Layout = Test Point = Test Point Art # A-11675 ���� APPENDIX Manual 0-5272
ULTRA-CUT 100 XT CCM CPU PCB Test Points TP1 GND TP2 ISO +5.0V TP3 +24V TP4 +3.3V TP5 ISO GND TP6 +5.0V TP7 TOTAL DEMAND 3.3V=400A TP9 /WR TP10 /RD TP11 CPU TEMP SENSE TP12 +3.
ULTRA-CUT 100 XT Appendix 9: CCM I/O PCB Layout = Test Point 19 Art # A-11676_AB WORK CURRENT = Test Point ���� APPENDIX Manual 0-5272
ULTRA-CUT 100 XT CCM I/O PCB J Connectors Test Points J21 BASIC CNC TP1 GND J22 EXTENDED CNC TP2 /COOLANT FANS ON J23 RELAY - INTERFACE BOARD TP3 /TORCH PUMP ON J24 ARC / TIP VOLTS TP4 LOW COOLANT FLOW (SW) J25 TEST TP5 COOLANT FLOW SIGNAL (PULSE) J26 GAS BOX TP6 +15V ISOLATED J28 TO CPU TP7 -15V ISOLATED J29 TO CPU TP8 +18V ISOLATED TP9 ANALOG CURRENT CONTROL 0-3.
ULTRA-CUT 100 XT Appendix 10: Pilot PCB Layout = Test Point = Test Point Art # A-11677 ���� APPENDIX Manual 0-5272
ULTRA-CUT 100 XT Pilot PCB Test Points TP1 GND TP2 PILOT GATE TP3 +5V TP4 TIP LED Reference D2 Green PILOT ENABLE D11 Green +5V Manual 0-5272 APPENDIX A-21
ULTRA-CUT 100 XT Appendix 11: Relay and Interface PCB Layout = Test Point = Test Point Art # A-11678 ���� APPENDIX Manual 0-5272
ULTRA-CUT 100 XT Relay and Interface PCB Test Points TP1 GND TP2 -15V TP3 +5VDC TP4 +12V TP5 +24V TP6 +15V TP7 +5VDC LED Reference D2 Green 1 TORCH GAS ON D7 Green PILOT ENABLE D11 Green PILOT CURRENT DETECTED D12Green WORK CURRENT DETECTED D22Green CONTACTORS ON D23Green RF ON D24Green FANS ON D25Green PLASMA ENABLED D26Green 1 TORCH ON D27Green TORCH COOLANT ON Manual 0-5272 APPENDIX A-23
ULTRA-CUT 100 XT Appendix 12: Display PCB Layout = Test Point = Test Point Art # A-11679 ���� APPENDIX Manual 0-5272
ULTRA-CUT 100 XT Display PCB Test Points TP1 GND TP2 +5VDC TP3 +24VDC Manual 0-5272 APPENDIX A-25
ULTRA-CUT 100 XT Appendix 13: System Bias PCB Layout = Test Point = Test Point Art # A-11680 ���� APPENDIX Manual 0-5272
ULTRA-CUT 100 XT System Bias PCB Test Points TP1 GND TP2 24VDC TP3 DC INPUT POSITIVE TP4 Vcc1 TP5 Vcc2 TP6 GATE TP7 PRIMARY GND TP8 +12V PRIMARY TP9 P_ISOL_GND TP10 DC SENSE POSITIVE LED Reference D3 Red MISSING PHASE D4 Red AC V HIGH D14Red AC V LOW D15Green VAC_IDA D26Green +12V PRIMARY D27Green VAC_IDB D30Green 24VDC D44Green TRANSFORMER ON Manual 0-5272 APPENDIX A-27
ULTRA-CUT 100 XT Appendix 14: Main Inverter Bottom PCB Layout ���� Art # A11681 = Test Point = Test Point APPENDIX Manual 0-5272
ULTRA-CUT 100 XT Main Inverter Bottom PCB Test Points TP1 GND TP2 GATE 2A TP3 GATE 1A TP4 GATE 3A TP5 GATE 4A TP6 GATE 2B TP7 GATE 1B TP8 GATE 4B TP9 GATE 3B TP10 +12VP TP11 +12VDC TP12 THERMISTOR SIDE A TP13 THERMISTOR SIDE B TP14 +5VDC TP15 PGND LED Reference D3 Red D4 Green READY Manual 0-5272 CAP IMBALANCE APPENDIX A-29
