VIC DocLib 2213 0-4816

20O2
™
AUTO-CUT
PLASMA CUTTING SYSTEM
Art# A-08582
Operating Manual
Rev: AQ
Operating Features:
Issue Date: August 26, 2010 Manual No.: 0-4816
3 208-
200 400 400 460 600
230
AMP PHASE V V V (CE) V V
WE APPRECIATE YOUR BUSINESS!
Congratulations on your new Thermal Dynamics product. We are
proud to have you as our customer and will strive to provide you
with the best service and reliability in the industry. This product is
backed by our extensive warranty and world-wide service network.
To locate your nearest distributor or service agency call 1-800-
426-1888, or visit us on the web at www.thermal-dynamics.com.
This Operating Manual has been designed to instruct you on the

correct use and operation of your Thermal Dynamics product.
Your satisfaction with this product and its safe operation is our
ultimate concern. Therefore please take the time to read the entire
manual, especially the Safety Precautions. They will help you to
avoid potential hazards that may exist when working with this
product.
YOU ARE IN GOOD COMPANY!

The Brand of Choice for Contractors and Fabricators Worldwide.
Thermal Dynamics is a Global Brand of manual and automation
Plasma Cutting Products for Thermadyne Industries Inc.
We distinguish ourselves from our competition through market-

leading, dependable products that have stood the test of time.
We pride ourselves on technical innovation, competitive prices,
excellent delivery, superior customer service and technical
support, together with excellence in sales and marketing expertise.
Above all, we are committed to developing technologically

advanced products to achieve a safer working environment within
the welding industry.
! 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 judge-
ment, the Manufacturer assumes no liability for its use.
Plasma Cutting Power Supply, Auto-Cut® 20O2

Operating Manual No. 0-4816
Published by:
Thermadyne Corporation
82 Benning Street
West Lebanon, New Hampshire, USA 03784
(603) 298-5711
www.thermal-dynamics.com
© Copyright 2006, 2007, 2008, 2009, 2010 by

Thermadyne Corporation
All rights reserved.
Reproduction of this work, in whole or in part, without written per-

mission of the publisher is prohibited.
The publisher does not assume and hereby disclaims any liability to
any party for any loss or damage caused by any error or omission
in this Manual, whether such error results from negligence, acci-
dent, or any other cause.
Printed in the United States of America
Licensed under U. S. Patent No. 5,070,227
Original Publication Date: March 16, 2006

Revision Date: August 26, 2010
Record the following information for Warranty purposes:
Where Purchased: ___________________________________
Purchase Date:______________________________________
Power Supply Serial #:_______________________________
Torch Serial #:_______________________________________

This page intentionally blank
TABLE OF CONTENTS
SECTION 1:
GENERAL INFORMATION ................................................................................................ 1-1
1.01 Notes, Cautions and Warnings ...................................................................... 1-1
1.02 Important Safety Precautions ....................................................................... 1-1
1.03 Publications .................................................................................................. 1-2
1.04 Note, Attention et Avertissement .................................................................. 1-3
1.05 Precautions De Securite Importantes ........................................................... 1-3
1.06 Documents De Reference ............................................................................. 1-5
1.07 Declaration of Conformity ............................................................................. 1-6
1.08 Statement of Warranty .................................................................................. 1-7
SECTION 2: SPECIFICATIONS ................................................................................................. 2-1

2.01 General Description Of The System .............................................................. 2-1
2.02 Plasma Power Supply ................................................................................... 2-1
2.03 Remote Arc Starter ...................................................................................... 2-1
2.04 Gas Control Module ...................................................................................... 2-1
2.05 Conventional Plasma Cutting Torch ............................................................... 2-1
2.06 Specifications & Electrical Requirements ..................................................... 2-2
2.07 System Layout ............................................................................................. 2-3
2.08 Power Supply Dimensions ............................................................................ 2-4
2.09 Power Supply Rear Panel Features ............................................................... 2-5
2.10 Gas Specifications ....................................................................................... 2-6
2.11 Gas Applications .......................................................................................... 2-6
2.12 XTTM-301 Torch Specifications .................................................................... 2-7
SECTION 3: INSTALLATION ...................................................................................................... 3-1

3.01 Installation Requirements ............................................................................. 3-1
3.02 System Layout ............................................................................................. 3-2
3.03 Cables & Leads Identification ....................................................................... 3-3
3.04 Lift the Power Supply .................................................................................... 3-4
3.05 Primary Power Connections .......................................................................... 3-5
3.06 Ground Connections .................................................................................... 3-10
3.07 Connect Work Cable and Pilot and Negative / Torch Leads .......................... 3-12
3.08 Connect Coolant Leads ................................................................................ 3-13
3.09 Connect Control Cables for CNC, Remote Arc Starter, and GCM ................. 3-14
3.10 Connect Fiber Optic Cable to CCM ............................................................. 3-15
3.11 Set Switches on the Command - Control Module ......................................... 3-16
3.12 Height Control Connections ......................................................................... 3-18
3.13 Install Gas Control Module .......................................................................... 3-19
3.14 Connect Fiber Optic Cable to Gas Control Module ....................................... 3-21
3.15 Connect Control, Input, and Outputs to Gas Control Module ........................ 3-23
3.16 Install Remote Arc Starter ........................................................................... 3-24
3.17 Install Torch Valve ........................................................................................ 3-34
3.18 Prepare the Torch Head ................................................................................ 3-35
3.19 Connect Torch .............................................................................................. 3-36
3.20 Install Consumable Torch Parts .................................................................... 3-38
3.21 Install Coolant.............................................................................................. 3-41
TABLE OF CONTENTS (continued)
SECTION 4: OPERATION .......................................................................................................... 4-1

4.01 Power Supply Control Panel .......................................................................... 4-1
4.02 Start-Up Sequence ....................................................................................... 4-2
4.03 Gas Control Module Operation ...................................................................... 4-3
4.04 Gas Control Sequence Of Operation ............................................................. 4-7
4.05 Gas Selection .............................................................................................. 4-10
4.06 Power Supply Status Codes ........................................................................ 4-12
4.07 Remote Arc Starter: Service Chart ............................................................. 4-16
4.08 Remote Arc Starter: Spark Gap Adjustment ............................................... 4-17
SECTION 5: MAINTENANCE .................................................................................................... 5-1

5.01 General Maintenance .................................................................................... 5-1
5.02 External Coolant Filter Cleaning Procedure ................................................... 5-1
5.03 Internal Coolant Filter Cleaning Procedure .................................................... 5-2
5.04 Coolant Replacement Procedure ................................................................... 5-2
SECTION 6: REPLACEMENT ASSEMBLIES & PARTS ........................................................... 6-1

6.01 Replacement Power Supply .......................................................................... 6-1
6.02 Auto-Cut 20O2System Layout ...................................................................... 6-2
6.03 Recommended Gas Supply Hose ................................................................. 6-2
6.04 Cables and Leads ......................................................................................... 6-3
6.05 Power Supply External Replacement Parts ................................................... 6-9
6.06 Power Supply Replacement Parts - Right Side ............................................ 6-10
6.09 Power Supply Replacement Parts - Front Panel ........................................... 6-13
6.10 Power Supply Replacement Parts - Front Panel ........................................... 6-14
6.12 Power Supply Replacement Parts - Rear Panel ............................................ 6-16
6.14 Power Supply Replacement Parts ................................................................ 6-18
6.16 Power Supply Replacement Parts ................................................................ 6-20
6.18 Gas Control Module (GCM-2000) Replacement Parts .................................. 6-22
6.19 Remote Arc Starter (RAS-1000) Replacement Parts .................................... 6-24
6.20 Remote Arc Starter (RAS-1000) Replacement Parts .................................... 6-25
6.21 Command & Control Module Type 2 - Replacement Parts ......................... 6-26
6.22 Torch Valve Assembly Replacement Parts ................................................... 6-27
SECTION 7: TORCH MAINTENANCE .................................................................................. 7-1

7.01 Consumable Removal ................................................................................... 7-1
7.02 O-Ring Lubrication ........................................................................................ 7-2
7.03 Parts Wear .................................................................................................... 7-3
7.04 Torch Consumables Installation .................................................................... 7-4
7.05 Coolant Leak Trouble-Shooting ...................................................................... 7-7
TABLE OF CONTENTS (continued)
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: CCM CPU Board Layout ...................................................................................... A-6
APPENDIX 6: CCM Input / Output PCB Layout ........................................................................ A-7
APPENDIX 7: CNC - Control Module PCB Connections ............................................................ A-8

CNC functions. ..................................................................................................... A-9
CNC Input / Output Descriptions ......................................................................... A-10
Simplified CNC Circuit. ....................................................................................... A-11
APPENDIX 8: Schematic, 230-460V Unit ................................................................................. A-12
APPENDIX 8: Schematic, 230-460V Unit Cont. ....................................................................... A-14
APPENDIX 9: Schematic, CCC 400V Unit ............................................................................... A-16
APPENDIX 9: Schematic, CCC 400V Unit Cont. ...................................................................... A-18
APPENDIX 10: Schematic, CE 400V Unit ................................................................................ A-20
APPENDIX 10: Schematic, CE 400V Unit Cont. ...................................................................... A-22
APPENDIX 11: Schematic, CSA 600V Unit ............................................................................. A-24
APPENDIX 11: Schematic, CSA 600V Unit Cont. .................................................................... A-26
APPENDIX 12: Publication History ......................................................................................... A-28

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AUTOCUT 20O2
SECTION 1: • Use an air-supplied respirator if ventilation is not adequate to
remove all fumes and gases.
GENERAL INFORMATION • The kinds of fumes and gases from the plasma arc depend on the
kind of metal being used, coatings on the metal, and the different
processes. You must be very careful when cutting or welding
1.01 Notes, Cautions and Warnings any metals which may contain one or more of the following:
Antimony Chromium Mercury
Throughout this manual, notes, cautions, and warnings are used to Arsenic Cobalt Nickel
highlight important information. These highlights are categorized as Barium Copper Selenium
follows: Beryllium Lead Silver
Cadmium Manganese Vanadium
NOTE
• Always read the Material Safety Data Sheets (MSDS) that should
An operation, procedure, or background information be supplied with the material you are using. These MSDSs will
which requires additional emphasis or is helpful in effi- give you the information regarding the kind and amount of fumes
cient operation of the system. and gases that may be dangerous to your health.
• For information on how to test for fumes and gases in your
workplace, refer to item 1 in Subsection 1.03, Publications in
CAUTION this manual.
• Use special equipment, such as water or down draft cutting
A procedure which, if not properly followed, may cause tables, to capture fumes and gases.
damage to the equipment. • Do not use the plasma torch in an area where combustible or
explosive gases or materials are located.
!
• Phosgene, a toxic gas, is generated from the vapors of chlori-
WARNING nated solvents and cleansers. Remove all sources of these va-
pors.
A procedure which, if not properly followed, may cause • This product, when used for welding or cutting, produces fumes
injury to the operator or others in the operating area. or gases which contain chemicals known to the State of Califor-
nia to cause birth defects and, in some cases, cancer. (California
Health & Safety Code Sec. 25249.5 et seq.)
1.02 Important Safety Precautions
ELECTRIC SHOCK
WARNINGS
Electric Shock can injure or kill. The plasma arc process uses and
produces high voltage electrical energy. This electric energy can cause
OPERATION AND MAINTENANCE OF PLASMA ARC severe or fatal shock to the operator or others in the workplace.
EQUIPMENT CAN BE DANGEROUS AND HAZARDOUS
• Never touch any parts that are electrically “live” or “hot.”
TO YOUR HEALTH.
• Wear dry gloves and clothing. Insulate yourself from the work
Plasma arc cutting produces intense electric and mag- piece or other parts of the welding circuit.
netic emissions that may interfere with the proper func-
tion of cardiac pacemakers, hearing aids, or other elec- • Repair or replace all worn or damaged parts.
tronic health equipment. Persons who work near plasma • Extra care must be taken when the workplace is moist or damp.
arc cutting applications should consult their medical health • Install and maintain equipment according to NEC code, refer to
professional and the manufacturer of the health equip- item 9 in Subsection 1.03, Publications.
ment to determine whether a hazard exists.
• Disconnect power source before performing any service or re-
To prevent possible injury, read, understand and follow pairs.
all warnings, safety precautions and instructions before
• Read and follow all the instructions in the Operating Manual.
using the equipment. Call 1-603-298-5711 or your local
distributor if you have any questions.
FIRE AND EXPLOSION
GASES AND FUMES Fire and explosion can be caused by hot slag, sparks, or the plasma arc.
• Be sure there is no combustible or flammable material in the

Gases and fumes produced during the plasma cutting process can be workplace. Any material that cannot be removed must be pro-
dangerous and hazardous to your health. tected.
• Keep all fumes and gases from the breathing area. Keep your • Ventilate all flammable or explosive vapors from the workplace.
head out of the welding fume plume. • Do not cut or weld on containers that may have held combus-
tibles.
Manual 0-4816 Auto-Cut 2002 1-1
AUTOCUT 20O2
• Provide a fire watch when working in an area where fire hazards 1.03 Publications
may exist.
• Hydrogen gas may be formed and trapped under aluminum Refer to the following standards or their latest revisions for more infor-
workpieces when they are cut underwater or while using a water mation:
table. DO NOT cut aluminum alloys underwater or on a water
1. OSHA, SAFETY AND HEALTH STANDARDS, 29CFR 1910,
table unless the hydrogen gas can be eliminated or dissipated.
Trapped hydrogen gas that is ignited will cause an explosion. 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,
NOISE
obtainable from the American Welding Society, 550 N.W.
LeJeune Rd, Miami, FL 33126
Noise can cause permanent hearing loss. Plasma arc processes can
cause noise levels to exceed safe limits. You must protect your ears 3. NIOSH, SAFETY AND HEALTH IN ARC WELDING AND GAS
from loud noise to prevent permanent loss of hearing. WELDING AND CUTTING, obtainable from the Superinten-
dent of Documents, U.S. Government Printing Office, Wash-
• To protect your hearing from loud noise, wear protective ear ington, D.C. 20402
plugs and/or ear muffs. Protect others in the workplace.
• Noise levels should be measured to be sure the decibels (sound)
4. ANSI Standard Z87.1, SAFE PRACTICES FOR OCCUPATION
do not exceed safe levels. AND EDUCATIONAL EYE AND FACE PROTECTION, obtain-
able from American National Standards Institute, 1430
• For information on how to test for noise, see item 1 in Subsec- Broadway, New York, NY 10018
tion 1.03, Publications, in this manual.
5. ANSI Standard Z41.1, STANDARD FOR MEN’S SAFETY-TOE
FOOTWEAR, obtainable from the American National Stan-
PLASMA ARC RAYS dards Institute, 1430 Broadway, New York, NY 10018
6. ANSI Standard Z49.2, FIRE PREVENTION IN THE USE OF
Plasma Arc Rays can injure your eyes and burn your skin. The plasma
CUTTING AND WELDING PROCESSES, obtainable from
arc process produces very bright ultra violet and infra red light. These
American National Standards Institute, 1430 Broadway,
arc rays will damage your eyes and burn your skin if you are not
New York, NY 10018
properly protected.
7. AWS Standard A6.0, WELDING AND CUTTING CONTAIN-
• To protect your eyes, always wear a welding helmet or shield.
Also always wear safety glasses with side shields, goggles or ERS WHICH HAVE HELD COMBUSTIBLES, obtainable from
other protective eye wear. American Welding Society, 550 N.W. LeJeune Rd, Miami,
FL 33126
• Wear welding gloves and suitable clothing to protect your skin
from the arc rays and sparks. 8. NFPA Standard 51, OXYGEN-FUEL GAS SYSTEMS FOR
• Keep helmet and safety glasses in good condition. Replace WELDING, CUTTING AND ALLIED PROCESSES, obtainable
lenses when cracked, chipped or dirty. from the National Fire Protection Association, Batterymarch
Park, Quincy, MA 02269
• Protect others in the work area from the arc rays. Use protective
booths, screens or shields. 9. NFPA Standard 70, NATIONAL ELECTRICAL CODE, obtain-
• Use the shade of lens as suggested in the following per ANSI/ able from the National Fire Protection Association,
ASC Z49.1: Batterymarch Park, Quincy, MA 02269
Minimum Protective Suggested
Arc Current Shade No. Shade No. 10. NFPA Standard 51B, CUTTING AND WELDING PROCESSES,
obtainable from the National Fire Protection Association,
Less Than 300* 8 9 Batterymarch Park, Quincy, MA 02269
300 - 400* 9 12
11. CGA Pamphlet P-1, SAFE HANDLING OF COMPRESSED
400 - 800* 10 14 GASES IN CYLINDERS, obtainable from the Compressed
Gas Association, 1235 Jefferson Davis Highway, Suite 501,
* These values apply where the actual arc is clearly seen.
Arlington, VA 22202
Experience has shown that lighter filters may be used
when the arc is hidden by the workpiece. 12. CSA Standard W117.2, CODE FOR SAFETY IN WELDING
AND CUTTING, obtainable from the Canadian Standards
Association, Standards Sales, 178 Rexdale Boulevard,
LEAD WARNING Rexdale, Ontario, Canada M9W 1R3
13. NWSA booklet, WELDING SAFETY BIBLIOGRAPHY obtain-
This product contains chemicals, including lead, or otherwise pro- able from the National Welding Supply Association, 1900
duces chemicals known to the State of California to cause cancer, birth Arch Street, Philadelphia, PA 19103
defects and other reproductive harm. Wash hands after handling.
14. American Welding Society Standard AWSF4.1, RECOM-
(California Health & Safety Code § 25249.5 et seq.)
MENDED SAFE PRACTICES FOR THE PREPARATION FOR
WELDING AND CUTTING OF CONTAINERS AND PIPING
1-2 Manual 0-4816 Auto-Cut 2002
AUTOCUT 20O2
THAT HAVE HELD HAZARDOUS SUBSTANCES, obtainable
from the American Welding Society, 550 N.W. LeJeune Rd,
FUMÉE et GAZ
Miami, FL 33126
15. ANSI Standard Z88.2, PRACTICE FOR RESPIRATORY PRO- La fumée et les gaz produits par le procédé de jet de plasma peuvent
TECTION, obtainable from American National Standards présenter des risques et des dangers de santé.
Institute, 1430 Broadway, New York, NY 10018
• Eloignez toute fumée et gaz de votre zone de respiration. Gardez
1.04 Note, Attention et Avertissement votre tête hors de la plume de fumée provenant du chalumeau.
• Utilisez un appareil respiratoire à alimentation en air si l’aération
Dans ce manuel, les mots “note,” “attention,” et “avertissement” sont fournie ne permet pas d’éliminer la fumée et les gaz.
utilisés pour mettre en relief des informations à caractère important.
Ces mises en relief sont classifiées comme suit : • Les sortes de gaz et de fumée provenant de l’arc de plasma dépendent
du genre de métal utilisé, des revêtements se trouvant sur le métal et
NOTE des différents procédés. Vous devez prendre soin lorsque vous
Toute opération, procédure ou renseignement général sur coupez ou soudez tout métal pouvant contenir un ou plusieurs des
lequel il importe d’insister davantage ou qui contribue à éléments suivants:
l’efficacité de fonctionnement du système. antimoine cadmium mercure
argent chrome nickel
arsenic cobalt plomb
ATTENTION baryum cuivre sélénium
béryllium manganèse vanadium
Toute procédure pouvant résulter l’endommagement du • Lisez toujours les fiches de données sur la sécurité des matières
matériel en cas de non-respect de la procédure en (sigle américain “MSDS”); celles-ci devraient être fournies avec le
question. matériel que vous utilisez. Les MSDS contiennent des
renseignements quant à la quantité et la nature de la fumée et des gaz
pouvant poser des dangers de santé.
! AVERTISSEMENT • Pour des informations sur la manière de tester la fumée et les gaz de
votre lieu de travail, consultez l’article 1 et les documents cités à la
page 5.
Toute procédure pouvant provoquer des blessures de
l’opérateur ou des autres personnes se trouvant dans la • Utilisez un équipement spécial tel que des tables de coupe à débit
zone de travail en cas de non-respect de la procédure en d’eau ou à courant descendant pour capter la fumée et les gaz.
question.
• N’utilisez pas le chalumeau au jet de plasma dans une zone où se
trouvent des matières ou des gaz combustibles ou explosifs.
1.05 Precautions De Securite Importantes • Le phosgène, un gaz toxique, est généré par la fumée provenant des
solvants et des produits de nettoyage chlorés. Eliminez toute source
de telle fumée.
AVERTISSEMENTS
• Ce produit, dans le procéder de soudage et de coupe, produit de la
fumée ou des gaz pouvant contenir des éléments reconnu dans
L’OPÉRATION ET LA MAINTENANCE DU MATÉRIEL DE L’état de la Californie, qui peuvent causer des défauts de naissance et
SOUDAGE À L’ARC AU JET DE PLASMA PEUVENT le cancer. (La sécurité de santé en Californie et la code sécurité Sec.
PRÉSENTER DES RISQUES ET DES DANGERS DE 25249.5 et seq.)
SANTÉ.
Coupant à l’arc au jet de plasma produit de l’énergie CHOC ELECTRIQUE
électrique haute tension et des émissions magnétique qui
peuvent interférer la fonction propre d’un “pacemaker”
cardiaque, les appareils auditif, ou autre matériel de santé Les chocs électriques peuvent blesser ou même tuer. Le procédé au jet de
electronique. Ceux qui travail près d’une application à plasma requiert et produit de l’énergie électrique haute tension. Cette
l’arc au jet de plasma devrait consulter leur membre énergie électrique peut produire des chocs graves, voire mortels, pour
professionel de médication et le manufacturier de matériel l’opérateur et les autres personnes sur le lieu de travail.
de santé pour déterminer s’il existe des risques de santé.
• Ne touchez jamais une pièce “sous tension” ou “vive”; portez des
Il faut communiquer aux opérateurs et au personnel TOUS gants et des vêtements secs. Isolez-vous de la pièce de travail ou des
les dangers possibles. Afin d’éviter les blessures autres parties du circuit de soudage.
possibles, lisez, comprenez et suivez tous les
avertissements, toutes les précautions de sécurité et toutes • Réparez ou remplacez toute pièce usée ou endommagée.
les consignes avant d’utiliser le matériel. Composez le + • Prenez des soins particuliers lorsque la zone de travail est humide
603-298-5711 ou votre distributeur local si vous avez ou moite.
des questions.

AUTOCUT 20O2
• Montez et maintenez le matériel conformément au Code électrique • Utilisez la nuance de lentille qui est suggèrée dans le recommenda-
national des Etats-Unis. (Voir la page 5, article 9.) tion qui suivent ANSI/ASC Z49.1:
• Débranchez l’alimentation électrique avant tout travail d’entretien Nuance Minimum Nuance Suggerée
ou de réparation. Courant Arc Protective Numéro Numéro
Moins de 300* 8 9
• Lisez et respectez toutes les consignes du Manuel de consignes.
300 - 400* 9 12
400 - 800* 10 14
INCENDIE ET EXPLOSION
* Ces valeurs s’appliquent ou l’arc actuel est observé
clairement. L’experience a démontrer que les filtres moins
Les incendies et les explosions peuvent résulter des scories chaudes,
foncés peuvent être utilisés quand l’arc est caché par
des étincelles ou de l’arc de plasma. Le procédé à l’arc de plasma
moiceau de travail.
produit du métal, des étincelles, des scories chaudes pouvant mettre le
feu aux matières combustibles ou provoquer l’explosion de fumées
inflammables.
BRUIT
• Soyez certain qu’aucune matière combustible ou inflammable ne se
trouve sur le lieu de travail. Protégez toute telle matière qu’il est
impossible de retirer de la zone de travail. Le bruit peut provoquer une perte permanente de l’ouïe. Les procédés
de soudage à l’arc de plasma peuvent provoquer des niveaux sonores
• Procurez une bonne aération de toutes les fumées inflammables ou supérieurs aux limites normalement acceptables. Vous dú4ez vous
explosives. protéger les oreilles contre les bruits forts afin d’éviter une perte
permanente de l’ouïe.
• Ne coupez pas et ne soudez pas les conteneurs ayant pu renfermer
des matières combustibles. • Pour protéger votre ouïe contre les bruits forts, portez des tampons
protecteurs et/ou des protections auriculaires. Protégez également
• Prévoyez une veille d’incendie lors de tout travail dans une zone les autres personnes se trouvant sur le lieu de travail.
présentant des dangers d’incendie.
• Il faut mesurer les niveaux sonores afin d’assurer que les décibels
• Le gas hydrogène peut se former ou s’accumuler sous les pièces de (le bruit) ne dépassent pas les niveaux sûrs.
travail en aluminium lorsqu’elles sont coupées sous l’eau ou sur
une table d’eau. NE PAS couper les alliages en aluminium sous • Pour des renseignements sur la manière de tester le bruit, consultez
l’eau ou sur une table d’eau à moins que le gas hydrogène peut l’article 1, page 5.
s’échapper ou se dissiper. Le gas hydrogène accumulé explosera si
enflammé.
PLOMB AVERTISSEMENT
RAYONS D’ARC DE PLASMA
Ce produit contient des produits chimiques, comme le plomb, ou
engendre des produits chimiques, reconnus par l’état de Californie
Les rayons provenant de l’arc de plasma peuvent blesser vos yeux et
comme pouvant être à l’origine de cancer, de malformations fœtales ou
brûler votre peau. Le procédé à l’arc de plasma produit une lumière
d’autres problèmes de reproduction. Il faut se laver les mains après
infra-rouge et des rayons ultra-violets très forts. Ces rayons d’arc nuiront
toute manipulation. (Code de Californie de la sécurité et santé,
à vos yeux et brûleront votre peau si vous ne vous protégez pas
paragraphe 25249.5 et suivants)
correctement.
• Pour protéger vos yeux, portez toujours un casque ou un écran de
soudeur. Portez toujours des lunettes de sécurité munies de parois
latérales ou des lunettes de protection ou une autre sorte de protec-
tion oculaire.
• Portez des gants de soudeur et un vêtement protecteur approprié
pour protéger votre peau contre les étincelles et les rayons de l’arc.
• Maintenez votre casque et vos lunettes de protection en bon état.
Remplacez toute lentille sale ou comportant fissure ou rognure.
• Protégez les autres personnes se trouvant sur la zone de travail
contre les rayons de l’arc en fournissant des cabines ou des écrans
de protection.

