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AUTO-CUT 300 XT
PLASMA CUTTING SYSTEM
™
380V
Operating
Manual
Revision:
AG
Issue Date:
January 14, 2016
Manual No.:
0-5261
ThermalDynamics.com
®
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 1-800-752-7622, 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.
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 plasma and welding industry.
!
WARNING
Read and understand this entire Manual and your employer’s safety practices before installing, operating, or servicing the equipment.
While the information contained in this Manual represents the Manufacturer’s best judgement, the Manufacturer assumes no liability for its use.
Plasma Cutting Power Supply, Auto-Cut ® 300 XT™
Operating Manual No. 0-5261
Published by:
Thermal Dynamics Corporation.
2800 Airport Rd.
Denton, Texas 76207 www.thermal-dynamics.com
© Copyright 2013, 2014, 2015, 2016 by
Thermal Dynamics Corporation.
All rights reserved.
Reproduction of this work, in whole or in part, without written permission 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, accident, or any other cause.
For Printing Material Specification refer to document 47x1927.
Publication Date: April 17, 2013
Revision Date: January 14, 2016
Record the following information for Warranty purposes:
Where Purchased: ___________________________________
Purchase Date:______________________________________
Power Supply Serial #:_______________________________
Torch Serial #:_______________________________________
Be sure this information reaches the operator.
You can get extra copies through your supplier.
CAUTION
These INSTRUCTIONS are for experienced operators. If you are not fully familiar with the principles of operation and safe practices for arc welding and cutting equipment, we urge you to read our booklet, “Precautions and Safe Practices for Arc Welding,
Cutting, and Gouging,” Booklet 0-5407. Do NOT permit untrained persons to install, operate, or maintain this equipment. Do NOT attempt to install or operate this equipment until you have read and fully understand these instructions. If you do not fully understand these instructions, contact your supplier for further information. Be sure to read the Safety Precautions before installing or operating this equipment.
USER RESPONSIBILITY
This equipment will perform in conformity with the description thereof contained in this manual and accompanying labels and/or inserts when installed, operated, maintained and repaired in accordance with the instructions provided. This equipment must be checked periodically. Malfunctioning or poorly maintained equipment should not be used. Parts that are broken, missing, worn, distorted or contaminated should be replaced immediately. Should such repair or replacement become necessary, the manufacturer recommends that a telephone or written request for service advice be made to the
Authorized Distributor from whom it was purchased.
This equipment or any of its parts should not be altered without the prior written approval of the manufacturer. The user of this equipment shall have the sole responsibility for any malfunction which results from improper use, faulty maintenance, damage, improper repair or alteration by anyone other than the manufacturer or a service facility designated by the manufacturer.
!
READ AND UNDERSTAND THE INSTRUCTION MANUAL BEFORE INSTALLING OR
OPERATING.
PROTECT YOURSELF AN D OTHERS!
ASSUREZ-VOUS QUE CETTE INFORMATION EST DISTRIBUÉE À L’OPÉRATEUR.
VOUS POUVEZ OBTENIR DES COPIES SUPPLÉMENTAIRES CHEZ VOTRE FOURNISSEUR.
ATTENTION
Les INSTRUCTIONS suivantes sont destinées aux opérateurs qualifiés seulement.
Si vous n’avez pas une connaissance approfondie des principes de fonctionnement et des règles de sécurité pour le soudage à l’arc et l’équipement de coupage, nous vous suggérons de lire notre brochure « Precautions and Safe Practices for Arc Welding, Cutting and Gouging, » Brochure 0-5407. Ne permettez PAS aux personnes non qualifiées d’installer, d’opérer ou de faire l’entretien de cet équipement. Ne tentez
PAS d’installer ou d’opérer cet équipement avant de lire et de bien comprendre ces instructions. Si vous ne comprenez pas bien les instructions, communiquez avec votre fournisseur pour plus de renseignements. Assurez-vous de lire les Règles de
Sécurité avant d’installer ou d’opérer cet équipement.
RESPONSABILITÉS DE L’UTILISATEUR
Cet équipement opérera conformément à la description contenue dans ce manuel, les étiquettes d’accompagnement et/ ou les feuillets d’information si l’équipement est installé, opéré, entretenu et réparé selon les instructions fournies. Vous devez faire une vérification périodique de l’équipement. Ne jamais utiliser un équipement qui ne fonctionne pas bien ou n’est pas bien entretenu. Les pièces qui sont brisées, usées, déformées ou contaminées doivent être remplacées immédiatement. Dans le cas où une réparation ou un remplacement est nécessaire, il est recommandé par le fabricant de faire une demande de conseil de service écrite ou par téléphone chez le Distributeur Autorisé de votre équipement.
Cet équipement ou ses pièces ne doivent pas être modifiés sans permission préalable écrite par le fabricant. L’utilisateur de l’équipement sera le seul responsable de toute défaillance résultant d’une utilisation incorrecte, un entretien fautif, des dommages, une réparation incorrecte ou une modification par une personne autre que le fabricant ou un centre de service désigné par le fabricant.
!
ASSUREZ-VOUS DE LIRE ET DE COMPRENDRE LE MANUEL D’UTILISATION AVANT
D’INSTALLER OU D’OPÉRER L’UNITÉ.
PROTÉGEZ-VOUS ET LES AUTRES!
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TABLE OF CONTENTS
1.02 Précautions de sécurité - FRENCH CANADIAN ...............................................1-6
2.05 Power Supply Specifications & Electrical Requirements ...................................2-2
3.10 Cables for CNC, Remote Arc Starter/Gas Control ..........................................3-11
3.11 Set Switches on the Command - Control Module ...........................................3-12
3.13 Connect Torch Leads to the Gas Control Module / Arc Starter .......................3-15
TABLE OF CONTENTS
6.04 Power Supply Replacement Parts - Lower Right Side ......................................6-4
6.05 Power Supply Replacement Parts - Upper Right Side ......................................6-5
6.07 Power Supply Replacement Parts RAS - GCM 1000 XT .................................6-7
6.08 Power Supply Replacement Parts - Rear Panel ...............................................6-8
6.09 Power Supply Replacement Parts - Front of GCM1000 XT ..............................6-9
APPENDIX 8: MAIN INVERTER BOTTOM PCB LAYOUT .................................................. A-22
TABLE OF CONTENTS
INTERNATIONAL CONTACT INFORMATION.........................................................BACK COVER
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TABLE OF CONTENTS
AUTO-CUT 300 XT
SECTION 1: SAFETY
1.01 Safety Precautions - ENGLISH
WARNING: These Safety Precautions are for your protection. They summarize precautionary information from the references listed in Additional Safety Information section. Before performing any installation or operating procedures, be sure to read and follow the safety precautions listed below as well as all other manuals, material safety data sheets, labels, etc. Failure to observe Safety Precautions can result in injury or death.
PROTECT YOURSELF AND OTHERS -- Some welding, cutting, and gouging processes are noisy and require ear protection. The arc, like the sun, emits ultraviolet (UV) and other radiation and can injure skin and eyes. Hot metal can cause burns. Training in the proper use of the processes and equipment is essential to prevent accidents. Therefore:
1. Always wear safety glasses with side shields in any work area, even if welding helmets, face shields, and goggles are also required.
2. Use a face shield fitted with the correct filter and cover plates to protect your eyes, face, neck, and ears from sparks and rays of the arc when operating or observing operations. Warn bystanders not to watch the arc and not to expose themselves to the rays of the electric-arc or hot metal.
3. Wear flameproof gauntlet type gloves, heavy long-sleeve shirt, cuffless trousers, high-topped shoes, and a welding helmet or cap for hair protection, to protect against arc rays and hot sparks or hot metal. A flameproof apron may also be desirable as protection against radiated heat and sparks.
4. Hot sparks or metal can lodge in rolled up sleeves, trouser cuffs, or pockets. Sleeves and collars should be kept buttoned, and open pockets eliminated from the front of clothing.
5. Protect other personnel from arc rays and hot sparks with a suitable non-flammable partition or curtains.
6. Use goggles over safety glasses when chipping slag or grinding. Chipped slag may be hot and can fly far.
Bystanders should also wear goggles over safety glasses.
FIRES AND EXPLOSIONS -- Heat from flames and arcs can start fires. Hot slag or sparks can also cause fires and explosions. Therefore:
1. Remove all combustible materials well away from the work area or cover the materials with a protective non-flammable covering. Combustible materials include wood, cloth, sawdust, liquid and gas fuels, solvents, paints and coatings, paper, etc.
2. Hot sparks or hot metal can fall through cracks or crevices in floors or wall openings and cause a hidden smoldering fire or fires on the floor below. Make certain that such openings are protected from hot sparks and metal.“
3. Do not weld, cut or perform other hot work until the work piece has been completely cleaned so that there are no substances on the work piece which might produce flammable or toxic vapors. Do not do hot work on closed containers. They may explode.
4. Have fire extinguishing equipment handy for instant use, such as a garden hose, water pail, sand bucket, or portable fire extinguisher. Be sure you are trained in its use.
5. Do not use equipment beyond its ratings. For example, overloaded welding cable can overheat and create a fire hazard.
6. After completing operations, inspect the work area to make certain there are no hot sparks or hot metal which could cause a later fire. Use fire watchers when necessary.
7. For additional information, refer to NFPA Standard 51B, “Fire Prevention in Use of Cutting and Welding
Processes”, available from the National Fire Protection Association, Battery march Park, Quincy, MA 02269.
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ELECTRICAL SHOCK -- Contact with live electrical parts and ground can cause severe injury or death.
DO NOT use AC welding current in damp areas, if movement is confined, or if there is danger of falling.
1. Be sure the power source frame (chassis) is connected to the ground system of the input power.
2. Connect the work piece to a good electrical ground.
3. Connect the work cable to the work piece. A poor or missing connection can expose you or others to a fatal shock.
4. Use well-maintained equipment. Replace worn or damaged cables.
5. Keep everything dry, including clothing, work area, cables, torch/electrode holder, and power source.
6. Make sure that all parts of your body are insulated from work and from ground.
7. Do not stand directly on metal or the earth while working in tight quarters or a damp area; stand on dry boards or an insulating platform and wear rubber-soled shoes.
8. Put on dry, hole-free gloves before turning on the power.
9. Turn off the power before removing your gloves.
10. Refer to ANSI/ASC Standard Z49.1 (listed on next page) for specific grounding recommendations. Do not mistake the work lead for a ground cable.
ELECTRIC AND MAGNETIC FIELDS — May be dangerous. Electric current flowing through any conductor causes localized Electric and Magnetic Fields (EMF ). Welding and cutting current creates EMF around welding cables and welding machines. Therefore:
1. Welders having pacemakers should consult their physician before welding. EMF may interfere with some pacemakers.
2. Exposure to EMF may have other health effects which are unknown.
3. Welders should use the following procedures to minimize exposure to EMF:
A. Route the electrode and work cables together. Secure them with tape when possible.
B. Never coil the torch or work cable around your body.
C. Do not place your body between the torch and work cables. Route cables on the same side of your body.
D. Connect the work cable to the work piece as close as possible to the area being welded.
E. Keep welding power source and cables as far away from your body as possible.
FUMES AND GASES -- Fumes and gases, can cause discomfort or harm, particularly in confined spaces. Do not breathe fumes and gases. Shielding gases can cause asphyxiation.
Therefore:
1. Always provide adequate ventilation in the work area by natural or mechanical means. Do not weld, cut, or gouge on materials such as galvanized steel, stainless steel, copper, zinc, lead, beryllium, or cadmium unless positive mechanical ventilation is provided. Do not breathe fumes from these materials.
2. Do not operate near degreasing and spraying operations. The heat or arc rays can react with chlorinated hydrocarbon vapors to form phosgene, a highly toxic gas, and other irritant gases.
3. If you develop momentary eye, nose, or throat irritation while operating, this is an indication that ventilation is not adequate. Stop work and take necessary steps to improve ventilation in the work area. Do not continue to operate if physical discomfort persists.
4. Refer to ANSI/ASC Standard Z49.1 (see listing below) for specific ventilation recommendations.
5. WARNING: This product contains chemicals, including lead, known to the State of California to cause birth defects and other reproductive harm. Wash hands after handling.
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AUTO-CUT 300 XT
CYLINDER HANDLING -- Cylinders, if mishandled, can rupture and violently release gas. Sudden rupture of cylinder, valve, or relief device can injure or kill. Therefore:
1. Use the proper gas for the process and use the proper pressure reducing regulator designed to operate from the compressed gas cylinder. Do not use adaptors. Maintain hoses and fittings in good condition.