ULTRA-CUT 100 XT Appendix 15: Main Inverter Top PCB Layout ���� Art # A11682 = Test Point = Test Point APPENDIX Manual 0-5272
ULTRA-CUT 100 XT Main Inverter Top PCB Test Points TP1 GND TP2 GATE 2A TP3 GATE 1A TP4 GATE 3A TP5 GATE 4A TP6 GATE 2B TP7 GATE 1B TP8 GATE 4B TP9 GATE 3B TP10 +12VP TP11 +12VDC TP12 THERMISTOR SIDE A TP13 THERMISTOR SIDE B TP14 +5VDC TP15 PGND LED Reference D3 Red D4 Green READY Manual 0-5272 CAP IMBALANCE APPENDIX A-31
ULTRA-CUT 100 XT Appendix 16: Control and Fault PCB Layout = Test Point = Test Point /230V Art # A11683 ���� APPENDIX Manual 0-5272
ULTRA-CUT 100 XT Control and Fault PCB Test Points TP1 GND TP22 +12VDC TP23 +5VDC TP24 GATE 1+ TP25 A_OUT1 TP26 B_OUT1 TP27 GATE 1- TP28 I_SNS1 TP29 GATE 2+ TP30 I_DMD1 0.5V-6.
ULTRA-CUT 100 XT Appendix 17: Cap Bias Bottom PCB Layout Art # A-11685 ���� APPENDIX Manual 0-5272
ULTRA-CUT 100 XT Appendix 18: Cap Bias Top PCB Layout Art # A-11686 Manual 0-5272 APPENDIX A-35
ULTRA-CUT 100 XT Appendix 19: Suppressor PCB Layout Art # A-11684 ���� APPENDIX Manual 0-5272
Manual 0-5272 APPENDIX Art # A-12268 Over Flow Supply Coolant tank Cold Plate 1 Cold Plate 2 Cold Plate 3 Pump Pressure Relief Level Switch Coolant Return Radiator HS1 Temp Sensor Flow Flow Bubble Sensor Flow Switch DESCRIPTION ECO B2502 Torch Coolant Supply Torch Coolant Return Filter 1 REV AA APPROVED AJR XT-300 RAS 1000 **FOR 400 AMP SYSTEMS HE400 DATE 8-8-2013 ULTRA CUT XT POWER SUPPLIES 100A-400A ULTRA-CUT 100 XT Appendix 20: COOLING DIAGRAM A-37
ULTRA-CUT 100 XT APPENDIX 21: System Schematic 100A, 480V PG 1 1 3 2 5 4 A W1A B L1 L2 J105B (1) 1 (23) INVERTER MODULE (IM) #1 (24) MAIN PCB LEDS D3, RED, CAP IMBALANCE D4, GREEN, READY 1 2 (24) J103B L3 Earth (25) (3) 1 1 2 (25) CAP BIAS PCB LEDS D6, GREEN, -12V D11, GREEN, +12VP D13, GREEN, +12V 019X502700 W1C 1 IM #1 Section B (upper) AC INPUT J104B W1B (2) 1 1 2 (23) J105A AC INPUT IM #1 Section A (lower) 1 2 (23) J100 -- 30 CKT RIBBON CONTROL PCB LEDS D1, R
ULTRA-CUT 100 XT 6 7 8 9 (49) (49) TEST POINTS TP1 GND TP2 PILOT GATE TP3 +5V TORCH 1 A C (49) J43 ELECTRODE RAS 1 PILOT BOARD LED'S D2 PILOT ENABLE D11 +5V 10 PILOT PCB J58A (52) J44 R3 & R4 PILOT 1 SHIELD EARTH GROUND 1 CHASSIS GND J58C 2 1 019X501600 WORK (+) (51B) TO RELAY BOARD TO I/O BOARD (+) TO CCM CPU PCB J31 Work TIP VOLTS To J24 on I-O PCB B Tip (53) (Sht 2, A5) (Sht 2, C3) J45 10 ckt Ribbon TO J3 on RELAY PCB J102B OUTPUT J42 L1 1 2 3 4 5 6 7 8 2