AUTOCUT 20O2
1.06 Documents De Reference 14. Norme AWSF4.1 de l’Association Américaine de Soudage,
RECOMMANDATIONS DE PRATIQUES SURES POUR LA
Consultez les normes suivantes ou les révisions les plus récentes ayant PRÉPARATION À LA COUPE ET AU SOUDAGE DE CONTENEURS
été faites à celles-ci pour de plus amples renseignements : ET TUYAUX AYANT RENFERMÉ DES PRODUITS DANGEREUX ,
disponible auprès de la American Welding Society, 550 N.W. LeJeune
1. OSHA, NORMES DE SÉCURITÉ DU TRAVAIL ET DE PROTECTION
Rd., Miami, FL 33126
DE LA SANTÉ, 29CFR 1910, disponible auprès du Superintendent
of Documents, U.S. Government Printing Office, Washington, D.C. 15. Norme ANSI Z88.2, PRATIQUES DE PROTECTION RESPIRATOIRE,
20402 disponible auprès de l’American National Standards Institute, 1430
Broadway, New York, NY 10018
2. Norme ANSI Z49.1, LA SÉCURITÉ DES OPÉRATIONS DE COUPE ET
DE SOUDAGE, disponible auprès de la Société Américaine de
Soudage (American Welding Society), 550 N.W. LeJeune Rd., Mi-
ami, FL 33126
3. NIOSH, LA SÉCURITÉ ET LA SANTÉ LORS DES OPÉRATIONS DE
COUPE ET DE SOUDAGE À L’ARC ET AU GAZ, disponible auprès du
Superintendent of Documents, U.S. Government Printing Office,
Washington, D.C. 20402
4. Norme ANSI Z87.1, PRATIQUES SURES POUR LA PROTECTION
DES YEUX ET DU VISAGE AU TRAVAIL ET DANS LES ECOLES,
disponible de l’Institut Américain des Normes Nationales (American
National Standards Institute), 1430 Broadway, New York, NY 10018
5. Norme ANSI Z41.1, NORMES POUR LES CHAUSSURES
PROTECTRICES, disponible auprès de l’American National Stan-
dards Institute, 1430 Broadway, New York, NY 10018
6. Norme ANSI Z49.2, PRÉVENTION DES INCENDIES LORS DE
L’EMPLOI DE PROCÉDÉS DE COUPE ET DE SOUDAGE, disponible
auprès de l’American National Standards Institute, 1430 Broadway,
New York, NY 10018
7. Norme A6.0 de l’Association Américaine du Soudage (AWS), LE
SOUDAGE ET LA COUPE DE CONTENEURS AYANT RENFERMÉ DES
PRODUITS COMBUSTIBLES, disponible auprès de la American
Welding Society, 550 N.W. LeJeune Rd., Miami, FL 33126
8. Norme 51 de l’Association Américaine pour la Protection contre les
Incendies (NFPA), LES SYSTEMES À GAZ AVEC ALIMENTATION
EN OXYGENE POUR LE SOUDAGE, LA COUPE ET LES PROCÉDÉS
ASSOCIÉS, disponible auprès de la National Fire Protection Asso-
ciation, Batterymarch Park, Quincy, MA 02269
9. Norme 70 de la NFPA, CODE ELECTRIQUE NATIONAL, disponible
auprès de la National Fire Protection Association, Batterymarch Park,
Quincy, MA 02269
10. Norme 51B de la NFPA, LES PROCÉDÉS DE COUPE ET DE
SOUDAGE, disponible auprès de la National Fire Protection Asso-
ciation, Batterymarch Park, Quincy, MA 02269
11. Brochure GCA P-1, LA MANIPULATION SANS RISQUE DES GAZ
COMPRIMÉS EN CYLINDRES, disponible auprès de l’Association
des Gaz Comprimés (Compressed Gas Association), 1235 Jefferson
Davis Highway, Suite 501, Arlington, VA 22202
12. Norme CSA W117.2, CODE DE SÉCURITÉ POUR LE SOUDAGE ET
LA COUPE, disponible auprès de l’Association des Normes
Canadiennes, Standards Sales, 178 Rexdale Boulevard, Rexdale,
Ontario, Canada, M9W 1R3
13. Livret NWSA, BIBLIOGRAPHIE SUR LA SÉCURITÉ DU SOUDAGE,
disponible auprès de l’Association Nationale de Fournitures de
Soudage (National Welding Supply Association), 1900 Arch Street,
Philadelphia, PA 19103

AUTOCUT 20O2
1.07 Declaration of Conformity
Manufacturer: Thermal Dynamics Corporation
Address: 82 Benning Street
West Lebanon, New Hampshire 03784
USA
The equipment described in this manual conforms to all applicable aspects and regulations of the ‘Low Voltage Directive’
(European Council Directive 73/23/EEC as amended by Council Directive 93/68/EEC) and to the National legislation for the
enforcement of this Directive.
The equipment described in this manual conforms to all applicable aspects and regulations of the "EMC Directive" (European
Council Directive 89/336/EEC) and to the National legislation for the enforcement of this Directive.
Serial numbers are unique with each individual piece of equipment and details description, parts used to manufacture a unit and
date of manufacture.
National Standard and Technical Specifications
The product is designed and manufactured to a number of standards and technical requirements. Among them are:
* CSA (Canadian Standards Association) standard C22.2 number 60 for Arc welding equipment.
* UL (Underwriters Laboratory) rating 94VO flammability testing for all printed-circuit boards used.
* CENELEC EN50199 EMC Product Standard for Arc Welding Equipment.
* ISO/IEC 60974-1 (BS 638-PT10) (EN 60 974-1) (EN50192) (EN50078) applicable to plasma cutting equipment and associated
accessories.
* For environments with increased hazard of electrical shock, Power Supplies bearing the 'S' mark conform to EN50192 when
used in conjunction with hand torches with exposed cutting tips, if equipped with properly installed standoff guides.
* Extensive product design verification is conducted at the manufacturing facility as part of the routine design and manufactur-
ing process. This is to ensure the product is safe, when used according to instructions in this manual and related industry
standards, and performs as specified. Rigorous testing is incorporated into the manufacturing process to ensure the manufac-
tured product meets or exceeds all design specifications.
Thermal Dynamics has been manufacturing products for more than 30 years, and will continue to achieve excellence in our area
of manufacture.
Manufacturers responsible representative: Steve Ward

Operations Director
Thermadyne Europe
Europa Building
Chorley N Industrial Park
Chorley, Lancashire,
England PR6 7BX

AUTOCUT 20O2
1.08 Statement of Warranty
LIMITED WARRANTY: Thermal Dynamics® Corporation (hereinafter “Thermal”) warrants that its products will be free of defects in workmanship
or material. Should any failure to conform to this warranty appear within the time period applicable to the Thermal products as stated below,
Thermal shall, upon notification thereof and substantiation that the product has been stored, installed, operated, and maintained in accordance
with Thermal’s specifications, instructions, recommendations and recognized standard industry practice, and not subject to misuse, repair,
neglect, alteration, or accident, correct such defects by suitable repair or replacement, at Thermal’s sole option, of any components or parts
of the product determined by Thermal to be defective.
THIS WARRANTY IS EXCLUSIVE AND IS IN LIEU OF ANY WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR
PURPOSE.
LIMITATION OF LIABILITY: Thermal shall not under any circumstances be liable for special or consequential damages, such as, but not
limited to, damage or loss of purchased or replacement goods, or claims of customers of distributor (hereinafter “Purchaser”) for service
interruption. The remedies of the Purchaser set forth herein are exclusive and the liability of Thermal with respect to any contract, or anything
done in connection therewith such as the performance or breach thereof, or from the manufacture, sale, delivery, resale, or use of any goods
covered by or furnished by Thermal whether arising out of contract, negligence, strict tort, or under any warranty, or otherwise, shall not,
except as expressly provided herein, exceed the price of the goods upon which such liability is based.
THIS WARRANTY BECOMES INVALID IF REPLACEMENT PARTS OR ACCESSORIES ARE USED WHICH MAY IMPAIR THE SAFETY OR
PERFORMANCE OF ANY THERMAL PRODUCT.
THIS WARRANTY IS INVALID IF THE PRODUCT IS SOLD BY NON-AUTHORIZED PERSONS.
The limited warranty periods for this product shall be: A maximum of three (3) years from date of sale to an authorized distributor and a
maximum of two (2) years from date of sale by such distributor to the Purchaser, and with further limitations on such two (2) year period (see
chart below).
Parts Labor
© ©
AutoCut and UltraCut Power Supplies and Components 2 Years 1 Year
Torch And Leads
XTTM-300 / XTTM-301 Torch (Excluding Consumable Parts) 1 Year 1 Year
Repair/Replacement Parts 90 Days 90 Days
Warranty repairs or replacement claims under this limited warranty must be submitted by an authorized Thermal Dynamics® repair facility
within thirty (30) days of the repair. No transportation costs of any kind will be paid under this warranty. Transportation charges to send
products to an authorized warranty repair facility shall be the responsibility of the customer. All returned goods shall be at the customer’s risk
and expense. This warranty supersedes all previous Thermal warranties.
Effective August 19, 2005

AUTOCUT 20O2

SECTION 2: SPECIFICATIONS
2.01 General Description Of The System

A typical Auto-Cut® 20O2 system configuration includes:
• One Power Supply
• Remote Arc Starter
• Gas Control Module
• Torch Valve Assembly
• Conventional Plasma Cutting Torch
• Set Of Connecting Leads
The components are connected at installation.
2.02 Plasma Power Supply

The power supply provides the necessary current for cutting operations. The power supply also monitors system
performance, and cools and circulates the liquid coolant for the torch and leads.
2.03 Remote Arc Starter

This unit produces a temporary HF pulse to start the pilot arc. The pilot arc creates a path for the main arc to
transfer to the work. When the main arc is established, the pilot arc shuts off.
2.04 Gas Control Module

This module allows remote setting of gas selection, pressures, and flows together with setting of cutting current.
2.05 Conventional Plasma Cutting Torch

The torch delivers the controlled current to the work through the main arc, causing the metal to be cut.
Manual No. 0-4816 Auto-Cut 2002 2-1 SPECIFICATIONS

2.06 Specifications & Electrical Requirements
Auto-Cut® 20O2 Power Supply Specifications

Maximum OCV (U0 ) 380 vdc
Maximum Output Current 200 Amps
Maximum Output Voltage 230 vdc
100% @ 200A, 180vdc (32 kW),
Duty Cycle Rating
@ 104F° (40°C) Ambient Temperature
Operating range 14°F to 122°F (-10°C to + 50°C)
Power Factor 0.70 @ 100 ADC Output
Cooling Forced Air (Class F)
Auto-Cut 20O2 Power Supply Electrical Inputs

Input Power Input Current Suggested Sizes (See Note)
Voltage Freq. 3-Ph 3-Ph Fuse (Amps) Wire (AWG)
(Volts) (Hz) (kVA) (Amps) 3-Ph 3-Ph
208 60 47 130 160 #22
230 60 49 125 150 #22
400 50 54 77 100 #21
400 (CE) 50 54 77 100 #21
460 60 59 75 90 #21
Line Voltages with Suggested Circuit Protection and Wire Sizes
Based on National Electric Code and Canadian Electrical Code
1
Extra Hard Usage Type SO, SOW, SOO, SOOW, ST, STW, STO, STOW, STOO, STOOW
2
Extra Hard Usage Type G, G-GC, W
XTTM-301 Torch Data (with Auto-Cut® 20O2 Power Supply)
TM
XT -301 Torch Ratings
(when used with Auto-Cut 20O2 Power Supply)
Ambient 104° F
Temperature 40° C
Duty Cycle 100% @ 200 Amps
Maximum Current 200 Amps
Voltage (Vpeak ) 500V
Arc Striking Voltage 10kV
Up to 200 Amps, DC,
Current
Straight Polarity
TM
XT -301 Torch Gas Specifications
Compressed Air, Oxygen,
Plasma Gases:
Nitrogen, H35
Compressed Air,
Shield Gases:
Nitrogen, Water
125 psi ± 10 psi
Operating Pressure
8.6 bar ± 0.7 bar
Maximum Input Pressure 135 psi / 9.3 bar
Gas flow 10 - 300 scfh
Power Supply used with: Auto-Cut 20O2

2.07 System Layout
Refer to section 3.11 for ground connections and ground cables.
175’ / 53.3 m Maximum Length
125’ / 38.1 m Maximum Length 100’ / 30.5 m Maximum Length
Pilot Return A Pilot Return

Negative Shield
B
Coolant Supply C Remote
Coolant Supply
Arc
Coolant Return D Starter Coolant Return
Primary power Power
Supply Control Cable E Shield
Fiber L Plasma Gas H Plasma Gas I

CNC P G
Optic Shield Gas Torch Shield Gas J
Q
Cable Gas Control Valve
Module Preflow Gas R Positioning Tube
Control Assembly
Cable K Control Cable S
T Torch
Water Shield
Work
Work Cable O
Art # A-07233_AB

2.08 Power Supply Dimensions
27 inch
680 mm
41.25 inch
1050 mm
33 inch 27.5 inch

840 mm 700 mm
Art # A-04793
37.75 inch
960 nm 343 lb / 156 kg

2.09 Power Supply Rear Panel Features
Torch (Neg) Terminal

AC Power Lamp
Pilot (Pos) Terminal
Circuit Breaker Input Power
Panel Terminals
Gas Control Ground Terminals

Console Connector
CNC Connector Terminal Cover

Work Cable Terminal
Remote Arc Starter

Connector
Terminal Cover
RETURN SUPPLY Support Panel
Coolant Connections
Coolant Filter
Coolant Tank
Leads
Bracket
Art # A-04794

2.10 Gas Specifications
The customer will provide all gases and pressure regulators. Gases must be of high quality. Pressure regulators
shall be double stage.
Auto-Cut 200 O2 Power Supply: Gas Pressures, Flows, and Quality Requirements
Gas Quality Minimum Pressure Flow
99.5% Purity 120 psi

O2 (Oxygen) 200 scfh (5700 l/h)
(Liquid recommended) 8.3 bar / 827 kPa
99.5% Purity
(Liquid recommended) 120 psi
N 2 (Nitrogen) 300 scfh (8496 l/h)
<1000 ppm O2, <32 ppm 8.3 bar / 827 kPa
H2O)
Compressed Clean, Dry, 120 psi

450 scfh (12743 l/h)
or Bottled Air Free of Oil (see Note 1) 8.3 bar / 827 kPa
H35 (Argon-Hydrogen)
99.995% Purity 120 psi
H35 = 35% Hydrogen, 200 scfh (5664 l/h)
(gas recommended) 8.3 bar / 827 kPa
65% Argon
H2O (Water) See Note 2 50 psi (3.5 bar) 10 gph (38 lph)
Note 1: The air source must be adequately filtered to remove all oil or grease. Oil or grease
contamination from compressed or bottled air can cause fires in conjunction with oxygen.
For filtering, a coalescing filter able to filter to 0.01 microns should be placed as close as
possible to the gas inlets on the Gas Control Module.
Note 2: The tap water source does not need to be deionized, but in water systems with extremely high mineral
content a water softener is recommended. Tap water with high levels of particulate matter must be filtered.
Note 3: Water Pressure Regulator No. 8-6118 is recommended to ensure proper water pressure.
2.11 Gas Applications
MATERIAL MILD STEEL STAINLESS STEEL ALUMINUM

GAS TYPE GAS TYPE GAS TYPE
CUTTING
OUTPUT PRE- PRE- PRE-
PLASMA SHIELD PLASMA SHIELD PLASMA SHIELD
FLOW FLOW FLOW
Air Air Air
55 A Air Air Air Air Air Air
Air O2 Air
Air Air Air Air Air Air Air Air Air
100 A N2 N2 H20 N2 N2 H20
Air O2 Air
N2 H35 N2 N2 H35 N2
Air Air Air
200 A
Air O2 Air

2.12 XTTM-301 Torch Specifications
A. Torch Dimensions
Art # A-04897
End Cap
19.00"
482.68 mm 2.25"
57.15 mm
Mounting Tube
15.50" 2.0"
393.78 mm 50.8 mm
6.30"
160.10 mm
2.39"
3.54" 60.81 mm
89.87 mm
2.74"
69.55 mm
1.57"
39.96 mm
1.49"
37.8 mm

B. Torch Leads Lengths
Torch Leads Lengths

feet meters
10 3.05
15 4.5
20 6.1
25 7.6
50 15.2
75 22.8
100 30.5
C. Torch Parts (Generic Parts Shown)
Art # A-04741
Shield Gas Plasma Gas
Distributor Distributor
Shield Cap Tip Electrode

Shield Cup Cartridge
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. Coolant leakage from the torch also indicates that torch parts are
absent or installed improperly.
E. Type of Cooling
Combination of gas stream through torch and liquid cooling.

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.
Auto-Cut 20O2 Power Supply Electrical Inputs

Input Power Input Current Suggested Sizes (See Note)
Voltage Freq. 3-Ph 3-Ph Fuse (Amps) Wire (AWG)
(Volts) (Hz) (kVA) (Amps) 3-Ph 3-Ph
208 60 47 130 160 #22
230 60 49 125 150 #22
400 50 54 77 100 #21
400 (CE) 50 54 77 100 #21
460 60 59 75 90 #21
Line Voltages with Suggested Circuit Protection and Wire Sizes
Based on National Electric Code and Canadian Electrical Code
1
Extra Hard Usage Type SO, SOW, SOO, SOOW, ST, STW, STO, STOW, STOO, STOOW
2
Extra Hard Usage Type G, G-GC, W
CAUTION
Fuse and wire sizes are for reference only. The installation must conform to national and local codes for the type of
wire being used and method of installation.
Gas Supply
The customer must supply all gases and pressure regulators. Gases must be of high quality. Pressure
regulators must be double-stage and installed as close as possible to the gas console. Contaminated gas
can cause one or more of the following problems:
• Reduced cutting speed
• Poor cut quality
• Poor cutting precision
• Reduced consumables life.
• Oil or grease contamination from compressed or bottled air can cause fires in conjunction with oxygen.
NOTE
Gas supply leads must be #8 (1/2 in. ) hose or larger
Cooling System Requirements
Coolant must be added to the system on installation. The amount required varies with torch leads length.
Thermal Dynamics recommends its coolants 7-3580 and 7-3581 (for low temperatures).
Coolant Capabilities
Cat. Number and Mixture Mixture Protects To
TM 25 / 75 10° F / -12° C
7-3580 'Extra-Cool '
TM 50 / 50 -27° F / -3° C
7-3581 'Ultra-Cool '
7-3582 'Extreme Cool 'TM
Concentrate* -65° F / -51° C
* For mixing with D-I CoolTM 7-3583
Manual No. 0-4816 Auto-Cut 2002 3-1 INSTALLATION

3.02 System Layout

Pilot Return A, Pilot Return
Negative B, Shield
Coolant Supply C, Remote Coolant Supply
Arc
Coolant Return D, Coolant Return
Primary power Power Starter
Control Cable E
Supply Shield
Fiber L Plasma Gas H, Plasma Gas I

CNC P G
Optic Shield Gas Q, Shield Gas
Torch J
Cable Gas Control
Preflow Gas R, Valve
Module Assembly Positioning Tube
Control K Control Cable S,
Cable Torch
Water Shield T
Work
Art # A-07328_AB
Work Cable O

3.03 Cables & Leads Identification
#8 AWG Cable
Art # A-07473
Pilot Return, Power Supply
A to Arc Starter
#1 AWG Cable
Negative Lead, Power Supply
B to Arc Starter
C Green Coolant Supply Lead,

Green
Power Supply to Arc Starter
Red Coolant Return Lead,

D Red
Control Cable, Power Supply

E 14 to Arc Starter
F Green / Yellow # 4 AWG Ground Cable
Ground Cable,
Green / Yellow 1/0 (50 mm 2)
Remote Arc Starter
F1 To Earth Ground
Shielded Torch Lead

G Assembly, Remote
Arc Starter to Torch
Plasma Gas Lead,

I
Torch Valve to Torch
Shield Gas Lead,

J Torch Valve to Torch
Control Cable,
K 37 Power Supply to
Gas Control Module
Fiber Optic Cable,

L Power Supply to
Gas Control Module
H, Q,
R, S,T
O 1/0 Cable (1/0 (50 mm 2) Work Cable
P 14 CNC Cable (14 Wire)

3.04 Lift the Power Supply
WARNINGS
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 all four lifting eyes when using lifting straps to lift the power supply.
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.
Art # A-04796
Set the power supply on a solid, level surface. The installer may fasten the power supply to the floor or a
supporting fixture with hardware passing through the horizontal parts of the power supply feet.

3.05 Primary Power Connections
The primary power cable must be supplied by the end user and connected to the power supply.
Remove the connections cover on the rear of the Power Supply. Use caution when removing the panel; there is a
ground wire connected to the inside of the panel. Do not disconnect this wire.
Connections Cover
(Removed)
Connection Panel
Art # A-04797

Check / Adjust Input Voltage Configuration
1. The 230/460VAC power supply includes a voltage configuration board which must be positioned to match the
primary input voltage. Remove the power supply left side panel and locate the voltage configuration board on
the inverter module. The input voltage configuration is shown at the top of the board.
WARNING
There is a voltage configuration board on each inverter module. Power supplies with more than one inverter
module require that all voltage configuration boards must be configured identically.
2. If necessary, unplug the connector at the top right corner of the board, remove the board and re-install it with the
correct input voltage shown at the top of the board.
3. Re-connect the connector. Re-install the power supply side panel.
Inverter Module
1. Unplug connector
208/230V / 460V 2. Remove bolts.

Input Voltage Board 3. Invert board.
(Shown in 460V Position) 4. Re-install board.
5. Plug in connector.
Art # A-04856_AB

Connect Input Power and System Ground Cables
1. 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 the connections cover support panel
on the rear panel of the power supply.
2. Insert the individual wires into the proper lug and tighten the nut onto the wires.
3. Pass the ground and input power cables through the leads bracket as shown. Connect the individual wires as
shown. Connect the power cable ground wire to the ground terminal block.
CAUTION
The clear connections cover must remain in place.

4. If required, pass a system ground cable (F1) through the last opening in the connections cover support panel
next to the input power cable. Connect the cable to the ground terminal block on the power supply rear panel.
Refer to the Ground Connections Section for full details and procedures on proper system grounding.
Ground Terminal Block
Connections Cover
Connection Panel
PUT L3
AC 2IN
L
to Remote Arc Starter L1
H
TORC
K
WOR
T
PILO
L3 System Ground Cable

L2
L1
Input power cable ground
Connections Cover
Support Panel
System Ground Cable

Input power cable
Leads Bracket
to Remote Arc Starter
Art # A-07658_AB
5. Re-install the connections cover on the power supply. Snug the hardware securely by hand. Do not over-
tighten.

200Amp or less
Ultra-Cut
Star Ground on Cutting Table
or
Auto-Cut O2
Remote Arc See
Starter (RAS-1000) Manufacturer Power Supply
CNC Gas Control Module
Note: The gas control module can
Torch Device Primary location
Cutting Machine / Gantry be mounted on top of the power
supply.
#4 AWG If it is, it should be grounded
Cutting Table Ground directly to the power supply with
(F) #4 AWG ground, (F).
1/0 This alternate location requires
Ground Cable grounding the power supply to the
(F1) ‘Star’ ground with the 1/0 Ground
Cable (F1).
1/0
Ground Cable 1/0 Work Cable
Customer supplied
Earth Ground 1/0 Ground Cable
Rod
‘Star’
0 - 10 ft (0 - 3 m) Ideal Ground
20 ft (6 m) Maximum
Star Ground on Cutting Table

Auto-Cut W/RAS
Remote Arc 200Amp or less
Starter (RAS-1000) See
Manufacturer Gas Control Module
Torch CNC
Cutting Machine / Gantry Device Power Supply
Cutting Table #4 AWG Ground (F)

(Factory Installed)
1/0
Ground Cable
(F1)
1/0
Customer supplied
Rod
‘Star’
0 - 10 ft (0 - 3 m) Ideal Ground Art # A-08253_AB
20 ft (6 m) Maximum

Auto-Cut Basic System
Without RAS
Cutting Machine / Gantry Torch CNC Auto-Cut GCM-1000

Device Power Supply Gas Control Module
Cutting Table
#4 AWG Ground (F)
(Factory Installed)
1/0
Customer Supplied
Rod (F1)
‘Star’ Art # A-08254_AC

0 - 10 ft (0 - 3 m) Ideal Ground
20 ft (6 m) Maximum

3.06 Ground Connections
A. Electromagnetic Interference (EMI)
Pilot arc starting generates a certain amount of electromagnetic interference (EMI), commonly called RF (Radio
Frequency) noise. This RF noise may interfere with other electronic equipment such as CNC controllers, remote
controls, height controllers, etc. To minimize RF interference, follow these grounding procedures when installing
mechanized systems:
B. Grounding
1. The preferred grounding arrangement is a single point or “Star” ground. The single point, usually on the cutting
table, is connected with 1/0 AWG (European 50 mm2) or larger wire to a good earth ground (measuring less than
3 ohms; an ideal ground measures 1 ohm or less. Refer to paragraph ‘C’, Creating An Earth Ground. The ground
rod must be placed as close as possible to the cutting table, ideally less than 10 ft (3.0 m), but no more than
20 ft (6.1 m) from the cutting table.
NOTE
All ground wires should be as short as possible. Long wires will have increased resistance to RF
frequencies. Smaller diameter wire has increased resistance to RF frequencies, so using a larger
diameter wire is better.
2. Grounding for components mounted on the cutting table (CNC controllers, height controllers, plasma remote
controls, etc.) should follow the manufacturer’s recommendations for wire size, type, and connection point
locations.
For Thermal Dynamics components (except Remote Arc Starter and Gas Control Module) it is recommended
to use a minimum of 10 AWG (European 6 mm2) wire or flat copper braid with cross section equal to or greater
than 10 AWG connected to the cutting table frame. The Remote Arc Starter uses 1/0 earth ground wire and the
Gas Control Module should use minimum # 4 AWG wire. The connection point must be to clean bare metal; rust
and paint make poor connections. For all components, wires larger than the recommended minimum can be
used and may improve noise protection.
3. The cutting machine frame is then connected to the “Star” point using 1/0 AWG (European 50 mm2) or larger wire.
4. The plasma power supply work cable (see NOTE) is connected to the cutting table at the single point “Star” ground.
NOTE
Do Not connect the work cable directly to the ground rod.
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. Using electrical
joint compound to prevent corrosion is also recommended.
6. The plasma power supply chassis is connected to the power distribution system ground as required by electri-
cal codes. If the power supply is close to the cutting table (see NOTE) a second ground rod is not usually
needed, in fact it could be detrimental as it can set up ground loop currents that cause interference.
When the plasma power supply is far away from the ground rod and interference is experienced, it may help to
install a second earth ground rod next to the plasma power supply. The plasma power supply chassis would
then be connected to this ground rod.
NOTE
It is recommended that the Plasma Power Supply be within 20 - 30 ft (6.1 – 9.1 m) of the cutting table,
if possible.
7. The plasma control cable should be shielded with the shield connected only at the cutting machine end.
Connecting the shield at both ends will allow ground loop currents which may cause more interference than with
no shield at all.