Follow manufacturer’s operating instructions for mounting regulator to a compressed gas cylinder.
2. Always secure cylinders in an upright position by chain or strap to suitable hand trucks, undercarriages, benches, walls, post, or racks. Never secure cylinders to work tables or fixtures where they may become part of an electrical circuit.
3. When not in use, keep cylinder valves closed. Have valve protection cap in place if regulator is not connected. Secure and move cylinders by using suitable hand trucks. Avoid rough handling of cylinders.
4. Locate cylinders away from heat, sparks, and flames. Never strike an arc on a cylinder.
5. For additional information, refer to CGA Standard P-1, “Precautions for Safe Handling of Compressed
Gases in Cylinders”, which is available from Compressed Gas Association, 1235 Jefferson Davis Highway,
Arlington, VA 22202.
EQUIPMENT MAINTENANCE -- Faulty or improperly maintained equipment can cause injury or death.
Therefore:
1. Always have qualified personnel perform the installation, troubleshooting, and maintenance work. Do not perform any electrical work unless you are qualified to perform such work.
2. Before performing any maintenance work inside a power source, disconnect the power source from the incoming electrical power.
3. Maintain cables, grounding wire, connections, power cord, and power supply in safe working order. Do not operate any equipment in faulty condition.
4. Do not abuse any equipment or accessories. Keep equipment away from heat sources such as furnaces, wet conditions such as water puddles, oil or grease, corrosive atmospheres and inclement weather.
5. Keep all safety devices and cabinet covers in position and in good repair.
6. Use equipment only for its intended purpose. Do not modify it in any manner.
ADDITIONAL SAFETY INFORMATION -- For more information on safe practices for electric arc welding and cutting equipment, ask your supplier for a copy of “Precautions and Safe Practices for Arc Welding,
Cutting and Gouging”, Form 52-529.
The following publications, which are available from the American Welding Society, 550 N.W. LeJuene Road,
Miami, FL 33126, are recommended to you:
1. ANSI/ASC Z49.1 - “Safety in Welding and Cutting”.
2. AWS C5.1 - “Recommended Practices for Plasma Arc Welding”.
3. AWS C5.2 - “Recommended Practices for Plasma Arc Cutting”.
4. AWS C5.3 - “Recommended Practices for Air Carbon Arc Gouging and Cutting”.
5. AWS C5.5 - “Recommended Practices for Gas Tungsten Arc Welding“.
6. AWS C5.6 - “Recommended Practices for Gas Metal Arc Welding”.
7. AWS SP - “Safe Practices” - Reprint, Welding Handbook.
8. ANSI/AWS F4.1, “Recommended Safe Practices for Welding and Cutting of Containers That Have Held
Hazardous Substances.”
9. CSA Standard - W117.2 = Safety in Welding, Cutting and Allied Processes.
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AUTO-CUT 300 XT
Meaning of symbols - As used throughout this manual: Means Attention! Be Alert! Your safety is involved.
DANGER
Means immediate hazards which, if not avoided, will result in immediate, serious personal injury or loss of life.
CAUTION
Means potential hazards which could result in personal injury or loss of life.
WARNING
Means hazards which could result in minor personal injury.
Enclosure Class
The IP code indicates the enclosure class, i.e. the degree of protection against penetration by solid objects or water.
Protection is provided against touch with a finger, penetration of solid objects greater than 12mm and against spraying water up to 60 degrees from vertical. Equipment marked IP21S may be stored, but is not intended to be used outside during precipitation unless sheltered.
CAUTION
This product is solely intended for plasma cutting. Any other use may result in personal injury and / or equipment damage.
CAUTION
If equipment is placed on a surface that slopes more than 15°, toppling over may occur. Personal injury and
/ or significant damage to equipment is possible.
15 °
Art# A-12726
CAUTION
To avoid personal injury and/or equipment damage, lift using method and attachment points shown here.
Art# A-12736
1-4 SAFETY INSTRUCTIONS 0-5261
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AUTO-CUT 300 XT
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AUTO-CUT 300 XT
1.02 Précautions de sécurité - FRENCH CANADIAN
AVERTISSEMENT : Ces règles de sécurité ont pour but d’assurer votre protection. Ils récapitulent les informations de précaution provenant des références dans la section des Informations de sécurité supplémentaires. Avant de procéder à l’installation ou d’utiliser l’unité, assurez-vous de lire et de suivre les précautions de sécurité ci-dessous, dans les manuels, les fiches d’information sur la sécurité du matériel et sur les étiquettes, etc. Tout défaut d’observer ces précautions de sécurité peut entraîner des blessures graves ou mortelles.
PROTÉGEZ-VOUS -- Les processus de soudage, de coupage et de gougeage produisent un niveau de bruit élevé et exige l’emploi d’une protection auditive. L’arc, tout comme le soleil, émet des rayons ultraviolets en plus d’autre rayons qui peuvent causer des blessures à la peau et les yeux. Le métal incandescent peut causer des brûlures. Une formation reliée à l’usage des processus et de l’équipement est essentielle pour prévenir les accidents. Par conséquent:
1. Portez des lunettes protectrices munies d’écrans latéraux lorsque vous êtes dans l’aire de travail, même si vous devez porter un casque de soudeur, un écran facial ou des lunettes étanches.
2. Portez un écran facial muni de verres filtrants et de plaques protectrices appropriées afin de protéger vos yeux, votre visage, votre cou et vos oreilles des étincelles et des rayons de l’arc lors d’une opération ou lorsque vous observez une opération. Avertissez les personnes se trouvant à proximité de ne pas regarder l’arc et de ne pas s’exposer aux rayons de l’arc électrique ou le métal incandescent.
3. Portez des gants ignifugiés à crispin, une chemise épaisse à manches longues, des pantalons sans rebord et des chaussures montantes afin de vous protéger des rayons de l’arc, des étincelles et du métal incandescent, en plus d’un casque de soudeur ou casquette pour protéger vos cheveux. Il est également recommandé de porter un tablier ininflammable afin de vous protéger des étincelles et de la chaleur par rayonnement.
4. Les étincelles et les projections de métal incandescent risquent de se loger dans les manches retroussées, les rebords de pantalons ou les poches. Il est recommandé de garder boutonnés le col et les manches et de porter des vêtements sans poches en avant.
5. Protégez toute personne se trouvant à proximité des étincelles et des rayons de l’arc à l’aide d’un rideau ou d’une cloison ininflammable.
6. Portez des lunettes étanches par dessus vos lunettes de sécurité lors des opérations d’écaillage ou de meulage du laitier. Les écailles de laitier incandescent peuvent être projetées à des distances considérables. Les personnes se trouvant à proximité doivent également porter des lunettes étanches par dessus leur lunettes de sécurité.
INCENDIES ET EXPLOSIONS -- La chaleur provenant des flammes ou de l’arc peut provoquer un incendie. Le laitier incandescent ou les étincelles peuvent également provoquer un incendie ou une explosion.
Par conséquent :
1. Éloignez suffisamment tous les matériaux combustibles de l’aire de travail et recouvrez les matériaux avec un revêtement protecteur ininflammable. Les matériaux combustibles incluent le bois, les vêtements, la sciure, le gaz et les liquides combustibles, les solvants, les peintures et les revêtements, le papier, etc.
2. Les étincelles et les projections de métal incandescent peuvent tomber dans les fissures dans les planchers ou dans les ouvertures des murs et déclencher un incendie couvant à l’étage inférieur Assurez-vous que ces ouvertures sont bien protégées des étincelles et du métal incandescent.
3. N’exécutez pas de soudure, de coupe ou autre travail à chaud avant d’avoir complètement nettoyé la surface de la pièce à traiter de façon à ce qu’il n’ait aucune substance présente qui pourrait produire des vapeurs inflammables ou toxiques. N’exécutez pas de travail à chaud sur des contenants fermés car ces derniers pourraient exploser.
4. Assurez-vous qu’un équipement d’extinction d’incendie est disponible et prêt à servir, tel qu’un tuyau d’arrosage, un seau d’eau, un seau de sable ou un extincteur portatif. Assurez-vous d’être bien instruit par rapport à l’usage de cet équipement.
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AUTO-CUT 300 XT
5. Assurez-vous de ne pas excéder la capacité de l’équipement. Par exemple, un câble de soudage surchargé peut surchauffer et provoquer un incendie.
6. Une fois les opérations terminées, inspectez l’aire de travail pour assurer qu’aucune étincelle ou projection de métal incandescent ne risque de provoquer un incendie ultérieurement. Employez des guetteurs d’incendie au besoin.
7. Pour obtenir des informations supplémentaires, consultez le NFPA Standard 51B, “Fire Prevention in Use of Cutting and Welding Processes”, disponible au National Fire Protection Association, Batterymarch
Park, Quincy, MA 02269.
CHOC ÉLECTRI QUE -- Le contact avec des pièces électriques ou les pièces de mise à la terre sous tension peut causer des blessures graves ou mortelles. NE PAS utiliser un courant de soudage c.a. dans un endroit humide, en espace restreint ou si un danger de chute se pose.
1. Assurez-vous que le châssis de la source d’alimentation est branché au système de mise à la terre de l’alimentation d’entrée.
2. Branchez la pièce à traiter à une bonne mise de terre électrique.
3. Branchez le câble de masse à la pièce à traiter et assurez une bonne connexion afin d’éviter le risque de choc électrique mortel.
4. Utilisez toujours un équipement correctement entretenu. Remplacez les câbles usés ou endommagés.
5. Veillez à garder votre environnement sec, incluant les vêtements, l’aire de travail, les câbles, le porteélectrode/torche et la source d’alimentation.
6. Assurez-vous que tout votre corps est bien isolé de la pièce à traiter et des pièces de la mise à la terre.
7. Si vous devez effectuer votre travail dans un espace restreint ou humide, ne tenez vous pas directement sur le métal ou sur la terre; tenez-vous sur des planches sèches ou une plate-forme isolée et portez des chaussures à semelles de caoutchouc.
8. Avant de mettre l’équipement sous tension, isolez vos mains avec des gants secs et sans trous.
9. Mettez l’équipement hors tension avant d’enlever vos gants.
10. Consultez ANSI/ASC Standard Z49.1 (listé à la page suivante) pour des recommandations spécifiques concernant les procédures de mise à la terre. Ne pas confondre le câble de masse avec le câble de mise
à la terre.
CHAMPS ÉLECTRIQUES ET MAGNÉTIQUES — comportent un risque de danger. Le courant électrique qui passe dans n’importe quel conducteur produit des champs électriques et magnétiques localisés.
Le soudage et le courant de coupage créent des champs électriques et magnétiques autour des câbles de soudage et l’équipement. Par conséquent :
1. Un soudeur ayant un stimulateur cardiaque doit consulter son médecin avant d’entreprendre une opération de soudage. Les champs électriques et magnétiques peuvent causer des ennuis pour certains stimulateurs cardiaques.
2. L’exposition à des champs électriques et magnétiques peut avoir des effets néfastes inconnus pour la santé.
3. Les soudeurs doivent suivre les procédures suivantes pour minimiser l’exposition aux champs électriques et magnétiques :
A. Acheminez l’électrode et les câbles de masse ensemble. Fixez-les à l’aide d’une bande adhésive lorsque possible.
B. Ne jamais enrouler la torche ou le câble de masse autour de votre corps.
C. Ne jamais vous placer entre la torche et les câbles de masse. Acheminez tous les câbles sur le même côté de votre corps.
D. Branchez le câble de masse à la pièce à traiter le plus près possible de la section à souder.
E. Veillez à garder la source d’alimentation pour le soudage et les câbles à une distance appropriée de votre corps.
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LES VAPEURS ET LES GAZ -- peuvent causer un malaise ou des dommages corporels, plus particulièrement dans les espaces restreints. Ne respirez pas les vapeurs et les gaz. Le gaz de protection risque de causer l’asphyxie.
Par conséquent :
1. Assurez en permanence une ventilation adéquate dans l’aire de travail en maintenant une ventilation naturelle ou à l’aide de moyens mécanique. N’effectuez jamais de travaux de soudage, de coupage ou de gougeage sur des matériaux tels que l’acier galvanisé, l’acier inoxydable, le cuivre, le zinc, le plomb, le berylliym ou le cadmium en l’absence de moyens mécaniques de ventilation efficaces. Ne respirez pas les vapeurs de ces matériaux.