ULTRA-CUT 100 XT APPENDIX 22: System Schematic 100A, 480V PG 2 (89) r b g 1 2 1 5 2 6 3 7 4 8 J12 3 T1 Mini-Fit Jr 1 2 3 4 5 6 7 8 1 2 3 4 (81) (82) J49 460V 24V RET BLUE RED 24V B 400V YELLOW BLUE 120V_2 RET RED 5 4 3 2 YELLOW 120V_2 220V 120V-1 RET J6 (79) 6 1 12 11 10 9 8 7 6 5 4 3 2 1 (77) (78) CB2 5 A (76) (74) (75) CB3 5 A (73) (71) (72) CB4 5 A J9 J14 0V SIGNAL (pulse) TORCH FLOW SENSOR 120VAC_2 24VAC D2, GREEN, 1TORCH GAS ON D7, GREEN, PILOT ENABLED D11, GREEN,
ULTRA-CUT 100 XT 6 7 TO PILOT PCB (Sht 1, B8) (162) / PILOT ENABLE / PILOT ENABLE RET (161) MC3 SA4 J8 SA1 ARC_SUPPRESSOR 120 VAC_1 J4 -- 40 CKT RIBBON CABLE (101) (102) (103) (104) (62) (106) (63) (113) (61) AC 120V - GCM J19 120 VAC Ret (98) MC1 (107) (101) (102) (109) (108) (115) AC 24V Ret- GCM1 (63) AC 120V- Ret- GCM (116) (117) Harness AC 24V- Ret -TB4-1 (62) 1 AC 120V- Ret- TB4-3 (118) K1 (119) (120) 2 1 2 3 4 (63) 5 GND GND 4 WIRE RxTx+ Rx+ Tx- 1 2 3 4
ULTRA-CUT 100 XT Appendix 23: Advanced Troubleshooting System Overview The Auto-Cut 200 & 300 XT & Ultra-Cut 100, 200, 300 & 400 XT power supplies include one, two or three inverter modules (IM). Each IM may have either 1 or 2 inverter sections designated A or B sections. The IMs are mounted one over the other numbered from bottom to top. The sections are also designated from bottom to top with section A being on the bottom of each module.
ULTRA-CUT 100 XT section (INV 1A, INV 1B, etc.). A 100A unit will only have ribbon cables in J31 & J32; a 200A will have J31-J33 filled with the others empty. 300A will have J34 missing with the others filled. Other boards in the system include the System Bias Supply, the Relay & Interface PCB, Display PCB, Pilot PCB and AC Suppression PCB. The CCM has 2 boards, the I/O (input/output) and the CPU (central processing unit) board.
ULTRA-CUT 100 XT The AC Suppression PCB has capacitors and other transient suppression components to protect the system from transients on the AC lines. It also provides power for the neon AC present indicators which illuminate when AC power is connected even with ON-OFF switch, CB1, off. Differences between various models.
ULTRA-CUT 100 XT Status codes. The codes for the power supply are displayed on the Display PCB 4 digit numerical display. Some codes refer to the Gas Controls but more detailed Gas Control codes will be found on the individual gas controls. The gas controls used with the XT family of plasma supplies have not changed. They have their own set of status codes which should be covered in another section.