C. Creating An Earth Ground
1. To create a solid, low resistance, earth ground, drive a 1/2 in (12 mm) or greater diameter copper clad ground
rod at least 6 - 8 ft (1.8 - 2.4 m) into the earth so that the rod contacts moist soil over most of its length.
Depending on location, a greater depth may be required to obtain a low resistance ground (see NOTE). Ground
rods, typically 10 ft (3.0 m) long, may be welded end to end for greater lengths. Locate the rod as close as
possible to the work table. Install a ground wire, 1/0 AWG (European 50 mm2) or greater, between the ground
rod and the star ground point on the cutting table.
NOTE
Ideally, a properly installed ground rod will have a resistance of one ohms or less.
To test for a proper earth ground, refer to the following diagram. Ideally, the reading on the multimeter should be
1 VAC for 115VAC line, or 0.5 VAC for 230 VAC line.
CAUTION
Remove all other connections from the ground rod during this test.
This test assumes the 115 or 230 VAC source neutral is connected to the utility earth ground.
Ground Rod
NEUTRAL WARNING
with other
Earth Grounded Use extreme caution. This connections removed
test uses live voltage.
HOT
On 115V AC Line:
3VAC = 3 ohms
100W Incandescent 1VAC = 1 ohm
light bulb*
VAC On 230V AC Line:
1.5VAC = 3 ohms
0.5VAC = 1 ohm
HOT
PROBE
NEUTRAL * Can replace light bulb with
PROBE a 100w resistor.
Use 100 ohm for 115VAC.
Use 500 ohm for 230VAC Art # A-07252
Ground Testing
2. Increasing the ground rod length beyond 20 - 30 ft (6.1 – 9.1 m) does not generally increase the effectiveness
of the ground rod. A larger diameter rod which has more surface area may help. Sometimes keeping the soil
around the ground rod moist by continuously running a small amount of water into it will work. Adding salt to the
soil by soaking it in salt water may also reduce its resistance. When these methods are used, periodic
checking of the ground resistance is required to make sure the ground is still good.
D. Routing Of Torch Leads
1. To minimize RF interference, position torch leads as far as possible from any CNC components, drive motors,
control cables, or primary power lines. If cables have to pass over torch leads, do so at an angle. Do not run
the plasma control or other control cables in parallel with the torch leads in power tracts.
2. Keep torch leads clean. Dirt and metal particles bleed off energy, which causes difficult starting and increased
chance of RF interference.

3.07 Connect Work Cable and Pilot and Negative / Torch Leads
1. Pass the ends of the work cable and pilot and negative / torch leads upward through the leads bracket at
the bottom of the power supply rear panel, and through the openings in the connections cover support
panel.
2. Refer to the illustration. Connect the leads as shown. Tighten securely. Do not overtighten.
CAUTION
The clear connections cover must remain in place.

NOTE
Negative Lead and Torch Lead are used interchangably during this operation
Connections Cover Connection Panel
Torch
Work PUT L3
Pilot AC LIN
2
L1
H
TORC
K
WOR
PILOT
Torch Lead - To Remote Arc Starter
Work Lead
Connections Cover
Support Panel
Pilot Lead -
To Remote Arc Starter
Lead Connection Detail
Art # A-07661_AB To Cutting Table

Leads Bracket

3.08 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.
COOLANT
RETURN SUPPLY
RETURN SUPPLY
RED
Coolant Connections
GREEN
Art # A-04800

3.09 Connect Control Cables for CNC, Remote Arc Starter, and GCM
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 of the cable. Do not ground to the Plasma
Power Supply.
Customer Wiring
Access Hole
To Gas Control Module
To CNC
RETURN SUPPLY
Art # A-04802

3.10 Connect Fiber Optic Cable to CCM
1. Remove the strain relief securing nut from the strain relief on the fiber optic cable(s). Loosen the strain
relief dome nut from the strain relief.
2. Pass the cable connector through the appropriate opening. Slide the strain relief securing nut onto the
cable. Make a loop of the cable; carefully press the cable connector into the appropriate receptacle on the
internal control module.
3. Tighten the strain relief onto the cable(s). Do not overtighten.
Cable Receptacles To Gas Control Module
To Remote HMI
(if installed)
To Slave Power
Supply
(if installed)
Profile Detail, Fiber Optic Cable Installation Art # A-06793

3.11 Set Switches on the Command - Control Module
Remove the power supply right side. Set switches on the CCM (Command-Control Module) per the illustrations.
Switch settings and connection details are provided in the Appendix.
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.
Future Use
SW1 SW3 SW4 SW5 SW8 O

O N
N
1 2 3 4 1 2 1 2 1 2 1 2 3 4 1 2
SW-1-1: Auto Pilot Restart. 1 = ON = Auto Pilot Function enabled.

1 = OFF = Auto Pilot Function disabled (Factory default setting).
SW-1-2: Pilot Delay 2 = OFF, 3 = OFF, 4 = OFF: 0 Seconds (Factory default setting).
SW-1-3: Pilot Delay 2 = ON, 3 = OFF, 4 = OFF: 0.1 Seconds
SW-1-4: Pilot Delay 2 = OFF, 3 = ON, 4 = OFF: 0.2 Seconds
2 = ON, 3 = ON, 4 = OFF: 0.4 Seconds Active only when
2 = OFF, 3 = OFF, 4 = ON: 0.8 Seconds SW-1-1 is set to O N.
2 = ON, 3 = OFF, 4 = ON: 1.0 Seconds
2 = OFF, 3 = ON, 4 = ON: 1.5 Seconds
2 = ON, 3 = ON, 4 = ON: 2.0 Seconds
SW-3: Gas Preflow Time 1 = Off, 2 = OFF: 2 seconds
1 = ON, 2 = OFF: 4 seconds
1 = OFF, 2 = ON: 6 seconds
1 = ON, 2 = ON: 8 seconds
SW-4: Postflow Time 1 = OFF, 2 = OFF: 10 Seconds (Factory default setting).
1 = ON, 2 = OFF: 20 Seconds
1 = OFF, 2 = ON: 5 Seconds
1 = ON, 2 = ON: 0 Seconds
SW-5-1: Tip Saver Reserved for Factory use.
SW-5-2: Off Plate Reserved for Factory use.
SW 8-1: Pilot Time 1 = OFF = Short (85 ms.) (Factory default setting).
1 = ON = Long (3 s.)
SW 8-2: Remote Current 1 = OFF = Disabled (Factory default setting). * SW 8-3 is reserved for
1 = ON = (Remote Analog Current Control) Factory use prior to
Firmware V3.5
*SW 8-3: Auto Transfer Retry1 = OFF = Enabled Up to 3 tries (Factory default setting).
1 = ON = Disabled
SW 8-4: Reserved for Factory use.
Art # A-06791_AB

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, rated at 120VAC @ 1A Max. (Factory default setting) or
DC Volts (16-18vdc@ up to 100 ma.)
SW-11: Analog Current Control. B = from Gas Control (Factory default setting) or A = from CNC.
Position A requires that SW-8-2 be ON.
SW-12-1/2/3/4: Divided Arc signal All = OFF = 50:1 (Factory default setting)
1 = ON = 16.6:1
2 = ON = 30:1
Only 1 on at a time.
3 = ON = 40:1
4 = Not used.
Art # A-06922_AB
SW13-1, SW13-2: Reserved for Factory Use.

3.12 Height Control Connections
The terminal strip has Arc Volts (-) connection to power supply negative output TORCH terminal, Arc Volts (+)
connection to power supply positive output WORK terminal. These are for a height control that requires
connection to the full non-divided arc voltage. Also available on the terminal strip are 120VAC (120,0) and 24
VAC (24, 0). Note that the two 0’s are not common. The allowable current draw is 100ma @ 120VAC and 1Amp
@ 24 VAC.
Art # A-08404
There is also a hole added in the rear panel above the J55-GCM receptacle for customer wiring. This, rather
than the one in the CCM will be the preferred place for customer added wiring (and strain relief) for connec-
tions to height controls, etc..

3.13 Install Gas Control Module
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. It
is acceptable to locate the control cable in the same track as the cables from the Arc Starter.
The Module includes feet which lift the bottom panel off the mounting surface. There are ventilation holes on the
bottom panel; the space between the bottom panel and the mounting surface must remain open for ventilating air
to enter the module. Louvers on the back panel of the module must also remain unblocked, for the free passage
of ventilating air.
Mounting Dimensions
NOTE
Height not shown is 14.125” (359 mm)
Gas Box 410.97mm

16.18”
7.14mm 347.47mm
0.28” 13.68”
279.40mm 215.90mm
11.00” 8.50”
Art # A-07962
NOTE
The unit must be mounted so that the Flowmeters are plumb. If the Flowmeters are not plumb, incorrect
flow indications may occur.

Preparation
1. Remove the screws securing the Cover Panel to the Module.
2. Remove the Cover from the Module. Remove the ground wire if needed.
Gas Control Module Cover
Remove Ground
Wire
Do not remove
Art # A-06882
Cover Removal

3.14 Connect Fiber Optic Cable to Gas Control Module
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 tight-radius turns.
Circuit Board
3
Fiber Optic Cable
MM
CO
J56
J57
ER
POW LY
PP
TVA F5 SU
W
FLO H35
PRE UT
A O
SM
PLA T UTS O2
INP
OU N2
AIR
H2O
LD
SHIET
OU
1
MM
CO
J56
J57
R
WE
PO LY
PP
LOW TVA
F5 SU
PREF
MA H35
PLAS
D UTS O2
SHIEL INP
N2
AIR
H2O
H2O
SHIELD
Art # A-04772

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.

5. Reinstall the Cover Panel.

3.15 Connect Control, Input, and Outputs to Gas Control Module
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 #4 AWG (European 21 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. Fasten the Module to the mounting surface.
5. Connect all gas / water inputs to the rear panel of the module.
CAUTION
When cutting with O2 (oxygen) plasma, air must be connected to the Module.
6. Connect the appropriate control cables to terminals marked ‘TVA’ (torch valve assembly) and ‘power sup-
ply’.
To Torch Valve Assembly To Power Supply
J57 J56
SHIELD PLASMA COMM
PREFLOW
When Cutting With O2 Plasma
Air MUST BE Connected TVA
POWER
INPUTS SUPPLY
H 2O H2O H35
SHIELD
AIR N2 O2
Gas & Water Inputs (Check Valves) Ground Stud

To Torch Valve Assembly
Gas Control Module

Rear Panel
J57 J56
SHIELD PLASMA COMM
PREFLOW
When Cutting With O2 Plasma
Air MUST BE Connected TVA
POWER
INPUTS SUPPLY
H 2O H 2O H35
Connection Panel SHIELD
AIR N2 O2
Art # A-07283

3.16 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 crimping.
Mounting Dimensions
NOTE
Height not shown is 7.375” ( 187mm )
190.83mm
Arc Starter Box 7.51”
12.70mm
6.35mm
.50”
D.250”
3 PLACES
304.80mm 203.20mm
12.00” 8.00”
50.80mm
2.00”
37.77mm
1.49”
Art # A-07961
266.70mm
10.50”

Installation
The Remote Arc Starter must be installed in a suitable location near the torch head. If the Arc Starter is mounted
to a gantry or to any other support subject to motion or vibration, fasten the Arc Starter to the support securely.
1. Loosen, but do not remove, the lower screws securing the cover to the Arc Starter. Remove the upper
screws securing the Cover Panel to the Arc Starter.
NOTE
A wire grounds the cover to the Arc Starter base as shown below. This wire must remain in place.
2. Remove the Cover Panel from the Arc Starter.
Upper screws (2 per side)
Cover
Ground Wire
Lower screws
(2 per side)
Art # A-09625
Cover Removal

3. If not mounting the Arc Starter on a flat, horizontal surface, then mount it so the torch coolant connections
are lower so that coolant from leaks or changing leads will not drain into the other side of the unit..
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.
Minimum 2
Art # A-09626

Input Connections
1. Refer to the illustrations. Make the following input connections to the Arc Starter.
• Coolant Supply and Return Hoses (from power supply). Hoses and connectors are color-coded; Red
for Return, Green for Supply.
Art # A-09627
Return
Supply
Coolant Supply and Return Hoses
(from power supply)
Art # A-09628
Red
Coolant Return (Red)
Green
Coolant Supply (Green)

Copper plate
Art # A-09629
Negative Cable from power supply.
Negative Cable (from Power Supply rear panel)

Art # A-09630
Pilot Return Cable

from Power supply
PILOT Return Cable (from Power Supply rear panel)
NOTE:
The pilot return cable has a strain relief connector that must be installed in the rear panel of the remote arc starter
box.
Art # A-09631
Control Cable from Power Supply rear panel

Output Connections
1. Refer to the illustrations. Make the following output connections to the Arc Starter.
NOTE:
For newer leads with only one black wire, it must be connected to the pilot return. There are no inner shield wires.
Pilot Lead
Art # A-09632
Pilot Lead
Connection Detail
Pilot Return Cable and Inner Shield Lead (from Torch Leads)

Art # A-09633
Some items are removed

for clarity.
Coolant Return Fitting

(Tagged with Red)
Coolant Supply Fitting
(Tagged with Green)
Coolant Supply
(Green) to Torch
Coolant Return (Red)

from Torch
Coolant Supply and Return Hoses (from Torch)
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-09625

The Arc Starter must be grounded; the grounding terminal is marked . Refer to the previous section for
grounding details.
Art # A-04758
Torch Leads
1 Nut and 1 Washer

Remain in Place
Ground Cable
• Use a clamp to secure the Torch Lead Shield brass ring to the port on the Remote Arc Starter as shown.
Art # A-04759
Torch Leads Shield

Shield Clamp
Coolant and Pilot Leads

to Torch Valve Assembly

Connect Control Cable
1. Connect the Remote Arc Starter cable to the Remote Arc Starter receptacle.
Power Supply Rear Panel
RETURN SUPPLY
COOLANT
RETURN SUPPLY
Remote Arc Starter
Remote Arc Starter -

Input Connection Panel
Art # A-04801

3.17 Install Torch Valve
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-08433
1. Mount the Valve Kit as close as possible to the Torch. The valve kit can be mounted in any convenient
position, provided the outlet side (with two fittings) is closer to the torch than the inlet side (with three fittings
and a control cable connector).
2. Connect the Valve Kit outlets to the torch leads as shown. (XTL shown)
Do not remove brass plugs
Outlet Side
Right-hand Thread:
To Torch Shield Gas fitting
Left-hand Thread:
To Torch Plasma Gas fitting
Art # A-04761

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.
Torch Valve, Inlet Side
Control Cable Connector
Water Shield Inlet
Shield Gas Inlet

Preflow Gas Inlet
Art # A-06926 Plasma Gas Inlet
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. All fittings must be checked for leaks after assembly.
3.18 Prepare the Torch Head

1. Remove and discard the jumper on the torch head, as shown.
Jumper
2
1
3
4 Discard
Art # A-07323

3.19 Connect Torch
Connect the Torch as follows:
Coolant Supply,
Coolant Return,
and Pilot Leads
Leads Cover
Torch Leads End Cap
Groove for O-Ring Shield Gas

O-Ring (Right Hand Thread)
Pilot Lead Insulating Paper
Plasma Gas To Torch Valve

Plasma Lead (Left Hand Thread)
Plasma Lead
Connector
O-Ring
Positioning Tube
Coolant Return
Check Valve
and Connector
Shield ('Secondary') Gas Connector
Insulating Paper
Coolant Supply Connector Art # A-07324

1. Lay out the torch leads on a clean, dry working surface.
2. Hold the Torch Leads End Cap stationary. Pull approximately 18" (0.5 m) of leads through the End Cap.
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. Ensure that
the O-Ring on the Tube engages the mating groove inside the Torch Leads End Cap.
d. Ensure that the Mounting Tube is free to rotate within the Torch Leads End Cap.
6. Connect the gas and coolant leads to the Torch Head.
a. Coolant supply and return connections to the Torch Head are of different lengths.
b. Plasma and secondary gas connections to the Torch Head are threaded differently; the plasma gas
connection is left-hand thread, the shield gas connection is right-hand thread.
c. Hold the Torch Head leads connectors stationary; turn the leads fittings with a wrench to secure the
leads to the Torch Head. Do not overtighten.
CAUTION
The gas and coolant leads include compression fittings. Do not use sealant on these connections.
Slowly apply pressure to the gas lines. Check for leaks at all connections before continuing. If there
are no leaks, shut off the gas supplies and continue with installation.
7. Connect the pilot lead to the Torch Head. Press the two ends of the connector firmly together. Thread the
plastic lead cover/connector onto the mating Torch Head connector.
8. Press the Torch Head Assembly upward to connect to the Mounting Tube. Pull the leads back as needed
to ensure a proper fit through the Mounting Tube and Torch Leads End Cap. Hold the Torch Head Assembly
stationary; rotate the Mounting Tube to thread it onto the Torch Head.
CAUTION
Ensure that the leads do not twist within the mounting tube. Leads must lie as shown in the installation sketch.
9. The lower end of the Mounting Tube includes four threaded holes. Install an Allen set screw in any of the
threaded holes to secure the Torch Head Assembly to the Mounting Tube.
10. Install the appropriate consumable parts as shown on the following pages. The torch manual includes
diagrams showing the correct parts to install, depending on the metal to be cut and the gases in use.

3.20 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. Check the appropriate cut chart for the right combination of parts for the cutting application.
2. For 200 Amp parts only, thread the Shield Retainer onto the Shield Cup.
3. Stack the consumable parts together.
Art # A-08303
ge
ut s
ut s
rib Ga
id
p
rib Ga
Ca
or
or
rtr
st a
de
Di ield
Di sm
Ca
Shield
d
tro
Shield Cup
iel
a
Sh
Tip
Pl
Sh
ec
st
Retainer
El
A B C
1 - Assemble “A” 200 A only. 2 - Assemble “B”. 3 - Assemble “B” to “C”. 4 - Assemble “A” to “B-C” assembly.
4. Insert the stack of consumable parts into the cartridge. Ensure that the large O-ring on the torch tip fits
completely into the cartridge. If any part of the O-ring protrudes from the cartridge, the parts are not seated
properly.
5. Use the cartridge tool to hold the cartridge assembly, while turning the shield cup (and shield retainer
for 200 Amp parts) onto the cartridge assembly. For 300 Amp parts turn the shield retainer onto the
shield cup now. When this group is fully assembled, the shield should protrude from the front of the
shield cup or shield retainer. Without this protrusion the shield cup is not properly tightened onto the
cartridge assembly.
6. Take the cartridge tool off the cartridge. Fit the cartridge assembly onto the torch head. The Speed Lok
ring should clidk 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
CAUTION
Do not force the cartridge if it will not fully tighten. Remove the cartridge and gently clean parts and apply
oxygen-compatible lubricant (supplied with the torch) to o-rings as needed.
7. Place the ohmic clip over the shield cup if using ohmic torch height sensing.
Ohmic Clip
Art # A-03393_AB
8. Connect the wire lead from the height finder to the ohmic clip if using ohmic torch height sensing.
NOTE
Ohmic height sensing is not recommended with water shield. Water on the plate interferes electrically with the
ohmic sensing circuit.

55 - 100 Amp Parts Assembly
1: Stack Parts 2: Press Cartridge onto Stacked Parts
Electrode
Plasma Gas
Distributor O-Ring
on Tip
Tip No Gaps
Between Parts
Shield Gas
Cartridge Covers
Distributor
O-Ring
Shield Cap on Torch Tip
3: Thread Shield Cup onto Cartridge 4: Check Shield Cap Protrusion
Shield Cup
Shield Cap
Shield Cap Protrudes Art # A-04873

0.063-0.083" (1.6 - 2.1 mm)
Installing Assembled Cartridge Onto Torch Head

3.21 Install Coolant
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. Number and Mixture Mixture Protects To
7-3580 'Extra-CoolTM' 25 / 75 10° F / -12° C
7-3581 'Ultra-CoolTM' 50 / 50 27° F / -3° C
7-3582 'Extreme CoolT M' Concentrate* -65° F / -51° C
* For mixing with D-I CoolTM 7-3583
COOLANT
RETURN SUPPLY
RETURN SUPPLY
Fill Range
Coolant Tank
Art # A-04803
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 30 seconds the system may shut down if the leads are not full of coolant.
c. Place the ON/OFF switch to OFF.
d. After 10 seconds place the ON/OFF switch to ON again.
e. Repeat steps ‘b’ through ‘d’ until the system no longer shuts down. Depending on the length of the torch
leads this sequence may need to be done three to five times.
f. After the system stays operational allow the pump to operate for ten minutes to properly purge any air
from the coolant lines before using the system.
3. Re-fill the reservoir and re-install the filler cap.
4. Purge coolant from the torch before firing the torch. Ensure there are no leaks before use. If leaks are
evident, consult the coolant leak trouble-shooting guide in the maintenance section of this manual.

SECTION 4: OPERATION
4.01 Power Supply Control Panel
AC Indicator Gas Indicator Status Indicator

Temp Indicator DC Indicator
Art # A-04862
AC Power Indicator
Indicates AC power is being supplied to the inverters when the ON/OFF switch is in ON position. When
switch is first set to ON, the indicator stays off until the inrush cycle is complete and the correct voltage is
confirmed.
TEMP Indicator: Normally OFF. Indicator turns ON when the internal temperature sensors detect tempera-
tures above normal limits. Let the unit cool before continuing operation.
GAS Indicator: The indicator blinks when the gas control is not ready. Causes for not being ready are when
purging, Mode switch is not set to Run, gas pressure is not correct or there are communiation errors. When gas
flow is called for (preflow, cutting, postflow ) the indicator is on steady. It is off at all other times.
DC Indicator: Indicates the power supply is generating output DC voltage.
Status Indicator: Shows system status. The number of flashes indicates the status. Refer to the Status
Code Section for details. On power supply start-up, the indicator flashes to show the revision level of the
operating software installed in the system.
Manual No. 0-4816 Auto-Cut 2002 4-1 OPERATION

4.02 Start-Up Sequence
1. Connect system to primary input power.
2. Turn ON/OFF switch to ON (up) position. AC Indicator turns ON after about 5 seconds.
POWER
I ON
OFF
O
O OFF
Art # A-04812
3. Check the AC indicator. If indicator is ON, system is ready to operate (pending fault checks by internal cir-
cuitry). If indicator does not light after a few seconds check that each inverter is correctly configured for the
input voltage and all 3 phases are present. Check Status Indicator for any codes that can help determine
problem.

4.03 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.
MODE GAS
RUN
O2 - AIR STATUS ENABLE
SET PREFLOW
H35 - N2
SET PLASMA AIR - AIR

& SHIELD
TEST N2 - H2O DISABLE
PLASMA
POWER SUPPLY
Thermal Dynamics
MODE GAS O2 - AIR
STATUS ENABLE
RUN
H35 - N2
SET PREFLOW
SET PLASMA
& SHIELD
TEST
AIR - AIR
N2 - H2O
AMPS
DISABLE
AMPS
Automated PLASMA
POWER
Plasma Cutting System SUPPLY
PREFLOW PLASMA SHIELD

9
H20
MIST
PRESSURE
GCM PRESSURE
GAS
GAS
2000 FLOW
Art # A-06889
FLOW

Gas Control Module: Controls & Indicators
1. MODE Selection Switch
RUN
SET PREFLOW
SET PLASMA
& SHIELD
TEST
MODE
Thermal Dynamics
MODE GAS O2 - AIR
STATUS ENABLE
RUN
SET PREFLOW H35 - N2
AMPS
& SHIELD
Automated PLASMA
POWER

9
9
H20
MIST
GCM PRESSURE
GAS
2000 FLOW
Art # A-06890
• Normally in the RUN position during torch operation.

• In the SET PREFLOW position, Preflow or Piloting gas (Air or N2) flows to the torch allowing the operator to
adjust pressure. Gas automatically shuts off after 2 minutes if left in the SET PREFLOW position.
• In the SET PLASMA & SHIELD position, selected cutting gases, Plasma & Shield, flow to the torch to allow
operator to set the pressure (regulator & gauge) and flow (knob at top of flowmeter). Gases automatically shut
off after 2 minutes if left in the SET PLASMA & SHIELD position. GCM 2000 gas control revision AC or later
includes inlet pressure sensors. In SET PLASMA & SHIELD if either gas pressure is outside the range of 100-
135 PSI the Status LED will blink a code fo 3 blinks followed by a space then repeating the 3 blinks. User must
determine which gas has to be adjusted.
• TEST mode will also cause selected PLASMA & SHIELD gasses to flow to the torch.