2. N’effectuez jamais de travaux à proximité d’une opération de dégraissage ou de pulvérisation. Lorsque la chaleur ou le rayonnement de l’arc entre en contact avec les vapeurs d’hydrocarbure chloré, ceci peut déclencher la formation de phosgène ou d’autres gaz irritants, tous extrêmement toxiques.
3. Une irritation momentanée des yeux, du nez ou de la gorge au cours d’une opération indique que la ventilation n’est pas adéquate. Cessez votre travail afin de prendre les mesures nécessaires pour améliorer la ventilation dans l’aire de travail. Ne poursuivez pas l’opération si le malaise persiste.
4. Consultez ANSI/ASC Standard Z49.1 (à la page suivante) pour des recommandations spécifiques concernant la ventilation.
5. AVERTISSEMENT : Ce produitcontient des produits chimiques, notamment du plomb, reconnu par l’Étatde la Californie pour causerdes malformations congénitaleset d’autresdommages touchant le système reproductif. Se laver les mainsaprès manipulation.
MANIPULATION DES CYLINDRES -- La manipulation d’un cylindre, sans observer les précautions nécessaires, peut produire des fissures et un échappement dangereux des gaz. Une brisure soudaine du cylindre, de la soupape ou du dispositif de surpression peut causer des blessures graves ou mortelles.
Par conséquent :
1. Utilisez toujours le gaz prévu pour une opération et le détendeur approprié conçu pour utilisation sur les cylindres de gaz comprimé. N’utilisez jamais d’adaptateur. Maintenez en bon état les tuyaux et les raccords. Observez les instructions d’opération du fabricant pour assembler le détendeur sur un cylindre de gaz comprimé.
2. Fixez les cylindres dans une position verticale, à l’aide d’une chaîne ou une sangle, sur un chariot manuel, un châssis de roulement, un banc, un mur, une colonne ou un support convenable. Ne fixez jamais un cylindre à un poste de travail ou toute autre dispositif faisant partie d’un circuit électrique.
3. Lorsque les cylindres ne servent pas, gardez les soupapes fermées. Si le détendeur n’est pas branché, assurez-vous que le bouchon de protection de la soupape est bien en place. Fixez et déplacez les cylindres
à l’aide d’un chariot manuel approprié. Toujours manipuler les cylindres avec soin.
4. Placez les cylindres à une distance appropriée de toute source de chaleur, des étincelles et des flammes.
Ne jamais amorcer l’arc sur un cylindre.
5. Pour de l’information supplémentaire, consultez CGA Standard P-1, “Precautions for Safe Handling of
Compressed Gases in Cylinders”, mis à votre disposition par le Compressed Gas Association, 1235 Jefferson Davis Highway, Arlington, VA 22202.
ENTRETIEN DE L’ÉQUIPEMENT -- Un équipement entretenu de façon défectueuse ou inadéquate peut causer des blessures graves ou mortelles. Par conséquent :
1. Efforcez-vous de toujours confier les tâches d’installation, de dépannage et d’entretien à un personnel qualifié. N’effectuez aucune réparation électrique à moins d’être qualifié à cet effet.
2. Avant de procéder à une tâche d’entretien à l’intérieur de la source d’alimentation, débranchez l’alimentation électrique.
3. Maintenez les câbles, les fils de mise à la terre, les branchements, le cordon d’alimentation et la source d’alimentation en bon état. N’utilisez jamais un équipement s’il présente une défectuosité quelconque.
1-8 SAFETY INSTRUCTIONS 0-5261
AUTO-CUT 300 XT
4. N’utilisez pas l’équipement de façon abusive. Gardez l’équipement à l’écart de toute source de chaleur, notamment des fours, de l’humidité, des flaques d’eau, de l’huile ou de la graisse, des atmosphères corrosives et des intempéries.
5. Laissez en place tous les dispositifs de sécurité et tous les panneaux de la console et maintenez-les en bon état.
6. Utilisez l’équipement conformément à son usage prévu et n’effectuez aucune modification.
INFORMATIONS SUPPLÉMENTAIRES RELATI VES À LA SÉCURITÉ -- Pour obtenir de l’information supplémentaire sur les règles de sécurité à observer pour l’équipement de soudage à l’arc électrique et le coupage, demandez un exemplaire du livret “Precautions and Safe Practices for Arc Welding, Cutting and
Gouging”, Form 52-529.
Les publications suivantes sont également recommandées et mises à votre disposition par l’American Welding
Society, 550 N.W. LeJuene Road, Miami, FL 33126 :
1. ANSI/ASC Z49.1 - “Safety in Welding and Cutting”.
2. AWS C5.1 - “Recommended Practices for Plasma Arc Welding”.
3. AWS C5.2 - “Recommended Practices for Plasma Arc Cutting”.
4. AWS C5.3 - “Recommended Practices for Air Carbon Arc Gouging and Cutting”.
5. AWS C5.5 - “Recommended Practices for Gas Tungsten Arc Welding“.
6. AWS C5.6 - “Recommended Practices for Gas Metal Arc Welding”.
7. AWS SP - “Safe Practices” - Reprint, Welding Handbook.
8. ANSI/AWS F4.1, “Recommended Safe Practices for Welding and Cutting of Containers That Have Held
Hazardous Substances.”
9. CSA Standard - W117.2 = Safety in Welding, Cutting and Allied Processes.
SIGNIFICATION DES SYMBOLES - Ce symbole, utilisé partout dans ce manuel, signifie “Attention” ! Soyez vigilant ! Votre sécurité est en jeu.
DANGER
Signifie un danger immédiat. La situation peut entraîner des blessures graves ou mortelles.
MISE EN GARDE
Signifie un danger potentiel qui peut entraîner des blessures graves ou mortelles.
AVERTISSEMENT
Signifie un danger qui peut entraîner des blessures corporelles mineures.
Classe de protection de l’enveloppe
L’indice de protection (codification IP) indique la classe de protection de l’enveloppe, c’est-à-dire, le degré de protection contre les corps solides étrangers ou l’eau. L’enveloppe protège contre le toucher, la pénétration d’objets solides dont le diamètre dépasse 12 mm et contre l’eau pulvérisée à un angle de jusqu’à 60 degrés de la verticale.
Les équipements portant la marque IP21S peuvent être entreposés à l’extérieur, mais ne sont pas conçus pour
être utilisés à l’extérieur pendant une précipitation à moins d’être à l’abri.
MISE EN GARDE Ce produit a été conçu pour la découpe au plasma seulement. Toute autre utilisation pourrait causer des blessures et/ou endommager l’appareil.
0-5261 SAFETY INSTRUCTIONS 1-9
AUTO-CUT 300 XT
MISE EN GARDE
L’équipement pourrait basculer s’il est placé sur une surface dont la pente dépasse 15°. Vous pourriez vous blesser ou endommager l’équipement de façon importante.
15 °
Art# A-12726
MISE EN GARDE
Soulevez à l’aide de la méthode et des points d’attache illustrés afin d’éviter de vous blesser ou d’endommager l’équipement.
Art# A-12736
1-10 SAFETY INSTRUCTIONS 0-5261
AUTO-CUT 300 XT
SECTION 2: SPECIFICATIONS
2.01 General Description Of The System
A typical Auto-Cut 300 XT™ plasma cutting system includes:
• One Power Supply
• General Purpose Plasma Cutting Torch with Connecting Leads
• Torch Spare Parts Kit
The components are connected at installation.
2.02 Plasma Power Supply
The power supply provides the necessary current for cutting operations, and monitors system performance. The power supply also cools and circulates the liquid coolant for the torch and leads.
2.03 Plasma Cutting Torch
The torch delivers the controlled current to the work through the main arc, causing the metal to be cut.
2.04 System Component Layout
Arc Starter /
Gas Control Module
(GCM-1000XT)
Pilot Return A
Negative
Coolant Supply
Coolant Return
Control Cable
CNC CNC Cable
B
C
D
E
P
Auto-Cut 300XT
Power Supply
K
Control
Cable
F F1
Ground
Cable
Primary power
G: Torch Lead Set, Shielded
- Coolant Supply w/ Negative
- Coolant Return
- Pilot Return
- Plasma Gas
- Shield Gas
Positioning
Tube
Torch
O Work Cable Work
Art # A-11902_AB
0-5261 SPECIFICATIONS 2-1
AUTO-CUT 300 XT
2.05 Power Supply Specifications & Electrical Requirements
300 Amp System
Auto-Cut 300 XT™ Specifications & Design Features
Max OCV (U0) 400 vdc
Minimum Output Current
Max Output Current
Output Voltage
5 Amps
300 Amps
60 - 180 vdc
Duty Cycle Rating
Ambient Temperature for Duty Cycle Rating
Operating range
Power Factor
Cooling
100% @ 300A, 200V, (60kW),
104F° (40°C)
14°F to 122°F (-10°C to + 50°C)
0.93 @ 300 A DC Output
Coolant and Forced Air (Class F)
Input
Voltage Freq.
(Volts) (Hz)
380
IEC 380
50/60
50/60
Auto-Cut 300 XT™ Power Supply
Power Input Current Suggested Sizes (See Note)
3-Ph
(kVA)
3-Ph
(Amps)
Fuse (Amps) Wire (AWG) Wire (mm 2 )
3-Ph 3-Ph 3-Ph
63
71
97
110
150
150
#4
#4
25
25
NOTE!
* Suggested wire size based on United States NFPA 70 National Electrical Code
2011 edition published by the National Fire Prevention Association. Listings are from table 400.5(A)(2) for flexible cord of certain types rated for 75 deg C in ambient temperatures up to 30 deg C. Using wires of lower temperature rating or different insulation type may require larger wire size. Derate for higher ambient.
These are suggestions only. Always refer to your local and national codes that apply to your region for final determination of correct wire type and size.
2-2 SPECIFICATIONS 0-5261
2.06 Power Supply Dimensions
55 inch
1397 mm
27.5 inch
698.5 mm
40.6 inch
1031.2 mm
Art # A-11918
610 lb / 277 kg
AUTO-CUT 300 XT
0-5261 SPECIFICATIONS 2-3
AUTO-CUT 300 XT
2.07 Power Supply Rear Panel Features
J56 Gas Control
J58 Arc Starter
Gas Selection Switch
Plasma Gas - In
Water - In
Shield Gas - In
C.C.M.
J55 To Gas Control
J15 To CNC Control
Customer Optional Port
J59 To Arc Starter
Fuses
Pilot Lead
Work Lead
Negative Return
Coolant Filter
System Earth
Ground
Customer
Optional Port
J54 TSC/Comm
Circuit Breakers
Coolant Return
Coolant Supply
AC Power Lamp
Factory installed
Ground (F)
Customer Port
Input Power
Art # A-11919
2-4 SPECIFICATIONS 0-5261
2.08 Gas Requirements
AUTO-CUT 300 XT
The customer will provide all gases and pressure regulators. Gases must be of high quality. Pressure regulators shall be equipped with stainless-steel diaphragms and installed as close as possible to the Gas Console.
N
O
2
Gas
Auto-Cut 300 XT™ Power Supply: Gas Pressures, Flows, and Quality Requirements
Quality Minimum Pressure Flow
(Oxygen)
99.5% Purity
(Liquid recommended)
120 psi
8.3 bar / 827 kPa
200 scfh (95 lpm)
2
(Nitrogen)
Compressed or Bottled Air
99.5% Purity
(Liquid recommended)
<1000 ppm O
H
2
2
O)
, <32 ppm
Clean, Dry,
Free of Oil (see Note 1)
120 psi
8.3 bar / 827 kPa
120 psi
8.3 bar / 827 kPa
300 scfh (141.6 lpm)
450 scfh (212.4 lpm)
H35 (Argon-Hydrogen)
H35 = 35% Hydrogen,
65% Argon
99.995% Purity
(gas recommended)
120 psi
8.3 bar / 827 kPa
200 scfh (94.4 lpm)
H
2
O (Water) See Note 2 55 psi (3.8 bar) 10 gph (0.6 lpm)
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. Soft tap water with an allowable water hardness of <10 ppm as CaCO3 or less, filtered at 5 microns. Resistivity must be at least 15 k ohm per cm.
Note 3: Water Pressure Regulator No. 8-6118 is recommended to ensure proper water pressure.