ULTRA-CUT 100 XT Power Supply Status Codes Group 1, Process Codes 101 Plasma Enable Is Disabled Code 101 is activated by either an open circuit between TB1-1 & 2 on CCM I/O PCB or Plasma Enable switched off on the GCM 2010 or on the TSC 3000. TB1-1 & 2 comes from the factory with a jumper installed. An installer may remove the jumper and connect a separate Plasma Enable switch or use the Plasma Enable wires included in the 37 pin CNC cable used with the Ultra-Cut XT & Auto-Cut 300XT.
ULTRA-CUT 100 XT If a TSC 3000 is not connected or unit is an Auto-Cut, K7 on the Relay PCB is de-energized and GND is connected through its normally closed contacts. If the TSC is connected, 24 VAC through a jumper in the TSC 3000 energizes K7, opening its NC contacts and now GND connects through the TDC 3000 Plasma Enable switch.
ULTRA-CUT 100 XT 102 Pilot Ignition Failure Code 102 is activated when there is no pilot current after 15 seconds of firing the Arc Starter. Pilot ignition requires the Pilot board to be enabled, pilot switch (IGBT) turned on and high voltage pulses (HF) from the arc Starter (either the Remote Arc Starter RAS 1000 XT or GCM 1000 XT or the arc starter built in to the AC 200 XT) applied between the tip and the electrode of the torch.
ULTRA-CUT 100 XT Arc starter without Spark Gap (Ultra-Cut) 1. Check for power to the RAS 1000XT’s Ignition Module during the 15 seconds following preflow (ignition phase). Arc starter power comes through the rear panel circuit breaker CB4, make sure it isn’t tripped. a. During the ignition phase, measure for 120 VAC at the input terminals marked 120 VAC on the Ignition module, a gray rectangular box with screw terminals on one side.
ULTRA-CUT 100 XT Reasons why RAS Control relay would not close: 6. Pilot current flowing. There actually is pilot current flowing somewhere. Unlikely as it would normally set the 208 fault but we have to rule it out. a. Disconnect J41 on the Pilot board, if HF still doesn’t fire and the Relay board Pilot LED, D11, is still on, it’s due to a fault in the detection circuits. 7. Faulty detection circuit.
ULTRA-CUT 100 XT Troubleshooting Pilot Board problems. 1. The Pilot board is behind the CCM in the AC 300 XT and all Ultra-Cut XTs or on the upper section of the second inverter module in an AC 200 XT and has two LEDs. The first one, D11, a green LED, indicates the board has bias power and should be on all the time when the unit is turned on. The second LED, D2, also green, is on when the pilot is enabled, that is the pilot IGBT switch is turned on.
ULTRA-CUT 100 XT 104 Transfer Lost Arc transferred to metal for at least 50 ms. then went out. Causes for 104 code: • Cut demand set much lower than recommended for torch parts, i.e. 100A consumables in torch but cut current set for 30 or 50A (or zero). Current may be too low to keep arc on. • Torch standoff too high for cutting process being used. • Plasma gas flow too low due to a leak somewhere between the plasma regulator or the DPC 3000 and the torch. Check for leaks.
ULTRA-CUT 100 XT • Cut current set too low for torch parts being used. Pilot current is set based on cut current. If cut current is too low pilot current will be lower and may not transfer at the height used for higher current consumables. • Preflow pressure/flow too low. • Remote Analog Current Control switches set wrong can also result in lower than normal pilot current setting. See section on these switch settings under section for code 104. • Defective work lead current sensor circuit.
ULTRA-CUT 100 XT 109 Part Process not Configured. This represents a status, not a fault. This is used with the DFC 3000 only. It means the operator hasn’t loaded the cutting process from either the TSC 3000 or from the program embedded in the cutting table CNC controller. The solution is to load a process. The code will continue to be displayed until the CNC Start is applied at which time the code will clear. 110 Not Used. This is one of the reserved codes from the earlier product.
