Tweco 400 Ultra-Cut User Manual

400 operating manual, Ultra-cut, Plasma cutting system

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Art# A-09430

400

400

Operating Manual

PLASMA CUTTING SYSTEM

ULTRA-CUT

™

Rev. AI

Date: September 20, 2012 Manual # 0-5164

Operating Features:

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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 XT 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 Cables for CNC, Remote Arc Starter, DMC-3000 and HE 400
    • 3.10 Handling and Installation of Fiber Optics
    • 3.11 Connect Fiber Optic Cable (Type 3 internal control module)
    • 3.12 Set Switches on the Command - Control Module (Type 3 Module)
    • 3.13 Height Control Connections
    • 3.14 Gas Control Module Installation
    • 3.15 Fiber Optic Cable Installation
    • 3.16 Gas Control Module: Control, Input, and Output Connections
    • 3.17 HE400 COOLER
    • 3.18 Install Remote Arc Starter
    • 3.19 Torch Valve Installation
    • 3.20 Connecting Torch
    • 3.21 Install Consumable Torch Parts
    • 3.22 Complete the Installation
  • SECTION 4: OPERATION
    • 4.01 Power Supply Control Panel
    • 4.02 Start-Up Sequence
    • 4.03 Gas Control Module Operation
    • 4.04 First Time Operation Matching Gas Control to Lead Length
    • 4.05 Sequence Of Operation
    • 4.06 Gas Selection
    • 4.07 Power Supply Status Codes
    • 4.08 Remote Arc Starter: Spark Gap Adjustment
  • 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
  • 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
    • 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 - Right Side
    • 6.17 Gas Control Module (GCM-2010) Replacement Parts
    • 6.18 Gas Control Module (GCM-2010) Replacement Parts
    • 6.19 Remote Arc Starter (RAS-1000) Replacement Parts
    • 6.20 Remote Arc Starter (RAS-1000) Replacement Parts
    • 6.21 Command & Control Module - Replacement Parts
    • 6.22 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: CCM Input / Output PCB Layout
  • APPENDIX 7: CCM CPU PCB Layout
  • APPENDIX 8: CNC - Control Module PCB Connections
  • APPENDIX 9: CNC
    • CNC functions
    • CNC Input / Output Descriptions
    • Simplified CNC Circuit.
    • CNC Connections.
  • APPENDIX 10: Schematic, 230-460V Power Supply
  • APPENDIX 10: Schematic, 230-460V, Power Supply Cont.
  • APPENDIX 11: Schematic, CCC 400V Power Supply
  • APPENDIX 11: Schematic, CCC 400V Power Supply Cont.
  • APPENDIX 12: Schematic, CE 400V Power Supply
  • APPENDIX 12: Schematic, CE 400V Power Supply Cont.
  • APPENDIX 13: PUBLICATION HISTORY
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