2. GAS Selection Switch
Selects combinations of plasma and shield gases. Each time the switch is changed it initiates a purge of the
new gas.
O2 - AIR
H35 - N2
AIR - AIR
N2 - H2O
GAS
Thermal Dynamics
O2 - AIR STATUS
RUN
ENABLE
H35 - N2
SET PREFLOW
AIR - AIR
AMPS
SET PLASMA
& SHIELD
N2 - H2O
TEST DISABLE
Automated PLASMA
GAS
MODE Plasma Cutting System POWER SUPPLY

9
H2O
9
MIST
GCM PRESSURE
GAS
FLOW
2000
Art # A-06891_AB

3. Amperage Control
Adjusts the output amperage of the power supply.
AMPS
3
Thermal Dynamics
MODE GAS O2 - AIR
STATUS ENABLE
RUN
H35 - N2
4
SET PREFLOW
AMPS
& SHIELD
Automated PLASMA
POWER
9
H20
MIST
5 6
7
GCM PRESSURE
GAS
2000 FLOW
Art # A-06892
8
4. Plasma Power Supply Enable / Disable Switch

The DISABLE position removes input power from the Power Supply inverters, disables the coolant pump and
fan, the pilot contactor & HF and removes AC power from the gsa control solenoids shutting off all gas flow.
When the switch is returned to the ENABLE position an automatic gas purge is started and then the system is
returned to normal operation under control of the CNC device.
5. PREFLOW Control Knob and Pressure Gauge
Used to set preflow gas pressure. MODE switch must be in SET PREFLOW position.
6. PLASMA and SHIELD Control Knobs, Pressure Gauges, and Flow Meters
Used to set plasma and shield gas pressures and flows. MODE switch must be in SET PLASMA & SHIELD
position.
7. H2O Mist Control Knob and Flow Meter
Used to set water flow rate. MODE switch must be in SET PLASMA & SHIELD position. GAS selection switch
must be in N2-H2O position.
NOTE
Water mist is not used in all applications. Ohmic height sensing is not recommended with water mist shield.
Water on the plate interferes electrically with the ohmic sensing system.
8. Shield Pressure / Flow Selector Switch
At lower flow rates the shield gas pressure is first set per the cut charts then the flow is set using the flow meter
with the Gas switch set in the “Flow” position. Some torch parts require higher flow rates that exceed the
capacity of the flow meter. In those cases, set the Gas switch to the Pressure position and use the regulator and
gauge to set the pressure per the cut charts.

4.04 Gas Control Sequence Of Operation
Some operations vary depending on the revision of the gas control and it’s firmware (program). The gas control
revision is found on the data tag. GCM 2000 revision AC or later with firmware version 3.1 (or later) includes a
Status LED. Refer to table for Status LED codes.
STATUS LED Codes

LED Description
Gas control is ready to operate or is in cutting
Steady sequence (preflow, pilot, cut or postflow)
Gas control is not ready. May be purging, mode
Continuous switch not in Run position or Gas Selection or
Blinking Mode switch in between positions
Power Supply Enable/Disable switch in Disable
2 Blinks position.
Gas supply pressure out of range. Must be
3 Blinks between 100 - 135 PSI
4 Blinks CANBus error, Unacknowledged message
5 Blinks CANBus error, Bus off
6 Blinks CANBus error, communication timed out.
Parts Change and Purge.

1. On the GCM set the Plasma Power Supply Enable / Disable switch to Disable.
2. Set Mode switch to RUN.
3. Inspect and change the torch parts if necessary.
4. Set the Gas Selection switch to the desired gas process.
5. Apply AC power and set the Plasma Power Supply Enable / Disable switch (on the Gas Control Module)
to Enable. The Module performs purges of coolant and gas from lines if new gas was selected.
6. Status LED blinks on/off during purge then on steady if Mode SW is in RUN position and inlet gas
pressure is OK.
Gas Supply Pressure.
For best results the gas supply pressure should be a minimum of 120 PSI and a maximum of 135 PSI. The following
process is for GCM 2000 systems with revision AC or after. These systems will have input pressure sensors.
1. Following the parts change and purge, if the inlet pressure is OK, (Status LED is on steady) proceed to the
next subsection of “Pressure and Flow Setting”.
2. If following the parts change and purge, the inlet pressure is not within the proper range of 100 to 135 PSI
the Status LED will repeatedly blink 3 times. Adjust the supply pressure as needed and set the Enable /
Disable switch to Disable then back to Enable to start another purge. Setting the Mode switch to “Set
Plasma & Shield” then back to “Run” will reset the pressure error code without purging the lines. Proceed
to next step to set pressures and flows.

Pressure and Flow Setting
1. Set the Preflow (Piloting) gas pressure.
a. Set the Mode switch to “SET PREFLOW”. Refer to the torch section of the manual (cut charts section 8)
for proper settings.
b. Use the Preflow regulator knob to set preflow gas pressure. If the Mode switch is left in the “SET
PREFLOW” position for 2 minutes, the flow will be shut off.
2. Set the Plasma gas pressures and flows.
a. Set the Mode switch to “SET PLASMA & SHIELD”. Refer to the torch section of the manual (cut charts
section 8) for proper settings.
b. Use the Plasma regulator knob and pressure gauge to set plasma pressures. Next, set the flow using the
flow meter and knob above it.
3. Shield gas pressures and flows (except for N2/H2O process).
section 8) for proper settings.
b. Some cut chart processes will specify both a pressure and a flow setting and other just a pressure
setting. If both are required, set the Shield Gas switch to “Flow”. If only the pressure is specified, set the
Shield Gas switch to “Pressure”.
c. Set the Shield Pressure using the Shield regulator knob and pressure gauge. If required, set the Shield
flow using the Shield Flow meter and knob above it.
4. N2/H2O process set H2O MIST
section 8) for H2O Mist settings.
b. Use the H2O Mist control knob and flow meter to set water flow rate.
5. Place the MODE switch to the “RUN” position.
6. Cutting Current
a. Adjust current control digital thumbwheel switch for the desired cutting current.
System is ready to cut.
NOTE
When switching gases between operations, allow enough purge time to clear the prior gas from the torch leads.
If during the set process either preflow or Plasma / Shield stops due to the 2 minute timeout, switching to RUN and
back to the SET position will give another 2 minutes of gas flow.
CAUTION
While nothing prevents the operator from switching gases during piloting or cutting it is not recommended to do
so. If the operator switches gases during piloting or cutting, the arc stops, then the system purges the new gas.
Switching gases during piloting or cutting may damage torch parts or the piece being cut.

Cut Quality
Cut quality requirements differ depending on application. For instance, nitride buildup and bevel angle may be
major factors when the surface will be welded after cutting. Dross-free cutting is important when finish cut quality
is desired to avoid a secondary cleaning operation. Cut quality will vary on different materials and thicknesses.
Kerf Width
Cut Surface
Bevel Angle
Left Side
Cut Angle Top
Right Side
Cut Angle Spatter
Top Edge
Rounding
Dross
A-00512
Build-Up
Cut Surface A-00007
Drag Lines
Cut Surface
The condition (smooth or rough) of the face of the cut.
Bevel Angle
The angle between the surface of the cut edge and a plane perpendicular to the surface of the plate. A perfectly
perpendicular cut would result in a 0° bevel angle.
Top-Edge Rounding
Rounding on the top edge of a cut due to wearing from the initial contact of the plasma arc on the workpiece.
Dross Buildup and Top Spatter
Dross is molten material which is not blown out of the cut area and resolidifies on the plate. Top spatter is
dross which accumulates on the top surface of the workpiece. Excessive dross may require secondary cleanup
operations after cutting.
Kerf Width
The width of material removed during the cut.
Nitride Buildup
Nitride deposits which may remain on the cut edge of the carbon steel when nitrogen is present in the plasma
gas stream. Nitride buildups may create difficulties if the steel is welded after the cutting process.

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.
Clockwise
Left Side
Cut Angle
Right Side Scrap
Cut Angle
Counter-
Clockwise
Scrap
Workpiece
A-00512
Art # A-04182
Swirl Effect on Side Characteristics Of Cut
To make a square - edged cut along an inside diameter of a circle, the torch should move counterclockwise
around the circle. To keep the square edge along an outside diameter cut, the torch should travel in a clockwise
direction.
Underwater Cutting
Cutting on a water table either underwater or with the water touching the plate or with a water muffler system
is not recommended. If a water table is used the water level must be a minimum of 4 inches from the bottom of
the plate. Failure to follow this recommendation could result in poor cut quality and short consumable parts
life.
Ohmic Height Sensing
Ohmic Height Sensing is not recommended with water shield (‘water mist secondary’). Water on the plate
interferes electrically with the ohmic height sensing system.
4.05 Gas Selection

A. Plasma Gases
1. Air Plasma
• Most often used on ferrous or carbon base materials for good quality at faster cutting speeds.
• Air plasma is normally used with air shield.
• Only clean, dry air is recommended for use as plasma gas. Any oil or moisture in the air supply will substan-
tially reduce torch parts life.
• Provides satisfactory results on nonferrous materials.
2. Argon/Hydrogen (H35) Plasma
• Recommended for use on 3/4 in (19 mm) and thicker stainless steel. Recommended for 1/2 inch (12 mm) and
thicker nonferrous materials. Ar/H2 is not normally used for thinner nonferrous materials because less
expensive gases can achieve similar cut quality.
• Poor cut quality on ferrous materials.
• Provides faster cutting speeds and high cut quality on thicker materials to offset the higher cost.
• A 65% argon / 35% hydrogen mixture should be used.

3. Oxygen (O2) Plasma
• Oxygen is recommended for cutting ferrous materials.
• Provides faster cutting speeds.
• Provides very smooth finishes and minimizes nitride buildup on cut surface (nitride buildup can cause
difficulties in producing high quality welds if not removed).
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.
B. Shield Gases
1. Compressed Air Shield
• Air shield is normally used when operating with air or oxygen plasma.
• Improves cut quality on some ferrous materials.
• Inexpensive - reduces operating costs.
2. Nitrogen (N2) Shield
• Nitrogen shield is used with nitrogen (N2) or Ar/H2 (H35) plasma.

• Provides smooth finishes on nonferrous materials.
• May reduce smoke when used with Ar/H2 plasma.
3. Water Shield
• Normally used with nitrogen.

• Provides very smooth cut surface.
• Reduces smoke and heat input to the workpiece.
• Effective up to 1/2 inch (12.7 mm) maximum material thickness.
• Tap water provides low operating expense.

4.06 Power Supply Status Codes
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 indicator on the control panel flashes a 2-part code
to indicate a code group and then a particular condition within the group. After 4 seconds, the sequence
repeats.
Example: Indicator flashes 4 times; the condition is in group 4. After a 1.2 second delay, the indicator blinks
3 times; the condition code is 4-3, indicating that the coolant is overheating. After a 4-second delay, the
indicator repeats the sequence until the condition is corrected.
Some conditions can be active indefinitely, while others are momentary. The power supply latches momentary
conditions; some momentary conditions can shut down the system. The indicator may show multiple condi-
tions in sequence; it is important to recognize all possible conditions that may be displayed.
Note
These codes are for systems with Firmware versions 2.4 or later. If your system’s Firmware is a prior version,
contact your distributor for updates.

Status Code Key
Status Message Cause/Remedy
Code
1-1 System not Enabled or Missing Plasma Enable Off ; External E-Stop Activated or CCM
AC Input Phase TB1-1&2 jumper missing; Missing AC Phase; No power
to GCM 2000 or 2010 Gas Control, check GCM control
cable connected, reset CP4 or CP5 circuit breaker in
power supply, blown fuse F19 in GCM.
1-2 Pilot Ignition Failure Pilot did not start within 15 seconds.
Preflow pressure too high; Defective Arc Starter
1-3 Lost Pilot Pilot went out without shutoff signal; Preflow pressure
too high; cut current set too low for consumables.
1-4 Loss of Transfer Arc transfer (>50 ms.) then arc lost with START still on.
Standoff too high; Current set too low.
1-5 Of the Plate Function not currently enabled.
1-6 Pilot Timed out w/o Transfer Must transfer from Pilot to Cutting Arc in 85 ms. (SW8-1
OFF) or 3 sec. (SW8-1 ON). Standoff too high or void in
work under torch; cut current too low for consumables;
Preflow pressure too low.
1-7 Tip Saver Function not currently enabled.
1-8 Possible Shorted Torch Detected tip voltage too close to electrode voltage.
Plasma flow/pressure too low; Plasma leak; cut current
too high; shorted torch body; consumable parts worn out.
2-1 Missing Phase Blown fuse, Broken or loose connection on power cable
2-2 Wrong input voltage Inverter(s) not configured correctly for input voltage;
Poor power quality (brownouts, dropouts);
Input power capacity / wiring too small causing voltage
drop; broken or loose power cable connections.
2-3 Inverter or Pilot Regulator Over Failed fan; Ambient above 40 deg C. (104 F); Blocked
Temperature airflow
2-4 Power Supply not Ready PCB7, PCB4, poor connection, Defective inverter
2-5 DC Output Low Output less than 60 VDC; Defective inverter, shorted
output; Shorted pilot regulator (chopper); CCM voltage
sense (J6) wire open or disconnected.
2-6 Primary over current or Over current or imbalance detected in inverter primary
imbalance fault circuit, remove power to reset; defective inverter; voltage
surge.
2-7 Unexpected current Current >20A in work or pilot leads before pilot ignition;
Possible shorted torch; Defective current sensor.
2-8 Unexpected current in pilot Current > 5A in pilot circuit; wrong or mismatched
circuit consumables; Pilot lead shorted to negative in torch tube;
Possible shorted torch
2-9 Unexpected current in work Current > 5A in work lead; Short to chassis in RAS;
lead Negative lead short to gnd.

Status Code Key (cond)
Code
3-1 Gas Control Communication If GCM 1000: Control cable not connected or Basic ID signal open.
fault, Cannot establish GCM 2010 & 2000: Dirt on fiber ends or in connectors, blow out with clean
Communication with gas dry air; fiber not locked into connector; sharp bends in fiber; fiber
control. defective; Gas Control PCB defective, replace. CCM defective, replace.
3-2 Gas Control Communication Gas Control did not reply to signal from CCM in allowed time. Dirt on fiber
reply fault, connection was ends or in connectors, blow out with clean dry air; fiber not locked into
established but CCM did connector; sharp bends in fiber; fiber defective. If problem persists Gas
receive a reply to a process Control PCB likely defective, replace board.
request.
3-3 Gas Pressure Low If GCM 1000, Plasma < 15 PSI; faulty or disconnected pressure SW.
If GCM2010_AG, GCM2000_AC or later or Gas Control has been updated
with 19X2219_AG or later PCB: Plasma or Shield input out of range 105-135
3-4 Gas Control not ready Purging; not in RUN mode; Gas Control faulty, replace PCB.
3-5 Gas Control Protocol Fault Application error or firmware compatibility fault
3-6 Invalid Current Control level GCM sent output current level outside the range of the power supply,
from GCM Check firmware compatibility
3-7 Gas Control returns wrong Check firmware compatibility
command sequence
3-8 CCM and Gas Control type Install correct CCM or Gas Control for system
(Autocut-Ultracut) mismatch
3-9 Gas Control Communication Reply not compatible with request; Check firmware compatibility
reply fault
3-10 Warning. -- Gas Control System will function but control may not be optimized for best
4-1 Coolant Level low fault Check coolant level, add as needed.
4-2 Low coolant flow after power Suction leak introducing air into coolant, suspect rear panel filter seal;
on purge. clogged filter; defective pump.
Not cutting: < 0.7 gal/min for 15
sec;
Cutting: flow between 0.35 to
0.7 gal/min for 3 sec. or
4-3 Coolant overheated (>70 Coolant fan failed; radiator fins clogged with dirt; Ambient temperature >
deg. C, 158 deg F) 40 deg C.
4-4 Coolant System not ready. If new installation recycle power to restart pump, may take a few times to
fill hoses;
During power on purge / Damaged torch coolant tube; Suction leak introducing air into coolant,
priming, flow did not reach 0.35 suspect rear panel filter seal; clogged filter; defective pump.
gal/min for at least 5 seconds
4-5 Low Coolant Level - Warning While cutting detected low coolant level, does not stop cut.
Add coolant as required.

Status Code Key (cond)
Code
5-1 CANBUS Failure to If GCM 1000, Basic ID signal missing; Other gas controls, Fiber
Acknowledge fault. disconnected or broken, Transceiver (what fiber plugs into) fault, replace
Gas control PCB or CCM
5-2 CANBUS Off due to Dirt on fiber ends or in connectors, blow out with clean dry air; fiber not
excessive data errors; locked into connector; sharp bends in fiber; fiber defective;
5-3 CANBUS data error warning. Dirt on fiber ends or in connectors, blow out with clean dry air; fiber not
Errors increasing, will soon locked into connector; sharp bends in fiber; fiber defective;
fault.
5-4 CCM Message not sent Dirt on fiber ends or in connectors, blow out with clean dry air; fiber not
locked into connector; sharp bends in fiber; fiber defective; CANBUS
hardware error (CCM or Gas Control PCB)
6-1 CCM Analog Voltage Error Replace CCM
6-2 CCM ADC or DAC error Replace CCM
6-3 Coolant Flow too High error, Torch coolant tube broken or missing;
flow > 2.7 gal/min CCM fault, replace CCM
6-4 CCM Data Memory error Replace CCM

4.07 Remote Arc Starter: Service Chart
Arc Starter Service Chart

Symptom Cause Check Remedy
Flush system,
Coolant has become conductive Use conductivity meter
replace coolant.
Pilot return wire not connected Visual inspection Connect Wire.
Spark gap set too close Check with feeler gauge Set to 0.063" ±0.002"
High Frequency cap (C4)
Use capacitance meter Reconnect or replace.
No Pilot ignition: possibly open
Spark in Arc Starter Broken or missing ferrites Visual inspection Replace.
but no ignition Remove short;
Short across in inductor (L1) Visual inspection
increase coil gaps.
Spark gap bus caps
(C1, C2, C3) Capacitance meter Replace.
broken or defective
Negative supply not
Visual inspection Reconnect.
connected correctly
Spark gap set too large Check with feeler gauge Set to 0.063" ±0.002"
Faulty transformer Resistance measurement Replace.
No Pilot ignition: Make connections;
No 120V supply Check input voltage at EMI filter
No Spark replace harness.
in Arc Starter No/ loose connection
Visual inspection Reconnect.
to spark gap
Faulty EMI filter Voltage/ Resistor measurement Replace.
Loose fitting(s) Visual inspection Tighten fittings.
No cooling or
Failure to braze joints (L1) Visual inspection Replace HF Coil.
insufficient cooling:
Leaks coolant Damaged or punctured
Visual inspection Replace coolant line(s).
coolant line(s).
Visual Inspection of color-coded Match coolant connection colors
No cooling or Supply & return hose reversed
connections to arc starter fitting colors.
insufficient cooling:
No Coolant Flow Blockage in coil or Loosen fitting slightly and check
Flush system.
supply/return hoses for coolant flow
Shield Drain / Torch lead inner
Visual inspection of lead Reconnect / tighten
shield connector
attachment to Arc Starter lead connectors.
missing or loose.
Erratic System
Make or tighten
Behavior Missing or loose Visual inspection of ground wire
connections to
(EMI Interference) ground connection to Arc Starter
good ground.
Cap C5 not connected, Visual inspection / capacitor
Replace PCB.
open or loose measurement

4.08 Remote Arc Starter: Spark Gap Adjustment
0.063" ± 0.002"
1.6 ± 0.05 mm
Art # A-04857

Intentionally Blank
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.
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.
Six Months
Clean or replace external coolant filter.
Clean coolant tank.
Vacuum out any dust buildup inside power supply.
Check internal coolant filter
5.02 External Coolant Filter Cleaning Procedure

Periodic cleaning of the coolant filter ensures maximum coolant flow efficiency. Poor coolant flow causes ineffi-
cient torch parts cooling with consequent faster consumable wear.
Clean the coolant filter as follows:
1. Disconnect the system from main input power.
Filter Screen
Filter Holder
Art # A-04811
2. Unscrew and remove the filter bowl by hand. Be sure to keep the O-ring.
3. Remove and clean the filter. Re-install the bowl, tightening it by hand. Be sure the O-ring is in place.
4. Turn the system on and check for leaks.
Manual No. 0-4816 Auto-Cut 2002 5-1 MAINTENANCE

5.03 Internal Coolant Filter Cleaning Procedure
The in-line filter screen should be cleaned periodically. To gain access to the In-Line Filter Assembly remove the
right side panel (viewed from the front of unit) of the Power Supply. Remove the filter screen by unscrewing the
filter holder from the In-Line Filter Assembly. Clean the filter screen by rinsing with hot soapy water. Remove soap
residue by rinsing with clean hot water. Be sure that all the soap has been removed and the screen is dry of water
before re-installing in the In-Line Filter Assembly.
5.04 Coolant Replacement Procedure

Replace coolant as follows:
1. Disconnect the system from main input power. At the bottom of the coolant tank, disconnect the coolant
line fitting and collect coolant in a disposable container.
2. Connect the system to main input power and turn it on to allow the pump to empty the tank. The pump will
run approximately for 20 seconds before the flow switch causes an interlock. This procedure may be
repeated a few times until the tank is completely empty.
3. Connect the coolant line fitting and fill the tank with fresh coolant until the right level is reached.
COOLANT
RETURN SUPPLY
RETURN SUPPLY
Fill Range
Coolant Tank
Art # A-04803
4. Turn system on, let it run for a few minutes and check coolant level, refill if necessary.
Manual No. 0-4816 Auto-Cut 2002 5-2 MAINTENANCE

SECTION 6: REPLACEMENT ASSEMBLIES & PARTS
6.01 Replacement Power Supply

Complete Unit / Component Catalog Number
Auto-Cut® 20O2 Power Supply, 208/230V 3-9114-1

Auto-Cut® 20O2 Power Supply, 460V 3-9114-2
Auto-Cut® 20O2 Power Supply, 400V 3-9114-3
Auto-Cut® 20O2 Power Supply, 400V, (CE) 3-9114-4
Auto-Cut® 20O2 Power Supply, 600V, (CSA) 3-9114-5
Gas Control Module (GCM-2000) with Torch Valve Assembly 3-9133

Gas Control Module (GCM-2000) Only 9-9435
Torch Valve Assembly Only 9-9436
Remote Arc Starter (RAS-1000) 3-9130
OPTIONAL EQUIPMENT:
Wheel Kit 9-9379
Manual No. 0-4816 Auto-Cut 2002 6-1 Power Supply Parts List
6.02 Auto-Cut 20O2System Layout

Pilot Return A, Pilot Return
Negative B, Shield
Coolant Supply C, Remote Coolant Supply
Arc
Coolant Return D, Coolant Return
Primary power Power Starter
Control Cable E
Supply Shield
Fiber L Plasma Gas H, Plasma Gas I

CNC P G
Optic Shield Gas Q, Shield Gas
Torch J
Cable Gas Control
Preflow Gas R, Valve
Module Assembly Positioning Tube
Control K Control Cable S,
Cable Torch
Water Shield T
Work
Art # A-07328_AB
Work Cable O
6.03 Recommended Gas Supply Hose

Item # Qty Description
Catalog #
1 3/8”Gray Synflex Hose. No fittings included. Catalog number per foot 9-3616
6.04 Cables and Leads
Catalog Numbers for Auto-Cut 20O2 Cables and Leads

A,B,C, H,Q,R,
F F1 G I,J K L O P
D,E S,T
Fiber
Supply Ground Gas Torch Optic
Lead Ground Wire, Torch Lead Lead Control Control Work Control
Length Set Wire RAS Lead Set Set Set Cable Cable Cable Cable
4' 9-4923 9-4931 9-4907 9-4898
4-3027 4-3026
3.1 m (3' / 1 m) (3' / 1 m) (3' / 1 m) (3' / 1 m)
10'
4-3028 4-3062 4-3035 9-9300
3.1 m
15'
4-3029 9-4924 9-4932 4-3063 4-3036 9-4908 9-4899 9-9301
4.5 m
20'
4-3064
6.1 m
25'
4-3030 9-4925 9-4933 4-3065 4-3037 9-4909 9-4900 9-9302 9-8312
7.6 m
30'
4-3066
9.1 m
35'
4-3050 4-3067 4-3051 9-9332 9-9335 9-9303
10.6 m
40'
4-3068
12 m
50'
4-3031 9-4926 9-4934 4-3069 4-3038 9-4910 9-4901 9-9304 9-8313
15.2 m
75'
4-3032 9-4927 9-4935 4-3070 4-3039 9-4911 9-4902 9-9305 9-8315
22.9 m
100'
4-3033 9-4928 9-4936 4-3071 4-3040 9-4912 9-4903 9-9306 9-8316
30.5 m
125'
4-3034 9-4929 9-4937 4-3041 9-4913 9-4904 9-9307 9-8317
38.1 m
150'
9-4930 9-4938 4-3042 9-4914 9-4905
45.7 m
175'
4-3043 9-4906
53.3 m
#8 AWG Cable
Art # A-07473
Pilot Return, Power Supply
A to Arc Starter
#1 AWG Cable
Negative Lead, Power Supply
B to Arc Starter
C Green Coolant Supply Lead,

Green
Red Coolant Return Lead,

D Red
Control Cable, Power Supply

E 14 to Arc Starter
F Green / Yellow # 4 AWG Ground Cable
Ground Cable,
Green / Yellow 1/0 (50 mm 2)
Remote Arc Starter
F1 To Earth Ground
Shielded Torch Lead

G Assembly, Remote
Arc Starter to Torch
Plasma Gas Lead,

I
Torch Valve to Torch
Shield Gas Lead,

J Torch Valve to Torch
Control Cable,
K 37 Power Supply to
Gas Control Module
Fiber Optic Cable,

L Power Supply to
Gas Control Module
H, Q,
R, S,T
O 1/0 Cable (1/0 (50 mm 2) Work Cable
P 14 CNC Cable (14 Wire)
Key Description Catalog #
A,B,C,D,E Supply Lead Set, 4’ / 1.3 m (See Note 1) 4-3027
A,B,C,D,E Supply Lead Set, 125' / 38.1 m (See Note 1) 4-3034
A Pilot Return Cable (only), 4' / 1.2 m 9-4890
A Pilot Return Cable (only), 10’ / 3.05 m 9-4891
A Pilot Return Cable (only), 75’ /22.8 m 9-4793
A Pilot Return Cable (only), 100’ /30.5 m 9-4794
A Pilot Return Cable (only), 125’ /38.1m 9-4796
B Negative Cable (only), 3’ / 1 m 9-4892