ULTRA-CUT 100 XT PWR Present • When power is first applied to the inverter (contactor closed) CCM checks for presence of the +12V bias on the Inverter Control and Fault board. If not present will set codes in the range of 265-270. IS_ID (A, B, or C) VAC_SEL (A or B) 201 Missing AC Phase The System Bias Supply board contains circuits to detect if one of the 3 AC input phases is missing. Along with that it can also detect if the AC voltage is too low or too high.
ULTRA-CUT 100 XT 202-204 Not used. Reserved codes from the earlier product. 205 DC Output Low DC output (voltage) low means one or more inverter sections are enabled but the output voltage is below a preset voltage. Shortly after receiving the Start signal from the CNC, but before the end of preflow, both sections of IM#1 are enabled and CCM measures the power supply output voltage between negative (Torch) to positive (Work) at the output terminals.
ULTRA-CUT 100 XT Relay PCB • Relay board LED D12, Work Current Detected, will light if the current sensor signal exceeds 0.05V. If D12 is on, measure the sensor output signal at J1-3 with signal common on J1-1. This signal should be 0V +/- 0.04VDC. If greater than +/- 0.04VDC with no work lead current, the sensor is defective. If the signal voltage is within the limits and D12 is on, then the Relay board is defective.
ULTRA-CUT 100 XT 2. 208 code comes on during preflow: IM#1 and the Pilot board are enabled near the end of preflow. To have unwanted current there must be a path (short) for current to flow between the inverter negative output (negative cable/torch electrode) and the Pilot return/tip before the arc starter is enabled for pilot ignition. Possible causes are: • Short between electrode and tip due to mismatch of consumables, damaged consumables or foreign matter between tip and electrode.
ULTRA-CUT 100 XT Troubleshooting: 1. For current too low due to a short disconnect work lead from back of unit. Check for continuity to chassis, there should be none. Inspect for incorrectly connected user equipment. 2. If no shorts were found or if fault was current signal too high see section on code 207 for detailed description of the power and signal paths for the work lead current sensor. 3.
ULTRA-CUT 100 XT 224 Inverter 1 not found. There must be an inverter connected in the 1st section, 1A, to be able to pilot. During the power up sequence, before power is connected to the inverters, the CCM does a continuity test to see if its section 1A ribbon cable (J31 on CCM) is connected. Causes & troubleshooting: • As this is just a continuity test it is very unlikely to be a bad inverter. Most likely a poor connection or defective ribbon cable.
ULTRA-CUT 100 XT Troubleshooting: 1. If System Bias board has either the wrong jumper or is defective it will call out the first inverter section, code 231, because all the inverters won’t match the incorrect signal and 1A is checked first. a. For the jumper Wire #48 should be connected from J61-1 to: i. J61-2 for 208-230 VAC ii. J61-3 for 400 VAC iii. J61-4 for 480 VAC Check for proper connection and continuity. b. System Bias may be defective reporting the wrong voltage ID.
ULTRA-CUT 100 XT 238 System Bias voltage identification is invalid. At power up the System Bias board measures the input voltage and sends signals to the CCM indicating which range of voltage it has detected. See section 231-236 for details. If one of the 3 voltage ranges, 208-230V, 380415V or 480V isn’t identified then both ID signals are high resulting in an invalid signal. Possible causes: • Unit is connected to voltage below the 208-230V range or above the 480V range.
ULTRA-CUT 100 XT Troubleshooting: 1. If the fault is L239 applying START will clear the fault unless it becomes active again. An occasional problem may be due to incoming voltage swells (voltage increases lasting from ½ cycle to as much as a minute). Usually, if the plasma is at fault the problem will be present all the time. 2. It is unlikely that an open connection on the J61 jumper would result in a 239 fault, more likely to be a Voltage Mismatch fault.