2.09 Gas Applications
MATERIAL MILD STEEL STAINLESS STEEL ALUMINUM
OPERATION PLASMA SHIELD PLASMA SHIELD PLASMA SHIELD
55A Cut
Air
O2
Air
Air
Air Air Air Air
100A Cut
Air
O2
Air
Air
Air
N2
H35
Air
H20
N2
Air
N2
H35
Air
H20
N2
200A Cut
300A Cut
Air
O2
Air
Air
Air
Air
Air
N2
H35
Air
Air
H20
N2
Air
Air
N2
H35
Air
Air
H20
N2
Air
0-5261 SPECIFICATIONS 2-5
AUTO-CUT 300 XT
2.10 XT
TM
-301 Torch Specifications
A. Torch Dimensions
End Cap
19"
482.7 mm
Mounting Tube
15.5"
393.8 mm
6.3"
160.1 mm
3.98"
101.1 mm
2.7"
69.6 mm
1.6"
40. mm
Art # A-11538
2.25"
57.15 mm
2.0"
50.8 mm
2.4"
61 mm
1.49"
37.8 mm
2-6 SPECIFICATIONS 0-5261
B. Torch Leads Lengths
C. Torch Parts (Generic Parts Shown)
Torch Lead Assembly
Feet
Lengths
Meters
10
15
25
50
75
100
3.05
4.6
7.6
15.2
22.8
30.4
Shield
Retainer
Shield Cap ibutor
Shield Gas
Tip ibutor
Plasma Gas Electrode
AUTO-CUT 300 XT
Cartridge
Assemble First
Art # A-11915
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 Cooling
Combination of gas stream through torch and liquid cooling.
0-5261 SPECIFICATIONS 2-7
AUTO-CUT 300 XT
F. XT TM -301 Torch Data (with Auto-Cut 300 XT™ Power Supply)
XT TM -301 Torch Ratings
(when used with Auto-Cut 300 XT™Power Supply)
Ambient
Temperature
Duty Cycle
104° F
40° C
100% @ 300 Amps
Maximum Current
Voltage (V peak
)
Arc Striking Voltage
Current
300 Amps
500V
10kV
Up to 300 Amps, DC,
Straight Polarity (See Note)
XT TM -301 Torch Gas Specifications
Plasma Gases:
Compressed Air, Oxygen,
Nitrogen, H35, F5
Shield Gases:
Compressed Air, Oxygen,
Nitrogen, Water
Operating Pressure
Maximum Input Pressure
Gas flow
Power Supply used with:
120 psi ± 10 psi
8.3 bar ± 0.7 bar
135 psi / 9.3 bar
10 - 450 scfh / 283-12743 l/hr
Auto-Cut 300 XT
2-8 SPECIFICATIONS 0-5261
AUTO-CUT 300 XT
SECTION 3: INSTALLATION
3.01 Installation Requirements
Electric Supply
The electrical supply network, the gas and water supply system must meet local safety standards. This conformity must be checked by qualified personnel.
Input
Voltage Freq.
(Volts)
380
IEC 380
(Hz)
50/60
50/60
Auto-Cut 300 XT™ Power Supply
Power Input Current Suggested Sizes (See Note)
3-Ph
(kVA)
63
71
3-Ph
(Amps)
97
110
Fuse (Amps) Wire (AWG) Wire (mm
3-Ph
150
150
3-Ph
#4
#4
3-Ph
25
25
2 )
NOTE!
* Suggested wire size based on United States NFPA 70 National Electrical Code 2011 edition published by the National Fire Prevention Association. Listings are from table
400.5(A)(2) for flexible cord of certain types rated for 75 deg C in ambient temperatures up to 30 deg C. Using wires of lower temperature rating or different insulation type may require larger wire size. Derate for higher ambient.
These are suggestions only. Always refer to your local and national codes that apply to your region for final determination of correct wire type and size.
!
CAUTION
Fuse and wire sizes are for reference only. The installation must conform to national and local codes for the type and method of wire being used.
Gas Supply
The customer must supply all gas 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.
Cooling System Requirements
Coolant must be added to the system on installation. The amount required varies with torch leads length.
Thermal Dynamics recommends the use of its coolants 7-3580 and 7-3581 (for low temperatures).
Coolant Capabilities
Cat. Number and Mixture Mixture
7-3580 ‘Extra-Cool TM ’ 25 / 75
7-3581 ‘Ultra-Cool TM ’
7-3582 ‘Extreme Cool
TM
’
50 / 50
Concentrate*
* For mixing with D-I Cool
TM
7-3583
Protects To
10° F / -12° C
27° F / -33° C
-65° F / -51° C
0-5261 INSTALLATION 3-1
AUTO-CUT 300 XT
3.02 Cables and Leads Identification
Refer to section 3.05 and 3.06 for ground connections and ground cables.
Arc Starter /
Gas Control Module
(GCM-1000XT)
Pilot Return
Negative
Coolant Supply
Coolant Return
Control Cable
A
B
C
D
E
Auto-Cut 300XT
Power Supply
K
Control
Cable
F
Ground
Cable
Primary power
F1
CNC CNC Cable P
O Work Cable
Art # A-11902_AB
G: Torch Lead Set, Shielded
- Coolant Supply w/ Negative
- Coolant Return
- Pilot Return
- Plasma Gas
- Shield Gas
Positioning
Tube
Torch
Work
3-2 INSTALLATION 0-5261
3.03 Cables & Leads Identification
#8 AWG Cable
A
2/0 (70 mm ) Cable
B
C
D
Green
Red
Green
Red
E 14
F
F1
Green / Yellow #4 AWG
G
K 37
O
P 37
AUTO-CUT 300 XT
Pilot Return, Power Supply to Arc Starter
Negative Lead, Power Supply to Arc Starter
Coolant Leads, Power Supply to Arc Starter
Control Cable, Power Supply to Arc Starter
Ground Cable
Ground Cable,
Arc Starter
To Earth Ground
Torch Lead Set
Control Cable,
Power Supply to
Gas Control Module
Work Cable
CNC Cable (28 Wire)
Art # A-11903
0-5261 INSTALLATION 3-3
AUTO-CUT 300 XT
3.04 Position the Power Supply
WARNING
Do not touch live electrical parts.
Disconnect input power conductors from de-energized supply line before moving unit.
FALLING EQUIPMENT can cause serious personal injury and equipment damage.
Use the lifting eye when using 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-11904
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.
3-4 INSTALLATION 0-5261
3.05 Connect Input Power and Ground Cables
AUTO-CUT 300 XT
Connect Input Power and System Ground Cables
1. Remove the input power cover to the right of the coolant filter at the rear of the power supply. To do this remove the two screws then lift up and pull away.
2. Carefully cut back the outer sheath on the primary input power cable to expose the individual wires. Cut back the insulation on the individual wires. Route the cable upward through Input Power Port at the bottom of the panel. There are 2 extra plates included at the cable entrance. Discarding one or both allows changing the opening size for larger cable/strain relief.
3. Install stripped end of 3 phase wires into the terminal block L1, L2 and L3 and connect the individual cables as shown.
4. Connect the power cable ground wire to the ground terminal block.
5. Route a system ground cable (F1) to the stud on the rear of the gas control/arc starter Refer to the Ground
Connections Section for full details and procedures on proper system grounding.
Stud
0-5261
COOLANT
RETURN SUPPLY
1/0 Ground (F1) to ‘Star’ Ground
Art # A-11916
Input Power and Ground
Factory installed
Ground (F)
Ground Terminals
INSTALLATION 3-5
AUTO-CUT 300 XT
3.06 Connect Work Cable to Power Supply
1. Remove the output power cover to the left of the coolant filter at the rear of the power supply. To do this remove the two screws then lift up and pull away.
2. Route the end of the work cable upward through the leads strain relief at the bottom edge of the left rear panel. Pilot and Torch are factory installed.
3. Refer to the illustration. Connect the leads as shown. Tighten securely. Do not overtighten.
+ -
Pilot
Work Cable
Torch
Art # A-11533
4. Reinstall the cover on the power supply. Secure with two screws removed earlier. Do not overtighten.
3.07 Ground Connections
Star Ground on Cutting Table
Remote Arc Starter
(Optional RAS-1000)
Torch
See
Manufacturer
CNC
Device
Cutting Machine / Gantry
Cutting Table
1/0
Ground Cable
(F1)
Earth Ground
Rod
1/0
Ground Cable
Customer Supplied
A good ground will be less than 3 ohm. Ideal 1.
0 - 10 ft (0 - 3 m) Ideal
20 ft (6 m) Maximum
Power Supply GCM-1000 XT
Gas Control Module
#4 AWG Ground (F)
(Factory Installed)
2/0 Work Cable
1/0 Ground Cable
‘Star’
Ground
1/0 Ground (F1)
Art # A-11914_AC
3-6 INSTALLATION 0-5261
3.08 Ground Connections
AUTO-CUT 300 XT
A. Electromagnetic Interference (EMI)
Pilot arc starting generates a certain amount of electromagnetic interference (EMI), commonly called RF 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 automation (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 mm 2 ) or larger wire to a good earth ground (measuring leass 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 it is recommended to use a minimum of 10 AWG (European 6 mm 2 ) wire or flat copper braid with cross section equal to or greater than 10 AWG connected to the cutting table frame. 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 mm 2 ) 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 electrical codes. If the plasma 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.
0-5261 INSTALLATION 3-7
AUTO-CUT 300 XT
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 three ohms or less.
D. Low Cost Ground Rod Tester
1. A key component of reduced EMI is a good low resistance earth ground rod. There are several very expensive instruments to measure the ground but cost from several hundred to a few thousand dollars. Below is a low cost alternative which can be constructed by qualified personnel familiar with established electrical construction and safety practices. Previously suggested method using an incandescent light bulb will not work with GFCI outlets which are increasingly being used and the bulbs are becoming obsolete.
2. This method, as well as the light bulb method and some of the expensive instruments, assumes the utility ground is perfect, Zero ohms. It connects the rod being tested in series with the utility ground and measures the resistance of both in series. If the utility ground is not zero ohms, no matter how good your rod is, you won’t get a low reading due the higher resistance of the utility ground. Fortunately this is rare. Also if your rod is right next to another earth grounded structure you may get a false lower reading of only resistance between that structure and your rod rather than to gnd.
NOTE!
In the United States most standard AC outlets are 120 VAC 60 Hz. Elsewhere most outlets are 220 VAC 50Hz.
3. Obtain a transformer rated for at least 25 VA with primary voltage and frequency matching your standard outlets.
The transformer should have an isolated secondary of either 220 VAC (220 -240 is OK) or 120 VAC (110-120 is
OK) and be rated for at least 100 ma. The transformer could also have dual 115VAC primaries wired in series for 220V or in parallel for 120 VAC. An example is Triad N-68X, shown below, rated 50VA, 50/60 Hz.
Obtain a power resistor of either 1200 (1.2K) ohms, 15-25W min, if using a 120V secondary or 2200 (2.2K) ohms,
25 -30W for a 220V secondary.
4. Assemble the transformer and power resistor in a metal box. Connect a 3 wire (w/gnd) power cord with ground wire attached to the metal box for safety. If a plastic box is used instead, connect the transformer core and the resistor mounts to the power cord ground wire. There should be a fuse ¼ - ½ A, in series with the transformer primary. From the transformer secondary connect one wire to the utility safety ground. This could be the cutting table frame, the ground terminal of the 120 or 220 VAC outlet or the test box if grounded as indicated.
An excellent ground measures 1 ohm or less. Up to 3 ohms is often acceptable, higher reduces the effectiveness of the EMI suppression.
3-8 INSTALLATION 0-5261
F
Triad N-68X
R = 1.2K, 15W
(2.2K, 25W for 220 VAC)
Triad N-68X
F
AUTO-CUT 300 XT
Ground Rod with other connec ti ons removed
0.1 VAC = 1 OHM,
0.3 VAC = 3 OHM, etc.
GND
220 VAC
GND
120 VAC
Utility (building) GND
Art # A-12710
WARNING
Dangerous high voltage is present when the power supply is connected to input power. Do not connect input power or operate the power supply unless the connections cover is fastened in place.
5. 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.
E. 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.
0-5261 INSTALLATION 3-9
AUTO-CUT 300 XT
3.09 Connect Gas and Coolant Supply Lines
1. Connect the gas supply lines to the appropriate input ports as shown, upper left. First illustration shows without air filter and the second one with the air filter.
Plasma Gas - In
Water - In
Shield Gas - In
Plasma Gas - In
Water - In
Shield Gas - In
COOLANT
RETURN SUPPLY
Shop Air Input
COOLANT
RETURN SUPPLY
IN OUT
Art # A-11906
Art # A-12264
3-10 INSTALLATION 0-5261
3.10 Cables for CNC, Remote Arc Starter/Gas Control
AUTO-CUT 300 XT
1. Connect one end of each cable to the power supply. Some cables shown are options and may not apply to your system.
2. Connect the other end of the CNC cable to the CNC device.
NOTE!