B Negative Cable (only), 10’ / 3.05 m 9-4897
C Hose, Coolant Supply, (only), 3’ / 1 m 9-4886
C Hose, Coolant Supply, (only), 10’ / 3.05 m 9-4887
NOTE 1:
Supply lead sets include Pilot Return Cable, Nega-
tive Cable, Coolant Supply & Return Hoses, and
Control Cable.
D Hose, Coolant Return, (only), 3’ / 1 m 9-4888
D Hose, Coolant Return, (only), 10’ / 3.05 m 9-4889
E Control Cable (only), Power Supply to Arc Starter 3’ / 1 m 9-4941
E Control Cable (only), Power Supply to Arc Starter 10’ / 3.05 m 9-4916
E Control Cable (only), Power Supply to Arc Starter 125' / 38.1 m 9-4922
F Ground Wire, Power Supply to Gas Control Module, 3' / 1 m 9-4923

F Ground Wire, Power Supply to Gas Control Module, 15’ / 4.5 m 9-4924
F Ground Wire, Power Supply to Gas Control Module, 125' / 38.1 m 9-4929
F1 Ground Wire, Remote Arc Starter to Earth, 3' / 1 m 9-4931

F1 Ground Wire, Remote Arc Starter to Earth, 15’ / 4.5 m 9-4932
F1 Ground Wire, Remote Arc Starter to Earth, 125' / 38.1 m 9-4937
G Assembly, Coolant Return Hose, 10’ / 3.05 m 9-4882
G Assembly, Pilot Return, 3’ / 1 m 9-4945
G Assembly, Pilot Return, 10’ / 3.05 m 9-4883
G Assembly, Negative/Coolant Supply, 10’ / 3.05 m 9-4939
G Assembly, Torch Lead, 3’ / 1 m 9-4884
G Assembly, Torch Lead, 10’ / 3.05 m 9-4885
H,Q,R,S,T Gas Lead Set, 10’ / 3.05 m (See Note 2) 4-3035

H,Q,R,S,T Gas Lead Set, 125' / 38.1 m (See Note 2) 4-3041
I Plasma Lead 4’ / 1.22 m (Torch Valve Assembly to Torch) 9-3333

J Shield Lead 4’/ 1.22 m (Torch Valve Assembly to Torch) 9-3334
L Control Cable, Fiber Optic, 3’ / 1 m 9-4898

L Control Cable, Fiber Optic, 15’ / 4.5 m 9-4899
L Control Cable, Fiber Optic, 125' / 38.1 m 9-4904
K Control Cable, Power Supply to Gas Control Module, 3’ / 1 m 9-4907

K Control Cable, Power Supply to Gas Control Module, 15’ / 4.5 m 9-4908
NOTE 2:
Gas lead sets include Plasma Gas Hose, Shield Gas
Hose, Preflow Gas Hose, and Control Cable.
K Control Cable, Power Supply to Gas Control Module, 125' / 38.1 m 9-4913
O Work Cable, 10’ / 3.05 m 9-9300
O Work Cable, 15’ / 4.5 m 9-9301
O Work Cable, 25’ / 7.6 m 9-9302
O Work Cable, 35' / 10.6 m 9-9303
O Work Cable, 50’ / 15.2 m 9-9304
O Work Cable, 75’ / 22.9 m 9-9305
O Work Cable, 100’ /30.5 m 9-9306
O Work Cable, 125' / 38.1 m 9-9307
P Control Cable, CNC to Power Supply, 25’ / 7.6 m 9-8312

P Control Cable, CNC to Power Supply, 125' / 38.1 m 9-8317
6.05 Power Supply External Replacement Parts
Item # Qty Description Catalog #
1 1 Power Supply Front Panel N/A
2 1 Power Supply Rear Panel N/A
3 1 Power Supply Top Panel 9-0445G/9-0445B
4 1 Power Supply Right Side 9-0442G/9-0442B
5 1 Power Supply Left Side 9-0443G/9-0443B
6 1 Louver Panel N/A
7 1 Power Supply Connections Cover N/A
8 1 Lifting Eye 9-9373
1
7
4
5
Art # A-06888_AB
6.06 Power Supply Replacement Parts - Right Side
Item # Qty Description Ref. Des. Catalog #
1 1 Heat Exchanger Fan FAN1 9-9338
2 1 Radiator 9-9339
2
1
Art # A-08308
1 1 Output Filter PC PCB8 9-9341
2 1 Sensor HCT2 9-9368
3 1 Magnetic Contactor, pilot MC2 9-9343
4 1 Resistor R6 9-9340
5 1 Resistor R9
6 1 Capacitor C2
Art # A-08309
1 Chopper Module 9-9389
1 Sensor HCT1 9-9342
Chopper Module
HCT1
Art # A-08311
6.09 Power Supply Replacement Parts - Front Panel
7 1 Main Power Switch (‘Circuit Protector’) CP1 9-9344
for 230-400-460 VAC units
Art # A-08312
6.10 Power Supply Replacement Parts - Front Panel
1 PC Board PCB3 9-9365
1 PC Board 230/460VAC PCB4 9-9370
1 PC Board 600VAC PCB4 9-9492
1 Display PC Board PCB6 9-9347
PCB3
PCB4
PCB6
Art # A-08313
1 1 PCBoard 230-400-460VAC PCB1 9-9362
1 1 PCBoard 600VAC PCB1 9-9491
2 1 Magnetic Contactor MC1,MC3 9-9364
1
2 2
Art # A-08314
6.12 Power Supply Replacement Parts - Rear Panel
Item # Qty Description Breaker Rating Cicuit Rating Ref. Des. Catalog #
12 1 Circuit Breaker (RAS) 125V, 2.5 A 120VAC @ 1A CP2 9-9348
13 1 Circuit Breaker (’TDC’) 125V, 3.15A 24VAC @ 1A CP3 9-9349
14 1 Circuit Breaker (AGC) 125V, 10A 24VAC @ 5A CP4 9-9350
15 1 Circuit Breaker (AGC) 125V, 2.5A 120VAC @ 1A CP5 9-9348
16 1 Circuit Breaker (AGC) 125V, 2.5A 15VDC @ 1A CP6 9-9348
17 1 Circuit Breaker (Pump) 250V, 10A 200VAC @ 3A CP7 9-9351
18 1 Circuit Breaker (Fan) 125V, 3.15A 24VDC @ 1A CP8 9-9349
1 Coolant Tank 9-5948
1 Tank Cap 8-5142
1 Filter, Coolant 8-4276
CIRCUIT
BREAKERS CP2
RAS
12 125V 2.5A
J55
G
CP3
C
M
13 CCM
125V3.15A
CP4
14 GCM
125V 10A
CP5
J15
C
15 N
C
GCM
125V2.5A
CP6
16 GCM
125V2.5A
CP7
COOLANT 17 PUMP
250V 10A
RETURN SUPPLY J59 CP8
Tank Cap R
A
S
18 FAN
125V 3.15A
Art # A-06017_AC
Filter
Coolant Tank
Art # A-04932_AB
1 1 Resistor R7 9-9363
2 1 Rectifier (Diode) D1 9-9345
3 1 Transformer T1 9-9355
for 230/460 VAC units
4 1 Diode D2 9-9486
5 1 Terminal Strip TB3 N/A
5
1
Art # A-08310
6.14 Power Supply Replacement Parts
29 2 Inverter Module 208/230V 9-9360D
2 Inverter Module 400V CE and 400V Non CE 9-9482D
2 Inverter Module 600V 9-9485D
Art # A-04786_AB
30 1 Sensor (Thermistor) TH1 9-9361
30
Art # A-04787
6.16 Power Supply Replacement Parts
1 1 Relay PC Board PCB7 9-9366
2 1 24 VDC Power Supply N/A N/A
3 1 Internal Control PC Board PCB5 9-9346
Art # A-08315
22 1 Sensor (Level Switch) LSW1 9-9354
24 1 Motor M 9-9381
25 1 Pump/Check Valve/Bypass Valve Assembly 9-9380
26 1 Bypass Valve (part of assembly)
27 1 Pump (part of assembly)
28 1 Sensor (Flow Indicator) F1 9-9359
Illustration is for Reference ONLY
28
25
24 22
26
27
Art # A-08236
6.18 Gas Control Module (GCM-2000) Replacement Parts
1 3 Solenoid 9-9393
2 1 Gas Selection Manifold Assembly Call
3 3 Check Valve, 1/4 NPT 0.5 PSI 9-9390
4 2 Mode Selection Switch Assembly 9-9406
5 2 Flowmeter, 0-150 8-6801
Not shown -
Valve Assembly 9-9382
Tube 9-9383
Knob 9-9384
6 1 Switching PCB Assembly (Current control) 9-9481
7 1 Pressure Transducer 100 PSI 9-5407
8 2 Toggle Switch 9-3426
9 1 Solenoid / Logic PC Board 9-9409
10 1 Cover 9-9410
11 2 Pressure Transducer 250 PSI 9-9508
12 3 Gauge, 160 PSI 8-6800
13 3 Regulator 9-9509
14 2 Knob 9-5221
15 1 Flowmeter, Water (H2O Mist) 9-7005
14 14 6
Thermal Dynamics
STATUS
RUN O2 - AIR ENABLE
SET PREFLOW H35 - N2 AMPS
& SHIELD
N2 - H2O
TEST DISABLE
12 MODE GAS
Automated PLASMA
POWER SUPPLY
Plasma Cutting System
9
H2O
9
MIST
12
12
15
GCM GAS
PRESSURE
2000 FLOW
5 5
12
7
13 4
12 4
6 9
12
8
13
1
M
COM
J56
J57
ER
LOW POW LY
1 PREF TVA SUP
P
MA
D PLAS H35
SHIEL TS
INPU O2
N2
AIR
H2O
H2O
D
SHIEL
11
10
3
3
3
Art # A-06894_AB
6.19 Remote Arc Starter (RAS-1000) Replacement Parts
1 1 Harness, Internal (Not Shown) 9-4956
2 1 Pilot Cap Assembly 9-9423
3 1 EMI Filter 9-1023
4 1 HF Water Cooled Coil Assembly 9-4958
5 1 HF Transformer Assembly, Arc Starter 9-4959
6 1 Enclosure, Arc Starter Base 9-4961
7 1 Spark Gap/Cap Assembly HF 9-4957
8 1 Ferrite Bead 2" Long 9-4965
To Torch
Valve 2
4 3
Art # A-09634
6.20 Remote Arc Starter (RAS-1000) Replacement Parts
1 1 Retainer, ABS Wall 9-4964
2 1 (Outer) Torch Lead Ground Assembly 9-4955
3 1 Bracket, Bulkhead Holder 9-4963
4 1 Cover, Arc Starter 9-4962
5 1 Strain Relief, large 9-7571
6 1 Strain Relief, small 8-7072
Coolant Leads,
from Power Supply
2 Art # A-09635
3
5
6.21 Command & Control Module Type 2 - Replacement Parts
1 1 Assembly, CCM (Auto-Cut) 9-9418
2 1 Plate, CCM Face 9-9419
3 1 Panel, CCM Mount Not Available
4 1 Harness, CCM I/O Board 9-9421
NOTE
This page covers parts for Command & Control module without an external connections cover. See previous
page for Command & Control modul an external connections cover.
2
3
Art # A-06867
6.22 Torch Valve Assembly Replacement Parts
1 1 Torch Valve Assembly 9-9436
2 1 Control Cable Harness 9-9479
3 1 Fuel B Fitting Call
4 1 Check Valve 9-7006
5 1 Fitting Call
6 1 Fitting Call
7 1 #6 JIC Fitting Call
8 1 1/8 NPT Str. Tee 8-0352
9 1 1/4 NPT Str. Elbow 8-3369
10 1 Adapter Call
11 1 Adapter Call
1 Inlet Side
9 2
4 3 5 8 6 7
Outlet Side
Art # A-06924
10 11
Intentionally Blank
SECTION 7: TORCH MAINTENANCE
7.01 Consumable Removal

1. Use the cartridge 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 Cartridge tool off the back of the Cartridge Assembly Use the cartridge tool to push the consumable
parts out of the Cartridge.
Cartridge Tool Cartridge Assembly
Art # A-04345_AB
Manual 0-4816 Auto-Cut 2002 7-1 TORCH MAINTENANCE

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.
O-Rings Torch Head
Inner O-Ring (Cat. No. 8-0545)

Cat. No. 9-9041
Location (Under Locking Ring)
Cat. No. 8-0539

O-Ring, Cat. No. 8-0544
O-Ring, Cat. No. 8-0540
Cat. No. 8-3487
Cartridge Assembly Cat. No. 8-0530
Snap Ring
Art # A-04071_AB
Art # A-04066_AB
CAUTION
Use only Thermal Dynamics No. 9-4893 O-Ring Lubricant (Christo Lube MCG-129) with this torch part. Use of
other lubricants may cause irreparable damage to the torch.

7.03 Parts Wear
Replace the Gas Distributor if it is charred or cracked.
Replace the Gas Distributor if the flange is damaged in any way.
Replace the tip and/or electrode if they are worn.
Good Tip Worn Tip Good Electrode Worn Electrode
Art # A-04745_AB

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
NOTE
For 200-Amp consumables, when replacing the shield retainer or the shield cup, assemble these two parts first before
assembling the other consumables.
e
to s
bu as
dg
bu a
ap
tri G
tri G
tri
r
r
C
to
de
is a
ar
is d
D sm
Shield
ld
D iel
tro
C
Shield Cup
ie
p
Sh
ec
Ti
Sh
Retainer
Pl
El
Assemble First Assemble Second
Art # A-07262

1. Install the consumables as follows:
1: Stack Parts 2: Press Cartridge onto Stacked Parts
Electrode
Plasma Gas
Distributor O-Ring
on Tip
Tip No Gaps
Between Parts
Shield Gas
Cartridge Covers
Distributor
O-Ring
Shield Cap on Torch Tip
3: Thread Shield Cup onto Cartridge 4: Check Shield Cap Protrusion
Shield Cup
Shield Cap
Shield Cap Protrudes Art # A-04873

0.063-0.083" (1.6 - 2.1 mm)

2. Remove the Cartridge tool from the Cartridge and install the assembled Cartridge onto the Torch Head.
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. Slide the ohmic clip over the shield cup if using ohmic torch height control sensing.
Ohmic Clip
A-03393
4. Connect the wire lead from the height finder to the ohmic clip.
NOTE
Ohmic height sensing is not recommended with water shield. Water on the plate interferes electrically with the
ohmic sensing circuitry.

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.
Torch leaks
Are Torch Leaking from Order Coolant

Consumable Parts No Coolant Supply or Return Check Valve
Installed? Coolant Return? Kit 9-4846
Order Coolant
Supply Tube Replacement Kit
Yes
The parts probably are worn out.

See chart for approximate life expectancy.
Are Parts New
Used
or Used? The torch may be damaged. See page
to determine if head damage has occurred.
New
Remove and Lubricate

Are Parts fully all O-rings on Torch Head,
assembled into Yes Is the Torch Damaged? No Consumables Cartridge,
the Torch? and Consumables.
Re-assemble Torch.
Still leaks?
Unsure?
Yes
Yes
Disassembly fully
and re-assemble
the Torch Properly. Replace Consumable
See Installation Manual. Replace Torch Head Yes Cartridge and Shield Cup.
Torch still leaks?
Amperage Plasma Gas Recommended Wear Depth

for Replacement
Inch mm
O2 0.04 1
30
Air 0.04 2
50 O2 0.04 1
Air 0.08 2
70 O2 0.04 1
Air 0.08 2
O2 0.04 1
100
H35 0.08 2
Torch
Electrodes Art # A-04704_AB

This Page Intentionally Blank

5 4 3 2 1
POWER SUPPLY ARC STARTER
8X291
C1
Manual 0-4816 Auto-Cut 2002

D
Jumper in Cable to ID D
Arc Starter Connected 1900 pf
C2
J59 --RAS J58
Water Cooled TORCH LEAD
1 CHASSIS GND 1 T1 Assembly Inductor INNER SHIELD
2 2 1900 pf
3 3 T1 C3
11X16 R1 6.8K 1W NEG & HF (to Torch) TORCH
4 4 8X290 3
5 5
6 6 Line1 Load1 <Part Number>
120 VAC 1
7 7 1900 pf
8 8 GND 2
L1
9 120 VAC RET 9 PILOT
C R2 6.8K 1W C4 0.1 uf 1000VDC C
10 10 Line2 Load2 PLT PILOT RETURN (from torch)
11 11 4
12 12 Line Filter 1ph <Part Number> GAP1
13 13 NEG
14 14 SPARK GAP 0.060" NEG (from PS)
14 PIN 15 0.1 uf 1000VDC WORK
16 C6 SHLD
16 PIN
C5 C7
0.047 uf 1000VDC 0.047 uf 1000VDC
A-1
NEG (from PS)
NEG CGND
PILOT CHASSIS GND
B B
WORK
A A
Rev Revisions By Date PCB No:

THERMAL DYNAMICS Assy No:
AA Initial Release TPM 8/26/05 INDUSTRIAL PARK #2 References
RS WEST LEBANON, NH 03784
AB ECO 101810 11/01/05
(603) 298-5711
Scale Supersedes
Information Proprietary to THERMAL DYNAMICS CORPORATION.
Not For Release, Reproduction, or Distribution without Written Consent.
Drawn: Date:
NOTE: UNLESS OTHERWISE SPECIFIED - DAT 9-21-04
1. RESISTOR VALUES ARE EXPRESSED IN OHMS, 1/4W 5%.
2. CAPACITOR VALUES ARE EXPRESSED IN MICROFARADS (uF). Chk: App: Sheet
1 of 1
TITLE: SCHEMATIC, Size DWG No:
Last Modified: Tuesday, November 01, 2005
14:47:17 RAS-1000 ARC STARTER 42X1191
APPENDIX 1: Remote Arc Starter Schematic
Art # A-06896_AB
5 4 3 2 1
APPENDIX
APPENDIX 2: Gas Control and Torch Valve Schematic
5 4
SW5
RUN
SW4 1
A 2 SET PREFLOW
1 O2 - AIR SET CUTFLOW
3
A 2 H35 - N2 TEST
4
3 AIR - AIR
4 N2 - H2O
MODE
GAS
To CCM
D (1)
Jumper Programs
Software for GCM 2000
STATUS
LED
(4) (5) (7) (9) (10) (12) (13) (14) (15)

FIBER-
OPTIC
10
1
2
3
1
2
1
2
3
4
5
6
J11 J7 J801 J802 J10 ENCODER
10 PIN 5 PIN
SW6 DISABLE (50) U36 U35 +5VDC

PLASMA ENABLE 1 J5
2
3 ENABLE 1
(51)
2
SW7 1 FLOW (52)
SHIELD FLOW / PRESSURE2 3
PRESSURE
3 4 PLASMA ENABLE
(53) + 1 IN-CIRCUIT SERIAL
5
PROGRAMMING
(54) 4 D25
6
GREEN
(55) 5
7
POWER SUPPLY J55 J56
8 2
PLASMA ENABLE + -
F1 0.125A SOL1
1 1 PLASMA ENABLE -
2 2 9 F2 0.125A SOL2
3 3 F3 0.125A SOL3
4 4 10 F4 0.125A SOL4
5 5
F5 0.125A SOL5
6 6 11 F20 1A
7 7 F6 0.125A SOL6
FERRITE (56) F7 0.125A SOL7
8 8 12
9 9 CORE (57) F8 0.125A SOL8
10 10 13 F9 0.125A SOL9
11 11 F10 0.125A SOL10
12 12 14
C 13 13
F11 0.125A SOL11
E-STOP (58) F12 0.125A SOL12
14 14 E-STOP - 15
15 15 24 VAC (59)
F13 0.125A SOL13
24 VAC 16 16 24 VAC RET 16 D13 F14 0.250A SOL14 *
17 17 16 PIN GREEN F15 0.250A SOL15 *
18 18 F16 0.125A SOL16
19 19
+15 VDC 20 20 F17 0.125A SOL17
21 21 F18 1.6A ( 120 VAC to Solenoids)
2
15 VDC RET 22 22 F19 1A ( 120 VAC to Low Voltage Power Supply)
-
23 23 Safety Gnd F20 1A ( to E-Stop Relay)
24 VAC RET 24 24 (low freq) E-STOP
25 25
26 26
* 19X2219_AG and earlier F14 & 15 are 0.125A
27 27
28 28 F18 1.6A
29 29 120 VAC to SOLENOIDS
4
5
30 30
31 31
32 32
120 VAC
J3 F19 1A
120 VAC 33 33 120 VAC (60) 120 VAC to BOARD POWER
34 34 120 VAC RET 1
120 VAC RET 35 35
36 36 2
37 37 (61)
3
RF Gnd
(Shield)
J12 J1
10
11
12
13
14
15
16
17
18
19
20
10
11
12
13
14
15
16
17
18
1
9
B
(16) (17) (18) (19) (20) (21)

(28) (29) (30) (31) (32) (33)
SOL3
SOL1
20 SOL7 SOL9 SOL11
23
SOL2
SOL4 SOL6
SOL8 31 SOL12
(22) 36
(34)
(23)
(35)
(24)
(36)
(25)
(37)
(26)
(38)
(27)
18 PIN (39)
SOLENOID LOCATIONS
SOLENOID MANIFOLD (from rear)
PS3
A
1 2 3 FRONT PANEL (rear)

PLASMA <
AIR N2 O2
13
PS4
Shield
8 9 Flow
SHIELD <
AIR N2
6 7 4 11
PREFLOW <
AIR N2 17 12 Plasma
H35 H2O
Shield Precharge
Press / Bypass
Shield
Art # A-07022_AC
5 4 3
Manual 0-4816 Auto-Cut 2002 A-2 APPENDIX

3 2 1
AUTOCUT GCM 2000 GAS CONTROL
1 PS1 Plasma Outlet Pressure

100 PSI
2 4
34 DUAL RIBBON HEADER
J8
2
10
12
14
16
18
20
22
24
26
28
30
32
34
4
JP1 Current Control
11
13
15
17
19
21
23
25
27
29
31
33
1
(Thumbwheel SW)
J6 J4 ( BCD Code)
+5VDC
19X1883 PCB
16 16
LCD DISPLAY CONNECTOR
8 15 15 8
1's
4 14 14 4
C
+5VDC 2 13 13 2
1 12 12 1
11 11
80 10 10 8
10's
40 9 9 4
C
20 8 8 2
10 7 7 1
J9 SW1 6 6
1 4
8
1 800 5 5
2 2 3 100's
4
3 400 4 4
C
4
5 BOTH SECTIONS ON FOR OPERATION 3 3 2
200
6 OFF ONLY FOR PROGRAMMING
1
100 2 2
IN-CIRCUIT SERIAL
PROGRAMMING 1 1 C
16 PIN
1 PS3 Plasma Inlet Pressure

JP3 250 PSI
+5VDC
2 2 4
3
Inlet sensors in
19X2219 PCB
(rev AG or later) 1 PS4 Shield Inlet Pressure
+5VDC JP4 250 PSI
2 2 4
3
10
11
12
13
14
15
16
J13
1
(46) (42) (44) (40) (47)
SOL13 SOL17 AUTOCUT TORCH VALVE

ASSEMBLY (TVA)
(49)
J57 J60
(40)
FERRITE 1 1
CORE SOL16 TVA SHIELD
(41)
(48) 2 2
3 3
(40)
4 4
SOL14 TVA PLASMA CUTFLOW
(42)
5 5
(43)
6 6
7 7
SOL15 TVA PLASMA PREFLOW
(44)
8 8
(45)
9 9
10 10
11 11
Safety Gnd RF Gnd 12 12
(low freq) 13 13
(Shield) 14 14
AB
TVA
A
Plasma 14
Plasma Art # A-07022_AC
<OrgName>
Preflow 15 AA ECO-B214 DAT 07/25/06 <OrgAddr1> Assy No:
Scale Supersedes
AB ECO-B367 <OrgAddr2>
RWH 01/29/07
<OrgAddr3>
AC ECO-B587 RWH 01/06/08
Date:
Shield Information Proprietary to THERMAL DYNAMICS CORPORATION.
Monday, February 21, 2005
Gas Shield Drawn: References
16 NOTE: UNLESS OTHERWISE SPECIFIED -
1. RESISTOR VALUES ARE EXPRESSED IN OHMS, 1/4W 5%.
DAT
H2O Shield 1 of 1
Last Modified: Tuesday, January 30, 200711:48:41
Autocut GCM 2000 Gas Control & TVA D 42X1224
2 1

APPENDIX 3: Gas Control Module Plumbing Diagram
New Plasma Inlet

SOL5 Pressure Sensor SOL11 TVA &
XTL-TVA
F5
Atmosphere
SOL4
H35 PLASMA
SOL19
SOL18
Pressure
Sensor SOL14
SOL1 SOL2 SOL3
PLASMA
SOL6 SOL15
PREFLOW
AIR
N2 SOL16 SHIELD
SOL7
O2
SOL12 SOL 18 & 19
in XTL-TVA
only.
SOL8 SOL9 SOL10
SOL13
SHIELD SOL 18 & 19
GAS MANIFOLD normally open.
Operate in parallel
with normally
closed SOL 14 &
New Shield Inlet 15.
Pressure Sensor SOL17
H2O WATER
Art # A-07577_AB

APPENDIX 4: Gas Control Module PCB Layout
F10 F8 J1 F17 F15 J13 F13
J13
F12 F11 F9 F7 F16 F14
J3
F19
F18
TP4
J12
F5
TP3 F3
TP2 F1
F2
F4
F6
TP7
F20
J5
JP1 TP8
TP9
TP5 TP10
TP6
TP1
Art # A-07621 TP11 TP12 TP13 TP15 J8 J10

TP19
J6 J7 J11 TP14 TP16 TP18

APPENDIX 5: CCM CPU Board Layout
Note: Switch Settings May Vary.
PRE POST SYS OK TO