ULTRA-CUT 100 XT 4. If the incoming voltage is OK and the problem persists it may be System Bias, CCM or connection between J62 and J27. a. If the incoming voltage is OK and D14, ACV LOW, is on or the signal “AC V LOW b” on J62-10 is “high” (about 24VDC, relative to TP1 or J62-8 ) the System Bias board is defective. b. If D14 is not on and signal “AC V HIGH b” on J62-10 is “low” (about 10-14VDC, relative to TP1 or J62-8) then System Bias is OK and problem is in the CCM. c.
ULTRA-CUT 100 XT 253-258 Inverter Over Temperature. Each inverter section (IS) contains one or more temperature sensors. If any of these detect an over temperature condition it activates the signal “OVERTEMP_FLT going to the CCM over the inverter sections ribbon cable. Inverters semiconductors (transistors and diodes) are liquid cooled. Anything that increases the coolant temperature too high can cause overheating of the inverters.
ULTRA-CUT 100 XT Troubleshooting: 1. If room temperature exceeds 40 deg C, cool the room, or operate the unit at reduced duty cycle or lower current. 2. Confirm that air is exhausting from opening in the right side panel. As the fan(s) are behind the radiator it’s hard to see them to confirm they are turning but perhaps you can use an inspection mirror. Be careful not to get the mirror or your hands into the blades. 100 & 200A units have 2 smaller fans, 300 & 400A have one larger one. 3.
ULTRA-CUT 100 XT 3. On the Relay board D22, CONTACTOR ON LED (green) next to relay K1 lights if K1 is being told to energize. a. If it’s on check for 120 VAC between J8-1 and J8-9. If present the relay board is OK. b. If D22 is on but 120 VAC is not present at J8-1 and J8-9 (make sure meter is set for ACV) then the relay board is defective. c. D22 is not on, go to the 40 pin ribbon cable test connector and measure voltage on pin 17 (relative to TP1 on either the Relay board or the CCM I/O Board).
ULTRA-CUT 100 XT Troubleshooting: 1. Check that the fiber-optic cable is fully plugged in to both sockets. Clean the cable ends with a soft cloth and blow out the sockets with air. 2. Check gas control cables. If any of the gas control cables are not connected there will be no communication as there will be no power to the control. This may show up as a 301 or 501 code.
ULTRA-CUT 100 XT 307 Gas Control returns wrong command sequence. Firmware incompatibility. Consult factory for latest firmware update. Possible electromagnetic interference from the Arc Starter; inspect grounding; bonding; and isolation. 308 Mismatch between the CCM and gas control type. The Auto-Cut XT CCM is designed to work with the GCM 1000 (AC 300 XT) or the built in gas control of the AC 200 XT. Attempting to use a GCM 2010 or DFC 3000 Auto Gas Control on an Auto-Cut will result in a 308 code.
ULTRA-CUT 100 XT 401 Coolant Level Low The coolant reservoir (tank) has a normally open (tank dry) float type level switch, LS1. When the coolant level in the tank is below about ½ full this fault will signal the need to add coolant. It will not stop the process during a cut but will instead show the 405 fault as a warning. As soon as the cut stops it will not allow another to start until the issue is corrected.
ULTRA-CUT 100 XT Troubleshooting: 1. First note whether the fault is an “E” meaning it’s currently low or an “L” meaning it was low but isn’t now. Flow that remains low could indicate a failed component or a blockage such as clogged filter or pinched hose. It also means you should be able to measure the flow to determine if it is really low or the sensor has a problem. 2. First recycle power. If flow is still low or a component is defective the code should change to 404.
ULTRA-CUT 100 XT 2. Fans are powered by 230 VAC. The 230 VAC for the fan(s) is switched by the MC2 control relay (except the AC 200 XT where the fan(s) is powered directly from the T1 transformer at J13). To J70-3 1 TP1 2 TP2 J13 3 To test fan relay jump TP2 to TP1.