The CNC cable shield must be attached to ground at the CNC end.
J56 To Gas Control
J58 Arc Starter
J55 To Gas Control
J15 To CNC Control
J59 To
Arc Starter
COOLANT
RETURN SUPPLY
J54 TSC/
Comm
Art # A-11907
0-5261 INSTALLATION 3-11
AUTO-CUT 300 XT
3.11 Set Switches on the Command - Control Module
Remove the power supply upper right side. Set switches on the CCM (Command-Control Module) per the illustrations. Switch settings and connection details are provided in the Appendix. Any changes made require a restart of the power supply.
!
CAUTION
Printed circuit boards in the Command - Control Module are static - sensitive. Discharge any built-up static charges in your body or surroundings before touching the printed circuit boards.
USB
Future Use
O
N
SW8 SW1 SW5 SW9 SW4 SW3 O
N
1 2 3 4 1 2 3 4 1 2
Switches shown in OFF position
SW-3: Gas Preflow Time 1 = Off, 2 = OFF: 3 seconds
1 = ON, 2 = OFF: 4 seconds
1 = OFF, 2 = ON: 6 seconds
1 = ON, 2 = ON: 8 seconds
1 2 1 2 1 2
Actual orientation
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).
1 = ON = (Remote Analog Current Control) Also set SW11 to “A” (down) position
*SW 8-3: Auto Transfer Retry1 = OFF = Enabled Up to 3 tries (Factory default setting).
SW 8-4:
1 = ON = Disabled
OFF = Disabled (Factory default setting).
ON = Remote Marking SW Enabled at TB3-1&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
2 = OFF, 3 = OFF, 4 = ON: 0.8 Seconds
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-5-1: Tip Saver Reserved for Factory use.
SW-5-2: Off Plate Reserved for Factory use.
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
Active only when
SW-1-1 is set to ON.
Art # A-11911_AB
3-12 INSTALLATION 0-5261
!
AUTO-CUT 300 XT
CAUTION
Printed circuit boards in the Command - Control Module are static - sensitive. Discharge any built-up static charges in your body or surroundings before touching the printed circuit boards.
0-5261
SW11
SW6
SW12
SW13
SW-6: OK-to-Move: Contact closure, 120VAC @ 1A (Factory default setting) or
DC Volts (16-18vdc@ up to 100 ma.)
SW-11: Set “B” position, (up) for default
SW-11: Set “A” position (down) for remote analog current control. SW-8-2 must be set to “ON”.
SW-12-1/2/3/4: Divided Arc signal All = OFF = 50:1 (Factory default setting)
1 = ON = 16.6:1
Only 1 on at a time.
2 = ON = 30:1
3 = ON = 40:1
4 = ON = 25:1
SW13: Auto-Cut XT Switch positions, off
Art # A-11912_AB
SW13 (Note positions 3-4 are not yet used)
INSTALLATION 3-13
AUTO-CUT 300 XT
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 and 24 VAC.
Note that the two 0’s are not common. The allowable current draw is 100ma @ 120VAC and 1Amp @ 24 VAC.
TB4
TB4
Art # A-11905
1 2 3 4 5 6 7
24 VAC
@ 1A
120 VAC
@ 100 ma.
Work
Tip Volts
(Pilot)
Arc Volts
(Torch)
Art # A-11954
There is also a hole added in the rear panel above the 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 connections to height controls, etc..
3-14 INSTALLATION 0-5261
AUTO-CUT 300 XT
3.13 Connect Torch Leads to the Gas Control Module / Arc Starter
1. Remove the top cover from the Gas Control Module / Arc Starter.
2. Pass the torch leads and coolant leads through the torch leads port on the back of the module. Ensure that the leads outer jacket slides into the port.
!
CAUTION
Use protective gloves when handling the leads. Do not kink or bend the leads.
3. Inside the module, slide the leads clamp over the leads.
4. Connect the leads to the module in the sequence shown. Coolant leads and connectors are color-tagged; red for coolant return, green for coolant supply. Shield gas and plasma gas connections are left- and right- hand threaded and will not interchange.
Torch Leads: Coolant Supply & Return
Plasma Gas
Shield Gas
1
Clamp * (Clamp type may vary)
3
2
Art # A-11929
0-5261 INSTALLATION 3-15
AUTO-CUT 300 XT
Coolant Return
Connection (Tagged Red)
Coolant Supply
Connection (Tagged Green)
Plasma Gas
Connection
Shield Gas
Connection
Torch Leads
Art # A-04832
5. Fold the end of the leads outer jacket back over the connection ring inside the module. Slide the leads clamp over the jacket and fasten the clamp and jacket to the connection ring. Re-install the module top cover.
5
Clamp
3-16
Art # A-11930
INSTALLATION 0-5261
3.14 Torch Head Installation and Connection
AUTO-CUT 300 XT
Install the Torch as follows:
1. Install the torch mounting block on the cutting table (gantry). Fasten the block in place.
2. Leave the end cap in place on the torch leads. Remove and discard the protective end caps from the Mounting Tube.
3. Install the O-ring in the groove at the upper end of the mounting tube. Slide the torch mounting tube onto the leads far enough to expose the fittings on the ends of the leads.
4. Connect the Torch Head to the torch leads. Follow the sequence shown. Do not let the leads twist.
0-5261
End Cap
Shown to illustrate assembly order only; parts must remain secured tightly.
Insulating Paper
O-Ring
Pilot Lead
Plasma Lead
1
2
Coolant Return
Check Valve and Connector
Plasma Lead
Connector
Positioning Tube
Torch Leads
O-Ring
Positioning Tube
Detail
Threaded
Holes
Shield ('Secondary')
Gas Connector
Insulating Paper
Coolant Supply Connector
Drain Holes
Art # A-06258
INSTALLATION 3-17
AUTO-CUT 300 XT
5. Slide the positioning tube down to the torch head. Hold the torch head stationary. Rotate the positioning tube onto the torch head. Pull the leads back as needed to ensure a proper fit through the Mounting Tube.
Do not let the torch leads twist.
!
CAUTION
Ensure that the leads do not twist within the mounting tube. Leads must lie as shown in the installation sketch.
6. The lower end of the Mounting Tube includes four threaded holes. Install an Allen set screw from the hardware kit in any of the threaded holes to secure the Torch Head Assembly to the Mounting Tube.
7. Fasten the positioning tube into the mounting block. Slide the leads end cap down onto the torch positioning tube. Ensure that the end cap engages the O-ring at the top of the positioning tube.
8. Install the shield cup, and cartridge assembly (including consumables) onto the torch head.
3.15 Install Consumable Torch Parts
1. Refer to the Torch Speed Charts to select the correct parts for the application. The application will determine which torch parts must be used. Refer to the speed charts for the proper torch parts to install for a selected application.
!
CAUTION
Do not interchange parts. Make sure both the tip and electrode in the torch correspond with the plasma and shield gas in use for the application.
2. Install the consumable parts as follows to ensure proper operation. These steps will help ensure that parts are seated correctly.
Shield
Retainer
Shield Cap Tip ibutor
Plasma Gas Electrode
Cartridge
Assemble First
3. Stack the consumable parts together.
Art # A-11915
3-18 INSTALLATION 0-5261
AUTO-CUT 300 XT
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.
1: Stack Parts 2: Press Cartridge onto Stacked Parts
Electrode
Plasma Gas
Distributor
Tip
O-Ring on Tip
Shield Gas
Distributor
Shield Cap
3: Thread Shield Cup onto Cartridge
No Gaps
Between Parts
4: Check Shield Cap Protrusion
Cartridge Covers
O-Ring on Torch Tip
Shield Cup
Shield Cap
Shield Cap Protrudes
0.063-0.083" (1.6 - 2.1 mm)
Art # A-04873
0-5261 INSTALLATION 3-19
AUTO-CUT 300 XT
5. Use the removal tool to hold the cartridge assembly, while turning the shield cap onto the cartridge assembly. When this group is fully assembled, the shield should protrude from the front of the shield cup 0.063” to 0.083” (1.6 - 2.1 mm). Without this protrusion the shield cup is not properly tightened onto the cartridge assembly.
Cartridge Tool
Assembled Cartridge
Art # A-04344_AB
Shield Cup
Installing Shield Cup Onto Cartridge
6. Take the removal tool off the cartridge. Fit the cartridge assembly onto the torch head. The cartridge should seal to the large O-ring on the torch body as shown. If the cartridge does not seal on the O-ring, the cartridge is not fully tightened.
!
CAUTION
Do not force the cartridge if it will not fully tighten. Remove the cartridge and gently clean the threads on the torch head body with a wire brush. Apply oxygen-compatible lubricant (supplied with the torch) to the threads.
Torch Head
Assembled Cartridge
Art # A-03893
Installing Assembled Cartridge Onto Torch Head
3-20 INSTALLATION 0-5261
7. Confirm proper parts assembly as shown.
Torch Head
AUTO-CUT 300 XT
Torch Head O-Ring
0.063 - 0.083"
(1.6 - 2.1 mm)
Protrusion
Art # A-07202_AB
8. Slide the ohmic clip over the shield cup 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.
Ohmic Clip
Art # A-03393_AB
9. Connect the wire lead from the height finder to the ohmic clip if using ohmic torch height sensing.
3.16 Voltage Divider for iHC Torch Height Control
For best plasma cutting performance it is necessary to maintain a constant height (standoff) above the metal while cutting. Cutting tables use a Torch Height Control (THC), also called a Z axis control, most of which use feedback from the arc voltage to control the height. Several of these, including the iHC, part of the Thermal Dynamics XT
CNC Controller, come with a Voltage Divider Printed Circuit Board that has to be installed inside the plasma power supply to divide the high arc voltage down to lower levels for use with control circuits.
There is a space for mounting the V-D Board located on the upper portion of an internal vertical panel near the rear of the power supply. Predrilled holes for mounting the iHT V-D board as well as another popular height control are provided.
!
CAUTION
If using another board that doesn’t align with the existing holes, remove the panel if possible before drilling. If not possible then every precaution must be taken to keep metal filings from being deposited inside the power supply.
0-5261 INSTALLATION 3-21
AUTO-CUT 300 XT
Install the V-D Board.
1. Locate the V-D Board which should be with the iCNC.
2. Inside the Power Supply, locate and remove the mounting panel’s 2 screws and panel.
3. Install the V-D board standoffs and the V-D Board from the XT iCNC then reattach the panel with the 2 screws, securing the V-D board in place. If using another V-D Board, follow the instructions provided mounting it in this same location.
Space for V-D Board Ohmic clip cable port
V-D Board installed
V-D Board connection
Art # A-12079
V-D Board shown with optional wire harness for iHC controller
Control Cable.
The iHC board can be supplied with a wire harness and connector (shown in previous image), to be installed in the rear panel hole labeled “Height Control” . The connector mates with a cable from the iHC. For other height control V-D boards a strain relief can be installed in this hole for those cables. Refer to Appendix for wiring diagram.
J55 - GCM
USER INPUT
J15 - CNC
HEIGHT CONTROL
Ohmic clip cable port
V-D Board connection
J54 - TSC /COMM
J59 - RAS
J70 - HE
F1 - 8A SB 230 VAC
CB2 - 5A 120 VAC
CB3 - 5A 24 VAC
CB4 - 5A 120 VAC
F2 - 8A SB 230 VAC
TB4
Art # A-12080
Arc Voltage Connections.
The XT plasma supplies provide a terminal strip, TB4, on the right side ahead of the CCM module for connections to Arc V- (Torch); Tip V (Pilot); Arc V + (Work). If the V-D board requires separate power, 24 VAC and 120 VAC is available on the terminal strip TB4. Refer to the wiring diagram in the Appendix for more information.
1 2 3 4 5 6 7
3-22
24 VAC
@ 1A
120 VAC
@ 100 ma.
Work
Tip Volts
(Pilot)
Arc Volts
(Torch)
Art # A-11954
INSTALLATION 0-5261
AUTO-CUT 300 XT
“Ohmic” or Shield (cup) cable.
Some height controls including the iHC find the plate using an electrical or resistance measurement, thus “ohmic”, contact between the conductive end of the torch and the metal or “plate” being cut. A wire, usually a single highly flexible wire that withstands the reflective heat from the arc, is connected between the V-D board and the torch shield cup. The XT torch includes a metal spring clip which slips into a groove in the shield cup allowing easy removal for parts change. The Ohmic wire can be connected to this clip with a ¼” female push-on terminal.
