Tweco 400 Ultra-Cut(October 2014) User Manual

Operating manual, Plasma cutting system

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This manual is related to the following products:

300 Ultra-Cut(October 2014), 200 Ultra-Cut(October 2014), 100 Ultra-Cut(October 2014)

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 100 - 200 Amp
- 3.03 System Layout 300 Amp
- 3.04 System Layout 400 Amp
- 3.05 Recommended Gas Supply Hose
- 3.06 Leads and Cables All Amperage
- 3.07 Lift the Power Supply
- 3.08 Connect Input Power and Ground Cables
- 3.09 Connect Work Cable and Pilot and Negative Leads
- 3.10 Ground Connections
- 3.11 Connect Coolant Leads
- 3.12 Connect Cables for CNC, Remote Arc Starter, GCM and HE 400
- 3.13 Handling and Installation of Fiber Optics
- 3.14 Set Switches on the Command - Control Module
- 3.15 Height Control Connections
- 3.16 Gas Control Module Installation
- 3.17 Fiber Optic Cable Installation
- 3.18 Gas Control Module: Control, Input, and Output Connections
- 3.19 HE400XT COOLER
- 3.20 Install Remote Arc Starter
- 3.21 Torch Valve Installation
- 3.22 Connecting Torch
- 3.23 Install Consumable Torch Parts
- 3.24 Voltage Divider for iHC Torch Height Control
- 3.25 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 100 - 200 Amp
- 6.03 System Layout 300 Amp
- 6.04 System Layout 400 Amp
- 6.05 Recommended Gas Supply Hose
- 6.06 Leads And Cables All Amperages
- 6.07 Power Supply External Replacement Parts
- 6.08 Power Supply Replacement Parts - Upper Right Side
- 6.09 Power Supply Replacement Parts - Lower Right Side
- 6.10 Power Supply Replacement Parts - Rear Panel
- 6.11 Power Supply Replacement Parts - Left Side
- 6.12 Gas Control Module (GCM-2010) Replacement Parts
- 6.13 Gas Control Module (GCM-2010) Replacement Parts
- 6.14 Remote Arc Starter (RAS-1000 XT) Replacement Parts
- 6.15 HE400XT 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: SERIAL COMMUNICATIONS
- A8.01 Cables and Switch Settings for 2 and 4 Wire
Appendix 9: CCM CPU PCB Layout
Appendix 10: CCM I/O PCB Layout
Appendix 11: Pilot PCB Layout
Appendix 12: Relay and Interface PCB Layout
Appendix 13: Display PCB Layout
Appendix 14: System Bias PCB Layout
Appendix 15: Main Inverter Bottom PCB Layout
Appendix 16: Main Inverter Top PCB Layout
Appendix 17: Control and Fault PCB Layout
Appendix 18: Cap Bias Bottom PCB Layout
Appendix 19: Cap Bias Top PCB Layout
Appendix 20: Suppressor PCB Layout
Appendix 21: COOLING DIAGRAM
APPENDIX 22: System Schematic 100A, 380-415V PG 1
APPENDIX 23: System Schematic 100A, 380-415V PG 2
APPENDIX 24: System Schematic 200A, 380-415V PG 1
APPENDIX 25: System Schematic 200A, 380-415V PG 2
APPENDIX 26: System Schematic 300A, 380-415V PG 1
APPENDIX 27: System Schematic 300A, 380-415V PG 2
APPENDIX 28: System Schematic 400A, 380-415V PG 1
APPENDIX 29: System Schematic 400A, 380-415V PG 2
Appendix 30: ADVANCED TROUBLESHOOTING
APPENDIX 31: PUBLICATION HISTORY
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