ULTRA-CUT 100 XT Reasons for 404 faults (Coolant not flowing): • In new installation, coolant has not circulated all the way through the leads. Add more coolant if necessary and recycle the power to restart the pump and 4 minute timer. • Coolant supply & return leads are reversed, check valve in torch coolant return prevents reverse flow. • Torch parts removed or are wrong style so torch check valve shuts off flow. • Torch coolant tube damaged or the tube extension (if required) missing.
ULTRA-CUT 100 XT TP3 1 2 J13 3 230 VAC from T1 To test Pump relay jump TP3 to TP1.
ULTRA-CUT 100 XT Coolant flow is correct but system doesn’t detect it due to defective components: • Defective or disconnected FS1 flow switch. • Relay board. • CCM. Flow Switch FS1 disconnected – FS1 comes with wire about 1 ft. long and a connector that connects to a 3 wire harness. This could be disconnected at either end, J74 or J5 on the relay board. Defective FS1– The flow switch, normally open, closes when flow through it exceeds 0.75 GPM, could be open.
ULTRA-CUT 100 XT Troubleshooting: 1. GCM 1000XT (also called a Basic Gas Control) does not use CANBUS (fiber-optic) communication. A jumper in the gas control connector J56 pins 8 & 9, gives the signal “Basic ID” telling the CCM not to expect any CANBUS. If somewhere this circuit is open, in the Gas Control cable, connector pins, connection from the rear panel GCM connector, J55, to the CCM (J26) CCM will expect to see a CANBUS connection and report this error because there is no CANBUS connected. 2.
ULTRA-CUT 100 XT The black end of the fiber cable is inserted into the transmitter which is the gray housing on the PCB. The other end of the transmitting fiber is blue and goes into the receiver with the black housing. A few seconds after power is turned on and when the pump has started up the CCM will try to transmit continuously for a while. You can unplug the fiber from the CCM and should see the transmitter red LED on the CCM PCB blinking.
ULTRA-CUT 100 XT 613 USB Log File Creation Fault When updating the CCM, DMC and DPC programs from a flash drive, a log file called CCM_LOG.TXT is created on the flash which reports on the results of the update including any problems. If that log file can’t be created you get 613. This may be a problem with the flash drive having too many other files on it or a problem with its format that may not be compatible with the CCM. 1. Try putting the update files on a different, preferably empty, flash drive.
ULTRA-CUT 100 XT CNC Cable Color Code TABLE 1: CABLE ITEM#4 COLOR CODE TABLE PIN LOCATION 3 4 5 6 7 8 9 10 11 12 14 16 17 21 22 23 24 25 26 29 30 31 32 33 34 35 36 37 COLOR SIGNAL DESCRIPTION WHITE/BLUE WHITE/VIOLET WHITE/BROWN/VIOLET WHITE/BROWN YELLOW GREEN WHITE/BLACK/BROWN WHITE/BROWN/BLUE WHITE/BLACK BLACK BLUE WHITE/BROWN/YELLOW WHITE/BROWN/GREEN WHITE/BLACK/ORANGE WHITE/BLACK/RED WHITE/BROWN/ORANGE ORANGE RED BROWN WHITE/BROWN RED WHITE GRAY VIOLET WHITE/BLACK/YELLOW WHITE/BLACK/GRAY WHITE/BLACK/V
ULTRA-CUT 100 XT APPENDIX 24: PUBLICATION HISTORY Cover Date Rev Change(s) April 22, 2013 AA First issue May 21, 2013 AB Updated with new RAS 1000 XT per ECOB2428 July 2, 2013 Updated section 3 with information about V-D Board installation for height controller per ECOB2488 Updated many items, text and art throughout the manual. Added Advanced Trouble shooting and plumbing diagrams to Appendix per ECOB2552. Updated 6.07 Radiator Cat no., Part no., and CNC color table. AC Jan.
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