Significant amounts of high frequency (HF) energy causing electromagnetic interference (EMI) can be conducted along this wire due to it’s close coupling to the torch. This is the reason for mounting the V-D board away from the CCM and close to the rear panel where the Ohmic wire does not need to pass near other sensitive electronics.
It is especially recommended that the Ohmic wire not be routed near the CCM module or along the torch leads.
Refer to Appendix for wiring diagram.
Ferrite cores.
It is recommended that the Ohmic Sensing wire be wrapped through a ferrite core with several turns, at least 3 but more is better, to reduce the energy conducted to the V-D board and into the plasma supply. The ferrite core should be located on the wire where it enters the plasma supply. A second ferrite core added several feet (couple of meters) from the torch will further reduce the conducted EMI that may couple to other cable/wires and cause interference.
Refer to Appendix for wiring diagram.
3.17 Fill Cooling System
1. 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.
2. Replace the cap on the tank.
Coolant Capabilities
Cat. Number and Mixture Mixture
7-3580 ‘Extra-Cool TM ’
7-3581 ‘Ultra-Cool TM ’
25 / 75
50 / 50
7-3582 ‘Extreme Cool
TM
’ Concentrate*
* For mixing with D-I Cool
TM
7-3583
Protects To
10° F / -12° C
27° F / -33° C
-65° F / -51° C
0-5261 INSTALLATION 3-23
AUTO-CUT 300 XT
Coolant Tank
Fill Range
Art # A-11908
2. After the complete system has been installed, check that the coolant has been pumped through the system as follows (see NOTE):
NOTE!
The system will most likely require more coolant after turning the system ON for the first time. a. Place the ON/OFF Switch to ON. The power supply will start to circulate coolant throughout the system.
b. After about 4 minutes the system may shut down if the leads are not full of coolant.
c. Place the ON/OFF switch to OFF. Refill Coolant Tank as needed.
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.
NOTE!
Circuitry in the power supply will generate a ‘Low coolant’ message if the coolant level is too low.
3-24 INSTALLATION 0-5261
SECTION 4: OPERATION
4.01 Power Supply Indicators
AC Indicator Gas Indicator
Temp Indicator DC Indicator
A/ Status Indicator
AUTO-CUT 300 XT
A/
Art # A-11909
AC Power Lamp
Indicates unit has passed the input power tests and AC power is being supplied to the inverter modules via the input contactor when the ON/OFF switch is in ON position.
TEMP Lamp: Normally OFF. Lamp will come ON when the internal temperature sensors detect temperatures above normal limits. Let the unit cool before continuing operation.
GAS Lamp: Flashing during start up gas purge/pump priming, then whenever gas is flowing. Indicates adequate gas pressure and coolant flow for operation.
DC Lamp: Indicates the power supply is generating output DC voltage.
A/
Status Indicator: Shows CCM code version on start up followed by the Current Control setting and system status. Refer to Section 4.05 and Section for details.
Rear Panel AC Power Lamp
Indicates AC power is present inside the unit
0-5261 OPERATION 4-1
AUTO-CUT 300 XT
4.02 Control Console Features
Art # A-11917
Plasma Gas
Pressure Gauge
Shield Gas
Pressure Gauge
Run / Set Selector
RUN
SET
Amperage
Selector
PLASMA SHIELD
SHIELD GAS
CUT
OUT
A
GCM 1000 XT
GAS CONTROL MANAGEMENT SYSTEM
H20 MIST
H20 MIST
Shield
Selector
Plasma Gas Pressure
Control Knob
Shield Gas Pressure
Control Knob
Water Mist (Shield) Flow Meter and Control Knob
Run / Set Selector: Use SET position to adjust plasma and shield pressures and flows. Once these are set, switch to RUN position for operation.
Plasma and Shield Gas Pressure Control Knobs: Adjust plasma and shield gas pressures. Turn knobs to set desired levels.
Plasma and Shield Gas Pressure Gauges: Display plasma and shield gas pressures.
Shield Selector: Selects shield fluid, gas or H2O Mist (water).
Water Shield Mist (H2O) Flowmeter and Control Knob: Controls flow rate of shield water supply.
A/
Amperage Selector: Continuously adjustable up to 300 Amps. Visible here:
Plasma Gas Type Selector (rear panel): Selects proper operating voltage for either Air & O2 or N2 & H35. Also use N2/H35 setting for F5.
4-2 OPERATION 0-5261
4.03 System Operation
This section contains operating information which is specific to the power supply.
AUTO-CUT 300 XT
WARNING
Frequently review the safety precautions in Section 1.
If the power supply cord has a plug or is not permanently connected to power, be sure the power to the outlet is disconnected when inserting the plug into the outlet.
Disconnect primary power at the source before assembling or disassembling power supply, torch parts, or torch and leads assemblies, or adding coolant.
It is not enough to simply move the ON/OFF switch on the unit to OFF position when cutting operations have been completed. Always open the power supply disconnect switch five minutes after the last cut is made.
Prior to starting the system determine the process to be used. The process is determined by the type and thickness of the metal to be cut. Select and install the required consumables, connect the required gasses to the system.
1. Connect system to primary input power. An indicator will light on the rear panel when AC power is applied to the unit. Place the Gas Control in the RUN mode.
2. Turn ON/OFF switch to ON (up) position. System goes through the “Start up Sequence”.
• For about 10 seconds the decimal points of the 4 digit display blink from right to left.
• Next the 4 rectangular LED indicators illuminate all segments as a test.
• Then for about 6 seconds the display shows the letter “C” (code) followed by the CCM code version.
Example “C1.2.0” . During this time various input voltage tests are being performed. If a fault is found its code is displayed and the start up sequence halts. Faults will show “E” or “L”.
• The coolant pump and fan then starts and the Gas indicator blinks while the cutting gasses are purged for 20 seconds. Gas LED should stop blinking and gas flow (purge) stops unless gas control was left in the SET mode or the coolant flow is not satisfied. At the same time the display shows the current control setting. Example: “300”
• Once coolant flow is detected, usually within 5 seconds after the pump starts, the W1 and W2 input contactors close and the AC indicator lights. However if correct coolant flow was not obtained the contactors will not close and the Gas LED will continue blinking until required coolant flow has been obtained. The
Gas LED will blink for up to 4 minutes after which code E404 will be displayed indicated proper coolant flow was not established.
0-5261
Art # A-11910
I
POWER
OFF
O
OFF
O
OFF
O
ON
OFF
OPERATION 4-3
AUTO-CUT 300 XT
3. Set Gas Pressures a. Place RUN/SET switch in SET mode.
b. Adjust plasma and shield pressure regulators to correct pressure or correct flow if using H to cut chart manual for required pressure/flow.)
2
O Mist (refer c. Return RUN/SET switch to RUN mode. Attempting to START while in the SET mode will cause fault
L303, normally indicating low gas pressure but in Auto-Cut XT units also indicates trying to START while in SET.
4. Set cutting current.
a. Adjust the Current Control knob to the required output current on the 4 digit display.
5. Prepare to cut.
a. Protect your eyes and ears.
b. Position the Torch to the proper transfer distance above the work piece.
6. Apply START.
• Gas indicator lights; Gas pre-flow starts.
• During gas pre-flow power supply is enabled. DC lamp turns ON.
7. Pilot Arc
• At the end of pre-flow, ignition occurs (arc starter fires) and the Pilot Arc is established.
8. Transfer
• Almost immediately, if the torch is positioned correctly, the pilot arc transfers to the work and becomes a cutting (transferred) arc.
• Current quickly ramps up to the level set by the Current Control and the arc pierces through the metal.
• OK to Move signal becomes active and the torch is moved to perform the cut.
9. End of Cut
• START signal is removed; current ramps down and the arc goes out.
• Gases continue to flow for the selected Post-flow time then stops.
• Pump and fan will run for 4 minutes then shut off. Fan will remain on as long as power is on.
10. To make another cut repeat steps 5-9. A second cut can be started anytime after completing the first cut.
11. Shut off the system.
a. Set the ON/OFF power switch on the front panel of the unit to OFF.
WARNING
AC power is still present inside the unit.
• Fans and pump as well as all indicators turn off.
• The display may show a fault code for a moment, this is a normal part of shutting off power and does not indicate a fault.
b. Open (turn off) the main power disconnect. All power is now removed from the unit.
• Rear panel AC indicator turns OFF.
4-4 OPERATION 0-5261
Operational Suggestions
AUTO-CUT 300 XT
1. Wait four minutes before setting the ON/OFF switch to OFF after operation. This allows the cooling fans to run to dissipate operating heat from the power supply.
2. For maximum parts life, do not operate the pilot arc any longer than necessary.
3. Use care in handling torch leads and protect them from damage.
4. When using water as the shield note the following:
• Use clean drinking quality tap water to help prevent particulate build-up within the system water shield plumbing.
• Particulate contamination and build-up can cause reduced consumable parts life and premature torch failure.
• A cartridge type particulate water filter may help achieve optimum cutting performance.
4.04 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 substantially 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.
0-5261 OPERATION 4-5
AUTO-CUT 300 XT
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.
4.05 Power Supply s
NOTE!
See the Appendix for Advanced Troubleshooting
On start-up and during operation, the power supply control circuitry performs various tests. If the circuitry detects a condition requiring operator attention, the status display on the front panel shows a 3 digit code preceded by either letter “E” (currently active fault) or letter “L” (last or latched fault) meaning a fault occurred stopping the process but is not currently active.
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 conditions in sequence; it is important to recognize all possible conditions that may be displayed.
NOTE!
500 codes are not used for this system
4-6 OPERATION 0-5261
AUTO-CUT 300 XT
Code
101
102
103
104
Message
Plasma Disabled
Pilot Ignition Failure
Lost Pilot
Transfer Lost
CCM
Group 1 Plasma Process
Remedy / Comments
Plasma Enable Off ; External Disable activated or CCM TB1-1&2 jumper missing; 40 circuit ribbon cable from Relay PCB to CCM disconnected or defective;
Pilot did not start within 15 seconds. Torch consumable parts worn? Ensure current control setting matches consumables; Plasma pressure too high; Defective Arc Starter; Defective
Pilot PCB; defective Inverter section 1A.
Pilot went out while Start active. Torch consumable parts worn? Ensure current control setting matches consumables; Plasma pressure too high;
Arc was transferred to work for more than 50 ms and then went out while Start still active. Arc lost contact with work, run off edge, over hole, etc.; Standoff too high; Ensure current control setting matches consumables; Wrong gas pressure
105
106
107
108
109
110
Not used
Pilot Timeout, no
Transfer
Reserved for legacy product
Must transfer from Pilot to Cutting Arc in 0.085 seconds (SW8-1 OFF) or 3 sec. (SW8-1 ON).
Standoff too high or void in work under torch; Current Control setting too low for consumables resulting in: Pilot current too low for consumables; Wrong gas pressure.
Tip Saver Fault Tip remained in contact with work in excess of 15 seconds. ( Pak200i).
Tip to Electrode voltage fault.
Tip voltage too close to electrode voltage. Rear panel gas switch set to wrong gas; Torch consumable parts worn out; Wrong consumables installed causing tip to electrode short; Plasma pressure too low; Leak in Plasma hose to torch; Current Control set too high for consumables; Defective Pilot PCB; Shorted torch body .
Part process not configured.
Applies only to DFC 3000 Auto Gas Control. Select and load a cutting process.
Devise Locked DFC 3000: Process loading; wait until finished
CCM
Group 2 -- Plasma Power Supply
Code Message Remedy / Comments
201 Missing AC Phase Blown fuse, Bad power cable connection; Defective System Bias PCB
202 Not used Reserved for legacy product
203 Not used
204 Not used
Reserved for legacy product
Reserved for legacy product
205
206
207
208
209
210
211
DC Output Low
Not used
Unexpected current in work lead
Unexpected current in pilot circuit
Not used
Output Current Too
High
Output Current Too
Low
Less than 60 VDC; Negative lead short to work or ground; Defective inverter (output shorted); CCM voltage sense (J24) disconnected or wire broken; Defective CCM.
Reserved for legacy product
Current above 8A in work lead prior to pilot ignition or transfer. Negative lead short to ground or arc starter chassis; Defective HCT1 work lead current sensor; Defective Relay PCB.
