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
  • 1.08 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, GCM and HE 400
  • 3.11 Handling and Installation of Fiber Optics
  • 3.12 Set Switches on the Command - Control 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 Optional 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 Voltage Divider for iHC Torch Height Control
  • 3.23 Complete the Installation
• SECTION 4: OPERATION
  • 4.01 Power Supply Control Panel
  • 4.02 System Operation
  • 4.03 Gas Selection
  • 4.04 GCM 2010 Gas Control Module Operation
  • 4.05 GCM 2010 First Time Operation Matching Gas Control to Lead Length
  • 4.06 GCM 2010 Sequence Of Operation
  • 4.07 Power Supply Status Codes
  • 4.08 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 Gas Control Module (GCM-2010) Replacement Parts
  • 6.11 Gas Control Module (GCM-2010) Replacement Parts
  • 6.12 Remote Arc Starter (RAS-1000 XT) Replacement Parts
  • 6.13 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, 480V PG 1
• APPENDIX 22: System Schematic 100A, 480V PG 2
• Appendix 23: Advanced Troubleshooting
• APPENDIX 24: PUBLICATION HISTORY
• 0-5272-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
    • 1.08 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, GCM and HE 400
    • 3.11 Handling and Installation of Fiber Optics
    • 3.12 Set Switches on the Command - Control 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 Optional 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 Voltage Divider for iHC Torch Height Control
    • 3.23 Complete the Installation
  • SECTION 4: OPERATION
    • 4.01 Power Supply Control Panel
    • 4.02 System Operation
    • 4.03 Gas Selection
    • 4.04 GCM 2010 Gas Control Module Operation
    • 4.05 GCM 2010 First Time Operation Matching Gas Control to Lead Length
    • 4.06 GCM 2010 Sequence Of Operation
    • 4.07 Power Supply Status Codes
    • 4.08 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 Gas Control Module (GCM-2010) Replacement Parts
    • 6.11 Gas Control Module (GCM-2010) Replacement Parts
    • 6.12 Remote Arc Starter (RAS-1000 XT) Replacement Parts
    • 6.13 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, 480V PG 1
  • APPENDIX 22: System Schematic 100A, 480V PG 2
  • Appendix 23: Advanced Troubleshooting
  • APPENDIX 24: PUBLICATION HISTORY