AUTO PILOT FLOW FLOW FUNC CONT MOVE/D
SW1 SW3 SW4 SW5 SW8 SW9
O O
N N
1 1 1 1 1 1
1
1
2
3
4
2
3
4
1
1
2
2
R1 R2 R4 R5 CPU/COMMUNICATIONS
C1
R7
R6
SwitchesU5
R3
H2 U6 U7 R8
R9
1 H3
R10
C2 C3
+
1
R13
R14
R15
R16
1 2 R17 R18
R11
R19 R20
R12
R21
R22
J2 C5
R24
R23
R25 R26
C4
TP1 PRE POST SYS OK TO
GND R27 AUTO PILOT FLOW FLOW FUNC CONT MOVE/D
SW1 SW3 SW4 SW5 SW8 SW9
J2 C 2004 TDC AC
R28
19X2169 REV
R29
TP3
+5.0V
1 1 1 1 1 1
TP1 R30
C6
1
2
3
4
2
3
4
1
1
2
29 30 R31 2
C7 C8 D1 D2 U8
TP4 1
23 R36 /WR H6
R33 R32 U4
TP3 R35 D3 D4 44 TP4
R37
R40
R34
H5 R38 TP6 D6 D5
U9
TP7
C9
R41 TEMP R39 /RD

SENSE 1
U10 D7 D8 22 R42 C11
Y1
R43
GP1 R44 C10 R46

1
TP7
+
1 2 C16 R45
C13 C14
D9
C15
U11
D10
C17
C12 L1
1
J4
C19
TP6 120
C20 C23 R47 U13
C18 U12
R48
80
R52
R53
C24
J3
R51
C21 C22
R50
R49
1
R55 R57
R56
U15
R54
C25
C27
R59
R58
C30
D12 TPAD1
J3 TP5
U16
NC
C29
D11 C28
29 30 R65
1
R61
R62
R63
R60
C31 R67 C33

R64 160 R66
1
+ C32 40 R68
R69
U14
U19
C34 1 C35
R70
U18 C36 U17

1
TP5
R75
D13 R72
C40
GP2 U20 +3.3VA

R73
1 R71
D14
R74 C37 C38

C39
R77
TP8 L2 U21
U22 CLKO U25
L4
L3
R76
R78
C42 1
C41
R83
TP2
R82
R81
+ AGND
R79
R80
R84
1 U24 TP2
1
C45
U23 C43 + R87
R88 C46
R85
R86 C44
L5 C49
U28
1
R89 R90 + C52 R92

C47 + C51
C48
U26 R C C50 U29

U27 R93
C56
+15V -15V
U30
R91 J5 C55 DAC DAC +3.3V

R94
C54
TP9 TP10 TP11

C53
J1 U32 L6
U31
1 5
C57
C26
C58
C59
D15
1
6 9
H1 H4
+
Art # A-06906
J1
TP8 TP9 TP10 TP11

APPENDIX 6: CCM Input / Output PCB Layout
TP11 TP12 SW11 TP9

J1 TB1 TB2 J4 J9 J2 J5 J6 J7 J8
J5 J6 J7 J8
SW11 B
D1
D2
1 1
1 1 1
TB1 TB2
A
J4 PILOT V 1
GAS ON
R224 L2 TP9
E-STOP_PS
R2 TP12
R223
J1 R225 1 CC POT
C2
R4 U1
1 H6 R5 1
R3 C1
R6
R1
H2 R9 H3
1 R7 C4
U2
R11 C3 R10
U3 C5
J9 R8 TP11 C6 1
DC VOLTS K4-OK D3 R14 ARC V-
C7
1 2 C8 R12 R13
SW6 U4
C10
R17
R16
D5
1
R21
R15 2
C9
R19
K7-GAS ON
R25
R20
R22
R23
R24
R26
R27
R28
R29
R18
J2
OK TO MOVE SELECT
SW6
OK CNC K6
D7
R30 K3-E-STOP CNC

R227
D4 1
R154
R32
K5-E-STOP
1 1
D6
R228
U6
R31
U5
C12
C11
Q3 C15 D10
R33
C14
R34
R35
R36
C13
+ D13
D12 D8
CONTACTS K1-PSR
C26
C16 C17 C18 C22 C23 C24 C25 1 R39
Q2
R152
D11
D14
J36
C20
R42
C21
29 30
C27
R226
D9 R40 + R47
U7
R37
H8
C29
H7 R38
R55 J36
R54
R41
R52
R53
R51
C28
K2-START D15 C30

D16 D18
D17
R43 R44 R45 C19 R49 R50
R64
R48
L1 R60 R46 R68
PSR C31 R57
R62
R71
R69
R70
R56 R59 H10
1
U8 D19 R61 R63 R65
R67
C32 1
R66
R58
R72 R74 1 2 R77 R78 C TDC 2005
C36
1
C33 R76 U10

C34
D20
R73 C37
R75
R81
19X2174
C35
H9 D21 R80 C41 PILOT

R79 U9 DEMAND R86 R87
C40 1 U11 R84 C38 1
CNC_E-STOP
+ TP14 R85 C42 C39 REV AD+
R83
TP14
D22
R82 J3 R91 U12

D23 R89 33
34 C43
R88 R96 C44
C45 D24 R97
R93 CNC_START CUT R90 R92 R98
1 R99
D25
R95 TP13
R94
C46 U13 DEMAND C54 R107

R102
D26 R105
R104
C47 C48
C55
R100 C50 R108
C49
1 U15
C53
R103
C51
C56 R106 U14
+
R109 HOLD_START R101
C52
D27
D28 C60 R113

30 R112 C63
R114
TP4 R110 1 U16 R111 + C59 29 R121
D29
C57
CNC PREFLOW C58 R120

+5V D30 1 +
C61
ALL SW OFF FOR 50:1 (DEFAULT)
SW12-1 ON FOR 16.7:1 (SC-11)
J35
R115
R117
R116
R118
C66
R123
R125
C64
R119 1
C65
26
R122
R126 2
R124
C62 U17
C67
SW12-2 ON FOR 30:1
SW12-3 ON FOR 40:1
1 25 H11
D60
R127
R132 C69
+ R130
D61
R129
SW12-4 SPARE
U18
TP1
R128
C71
C68
C70 GND
1
C72 R133 C75

+
C78 R135
SW12 1 U19 TP5

+
R134
R131
R136 C73
-15V
D31 C74
TP3 TP2
C82 + + C79 C80
D33
4 R157 +15V +29-41 VDC D32

3 Q1 C83
SW12
R156 C81
C77
+ C90
C86
TP7 2 R155 R138 D34 D35 C89 +

+
C76
1 C85 U20 U22

R158
1
U21 R139 R140 D36

1
C88
C87
ISOLATED C84 C93 R144

U23 1
+
R142
TP6 TP7 SW13 1 C91

1
TP6 U24
+
1
T1
R141 R146 R143 D37

+15V -15V
C94
C92
H1
GND +18V D40 H4
D38
D39 R147
+ R150 R151
R149
1 H5 R145
TP10 TP8 C95 R148
1
2
Art # A-06901
J35 J3
TP10 TP8 TP4 TP3 TP2 SW13 TP5 TP1 TP13

APPENDIX 7: CNC - Control Module PCB Connections
TB1-1 E-Stop (Com) These points are jumpered together at the factory.
TB1-2 E-Stop Remove the jumper to use existing E-Stop circuits.
TB1-3
TB1-4 Stop Latched
TB1-5 Start / Stop Ret
TB1-6 Start / Stop or Start Latched (NO)
TB1
TB1-7 Divided Arc Voltage (-)

TB1-8 Divided Arc Voltage (+)
TB1-9 Remote Analog Current Control (0-10V) (-)
TB1-10 Remote Analog Current Control (0-10V) (+)
TB1-11
TB1-12
TB2-1 Hold Start (-)

TB2-2 Hold Start (+)
TB2-3 Preflow On (-)
TB2-4 Preflow On (+)
TB2-5
TB2-6 Pilot On (Relay Contacts NO)
TB2
TB2-7
TB2-8 Pilot On (Relay Contacts NO)
TB2-9
TB2-10 OK to Move (Contacts or DC Volts) (-)
TB2-11
TB2-12 OK to Move (Contacts or DC Volts) (+)
Start / Stop Circuit Configurations

TB1-5
Sustained Start / Stop
TB1-6
Stop
TB1-4
TB1-5 Momentary Start / Stop
Start
TB1-6
Art # A-04900

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 & 2 are common
to each other. J15 pins 1, 4, 5 & 10 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.
Rear Panel CNC Connector J15:

14 Circuit (Amp CPC) Remote Standard:
Chassis gnd (for SC-11 cable shield) 1
1
Start/Stop 3 (+); 4 (-)
1 2
Ok to Move (contacts or voltage ) 12(-); 14 (+)
1
Divided Arc volts (selectable
ratio 50:1; 40:1; 30:1; 16.6:1) 5 (-); 6 (+)
Arc Volts (w/100K series res) 7 (-); 9 (+)
1 3
Analog Current Control (0-10V) 10 (-); 11 (+)
Isolated Circuit Comm (for SC-11) 8
Chassis Gnd 13
1
These are also duplicated on TB1 & TB2, use one or the other not both. Additional functions are only available on TB1 & 2.
2
SW6 on CCM I/O PCB selects OK to Move for isolated contact closure or DC Volts (15-18V) at <100ma. When set for
contacts, OK to Move circuit is rated for 120 VAC / 28 VDC @ 1A.
Internal CNC connections. TB1 & TB2 on CCM module.
Connections are provided on the CCM module TB1 & TB2 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. User shall provide strain relief / cord grip for user installed cable.
Function Connection
E-Stop TB1-1 (comm.) & TB1-2
Stop Latched (NC) 4 TB1-4
Start/Stop Ret 4 TB1-5 (comm.)
Start /Stop or Start Latched (NO) 4 TB1-6
Divided Arc Voltage TB1-7(-); TB1- 8(+)
Remote Analog Current Control (0-10V) TB1-9(-); TB1-10(+)
Hold Start TB2-1(-); TB2-2(+)
Preflow On TB2-3(-); TB2-4(+)
Pilot On (Relay Contacts NO) TB2-6; TB2-8
OK to Move (Contacts or DC Volts) TB2-10(-); TB2-12(+)

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.
MOMENTARY START / STOP
SUSTAINED START / STOP STOP
TB1-4
TB1-5
START / STOP
TB1-5
TB1-6 START
TB1-6
Divided Arc Voltage output — Arc Voltage signal is isolated from plasma supply, however (-) is common with other
isolated CNC signals. Max Divided Arc Voltage signal level depends on actual arc voltage times divide ratio however
can not exceed approximately 12 V.
3
Analog Current Control input— Analog Current Control includes analog isolation module, separate isolation
module not usually required however it’s low input is common with the other isolated CNC inputs. Scaling of Analog
Current Control input is 0V = 0A, 10V. = MAX output and is linear in between. However MIN output is 10A. User is
responsible for setting correct analog voltage to maintain at least 10A output. To use Analog Current Control on the
I/O PCB set SW 11 to down position and on the CPU PCB set SW8-2 ON (up).
Hold Start input—Normally open, close to hold start. Circuit rating 10 ma. @ 20VDC. Delays pilot ignition, gas
preflow continues. Used for synchronizing starts when multiple plasma supplies are used on same cutting table. User
supplies circuit to keep Hold Start inputs active until all torches have found height.
Preflow On input— Normally open, close to start preflow prior to normal START signal. Circuit rating 10 ma. @
20VDC. Torch Height Controls (THC) normally issue START signal to plasma supply after torch height has been
found. Then the plasma takes 1-2 seconds (or more) to perform preflow before igniting pilot. Some THCs have an
output that can start preflow early during height finding saving 1-2 seconds on each cut.
Pilot On output – Relay contacts rated 1A @ 120 VAC / 28 VDC. Contacts close when pilot on. Can be wired parallel
with Ok to Move contacts to start machine motion when pilot established. Used when starting over holes. Starting over
holes requires setting SW8-1 ON (up) on the CPU PCB for extended pilot time. Using extended pilot time to start over
holes or for cutting over holes will reduce parts life.
OK to Move output — Active when cutting arc is established, arc is transferred. Used to signal cutting table to start
X-Y motion. Relay contacts rated 1A @ 120 VAC or 28 VDC when SW6 set for contacts. When SW6 is set for DCV, output
supplies 15-18 VDC @ 100 ma. May be wired parallel with Pilot On to start cutting machine motion as soon as pilot
established.

Simplified CNC Circuit.
CCM Module
SUSTAINED START / STOP
TB1
TB1-5 ALL SW OFF for 50:1 (default)
START / STOP E-STOP Ret (-) 1 Active LOW Logic Input
2 SW12-1 ON = 16.7:1 (SC-11)
E-STOP input (+)
3 Active LOW Logic Input SW12-2 ON = 30:1
TB1-6 STOP (NC) 4 SW12-3 ON = 40:1
U37A 6
START/STOP Ret (-) 5 SW12-4 ON =
START/STOP OR START LATCH (+) Active LOW Logic Input LT1013
6 8
DIVIDED ARC V (-) 7 -
5 SW12-4
SW12-2
7
SW12-1
SW12-3
DIVIDED ARC V (+) 8 1
Remote Analog Current Control ret (-) 9 +
MOMENTARY START / STOP Remote Analog Current Control input (+) SW11
10 3
6
STOP 11 1 2
12 2
TB1-4
4
TB1-5 To CPU PCB
START Analog Input
TB1-6
TB2
HOLD START (-) 1 Active LOW Logic Input
HOLD START (+) 2
PREFLOW ON (-) 3 Active LOW Logic Input
PREFLOW ON (+) 4
5
SW6
PILOT ON 6 1
output 7 PSR
2 Input Circuit
(Contacts) 8 3
9 Common
OK TO MOVE OK to MOVE (-) 10 (isolated)
4
output 11 5
(contacts or OK to MOVE (+) 12 6
OK to Move +16 to 18 VDC
DC Volts)
(isolated)
J4 100K
ARC V_100K (+) 1 ARC V (+)
2 100K
ARC V_100K (-) 3
ARC V (-)
J15 OK to MOVE (-)
4
5
6
1 OK to MOVE (+) 7
2
3
4
J15 CNC 5
14 pin CPC 6 J1
7
rear panel 8 1
9 2
10 Remote Analog Current Control (-) 3
11 START / STOP (+) 4
12 START / STOP (-) 5
13 Remote Analog Current Control (+) 6
14 Divided Arc V (-) 7
SC 11 Comm Ref 8
Divided Arc V (+) 1K
9
Art # A-07327

APPENDIX 8: Schematic, 230-460V Unit
1 2 3 4 5
100A INVERTER MODULE # 1 (top) N (-)

CN1-230V
1
A INRUSH
3 Phase
3
TB1
MC1-A 6 1 2
T
--230--
L1
6
4 - + 1
P1
+ +
TB2 4 3
V_CHANGE PCB
2
--460--
MC1-B S 1
208-230/460 VAC
L2
2
3
--230--
MC1-C TB3 + 1 2
R -
P (+)
L3 TB4 4 - + 1
5
N2
4 3
2
E CN4 - PCB12
CN2-460V
4
CN6
4
B
460
230
COM
PGND1
PGND2
MC3-A
T
ON / OFF 100A INVERTER MODULE # 2 (bottom) N (-)
MC3-B
C.P1 S (same as #1)
CN2-460V
CN1-230V
4
2
MC3-C CN4 - PCB1
4
2
1
CN1 R
3
1
3
P (+)
1
LINE to LINE,
LINE TO GND PCB 1 CN6
CAPS & VARISTORS
WK-5630
/ 230
/ 460
NE1
COM_A
230_A
CN3 FILTER PCB

460_A
C 4 From CN9 on PCB7

(D2, Sht 2)
INPUT POWER
VAC_IN
P_GND
INDICATOR TB1
REAR PANEL
CN4 CN2
4
NE2 CN1
INPUT POWER 7 PCB3 WK-5694
INDICATOR
6
BIAS SUPPLY PCB
INTERNAL
5
D1 4
AC
3
+
AC
C1 2
AC
CN2
1 VAC_IN
D 2 P_GND
/ 460
BIAS SUPPLY DC FAN

CN2 CN4 CN4 CN5 CN6 FOR PCB5 POWER
1
CN32 CN18
1
RY6 CN1 CN5 CN6

+12VDC
RIBBON CABLE SIGNALS
PCB4 WK-5604
+
RY2
RIBBON CABLE
DETECTOR PCB CN6 - 16 Ckt Ribbon Cable

FAN + (24 VDC)
FAN - (24 VDC)
2,4- I_REF (Scaled Cut Demand)

230V RY2 5- PS_START (Start)
+12VDC +12VDC
6- REDUNDANT_START (Start2)
8- INV_READY
9- / PS_START disabled by Input_NG
CN10 CN3 CN7
1
12- / OCR
16 CKT
(F2 -Sht2) 13- / PS_START disabled by OCR

GND
+5V
-15V
E
+15V
14- /TEMP_ERR
15- / PS_START disabled by Temp _Err
MISSING_PHASE
INPUT_NG
+15V
+15V
TEMP_C
GND_C
CN6 16 CKT
CN7 CN32 CN17
1
3
/ OVERTEMP <
+15V
LED4
MISSING PHASE
(pulses)<
CHOPPER TEMP
To T1 PRI - 0
To PCB7 TB3
To PCB7 CN2-1
To PCB7 CN2-2
To PCB7 CN2-4
To PCB7 CN2-5
LED3
(A1 Sht2)
(A1 Sht2)
(A1 Sht 2)
(A1 Sht 2)
(A2 Sht 2)
(A2 Sht 2)
LED2 INPUT NG
F MISSING PHASE
LED1 DIM = LOW, BRIGHT = OK

LED2 DIM = OK, BRIGHT = FAULT LED5
ERROR
PCB 5 WK-5602 (partial) LED3 DIM = OK, BRIGHT = FAULT
LED4 OFF = OK, ON = FAULT
INTERFACE PCB LED5 OFF = OK, ON + FAULT
Art # A-07004_AB
1 2 3 4 5

6 7 8 9 10
Power Supply
Rear Panel
NEG ARC VOLTS
(C7 & A9,Sht 2)
TB2 TB3 TORCH (-)

RAS
CN1 PCB 8 TB1

WK-5687 C2
N2
P1
R6 1
20K
2 2 UF A
3
30W 4 RC &
RF CAPS WORK
R9
50
CN2 CN3
PILOT REGULATOR
1
2
3
1
4
3
2
1
CN5 CN1
(CHOPPER)
-
TB2
BIAS 2
POWER 1
+
FAN3
PILOT REG. TB4
HCT1
PILOT
(CHOPPER )
THS1 HALL SENSOR
PCB1 SW_TEMP_NC PILOT (TIP) VOLTS
1
2
3
4
(C7, Sht 2)
WK-5750
COMMON
SIGNAL
+12V
-12V
TB5 TB1
CN3 CN4 CN2 B

2
1
5
4
3
2
1
3
2
1
2
D2
K2
K1
A2
CN6
2
1
5
4
3
2
1
3
2
1
1
2
A1
CN8 CN7 CN9
1
PILOT REG. CN1
> P_Enable (P_ena)
(CHOPPER )
> P_DEM (P_Iref)
1
< /OVER_TEMP
2
PCB2 3
4 MC2-A
I_DET
WK-5754
I_SE
MC2-B
<
<
CN4 CN2 CN5

1
2
3
1
2
3
4
MC2-C
I_senseP
Iref_G
GNDP
TEMP_C
P_ena
P_ref
GND_C
C
HCT2
WORK (+)
HALL SENSOR
WORK
1
2
3
4
(C7 & A9,Sht 2)
Isense_W
GNDW
+15Vw
-15Vw
COMPONENT LOCATOR
C1 Capacitor, 0.1 uf, 1250 VDC (D2, Sht 2) HCT1 Hall Current Sensor, Pilot (B8, Sht 1)
C2 Capacitor, 2 uf, 430VAC (A9, Sht 1) HCT2 Hall Current Sensor, Work (C9, Sht 1)
C.P1 Circuit protector/ON-OFF SW (B2, Sht 1) LSW1 Level SW, coolant, NC (B5, Sht 2) D
15A, 460V, 3P
C.P2 Circuit protector 2.5A 125V (D2, Sht 1) MC1 Contactor, 3P ,Inv 1 input, Coil (B3, Sht 2)
C.P3 Circuit protector 3.15A 125V (D2, Sht 1) " Contacts (A2, B2, Sht 1)
C.P4 Circuit protector 10A 125V (E2, Sht 1) " Aux Contact (B3, Sht 2)
C.P5 Circuit protector 2.5A 125V (E2, Sht 1) MC2 Contactor, pilot, Coil (B3, Sht 2)
C.P6 Circuit protector 2.5A 125V (F2, Sht 1) " Contacts (C8, Sht 1)
C.P7 Circuit protector 5A 125V (E2, Sht 1)
C.P8 Circuit protector 3.15A 125V (F3, Sht 1) MC3 Contactor, 3P ,Inv 2 input, Coil (B3, Sht 2)
" Contacts (B2,C2, Sht 1)
D1 Diode Bridge 20A, 1600V, 3P (D2, Sht 1) " Aux Contact (B3, Sht 2)
D2 Diode, Dual, 2x100A, 600V (B8, Sht 1)
MOT1 Motor, Pump 200VAC, 1P (E4, Sht 2)
FAN1 Fan, Coolant, 24 VDC (F4, Sht 2)
FAN3 Fan, Chopper, 24 VDC (A8, Sht 1) NE1 Neon indicator, rear panel, 220VAC (C1, Sht 1)
NE2 Neon indicator, internal, 220VAC (D1, Sht 1)
FL1 Flow sensor (B5, Sht 2)
R6 Resistor, 20K ,30W (A8, Sht 1)
R7 Resistor, 1K ,30W (E2, Sht 2) E
R9 Resistor, 50 ,40W (A9, Sht 1)
T1 Aux Transformer (D-F1, Sht 2)
TH1 Thermal Sensor, coolant return (B5, Sht 2)

Isense_W
GNDW
+15Vw
I_senseP
-15Vw
GNDP
Iref_G
P_ena
P_ref
CN33 CN3 CN4

1
5
PILOT DEMAND >
/PILOT ENABLE >
PILOT CURRENT SIGNAL <
WORK CURRENT SIGNAL <
Art # A-07004_AB
AA ECO-B402
AB ECO-B448
DAT 2/26/07
DAT 4/13/07
Thermal Thermal Dynamics
Industrial Park #2
West Lebanon NH 03784
Assy No:
Scale Supersedes
F
AC ECO-B646 GAC 10/31/07 Dynamics 603-298-5711

Date:
Tuesday, October 03, 2006
Drawn: References
NOTE: UNLESS OTHERWISE SPECIFIED -
1. RESISTOR VALUES ARE EXPRESSED IN OHMS, 1/4W 5%. DAT
1 of 2
08:11:44
Last Modified: Wednesday, October 31, 2007 150/200 Amp Power Supply 208-230/460V(Chopper) D 42X1215
6 7 8 9 10

APPENDIX 8: Schematic, 230-460V Unit Cont.
1 2 3 4 5
To PCB7 CN2-1
To PCB7 CN2-2
To PCB7 CN2-4
To PCB7 CN2-5
(F1 Sht 1)
(F1 Sht 1)
(F1 Sht 1)
(F1 Sht 1)
(F2 Sht 1)
(F2 Sht 1)
To T1 PRI - 0
To PCB7 TB3
CN2 PCB 5 WK-5602 (partial) INTERFACE PCB

2
CN9
1
INDICATOR
(on PCB6)
INPUT CONTACTORs 2 LED1
TO AC
3 LEVEL
4
5
MC1 MC3
CN12 CN8 CN1 CN13 CN14
2
MC2
PILOT
CONTACTOR
+15V
+15V
B MC1 AUX
1 1
2 2
1 1
2 2
3 3
MC3 AUX
TH1
R G B
t
GND
SIG
+V
COOLANT TEMP LSW1-1
(ON COOLANT FL1
RETURN) FLOW_TURBINE_PULSE
SW_LIQUID_LEVEL_NC
CCM MODULE
C
I/O PCB
CN2
1
TP1 CIRCUIT COMM (GND)

TB3 TP2 29-41 VDC
TP3 +15VDC
TB4
+ TP4
230 RY1
+5VDC
TP5 -15VDC
TB5 TP9 ANALOG DEM to CPU
460
TP11 NEG ARC VOLTS
TP12 PILOT (TIP) VOLTAGE
TP13 CUT DEM to PS
From CN9 on PCB7 TP14 PILOT DEM to PS
(C2, Sht 1) CN9
460_A 1
460
T1 230_A 230 RELCOL_0
TP6 +15VDC_ISO
2 +
C.P2 TP7 -15VDC_ISO
COM_A 3
COM ISOLATED
460 120. RY2 TP8 +16 to +18VDC VOLTAGES
D TP10 ISOLATED COMM
CN10
1
460
220 0___
230
D1 GAS_ON
C.P3 2
COM
24_ 3 D2 E-STOP_PS
0___
0__
PCB7 WK-5628 D4 OK_CNC
C.P4 RELAY PCB CN8
D15 PSR
24. 1
+15V
AC24V-GCM
(D9, A10) 2
/PUMP D21 CNC_E-STOP
0_
RY5 RY4 RY3
0V-A (24V ret)
/FAN D23 CNC_START
C.P5 3
120. AC120V-GCM 4
/RAS
D26 HOLD_START
(D9, A10)
CN6 RY5 CN7 D28 CNC_PREFLOW
0... 0V-B (120V ret) AC120V @ 1A 1 1 AC120V-RAS
E 110 2 2
(C9) SW6 - OK to MOVE CONTACTS / VOLTS
3 3
R7 SW11 - ANALOG CURRENT SELECT
1K 30W
4 4 0V-RAS
0..
"B" DEFAULT, "A" REMOTE
C.P7 CN3 RY3 CN20 SW12 - DIVIDED ARC V RATIO SELECT
200 AC200V @ 3A 1 1 1 1 ' PUMP . SW13 - FACTORY ONLY
2 2 2 2
MOT1
3 3 3 3
RY4 CN10
0.
C.P8 1 1 1 + -
TB1
2 2 2
CPU PCB
100
FAN + (24 VDC)
FROM CN18 PCB3 3 FAN1 D11 INITIALIZING / PROGRAMMING
sht 1 TB2 4
0,,
FAN - (24 VDC) 5 D12 STATUS CODE
C.P6
6
13 D13 +5V
AC13V @ 2A CN12
1
F 0,
1 DC 15V
2
2 DC 0V
CN11
Art # A-07005_AB
1 2 3 4 5