Current above 6A in pilot circuit prior to ignition. Wrong or mismatched consumables causing tip - electrode short; Pilot lead shorted to negative in torch tube; Defective Relay PCB; Possible shorted torch.
Reserved for legacy product
Work lead current detected greater than 20% above process setting. Possible erroneous signal due to defective HCT1 Work lead current sensor or Relay PCB; Defective CCM.
Work current detected more than 20% below process setting. Possible erroneous signal due to defective HCT1 Work lead current sensor or Relay PCB; Possible defective pilot PCB
(shorted IGBT);
0-5261 OPERATION 4-7
AUTO-CUT 300 XT
Code
212
213
Message
Inverter 1A Output
Current Low
Inverter 1B Output
Current Low
214
Inverter 2A Output
Current Low
215 Not Used
216
Inverter 3A Output
Current Low
217
Inverter 3B Output
Current Low
218
219
220
Inverter 1A Output
Current High
Inverter 1B Output
Current High
Inverter 2A Output
Current High
221 Not Used
222
Inverter 3A Output
Current High
223
Inverter 3B Output
Current High
Remedy / Comments
Plasma work current low during cutting and attributed to Inverter Module 1 Section A output low; Inverter output disconnected; Possible defective ribbon cable; If problem persists replace Inverter Module 1
Plasma work current low during cutting and attributed to Inverter Module 1 Section B output low; Inverter output disconnected; Possible defective ribbon cable; If problem persists replace
Inverter Module 1
Plasma work current low during cutting and attributed to Inverter Module 2 Section A output low; Inverter output disconnected; Possible defective ribbon cable; If problem persists replace Inverter Module 2
Reserved for other Systems
Plasma work current low during cutting and attributed to Inverter Module 3 Section A output low; Inverter output disconnected; Possible defective ribbon cable; If problem persists replace Inverter Module 3
Plasma work current low during cutting and attributed to Inverter Module 3 Section B output low; Inverter output disconnected; Possible defective ribbon cable; If problem persists replace Inverter Module 3
Plasma work current high during cutting and attributed to Inverter Module 1 Section A output high; If problem persists replace Inverter Module 1
Plasma work current high during cutting and attributed to Inverter Module 1 Section B output high; If problem persists replace Inverter Module 1
Plasma work current high during cutting and attributed to Inverter Module 2 Section A output high; If problem persists replace Inverter Module 2
Reserved for other Systems
Plasma work current high during cutting and attributed to Inverter Module 3 Section A output high; If problem persists replace Inverter Module 3
Plasma work current high during cutting and attributed to Inverter Module 3 Section B output high; If problem persists replace Inverter Module 3
224 Inverter 1 Not Found Inverter Module 1 Section A required for Piloting; Ribbon cable CCM 1A to Inverter Module 1
225
Inverter 1A Incompatible Revision
Unsupported Inverter Revision; Ribbon cable CCM J31 to Inverter Module 1 Section A damaged; CCM code version incompatible with Inverter revision or model
226
Inverter 1B Incompatible Revision
Unsupported Inverter Revision; Ribbon cable CCM J32 to Inverter Module 1 Section B damaged ; CCM code version incompatible with Inverter revision or model
227
Inverter 2A Incompatible Revision
228 Not used
229
Inverter 3A Incompatible Revision
230
Inverter 3B Incompatible Revision
231
232
233
234
Inverter 1A VAC
Mismatch
Inverter 1B VAC
Mismatch
Inverter 2A VAC
Mismatch
Not used
Unsupported Inverter Revision; Ribbon cable CCM J33 to Inverter Module 2 Section A damaged; CCM code version incompatible with Inverter revision or model
Reserved for other model with another inverter section
Unsupported Inverter Revision; Ribbon cable CCM J35 to Inverter Module 3 Section A damaged ; CCM code version incompatible with Inverter revision or model
Unsupported Inverter Revision; Ribbon cable CCM J36 to Inverter Module 3 Section B damaged ; CCM code version incompatible with Inverter revision or model
Inverter AC Voltage rating incompatible with Power Supply voltage rating; Ribbon cable
CCM J31 to Inverter Module 1 Section B damaged or loose; Wrong voltage Inverter Module 1 installed; Defective Inverter module
Inverter AC Voltage rating incompatible with Power Supply voltage rating; Ribbon cable
CCM J32 to Inverter Module 1 Section B damaged or loose; Wrong voltage Inverter Module 1 installed; Defective Inverter module
Inverter AC Voltage rating incompatible with Power Supply voltage rating; Ribbon cable
CCM J33 to Inverter Module 2 Section A damaged or loose; Wrong voltage Inverter Module 2 installed; Defective Inverter module
Reserved for other model with another inverter section
4-8 OPERATION 0-5261
Code
235
Message
Inverter 3A VAC
Mismatch
236
Inverter 3B VAC
Mismatch
237
Too Few Inverters
Found
238 BIAS VAC Invalid
239 AC Voltage High
240 AC Voltage Low
241
242
243
244 Not used
245
246
Inverter 1A Input
Voltage Error
Inverter 1B Input
Voltage Error
Inverter 2A Input
Voltage Error
Inverter 3A Input
Voltage Error
Inverter 3B Input
Voltage Error
AUTO-CUT 300 XT
Remedy / Comments
Inverter AC Voltage rating incompatible with Power Supply voltage rating; Ribbon cable
CCM J35 to Inverter Module 3 Section A damaged or loose; Wrong voltage Inverter Module 2 installed; Defective Inverter module
Inverter AC Voltage rating incompatible with Power Supply voltage rating; Ribbon cable
CCM J36 to Inverter Module 3 Section B damaged or loose; Wrong voltage Inverter Module 3 installed; Defective Inverter module
Two or more Inverter Sections required to operate; Ribbon cable from CCM to Inverter Section damaged or disconnected;
Invalid AC Voltage Selection; Damaged or loose connection at J61 of System Bias Supply
System Bias PCB detected AC Voltage is higher than Power Supply rated Voltage; System
Bias Supply J61 Voltage Selection connection damaged or disconnected; Defective System
Bias PCB; Defective CCM
System Bias PCB detected AC Voltage is lower than Power Supply rated Voltage; System
Bias Supply J61 Voltage Selection connection damaged or disconnected; Defective System
Bias PCB; Defective CCM
Inverter Input Voltage fault; voltage out of range or missing phase at AC Input of Inverter
Module 1 Section A; Poor AC Power Quality; Defective W1 contactor; Loose or open connection between input terminals and W1 contactor or contactor and input of Inverter Section;
Defective Inverter module
Inverter Input Voltage fault; voltage out of range or missing phase at AC Input of Inverter
Module 1 Section B; Poor AC Power Quality; Defective W1 contactor; Loose or open connection between input terminals and W1 contactor or contactor and input of Inverter Section;
Defective Inverter module
Inverter Input Voltage fault; voltage out of range or missing phase at AC Input of Inverter
Module 2 Section A; Poor AC Power Quality; Defective W1 contactor; Loose or open connection between input terminals and W1 contactor or contactor and input of Inverter Section;
Defective Inverter module
Reserved for other model with another inverter section
Inverter Input Voltage fault; voltage out of range or missing phase at AC Input of Inverter
Module 3 Section A; Poor AC Power Quality; Defective W2 contactor; Loose or open connection between input terminals and W2 contactor or contactor and input of Inverter Section;
Defective Inverter module
Inverter Input Voltage fault; voltage out of range or missing phase at AC Input of Inverter
Module 3 Section B; Poor AC Power Quality; Defective W2 contactor; Loose or open connection between input terminals and W2 contactor or contactor and input of Inverter Section;
Defective Inverter module
Inverter Module 1 Section A detected a circuit fault; Damaged Inverter Module 1 247
248
249
Inverter 1A Circuit
Fault
Inverter 1B Circuit
Fault
Inverter 2A Circuit
Fault
250 Not used
251
252
253
Inverter 3A Circuit
Fault
Inverter 3B Circuit
Fault
Inverter 1A Over
Temp Ambient
Inverter Module 1 Section B detected a circuit fault; Damaged Inverter Module 1
Inverter Module 2 Section A detected a circuit fault; Damaged Inverter Module 2
Reserved for other model with another inverter section
Inverter Module 3 Section A detected a circuit fault; Damaged Inverter Module 3
Inverter Module 3 Section B detected a circuit fault; Damaged Inverter Module 3
Inverter circuitry is over temperature likely cause is ambient greater than 40 deg C; Reduce power supply cutting Duty Cycle; Reduce ambient air temperature; Add auxiliary cooler.
0-5261 OPERATION 4-9
AUTO-CUT 300 XT
Code
254
255
Message
Inverter 1B Over
Temp Ambient
Inverter 2A Over
Temp Ambient
Remedy / Comments
Inverter circuitry is over temperature likely cause is ambient greater than 40 deg C; Reduce power supply cutting Duty Cycle; Reduce ambient air temperature; Add auxiliary cooler.
Inverter circuitry is over temperature likely cause is ambient greater than 40 deg C; Reduce power supply cutting Duty Cycle; Reduce ambient air temperature; Add auxiliary cooler.
256 Not used
257
258
259
260
265
266
267
268
269
270
Reserved for other model with another inverter section
Inverter 3A Over
Temp Ambient
Inverter 3B Over
Temp Ambient
Inverter 1A No Input
Power
Inverter 1B No Input
Power
Inverter 1A No Input
Power
Inverter 1B No Input
Power
Inverter 2A No Input
Power
Inverter 2B No Input
Power
Inverter 3A No Input
Power
Inverter 3B No Input
Power
Inverter circuitry is over temperature likely cause is ambient greater than 40 deg C; Reduce power supply cutting Duty Cycle; Reduce ambient air temperature; Add auxiliary cooler.
Inverter circuitry is over temperature likely cause is ambient greater than 40 deg C; Reduce power supply cutting Duty Cycle; Reduce ambient air temperature; Add auxiliary cooler.
Inverter section may have no input power. Contactor not closed; Defective contactor or CB4 tripped; Inverter section input not connected; Defective Inverter.
Inverter section may have no input power. Contactor not closed; Defective contactor or CB4 tripped; Inverter section input not connected; Defective Inverter.
Inverter circuitry is over temperature likely cause is ambient greater than 40 deg C; Reduce power supply cutting Duty Cycle; Reduce ambient air temperature; Add auxiliary cooler.
Inverter circuitry is over temperature likely cause is ambient greater than 40 deg C; Reduce power supply cutting Duty Cycle; Reduce ambient air temperature; Add auxiliary cooler.
Inverter circuitry is over temperature likely cause is ambient greater than 40 deg C; Reduce power supply cutting Duty Cycle; Reduce ambient air temperature; Add auxiliary cooler.
Inverter circuitry is over temperature likely cause is ambient greater than 40 deg C; Reduce power supply cutting Duty Cycle; Reduce ambient air temperature; Add auxiliary cooler.
Inverter section may have no input power. Contactor W1 not closed; Defective contactor or CB4 tripped; Inverter section input not connected; Defective Inverter.
Inverter section may have no input power. Contactor W1 not closed; Defective contactor or CB4 tripped; Inverter section input not connected; Defective Inverter.
Inverter section may have no input power. Contactor W1 not closed; Defective contactor or CB4 tripped; Inverter section input not connected; Defective Inverter.
Inverter section may have no input power. Contactor W2 not closed; Defective contactor or
CB4 tripped; Inverter section input not connected; Defective Inverter.
Inverter section may have no input power. Contactor W2 not closed; Defective contactor or CB4 tripped; Inverter section input not connected; Defective Inverter.
Inverter section may have no input power. Contactor W2 not closed; Defective contactor or CB4 tripped; Inverter section input not connected; Defective Inverter.
CCM found ID values inconsistent during reading. CCM to an Inverter section ribbon damaged or disconnected; Improper ribbon cable routing.
4-10 OPERATION 0-5261
AUTO-CUT 300 XT
Code Message
301 Not used
302 Reserved
CCM Status Code
Group 3 -- Gas Controller Status & Protocol
Reserved for other models.
Remedy / Comments
No information available; Contact customer service
303
Gas Supply Pressure out of range.
Autocut is in SET mode or Plasma gas pressure is too low; Defective gas pressure sensor
(PS1).
304 Gas Control Purging Normal following power up or returning from Plasma Disable.
305 Not used
306 Not used
307
308
Not used
Gas Control Type
Mismatch
Reserved for other models.
Reserved for other future use.
Reserved for other models.
Wrong CCM, must be Auto-cut type.
309 Not used
310 * DPC fault
Reserved for other models.
Reserved for other models.