6 7 8 9 10
INTERNAL TERMINAL
PCB6 DISPLAY STRIP TB3
(Not in all units)
WK-5603 0V-A (24V ret) 24
24 VAC @ 1A
AC24V-GCM 13
GREEN (E2)
AC 0V-B (120V ret) 14
120 VAC @ 100ma.
CN23 CN24 AC120V-GCM 15
1
+15V 1
YELLOW TEMP 16
A
2
/ AC 2 18
3
/ TEMP 3 GREEN 17
/ GAS - COOLANT GAS
4 4 WORK 20
/ DC GREEN (C9, sht 1)
5 5 DC 19 UNDIVIDED ARC VOLTS
6
/ STATUS 6 21 FOR HEIGHT CONTROLS
RED
STATUS 23
NEG ARC VOLTS 22
(A9, sht 1)
POWER SUPPLY
REAR PANEL
J54-REMOTE HMI
CN10 26 CKT CN11 34 CKT
1 JUMPER IN
REMOTE
2 HMI
PILOT (TIP) VOLTS 3 B
RIBBON CABLE RIBBON CABLE 4
NEG ARC VOLTS
PLASMA ENABLE
5
(B9 SHT1)
6
(A9 SHT1)
7
(C9 SHT1)
J59-RAS
WORK
TEST SOCKET TEST SOCKET 2
3 KEY PLUG
4
J35 26 CKT J36 34 CKT 6

1
6
J6 J9
AC120V-RAS 7
24 VAC RET
RIBBON CABLE SIGNALS TP11 TP12 TP1 (E4) 8

/ = active low digital signal
24VAC
K6-1 0V-RAS (120V ret) 9

10
CN10-J35 - 26 Ckt Ribbon Cable 11
- ARC V K6 12
2- Cut Demand
13
14
C
4- Pilot Demand J5
6- / Start
7- / Start2 1
9- / Pilot Enable Signal - Basic ID 2
10- / HF Enable Used to identify J55-GCM
12- / Pump Enable GCM 1000 present 3
1
13- / Fan Enable 4
2
3
15- / DC Indicator 4
16- / Over Temperature Indicator 5
5
18- / Gas-Coolant OK Indicator 6
7
19- / Status Lamp 8
J7 9
PLASMA ENABLE 10
CN11-J36 - 34 Ckt Ribbon Cable 1 11
PLASMA ENABLE 12
1- Output Current Signal 2 13
PRESS OK (GCM 1000) 14
3- / Arc Transferred (CSR) 3 15
4- / Pilot On
4
AC24V-GCM 16
17
6- Coolant Flow (freq) (E2) 18
7- Coolant Temp (analog) 5 19
9- / Temp OK (Inverter/Chopper) POT HI (GCM1000) 0V-A (24V ret) 20
6 21
10- / Coolant Level OK 22
POT WIPER (GCM1000)
12- Missing Phase 7
DC 15V 23
13- / Ready to Operate 8
POT LOW (GCM 1000)
(F4)
24
25 D
15- / Input Volts OK 26
16- / Inverter OCR 9 DC 0V 27
28
18- / PS ID "00*"
J8 29
19- / PS ID "0*0" 30
GAS ON
20- / PS ID "*00" 1 AC120V-GCM 31
32
21- E-Stop
2
(E2) 33
22- E-Stop 34
29,31,33 - 24 VAC Supply
E-STOP
3
0V-B (120V ret) 35
36
30,32,34 - 24 VAC Return TB1 4
37
E-STOP - 1
E-STOP + 2 J1
STOP 3 1 J15-CNC
4 2 1
START - 5
START / STOP 3 2
+ 6 4 3
START / STOP
DIVIDED ARC V - 7 5 4
DIVIDED ARC V + 8 6 5
DIVIDED ARC VOLTS
REMOTE ANALOG CURRENT CONTROL - 9 1K 7 6
REMOTE ANALOG CURRENT CONTROL + 10 8 7

E
11 9 8
12 9
10 REMOTE ANALOG
TB2 11 CURRENT CONTROL
J4
HOLD START - 1 100K
12
HOLD START + 1
2 13 OK TO MOVE
PREFLOW ON - 3 100K
14
PREFLOW ON + 3
4
5 - ARC V
5
6
PILOT ON PSR
7
OUTPUT 7
8
9
OK to MOVE - 10
11 Art # A-07005_AB
OK to MOVE + 12 Rev Revisions By Date PCB No:
AA ECO-B402
AB ECO-B448
DAT
DAT
2/26/07
4/13/07
Industrial Park #2
Assy No:
Scale Supersedes
F

Date:
Drawn: References
2 of 2
08:11:44
Last Modified: Wednesday, October 31, 2007 150/200 Amp Power Supply 208-230/460V(Chopper) D 42X1215
6 7 8 9 10

APPENDIX 9: Schematic, CCC 400V Unit
1 2 3 4 5
CN1- not used

1
A INRUSH
3
TB1
MC1-A 6 1 2
L1 T
6
4 - + 1
3 Phase
P1
+ +
TB2 4 3
V_CHANGE PCB
2
--400--
MC1-B S 1
L2
400V only
2
3
400 VAC
3
MC1-C TB3 + 1 2
R -
P (+)
L3 TB4 4 - + 1
5
N2
4 3
2
E CN4 - PCB12
CN2 400V
4
CN6
4
B
400
200
COM
PGND1
PGND2
MC3-A
T
MC3-B
C.P1 S (same as #1)
CN2-400V
4
MC3-C CN4 - PCB12 2
4
2
1
CN1 R 3
1
3
P (+)
1
LINE to LINE, CN1- not used

CAPS & VARISTORS
WK-5630
/ 200
/ 400
NE1
COM_A
400_A
200_A
CN3 FILTER PCB

1

(D2, Sht 2)
INPUT POWER
VAC_IN
P_GND
INDICATOR TB1
REAR PANEL
CN4 CN2
4
NE2 CN1
INDICATOR
6
BIAS SUPPLY PCB
INTERNAL
5
D1 4
AC
3
+
AC
C1 2
AC
CN2
1 VAC_IN
D 2 P_GND
/ 400
BIAS SUPPLY DC FAN

1
CN32 CN18
1
RY2 CN1 CN5 CN6

+12VDC
PCB4 WK-5604 RIBBON CABLE SIGNALS

+
RY2
RIBBON CABLE
DETECTOR PCB
FAN + (24 VDC)
FAN - (24 VDC)
CN6 - 16 Ckt Ribbon Cable
200V RY2
+12VDC +12VDC 5- PS_START (Start)
8- INV_READY
CN10 CN3 CN7 9- / PS_START disabled by Input_NG
1
12- / OCR
16 CKT
(F2 -Sht2)
13- / PS_START disabled by OCR
GND
+5V
-15V
E
+15V
14- /TEMP_ERR
MISSING_PHASE
INPUT_NG
+15V
+15V
TEMP_C
GND_C
CN6 16 CKT
CN7 CN32 CN17
1
3
/ OVERTEMP <
+15V
LED4
MISSING PHASE
(pulses)<
CHOPPER TEMP
To T1 PRI - 0
To PCB7 TB3
To PCB7 CN2-1
To PCB7 CN2-2
To PCB7 CN2-4
To PCB7 CN2-5
LED3
(A1 Sht2)
(A1 Sht2)
(A1 Sht 2)
(A1 Sht 2)
(A2 Sht 2)
(A2 Sht 2)
LED2 INPUT NG
F MISSING PHASE
LED3 DIM = OK, BRIGHT = FAULT ERROR
PCB 5 WK-5602 (partial) LED4 OFF = OK, ON = FAULT
Art # A-07010_AB
1 2 3 4 5

6 7 8 9 10
Power Supply
Rear Panel
NEG ARC VOLTS
(C7 & A9,Sht 2)
TB2 TB3 TORCH (-)

RAS
CN1 PCB 8 TB1

WK-5687 C2
N2
P1
R6 1
20K
2 2 UF A
3
30W 4 RC &
RF CAPS WORK
R9
50
CN2 CN3
PILOT REGULATOR
1
2
3
1
4
3
2
1
CN5 CN1
(CHOPPER)
-
TB2
BIAS 2
POWER 1
+
FAN3
PILOT REG. TB4
HCT1
PILOT
(CHOPPER ) HALL SENSOR
THS1
1
2
3
4
(C7, Sht 2)
WK-5750
COMMON
SIGNAL
+12V
-12V
TB5 TB1
CN3 CN4 CN2 B

2
1
5
4
3
2
1
3
2
1
2
D2
K2
K1
A2
CN6
2
1
5
4
3
2
1
3
2
1
1
2
A1
CN8 CN7 CN9
1
PILOT REG. CN1
> P_Enable (P_ena)
(CHOPPER )
> P_DEM (P_Iref)
1
< /OVER_TEMP
2
PCB2 3
4 MC2-A
I_DET
WK-5754
I_SE
MC2-B
<
<
CN4 CN2 CN5

1
2
3
1
2
3
4
MC2-C
I_senseP
Iref_G
GNDP
TEMP_C
P_ena
P_ref
GND_C
C
HCT2
WORK (+)
HALL SENSOR
1
2
3
4
WORK
(C7 & A9,Sht 2)
Isense_W
GNDW
+15Vw
-15Vw
COMPONENT LOCATOR
C.P1 Circuit protector/ON-OFF SW (B2, Sht 1) LSW1 Level SW, coolant, NC (B5, Sht 2) D
15A, 460V, 3P
C.P2 Circuit protector 2.5A 125V (D2, Sht 1) MC1 Contactor, 3P ,Inv 1 input, Coil (B3, Sht 2)
C.P3 Circuit protector 3.15A 125V (D2, Sht 1) " Contacts (A2, B2, Sht 1)
C.P4 Circuit protector 10A 125V (E2, Sht 1) " Aux Contact (B3, Sht 2)
C.P5 Circuit protector 2.5A 125V (E2, Sht 1) MC2 Contactor, pilot, Coil (B3, Sht 2)
C.P6 Circuit protector 2.5A 125V (F2, Sht 1) " Contacts (C8, Sht 1)
C.P7 Circuit protector 5A 125V (E2, Sht 1)
" Contacts (B2,C2, Sht 1)
D1 Diode Bridge 20A, 1600V, 3P (D2, Sht 1) " Aux Contact (B3, Sht 2)
MOT1 Motor, Pump 200VAC, 1P (E4, Sht 2)
FAN1 Fan, Coolant, 24 VDC (F4, Sht 2)
FAN3 Fan, Chopper, 24 VDC (A8, Sht 1) NE1 Neon indicator, rear panel, 220VAC (C1, Sht 1)
NE2 Neon indicator, internal, 220VAC (C1, Sht 1)
FL1 Flow sensor (B5, Sht 2)
R7 Resistor, 1K ,30W (E2, Sht 2) E

Isense_W
GNDW
+15Vw
I_senseP
-15Vw
GNDP
Iref_G
P_ena
P_ref
CN33 CN3 CN4

1
PILOT CURRENT SIGNAL < 3

4
WORK CURRENT SIGNAL < 3

4
5
/PILOT ENABLE >
PILOT DEMAND >
Art # A-07010_AB
AA
AB
ECO-B402
ECO-B448
DAT
DAT
2/26/07
4/13/07
Industrial Park #2
Assy No:
Scale Supersedes
F

Date:
Drawn: References
1 of 2
Last Modified: Wednesday, October 31, 2007
08:11:44 150/200A Power Supply 400V CCC (Chopper) D 42X1218
6 7 8 9 10

APPENDIX 9: Schematic, CCC 400V Unit Cont.
1 2 3 4 5
To PCB7 CN2-1
To PCB7 CN2-2
To PCB7 CN2-4
To PCB7 CN2-5
(F1 Sht 1)
(F1 Sht 1)
(F1 Sht 1)
(F1 Sht 1)
(F2 Sht 1)
(F2 Sht 1)
To T1 PRI - 0
To PCB7 TB3
A
PCB 5 WK-5602 (partial) INTERFACE PCB
CN2
2
CN9
1
INDICATOR
(on PCB6)
TO AC
3 LEVEL
4
5
MC1 MC3
2
MC2
PILOT
CONTACTOR
+15V
+15V
B MC1 AUX
1 1
2 2
1 1
2 2
3 3
MC3 AUX
TH1
R G B
t
GND
SIG
+V
COOLANT TEMP LSW1-1
(ON COOLANT FL1
SW_LIQUID_LEVEL_NC
CCM MODULE
C
I/O PCB
CN2
1

TB3 TP2 29-41 VDC
TP3 +15VDC
TB4
+ TP4
200 (not used) RY1
+5VDC
TP5 -15VDC
400
TP11 NEG ARC VOLTS
TP13 CUT DEM to PS
(C2, Sht 1) CN9
400_A 1
400
T1 200_A 200 RELCOL_0
TP6 +15VDC_ISO
2 +
C.P2 TP7 -15VDC_ISO
COM_A 3
COM ISOLATED
CN10
1
400
200 0___
200
D1 GAS_ON
C.P3 2
COM
24_ 3 D2 E-STOP_PS
0___
0__
C.P4 RELAY PCB CN8
D15 PSR
24. 1
+15V
AC24V-GCM
(D9, A10) 2
0_
RY5 RY4 RY3
0V-A (24V ret)
/FAN D23 CNC_START
C.P5 3
120. AC120V-GCM 4
/RAS
D26 HOLD_START
(D9, A10)
E 110 2 2
3 3
1K 30W
4 4 0V-RAS
0..
2 2 2 2
MOT1
3 3 3 3
RY4 CN10
0.
C.P8 1 1 1 + -
TB1
2 2 2
CPU PCB
100
FAN + (24 VDC)
sht 1 TB2 4
0,,
C.P6
6
13 D13 +5V
AC13V @ 2A CN12
1
F 0,
1 DC 15V
2
2 DC 0V
CN11
TX1P8S
Art # A-07011_AB
1 2 3 4 5

6 7 8 9 10
INTERNAL TERMINAL
PCB6 DISPLAY STRIP TB3
(Not in all units)
WK-5603 0V-A (24V ret) 1
24 VAC @ 1A
AC24V-GCM 2
GREEN (E2)
AC 0V-B (120V ret) 3
120 VAC @ 100ma.
1
+15V 1
YELLOW TEMP 5
A
2
/ AC 2 6
3
/ TEMP 3 GREEN 7
/ GAS - COOLANT GAS
4 4 WORK 8
/ DC GREEN (C9, sht 1)
5 5 DC 9 UNDIVIDED ARC VOLTS
6
/ STATUS 6 10 FOR HEIGHT CONTROLS
RED
STATUS 11
NEG ARC VOLTS 12
(A9, sht 1)
POWER SUPPLY
REAR PANEL
J54-REMOTE HMI
1 JUMPER IN
REMOTE
2 HMI
3 B
PILOT (TIP) VOLTS

NEG ARC VOLTS
PLASMA ENABLE
5
(B9 SHT1)
6
(A9 SHT1)
7
(C9 SHT1)
J59-RAS
WORK
3 KEY PLUG
4
J35 26 CKT J36 34 CKT 6

1
J6 J9
AC120V-RAS 7
24 VAC RET
TP11 TP12 TP1 (E4) 8

24VAC
/ = active low digital signal 0V-RAS (120V ret) 9

K6-1 10
11
CN10-J35 - 26 Ckt Ribbon Cable K6 12
- ARC V 13 C
14
2- Cut Demand
4- Pilot Demand J5
6- / Start 1
7- / Start2 Signal - Basic ID 2
9- / Pilot Enable Used to identify J55-GCM
10- / HF Enable GCM 1000 present 3
1
12- / Pump Enable 4
2
13- / Fan Enable 3
4
5
7
19- / Status Lamp J7 9
PLASMA ENABLE 10
1 11
CN11-J36 - 34 Ckt Ribbon Cable 12
PLASMA ENABLE
2 13
14
1- Output Current Signal 3
PRESS OK (GCM 1000)
15
3- / Arc Transferred (CSR) AC24V-GCM 16
4- / Pilot On 4 17
6- Coolant Flow (freq)
(E2) 18
5 19
7- Coolant Temp (analog) POT HI (GCM1000) 0V-A (24V ret) 20
9- / Temp OK (Inverter/Chopper) 6 21
POT WIPER (GCM1000) 22
10- / Coolant Level OK 7 23
DC 15V
12- Missing Phase
8
POT LOW (GCM 1000)
(F4)
24
25 D
15- / Input Volts OK 9 DC 0V 27
16- / Inverter OCR 28
18- / PS ID "00*" J8 29
30
GAS ON
19- / PS ID "0*0" 1 AC120V-GCM 31
32
20- / PS ID "*00" (E2) 33
2
21- E-Stop 34
22- E-Stop E-STOP
3
0V-B (120V ret) 35
36
29,31,33 - 24 VAC Supply TB1 4
37
30,32,34 - 24 VAC Return
E-STOP - 1
E-STOP + 2 J1
STOP 3 1 J15-CNC
4 2 1
START - 5
START / STOP 3 2
+ 6 4 3
START / STOP
DIVIDED ARC VOLTS

E
11 9 8
12 9
10 REMOTE ANALOG
J4
HOLD START - 1 100K
12
HOLD START + 1
2 13 OK TO MOVE
PREFLOW ON - 3 100K
14
PREFLOW ON + 3
4
5 - ARC V
5
6
PILOT ON PSR
7
OUTPUT 7
8
9
OK to MOVE - 10
11 Art # A-07011_AB
AA
AB
ECO-B402
ECO-B448
DAT
DAT
2/26/07
4/13/07
Industrial Park #2
Assy No:
Scale Supersedes
F

Date:
Drawn: References
2 of 2
Last Modified: Wednesday, October 31, 2007
08:11:44 150/200 A Power Supply 400V CCC (Chopper) D 42X1218
6 7 8 9 10

APPENDIX 10: Schematic, CE 400V Unit
1 2 3 4 5
CN1- not used

100A INVERTER MODULE # 1 (top)
1
A L1 INRUSH
N (-)
3
NFC1 TB1
MC1-A
L1 T 6 1 2 L8
6
L1 L4 4 - + 1
3 Phase
P1
+ +
TB2 4 3
V_CHANGE PCB
2
EMI
--400--
MC1-B S 1
FILTER
L2
400V only
L2 L5 2
3
400 VAC
3
MC1-C TB3 + 1 2
R -
P (+)
L3 TB4 4 - + 1
L3 L6
5
N2
4 3
2
L2
E CN4 - PCB12
CN2 400V
4
CN6
4
L3
B
400
200
COM
PGND1
PGND2
L4
L9
L5 NFC2
L1 L4
MC3-A
L6 T L10
ON / OFF 100A INVERTER MODULE # 2 (bottom)
EMI
L7 C.P1
FILTER
MC3-B
S (same as #1) N (-)
L2 L5
CN2-400V
4
2
MC3-C CN4 - PCB12
4
2
1
R P (+)
3
1
CN1- not used

CN1 CN6
1
L3 L6
/ 200
/ 400
200_A
LINE to LINE,
COM_A
PCB 1
400_A
LINE TO GND
CAPS & VARISTORS
NE1 WK-5630
CN3 FILTER PCB
(D2, Sht 2)
4
INPUT POWER
VAC_IN
P_GND
INDICATOR TB1
REAR PANEL
CN4 CN2 CN1
4
7 PCB3 WK-5694
NE2
6
BIAS SUPPLY PCB
INPUT POWER
INDICATOR 5
INTERNAL D1 4
AC
3
+
AC
C1 2
AC
CN2
1 VAC_IN
D 2 P_GND
/ 400
BIAS SUPPLY DC FAN

1
CN32 CN18
1
RY2 CN1 CN5 CN6

+12VDC RIBBON CABLE SIGNALS
PCB4 WK-5604
+
RY2
RIBBON CABLE
FAN + (24 VDC)
FAN - (24 VDC)

+12VDC +12VDC 6- REDUNDANT_START (Start2)
8- INV_READY
CN10 CN3 CN7 12- / OCR
1

16 CKT
(F2 -Sht2)
14- /TEMP_ERR
GND
+5V
-15V
E
+15V

MISSING_PHASE
INPUT_NG
+15V
+15V
TEMP_C
GND_C
CN6 16 CKT
CN7 CN32 CN17
1
3
/ OVERTEMP <
+15V
LED4
MISSING PHASE
(pulses)<
CHOPPER TEMP
To T1 PRI - 0
To PCB7 TB3
To PCB7 CN2-1
To PCB7 CN2-2
To PCB7 CN2-4
To PCB7 CN2-5
LED3
(A1 Sht2)
(A1 Sht2)
(A1 Sht 2)
(A1 Sht 2)
(A2 Sht 2)
(A2 Sht 2)
LED2 INPUT NG
F MISSING PHASE
LED2 DIM = OK, BRIGHT = FAULT
PCB 5 WK-5602 (partial) LED4 OFF = OK, ON = FAULT ERROR
Art # A-07008_AB
1 2 3 4 5

6 7 8 9 10
Power Supply
Rear Panel
NEG ARC VOLTS
(C7 & A9,Sht 2)
TB2 TB3 TORCH (-)

RAS
CN1 PCB 8 TB1

R6 1 WK-5687 C2
20K
2 2 UF A
3
30W 4 RC &
N2
P1
RF CAPS WORK
R9
50
CN2 CN3
1
2
3
1
PILOT REGULATOR
(CHOPPER)
4
3
2
1
CN5 CN1
-
TB2
BIAS 2
POWER 1
+
FAN3
PILOT REG. TB4
HCT1
PILOT
THS1
1
2
3
4
(C7, Sht 2)
WK-5750
COMMON
SIGNAL
+12V
-12V
TB5 TB1
B
CN3 CN4 CN2
2
1
5
4
3
2
1
3
2
1
2
D2
K2
K1
A2
CN6
2
1
5
4
3
2
1
3
2
1
1
2
A1
CN8 CN7 CN9
1
PILOT REG. CN1
> P_Enable (P_ena)
(CHOPPER )
> P_DEM (P_Iref)
1
< /OVER_TEMP
2
PCB2 3
4 MC2-A
I_DET
WK-5754
I_SE
MC2-B
<
<
CN4 CN2 CN5

1
2
3
1
2
3
4
MC2-C
C
TEMP_C
GND_C
P_ena
I_senseP
Iref_G
GNDP
P_ref
HCT2
WORK (+)
HALL SENSOR
1
2
3
4 WORK
(C7 & A9,Sht 2)
Isense_W
GNDW
+15Vw
-15Vw
COMPONENT LOCATOR
C.P1 Circuit protector/ON-OFF SW (B2, Sht 1) L1,L9 Toroid Core input common mode filter (A2, B2, Sht 1)
15A, 460V, 3P L2-7 Toroid Core common mode filter (B1, C1, Sht 1)
C.P2 Circuit protector 2.5A 125V (D2, Sht 1) L8,L10 Toroid Core output common mode filter (A6, C6, Sht 1)
C.P3 Circuit protector 3.15A 125V (D2, Sht 1) D
C.P4 Circuit protector 10A 125V (E2, Sht 1) LSW1 Level SW, coolant, NC (B5, Sht 2)
C.P5 Circuit protector 2.5A 125V (E2, Sht 1)
C.P7 Circuit protector 5A 125V (E2, Sht 1) " Contacts (A2, B2, Sht 1)
C.P8 Circuit protector 3.15A 125V (F3, Sht 1) " Aux Contact (B3, Sht 2)
MC2 Contactor, pilot, Coil (B3, Sht 2)
D1 Diode Bridge 20A, 1600V, 3P (D2, Sht 1) " Contacts (C9, Sht 1)
MC3 Contactor, 3P ,Inv 2 input, Coil (B3, Sht 2)
FAN1 Fan, Coolant, 24 VDC (F4, Sht 2) " Contacts (B2,C2, Sht 1)
FAN3 Fan, Chopper, 24 VDC (A8, Sht 1) " Aux Contact (B3, Sht 2)
FL1 Flow sensor (B5, Sht 2)MOT1 Motor, Pump 200VAC, 1P (E4, Sht 2)
NE1 Neon indicator, rear panel, 220VAC (C1, Sht 1)

NE2 Neon indicator, internal, 220VAC (D1, Sht 1)
NFC1 & 2 Noise Filter, EMI, input (A3, B3, Sht 1) E

R7 Resistor, 1K ,30W (E2, Sht 2)

Isense_W
GNDW
+15Vw
I_senseP
-15Vw
GNDP
Iref_G
P_ena
P_ref
CN33 CN3 CN4

1
5

/PILOT ENABLE >
PILOT DEMAND >
Art # A-07008_AB
AA ECO-B402
AB ECO-B448
DAT
DAT
2/26/07
4/13/07
Industrial Park #2
Assy No:
Scale Supersedes
F

Date:
Drawn: References
1 of 2
08:11:44
Last Modified: Wednesday, October 31, 2007 150/200A Power Supply 400V CE (Chopper) D 42X1217
6 7 8 9 10

APPENDIX 10: Schematic, CE 400V Unit Cont.
1 2 3 4 5
To PCB7 CN2-1
To PCB7 CN2-2
To PCB7 CN2-4
To PCB7 CN2-5
(F1 Sht 1)
(F1 Sht 1)
(F1 Sht 1)
(F1 Sht 1)
(F2 Sht 1)
(F2 Sht 1)
To T1 PRI - 0
To PCB7 TB3

2
CN9
1
INDICATOR
(on PCB6)
TO AC
3 LEVEL
4
5
MC1 MC3
2
MC2
PILOT
CONTACTOR
+15V
+15V
MC1 AUX
B
1 1
2 2
1 1
2 2
3 3
MC3 AUX
TH1
R G B
t
GND
SIG
+V
COOLANT TEMP LSW1-1
(ON COOLANT FL1
SW_LIQUID_LEVEL_NC
CCM MODULE
C
I/O PCB
CN2
1

TB3 TP2 29-41 VDC
TP3 +15VDC
TB4
+ TP4
200 (not used) RY1
+5VDC
TP5 -15VDC
400
TP11 NEG ARC VOLTS
TP13 CUT DEM to PS
(C2, Sht 1) CN9
400_A 1
400
T1 200_A 200 RELCOL_0
TP6 +15VDC_ISO
2 +
C.P2 TP7 -15VDC_ISO
COM_A 3
COM ISOLATED
CN10
1
400
200 0___
200
D1 GAS_ON
C.P3 2
COM
24_ 3 D2 E-STOP_PS
0___
0__
C.P4 RELAY PCB CN8
D15 PSR
24. 1
+15V
AC24V-GCM
(D9, A10) 2
0_
RY5 RY4 RY3
0V-A (24V ret)
/FAN D23 CNC_START
C.P5 3
120. AC120V-GCM 4
/RAS
D26 HOLD_START
(D9, A10)
E 110 2 2
3 3
1K 30W
4 4 0V-RAS
0..
2 2 2 2
MOT1
3 3 3 3
RY4 CN10
0.
C.P8 1 1 1 + -
TB1
2 2 2
CPU PCB
100
FAN + (24 VDC)
sht 1 TB2 4
0,,
C.P6
6
13 D13 +5V
AC13V @ 2A CN12
1
F 0,
1 DC 15V
2
2 DC 0V
CN11
TX1P8S
Art # A-07009_AB
1 2 3 4 5

6 7 8 9 10
INTERNAL TERMINAL
STRIP TB3
PCB6 DISPLAY (Not in all units)
WK-5603 0V-A (24V ret) 1
24 VAC @ 1A
AC24V-GCM 2
(E2)
GREEN AC 0V-B (120V ret) 3
120 VAC @ 100ma.
1
+15V 1
YELLOW TEMP 5 A
2
/ AC 2
6
3
/ TEMP 3 GREEN 7
/ GAS - COOLANT GAS WORK 8
4 4 (C9, sht 1)
5
/ DC 5
GREEN
DC 9 UNDIVIDED ARC VOLTS
6
/ STATUS 6
10 FOR HEIGHT CONTROLS
RED 11
STATUS
NEG ARC VOLTS 12
(A9, sht 1)
POWER SUPPLY
REAR PANEL
J54-REMOTE HMI
1 JUMPER IN
REMOTE
2 HMI
PILOT (TIP) VOLTS 3 B
PLASMA ENABLE
NEG ARC VOLTS
5
(B9 SHT1)
6
(A9 SHT1)
7
(C9 SHT1)
J59-RAS
WORK
3 KEY PLUG
4
J35 26 CKT J36 34 CKT 6

1
J6 J9 6
AC120V-RAS 7
24 VAC RET
TP11 TP12 TP1 (E4) 8

24VAC
0V-RAS (120V ret) 9

/ = active low digital signal K6-1 10
11
CN10-J35 - 26 Ckt Ribbon Cable - ARC V K6 12
13
14
C
2- Cut Demand
J5
4- Pilot Demand
6- / Start 1
7- / Start2 Signal - Basic ID 2
9- / Pilot Enable Used to identify J55-GCM
10- / HF Enable GCM 1000 present 3
1
12- / Pump Enable 4
2
13- / Fan Enable 3
4
5
7
19- / Status Lamp J7 9
PLASMA ENABLE 10
1 11
CN11-J36 - 34 Ckt Ribbon Cable PLASMA ENABLE 12
2 13
PRESS OK (GCM 1000) 14
1- Output Current Signal 3 15
3- / Arc Transferred (CSR) AC24V-GCM 16
4- / Pilot On 4 17
6- Coolant Flow (freq)
(E2) 18
5 19
7- Coolant Temp (analog) POT HI (GCM1000) 0V-A (24V ret) 20
6 21
9- / Temp OK (Inverter/Chopper) 22
POT WIPER (GCM1000)
10- / Coolant Level OK 7 23
DC 15V
12- Missing Phase
8
POT LOW (GCM 1000)
(F4)
24
25 D
15- / Input Volts OK 9 DC 0V 27
28
16- / Inverter OCR
18- / PS ID "00*" J8 29
30
GAS ON
19- / PS ID "0*0" 1 AC120V-GCM 31
32
20- / PS ID "*00" (E2) 33
2
21- E-Stop 34
22- E-Stop
E-STOP
3
0V-B (120V ret) 35
36
29,31,33 - 24 VAC Supply TB1 4
37
30,32,34 - 24 VAC Return
E-STOP - 1
E-STOP + 2 J1
STOP 3 1 J15-CNC
4 2 1
START START / STOP - 5 3 2
+ 6 4 3
START / STOP
DIVIDED ARC VOLTS

E
11 9 8
12 9
10 REMOTE ANALOG
J4
HOLD START - 1 100K
12
HOLD START + 1
2 13 OK TO MOVE
PREFLOW ON - 3 100K
14
PREFLOW ON + 3
4
5 - ARC V
5
6
PILOT ON PSR
7
OUTPUT 7
8
9
OK to MOVE - 10
11 Art # A-07009_AB
AA
AB
ECO-B402
ECO-B448
DAT
DAT
2/26/07
4/13/07
Industrial Park #2
Assy No:
Scale Supersedes
F

Date:
Drawn: References
2 of 2
08:11:44
Last Modified: Wednesday, October 31, 2007 150/200A Power Supply 400V CE (Chopper) D 42X1217
6 7 8 9 10

APPENDIX 11: Schematic, CSA 600V Unit
1 2 3 4 5
CN1- not used

1
A INRUSH
3
TB1
MC1-A 6 1 2
L1 T
6
4 - + 1
3 Phase
P1
+ +
TB2 4 3
V_CHANGE PCB
2
--600--
MC1-B S 1
L2
600V only
2
3
600 VAC
3
MC1-C TB3 + 1 2
R -
P (+)
L3 TB4 4 - + 1
5
N2
4 3
2
E CN4 - PCB12
CN2 600V
4
CN6
1
4
B 600
230
COM
PGND1
PGND2
/ 230
/ 600
MC3-A
T
MC3-B
C.P1 S (same as #1)
CN2-400V
4
2
MC3-C CN4 - PCB12
4
2
1
CN1 R
3
1
3
P (+)
1
LINE to LINE, CN1- not used

CAPS & VARISTORS
WK-5857
/ 230
/ 600
NE1
COM_A
600_A
230_A
CN3 FILTER PCB

1

(D2, Sht 2)
INPUT POWER
VAC_IN
P_GND
INDICATOR TB1
REAR PANEL
CN4 CN2
4
NE2 CN1
INDICATOR
6
BIAS SUPPLY PCB
INTERNAL
5
D1 4
AC
3
+
AC
C1 2
AC
CN2
1 VAC_IN
D 2 P_GND
/ 600
BIAS SUPPLY DC FAN

1
CN32 CN18
1
RY2 CN1 CN5 CN6

+12VDC
PCB4 WK-5604
+
RY2
RIBBON CABLE

FAN + (24 VDC)
FAN - (24 VDC)

+12VDC +12VDC
8- INV_READY
CN10 CN3 CN7
1
12- / OCR
16 CKT
(F2 -Sht2)
GND
+5V
-15V
E
+15V
14- /TEMP_ERR
MISSING_PHASE
INPUT_NG
+15V
+15V
TEMP_C
CN6 16 CKT
CN7 CN32 CN17
1
1
/ OVERTEMP <
+15V
LED4
MISSING PHASE
(pulses)<
CHOPPER TEMP
To T1 PRI - 0
To PCB7 TB3
To PCB7 CN2-1
To PCB7 CN2-2
To PCB7 CN2-4
To PCB7 CN2-5
LED3
(A1 Sht2)
(A1 Sht2)
(A1 Sht 2)
(A1 Sht 2)
(A2 Sht 2)
(A2 Sht 2)
LED2 INPUT NG
F MISSING PHASE
LED3 DIM = OK, BRIGHT = FAULT ERROR
PCB 5 WK-5602 (partial) LED4 OFF = OK, ON = FAULT
Art # A-07012_AB
1 2 3 4 5

6 7 8 9 10
Power Supply
Rear Panel
NEG ARC VOLTS
(C7 & A9,Sht 2)
TB2 TB3 TORCH (-)

RAS
(C1, Sht 2)
N2 P1 CN1 PCB 8 TB1
R6 1 WK-5687 C2
20K
2 2 UF A
3
30W 4 RC &
RF CAPS WORK
R9
50
CN2 CN3
PILOT REGULATOR
1
2
3
1
4
3
2
1
CN5 CN1
(CHOPPER)
-
TB2
BIAS 2
POWER 1
+
FAN3
PILOT REG. TB4
HCT1
PILOT
THS1
1
2
3
4
(C7, Sht 2)
WK-5750
COMMON
SIGNAL
+12V
-12V
TB5 TB1
CN3 CN4 CN2 B

2
1
5
4
3
2
1
3
2
1
2
D2
K2
K1
A2
CN6
2
1
5
4
3
2
1
3
2
1
1
2
A1
CN8 CN7 CN9
1
PILOT REG. CN1
> P_Enable (P_ena)
(CHOPPER )
> P_DEM (P_Iref)
1
< /OVER_TEMP
2
PCB2 I_DET 3
4 MC2-A
WK-5754 I_SE
MC2-B
<
<
CN4 CN2 CN5

1
2
3
1
2
3
4
MC2-C
I_senseP
Iref_G
GNDP
TEMP_C
P_ena
P_ref
GND_C
C
HCT2
WORK (+)
HALL SENSOR
1
2
3
4
WORK
(C7 & A9,Sht 2)
Isense_W
GNDW
+15Vw
-15Vw
COMPONENT LOCATOR
C3 Capacitor 47 uf 400V (C1, Sht 2)
LSW1 Level SW, coolant, NC (B5, Sht 2)
C.P1 Circuit protector/ON-OFF SW (B2, Sht 1)
10A, 690V, 3Ph MC1 Contactor, 3P ,Inv 1 input, Coil (B3, Sht 2)
C.P2 Circuit protector 2.5A 125V (D2, Sht 1) " Contacts D
(A2, B2, Sht 1)
C.P3 Circuit protector 3.15A 125V (D2, Sht 1) " Aux Contact (B3, Sht 2)
C.P4 Circuit protector 10A 125V (E2, Sht 1) MC2 Contactor, pilot, Coil (B3, Sht 2)
C.P5 Circuit protector 2.5A 125V (E2, Sht 1) " Contacts (C8, Sht 1)
C.P6 Circuit protector 2.5A 125V (F2, Sht 1)
C.P7 Circuit protector 5A 125V (E2, Sht 1) MC3 Contactor, 3P ,Inv 2 input, Coil (B3, Sht 2)
C.P8 Circuit protector 3.15A 125V (F3, Sht 1) " Contacts (B2,C2, Sht 1)
" Aux Contact (B3, Sht 2)
D1 Diode Bridge 20A, 1600V, 3P (D2, Sht 1)
D2 Diode, Dual, 2x100A, 600V (B8, Sht 1) MOT1 Motor, Pump 200VAC, 1P (E4, Sht 2)
D3 Diode Bridge 25A, 800V, 1Ph (C1, Sht 2)
NE1 Neon indicator, rear panel, 220VAC (C1, Sht 1)
FAN1 Fan, Coolant, 24 VDC (F4, Sht 2) NE2 Neon indicator, internal, 220VAC (C1, Sht 1)
FAN3 Fan, Chopper, 24 VDC (A8, Sht 1)
FL1 Flow sensor (B5, Sht 2) R7 Resistor, 1K ,30W (E2, Sht 2)
T1 Aux Transformer (D-F1, Sht 2) E

Isense_W
GNDW
+15Vw
I_senseP
-15Vw
GND_C
GNDP
Iref_G
P_ena
P_ref
CN33 CN3 CN4

2
5
PILOT DEMAND >
/PILOT ENABLE >
Art # A-07012_AB
AA ECO-B402
AB ECO-B448
DAT 2/26/07
DAT 4/13/07
Industrial Park #2
Assy No:
Scale Supersedes
F

Date:
Drawn: References
1 of 2
08:11:44
Last Modified: Wednesday, October 31, 2007 150/200A Power Supply 600V CSA (Chopper) D 42X1219
6 7 8 9 10

APPENDIX 11: Schematic, CSA 600V Unit Cont.
1 2 3 4 5
To PCB7 CN2-1
To PCB7 CN2-2
To PCB7 CN2-4
To PCB7 CN2-5
(F1 Sht 1)
(F1 Sht 1)
(F1 Sht 1)
(F1 Sht 1)
(F2 Sht 1)
(F2 Sht 1)
To T1 PRI - 0
To PCB7 TB3

2
CN9
1
INDICATOR
(on PCB6)
TO AC
3 LEVEL
4
5
MC1 MC3
2
MC2
PILOT
CONTACTOR
+15V
+15V
B MC1 AUX
1 1
2 2
1 1
2 2
3 3
MC3 AUX
TH1
R G B
t
GND
SIG
+V
COOLANT TEMP LSW1-1
(ON COOLANT FL1
SW_LIQUID_LEVEL_NC
CCM MODULE
D3
C
AC
P1
+
C3 +
(A7, Sht 1) I/O PCB
CN2
1
N2
AC

TB3 TP2 29-41 VDC
TP3 +15VDC
TB4
+ TP4
230 (not used) RY1
+5VDC
TP5 -15VDC
600
TP11 NEG ARC VOLTS
TP13 CUT DEM to PS
(C2, Sht 1) CN9
600_A 1
600
T1 230_A 230 RELCOL_0
TP6 +15VDC_ISO
2 +
C.P2 TP7 -15VDC_ISO
COM_A 3
COM ISOLATED
CN10
1
600
0___
230
D1 GAS_ON
C.P3 2
COM
24_ 3 D2 E-STOP_PS
220
0__
C.P4 RELAY PCB CN8
D15 PSR
0___ 24. 1
+15V
AC24V-GCM
(D9, A10) 2
0_
RY5 RY4 RY3
0V-A (24V ret)
/FAN D23 CNC_START
C.P5 3
120. AC120V-GCM 4
/RAS
D26 HOLD_START
(D9, A10)
E 110 2 2
3 3
1K 30W
4 4 0V-RAS
0..
2 2 2 2
MOT1
3 3 3 3
RY4 CN10
0.
C.P8 1 1 1 + -
TB1
2 2 2
CPU PCB
100
FAN + (24 VDC)
sht 1 TB2 4
0,,
C.P6
6
13 D13 +5V
AC13V @ 2A CN12
1
F 0,
1 DC 15V
2
2 DC 0V
CN11
Art # A-07013_AB
1 2 3 4 5

6 7 8 9 10
INTERNAL TERMINAL
STRIP TB3
PCB6 DISPLAY (Not in all units)
WK-5603 0V-A (24V ret) 1
24 VAC @ 1A
AC24V-GCM 2
(E2)
GREEN AC 0V-B (120V ret) 3
120 VAC @ 100ma.
1
+15V 1
YELLOW TEMP 5 A
2
/ AC 2
6
3
/ TEMP 3 GREEN 7
/ GAS - COOLANT GAS
4 4
WORK 8
(C9, sht 1)
5
/ DC 5
GREEN
DC 9 UNDIVIDED ARC VOLTS
6
/ STATUS 6
10 FOR HEIGHT CONTROLS
RED 11
STATUS
NEG ARC VOLTS 12
(A9, sht 1)
POWER SUPPLY
REAR PANEL
J54-REMOTE HMI
1 JUMPER IN
REMOTE
2 HMI
3 B
PILOT (TIP) VOLTS
NEG ARC VOLTS
PLASMA ENABLE
(B9 SHT1) 5
6
(A9 SHT1)
(C9 SHT1) 7
J59-RAS
WORK
3 KEY PLUG
4
J35 26 CKT J36 34 CKT 6

1
6
J6 J9
AC120V-RAS 7
24 VAC RET
TP11 TP12 TP1 (E4) 8

24VAC
/ = active low digital signal 0V-RAS (120V ret) 9

K6-1 10
11
CN10-J35 - 26 Ckt Ribbon Cable K6 12
- ARC V 13 C
2- Cut Demand 14
4- Pilot Demand J5
6- / Start
1
7- / Start2
9- / Pilot Enable Signal - Basic ID 2
10- / HF Enable Used to identify J55-GCM
GCM 1000 present 3
12- / Pump Enable 1
2
13- / Fan Enable 4
3
4
6
19- / Status Lamp 8
J7 9
PLASMA ENABLE 10
CN11-J36 - 34 Ckt Ribbon Cable 1 11
PLASMA ENABLE 12
2 13
1- Output Current Signal PRESS OK (GCM 1000) 14
3- / Arc Transferred (CSR) 3 15
4- / Pilot On 4
AC24V-GCM 16
17
6- Coolant Flow (freq) (E2) 18
7- Coolant Temp (analog) 5 19
9- / Temp OK (Inverter/Chopper) POT HI (GCM1000) 0V-A (24V ret) 20
6 21
10- / Coolant Level OK POT WIPER (GCM1000) 22
7 23
12- Missing Phase DC 15V
POT LOW (GCM 1000)
(F4)
24
25 D
26
15- / Input Volts OK
9 DC 0V 27
16- / Inverter OCR 28
18- / PS ID "00*" J8 29
30
19- / PS ID "0*0" GAS ON
20- / PS ID "*00" 1 AC120V-GCM 31
32
21- E-Stop 2
(E2) 33
34
22- E-Stop E-STOP
3
0V-B (120V ret) 35
29,31,33 - 24 VAC Supply 36
30,32,34 - 24 VAC Return TB1 4
37
E-STOP - 1
E-STOP + 2 J1
STOP 3 1 J15-CNC
4 2 1
START - 5
START / STOP 3 2
+ 6 4 3
START / STOP
DIVIDED ARC VOLTS

E
11 9 8
12 9
10 REMOTE ANALOG
J4
HOLD START - 1 100K
12
HOLD START + 1
2 13 OK TO MOVE
PREFLOW ON - 3 100K
14
PREFLOW ON + 3
4
5 - ARC V
5
6
PILOT ON PSR
7
OUTPUT 7
8
9
OK to MOVE - 10
11 Art # A-07013_AB
AA ECO-B402
AB ECO-B448
DAT 2/26/07
DAT 4/13/07
Industrial Park #2
Assy No:
Scale Supersedes
F

Date:
Drawn: References
2 of 2
08:11:44
Last Modified: Wednesday, October 31, 2007 150/200 A Power Supply 600V CSA (Chopper) D 42X1219
6 7 8 9 10

APPENDIX 12: Publication History
Manual No. 0-4816

Cover Date Rev. Change(s)
March 16, 2006 AA First issue
August 30, 2006 AA.01 Added “Licensed Under U.S. Patent No. 5,070,227 to the copyright page per ECO
B201. Corrected art on pages 3-35, 5-2 and 6-13 removing ref. to de-ionizer bag and
strainer.
Oct. 10, 2006 AB.01 Added inverter module part numbers for 400V, 400V CE and 600V.
Jan. 10, 2007 AC.01 Updated Error codes in section 4 and added notice to update to Firmware revision
2.4 or later.
Mar. 5, 2007 AD.01 Added CCM page in spare parts section 6 to show original CCM.
Mar. 13, 2007 AE.01 Corrected Switch setting error page 3-5 for SW8-2.
Mar. 28, 2007 AF.01 Updated the Gas Requirement chart section 2.
July 10, 2007 AG.01 Added GCM, RAS and TVA mounting dimensions per ECOB514.
Oct. 15, 2007 AH Updated part numbers for Pump and Motor per ECOB444 in ssection 6.
Oct. 29, 2007 AI Updated o-ring part number per ECOB467 and added star grounding art in section
3 per ECOB653.
Jan. 14, 2008 AJ Added flow meter replacement parts per ECOB704. Updated schematics per
ECOB402
Jan. 28, 2008 AK Per ECOB738 added GCM plumbing diagram.
Feb. 5, 2008 AL Per ECOB646 added input terminal strip information to sections 3 and 6.
Mar. 14, 2008 AM Per ECOB844 updated section 4.
Apr. 11, 2008 AN Per ECOB475 updated art for GCM PCB on pg.A-5 and multiple additions and
corrections to sections 3, 4 and 6. Also added pilot transfer retry info switch
setting per ECOB799 pg. 3-16
July 24, 2008 AO Per ECOB1007 updated connection info for negative cable to the RAS section 3.
Nov. 11, 2008 AP Updated section 3 per ECOB1163 to show new single shielded leads. Also updated
some sheetmetal repair parts Catalog numbers from section 6.
Aug. 26, 2010 AQ Update RAS installation and replacement parts list sections 3 and 6 per
ECOB1704. Updated external sheet metal in section 6 per ECOB1737.
NOTE
The date and Revision letters on the manual cover indicate the most recent revision of the manual.

This Page Intentionally Blank
U.S. Customer Care: ARCAIR ® / STOODY ® / THERMAL ARC ® / THERMAL DYNAMICS ® / TWECO ® / VICTOR ®................... 800-426-1888 / FAX 800-535-0557
FIREPOWER ® ................. 800-858-4232 / FAX 800-535-0557 TDC AUTOMATION .................. 866-279-2628 / FAX 800-535-0557
TURBOTORCH ® ............. 800-238-0282 / FAX 800-535-0557 VICTOR MEDICAL .................... 800-382-8187 / FAX 800-535-0557
VICTOR SPECIALTY PRODUCTS ................... 800-569-0547 / FAX 800-535-0557
Canada Customer Care: 905-827-4515 / FAX 800-588-1714 • International Customer Care: 940-381-1212 / FAX 940-483-8178
CIGWELD Customer Care: 1300-654-674 / FAX 61-3-9474-7391 • www.thermadyne.com
A Global Cutting & Welding Market Leader™

W O R L D H E A D Q UA R T E R S : 16052 Swingley Ridge Road, Suite 300 • St. Louis, Missouri 63017 U. S. A .
THE AMERICAS EUROPE ASIA/PACIFIC

Denton, TX USA Miami, FL USA Chorley, United Kingdom Cikarang, Indonesia Melbourne, Australia Shanghai, China
U.S. Customer Care Sales Office, Latin America Customer Care Customer Care Australia Customer Care Sales Office
Ph: 1-800-426-1888 (tollfree) Ph: 1-954-727-8371 Ph: +44 1257-261755 Ph: 6221-8990-6095 Ph: 1300-654-674 (tollfree) Ph: +86 21-64072626
Fax: 1-800-535-0557 (tollfree) Fax: 1-954-727-8376 Fax: +44 1257-224800 Fax: 6221-893-6067 Ph: 61-3-9474-2988 Fax: +86 21-64483032
International Customer Care Fax: 61-3-9474-7391
Ph: 1-940-381-1212 Oakville, Ontario, Canada Milan, Italy Rawang, Malaysia International Singapore
Fax: 1-940-483-8178 Canada Customer Care Customer Care Customer Care Ph: 61-3-9474-7508 Sales Office
Ph: 1-905-827-4515 Ph: +39 0236546801 Ph: +603 6092-2988 Fax: 61-3-9474-7488 Ph: +65 6832-8066
Fax: 1-800-588-1714 (tollfree) Fax: +39 0236546840 Fax: +603 6092-1085 Fax: +65 6763-5812
Form No. 67-10xx (6/22/10) © 2010 Thermadyne Industries, Inc. www.thermadyne.com Printed in U.S.A.

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20O2

This Operating Manual has been designed to instruct you on the

YOU ARE IN GOOD COMPANY!

We distinguish ourselves from our competition through market-

Above all, we are committed to developing technologically

Plasma Cutting Power Supply, Auto-Cut® 20O2

© Copyright 2006, 2007, 2008, 2009, 2010 by

All rights reserved.

Reproduction of this work, in whole or in part, without written per-

Printed in the United States of America

Licensed under U. S. Patent No. 5,070,227

Original Publication Date: March 16, 2006

Where Purchased: ___________________________________

Power Supply Serial #:_______________________________

Torch Serial #:_______________________________________

SECTION 2: SPECIFICATIONS ................................................................................................. 2-1

SECTION 3: INSTALLATION ...................................................................................................... 3-1

SECTION 4: OPERATION .......................................................................................................... 4-1

SECTION 5: MAINTENANCE .................................................................................................... 5-1

SECTION 6: REPLACEMENT ASSEMBLIES & PARTS ........................................................... 6-1

SECTION 7: TORCH MAINTENANCE .................................................................................. 7-1

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: CCM CPU Board Layout ...................................................................................... A-6

APPENDIX 6: CCM Input / Output PCB Layout ........................................................................ A-7

APPENDIX 7: CNC - Control Module PCB Connections ............................................................ A-8

APPENDIX 8: Schematic, 230-460V Unit ................................................................................. A-12

APPENDIX 8: Schematic, 230-460V Unit Cont. ....................................................................... A-14

APPENDIX 9: Schematic, CCC 400V Unit ............................................................................... A-16

APPENDIX 9: Schematic, CCC 400V Unit Cont. ...................................................................... A-18

APPENDIX 10: Schematic, CE 400V Unit ................................................................................ A-20

APPENDIX 10: Schematic, CE 400V Unit Cont. ...................................................................... A-22

APPENDIX 11: Schematic, CSA 600V Unit ............................................................................. A-24

APPENDIX 11: Schematic, CSA 600V Unit Cont. .................................................................... A-26

APPENDIX 12: Publication History ......................................................................................... A-28

• Be sure there is no combustible or flammable material in the

Manual 0-4816 Auto-Cut 2002 1-3

1-4 Manual 0-4816 Auto-Cut 2002

Manual 0-4816 Auto-Cut 2002 1-5

National Standard and Technical Specifications

* CENELEC EN50199 EMC Product Standard for Arc Welding Equipment.

Manufacturers responsible representative: Steve Ward

1-6 Manual 0-4816 Auto-Cut 2002

THIS WARRANTY IS INVALID IF THE PRODUCT IS SOLD BY NON-AUTHORIZED PERSONS.

Torch And Leads

XTTM-300 / XTTM-301 Torch (Excluding Consumable Parts) 1 Year 1 Year

Repair/Replacement Parts 90 Days 90 Days

Effective August 19, 2005

Manual 0-4816 Auto-Cut 2002 1-7

1-8 Manual 0-4816 Auto-Cut 2002

2.01 General Description Of The System

2.02 Plasma Power Supply

2.03 Remote Arc Starter

2.04 Gas Control Module

2.05 Conventional Plasma Cutting Torch

Manual No. 0-4816 Auto-Cut 2002 2-1 SPECIFICATIONS

Auto-Cut® 20O2 Power Supply Specifications

Auto-Cut 20O2 Power Supply Electrical Inputs

XTTM-301 Torch Data (with Auto-Cut® 20O2 Power Supply)

Manual No. 0-4816 Auto-Cut 2002 2-2 SPECIFICATIONS

175’ / 53.3 m Maximum Length