311 * DPC valve control fault Reserved for other models.
312 * DMC fault Reserved for other models.
Reserved for other models.
* Applies to DFC 3000 (Auto Gas) only
CCM Status Code
Group 4 -- Torch Coolant System
Code Message
401 Coolant Level low Check coolant level, add as needed.
Remedy / Comments
402
403
404
Low coolant flow
Coolant flow as measured by flow switch FS1 is less than 0.7 gpm (0.25 for Pak200i); Clogged filter; Restriction in torch lead or head; Wrong style consumables; Bad O-ring on the torch check valve; broken or defective torch coolant tube/check valve; Defective pump or bypass valve. 402 code along with 104 code is probably a low flow problem.
Coolant overheated Coolant supply temperature exceeded 75 degrees Celcius (167 ℉ ). Operating with either lower side panel loose or removed; Coolant fan failed; radiator fins clogged with dirt.
Coolant System not ready.
Proper coolant flow of 0.7 gpm as measured by flow switch FS1 was not obtained during up to 4 minutes of Priming. New installation can require additional Priming cycle(s) to fill hoses with coolant; cycle power to restart Priming; Coolant hoses or torch hoses reversed; Clogged coolant filter; Restriction in torch lead or head; Wrong style consumables; broken or defective torch coolant tube/check valve; Defective pump or bypass valve.
405
Low Coolant Level
Warning
406 Not used
407
Low coolant level during cut, does not stop cut.
Add coolant as required.
Reserved for other models.
Coolant overheated, high ambient.
Ambient greater than 40 deg C results in coolant overheating. Reduce cutting duty cycle; Reduce ambient; Add separate cooler.
NOTE!
There are no 500 codes
0-5261 OPERATION 4-11
AUTO-CUT 300 XT
Code Message
CCM Status Code
Group 6 -- CCM
Remedy / Comments
601 Analog Voltage Error Defective CCM, replace.
602 ADC or DAC error
603 Reserved
604 Data Memory error
Defective CCM, replace.
No information available; Contact customer service
Defective CCM, replace.
605 Program memory fault Defective CCM, replace.
606 +5V Logic supply low Defective CCM, replace.
607
608
609
Processor over temperature
5V supply for RS
485/422 communication low.
Firmware Update
Device Error
Reduce ambient temperature; Defective CCM; replace
Defective CCM, replace.
Defective CCM; replace
610
Firmware Update
Protocol Error
Defective CCM; replace
611 USB Controller Fault Defective CCM; replace
612 USB Power Fault Remove faulty USB device; Defective CCM
613 USB Log Creation Fault Unable to create Log file on USB Flash drive last firmware update attempt; Use different USB
614
615
No USF File
No CCM Update File
File VTCCMFW.USF missing from Flash Drive; Add proper files to Flash Drive for Firmware
Update; Use different USB Flash Drive or Reformat
CCM Firmware file specified in VTCCMFW.USF not found ; Add proper files to Flash Drive for
Firmware updating
616
617
DPC Update Fault
DMC Update Fault
Fault occurred attempting to update DPC firmware; Add proper files to USB Flash drive for
Firmware updating; Refer to CCM_LOG.TXT on Flash Drive for details
Fault occurred attempting to update DMC firmware; Add proper files to USB Flash drive for
Firmware updating; Refer to CCM_LOG.TXT on Flash Drive for details
618 ADC Calibration Fault Error too large calibrating ADC; Fault persists defective CCM;
619
620
Flow Switch Fault
Non Volatile Memory
Error
Flow switch reporting coolant flow when pump off;
Non Volatile Memory Storage Corrupted and Erased; Fault persists defective CCM.
621 USB Format Fault
A USB flash drive was detected but could not be read by CCM. Backup any files currently on flash drive, reformat the USB flash drive to a FAT or FAT32 file system, replace only the CCM update files and try again. Use different USB flash drive formatted with FAT or FAT32 file system.
Possible EMI noise problem or code fault. Check for proper grounding and bonding of equipment and routing of torch leads and cables to reduce Electromagnetic Emission Interference onto CCM module. If problem persists, verify CCM code version is the latest supported revision. Replace CCM module.
4-12 OPERATION 0-5261
4.06 Cut Quality
AUTO-CUT 300 XT
Cut quality requirements differ depending on application. For instance, nitride build-up 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
Right Side
Cut Angle
Top
Spatter
Top Edge
Rounding
Dross
Build-Up
A-00512
Cut Surface
The condition (smooth or rough) of the face of the cut.
Bevel Angle
4. Place the RUN/SET switch to the RUN position.
Cut Surface
Drag Lines
A-00007
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 Build-up and Top Spatter
Dross is molten material which is not blown out of the cut area and re-solidifies on the plate. Top spatter is dross which accumulates on the top surface of the workpiece. Excessive dross may require secondary clean-up operations after cutting.
Kerf Width
The width of material removed during the cut.
Nitride Build-up
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.
0-5261 OPERATION 4-13
AUTO-CUT 300 XT
Direction of Cut
The plasma gas stream swirls as it leaves the torch to maintain a smooth column of gas. This swirl effect results in one side of a cut being more square than the other. Viewed along the direction of travel, the right side of the cut is more square than the left.
Left Side
Cut Angle
Clockwise
Right Side
Cut Angle
Scrap
A-00512
Swirl Effect on Side Characteristics Of Cut
Counter-
Clockwise
Scrap
Workpiece
Art # A-04182
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 Sensing
Ohmic height sensing is not recommended with water shield. Water on the plate interferes electrically with the ohmic sensing circuit.
4-14 OPERATION 0-5261
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.
Check cooling fan; clean as needed.
Weekly
Check O-Rings in Torch and Cartridge
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.
Clean water filter (if using H
2
O Mist)
Six Months
Clean or replace coolant filter.
Clean coolant tank.
Vacuum out any dust buildup inside power supply.
AUTO-CUT 300 XT
5.02 Coolant Filter Cleaning Procedure
Periodic cleaning of the coolant filter ensures maximum coolant flow efficiency. Poor coolant flow causes inefficient torch parts cooling with consequent faster consumable wear.
Clean the coolant filter as follows:
1. Disconnect system from main input power.
2. Unscrew and remove the filter canister by hand. Large canister located at the back of the power supply. Be sure to keep the O-ring.
3. Inspect and replace filter as needed. Re-install the canister, tightening it by hand. Be sure the O-ring is in place.
4. Turn the system on and check for leaks.
0-5261 MAINTENANCE 5-1
AUTO-CUT 300 XT
5.03 Coolant Replacement Procedure
Replace coolant as follows:
1. Disconnect the system from main input power.
2. Remove the lower right side panel.
3. Locate the coupling in the coolant line that comes from the bottom of the coolant tank, #1 in the following illustration. Disconnect the coolant line at this fitting and drain the coolant into a disposable container of sufficient size. Remember you will be draining more than the contents of the coolant reservoir.
4. Once coolant is draining, disconnect the gray hose coupling #2 in the illustration below. Allow excess coolant to drain, then apply a maximum of 5psi to clear the lines.
!
CAUTION
Applying more than 5 psi air pressure to the cooling system will result in damage. Extra caution must be used when performing this task.
5-2
2
1
Art # A11689
5. Reconnect those two fittings and then remove the filter bowl from the canister at the rear of the power supply. Pour this remaining coolant into the container and replace the filter bowl.
NOTE!
If you also need to replace the coolant still in the leads, disconnect the leads from the power supply and manually drain them.
6. Fill the tank with fresh coolant until the right level is reached checking for leaks.
7. Turn system on, let it run for a few minutes and check coolant level, refill as needed. Refer to Section 3:15
Fill Cooling System on the procedure for this.
MAINTENANCE 0-5261
5.04 Arc Starter Service
AUTO-CUT 300 XT
Symptom
No Pilot ignition:
Spark in Arc Starter but no ignition
Cause
Arc Starter Service Chart
Coolant has become conductive
Pilot return wire not connected
Spark gap set too close
High Frequency cap (C4)
possibly open
Broken or missing ferrites
Short across in inductor (L1)
Check
Use conductivity meter
Visual inspection
Check with feeler gauge
Use capacitance meter
Visual inspection
Visual inspection
Remedy
Flush system, replace coolant.
Connect Wire.
Set to 0.063” ±0.002”
Reconnect or replace.
Replace.
Remove short; increase coil gaps.
Spark gap bus caps
(C1, C2, C3) broken or defective
Negative supply not connected correctly
Spark gap set too large
Faulty transformer
Capacitance meter
Visual inspection
Replace.
Reconnect.
No Pilot ignition:
No Spark in Arc Starter
No cooling or insufficient cooling:
Leaks coolant
No 120V supply
No/ loose connection to spark gap
Faulty EMI filter
Loose fitting(s)
Failure to braze joints (L1)
Damaged or punctured coolant line(s).
Check with feeler gauge
Resistance measurement
Check input voltage at EMI filter
Visual inspection
Voltage/ Resistor measurement
Visual inspection
Visual inspection
Visual inspection
Set to 0.063” ±0.002”
Replace.
Make connections; replace harness.
Reconnect.
Replace.
Tighten fittings.
Replace HF Coil.
Replace coolant line(s).
No cooling or insufficient cooling:
No Coolant Flow Blockage in coil or supply/return hoses
Torch Lead Shield not connected or loose. F1 gnd cable not connected.
Erratic System
Behavior
(EMI Interference)
Missing or loose ground connection
Loosen fitting slightly and check for coolant flow
Visual inspection of lead attachment to Arc Starter
Visual inspection of ground wire to Arc Starter
Match coolant connection colors to arc starter fitting colors.
Flush system.
Reconnect / tighten lead connectors.
Make or tighten connections to good ground.
Cap C5 not connected, open or loose
Visual inspection / capacitor measurement
Replace PCB.
0-5261 MAINTENANCE 5-3
AUTO-CUT 300 XT
5.05 Arc Starter Spark Gap Adjustment
1. Shut off input power. Remove the top console cover.
2. Adjust the spark gap as shown. Re-install the top cover.
0.063" ± 0.002"
1.6 ± 0.05 mm
Art # A-11913
5-4 MAINTENANCE 0-5261
AUTO-CUT 300 XT
SECTION 6: REPLACEMENT ASSEMBLIES & PARTS
6.01 Replacement Power Supply
Complete Unit / Component Catalog Numbers
Auto-Cut 300 XT™ Power Supply, 400VAC +10 -15%
6.02 Leads and Cables
Refer to section 3.05 for ground connections and ground cables.
Arc Starter /
Gas Control Module
(GCM-1000XT)
Pilot Return
Negative
Coolant Supply
Coolant Return
Control Cable
A
B
C
D
E
Auto-Cut 300XT
Power Supply
K
Control
Cable
F
Ground
Cable
Primary power
F1
CNC CNC Cable P
Catalog Number
3-8113-3
G: Torch Lead Set, Shielded
- Coolant Supply w/ Negative
- Coolant Return
- Pilot Return
- Plasma Gas
- Shield Gas
Positioning
Tube
Torch
Art # A-11902_AB
O Work Cable Work
Key
Leads Catalog Numbers; Auto-Cut 300 XT Power Supply, XT-301 Torch
Leads Length
Description
3 ft
1 m
5 ft
1.52 m
10 ft
3.05 m
15 ft
4.5 m
25 ft
7.6 m
35 ft
10.6 m
50 ft
15.2 m
60 ft
18.3 m
75 ft
22.8 m
100 ft
30.5 m
125 ft
38.1 m
A,B,C,D,E
A
B
C
D
E
Supply Lead Set
Pilot Return Cable
(4 ft / 1.2 m)
Negative Cable
Coolant Hose, Supply
Coolant Hose, Return
Control Cable, Power Supply to Arc Starter
4-3096
9-7356
4-3097 4-3098 4-3099 4-3100 4-3101 4-3105 4-3102 4-3103 4-3104
9-4890 9-4891 9-4790 9-4791 9-9426 9-4792 4-3200 9-4793 9-4794 9-4796
9-7357 9-7358 9-7359 9-7360 9-7361 4-3201 9-7362 9-7363 9-7364
9-4886 9-4887 9-4780 9-4782 9-4784 9-4786 4-3202 9-4787 9-4788
9-4888 9-4889 9-4762 9-4764 9-4766 9-4768 4-3203 9-4769 9-4770
9-4941 9-4916 9-4917 9-4918 9-4942 4-3204 9-4943 9-4944 9-4922
F 9-4923 9-4924 9-4925 9-4926 9-4927 9-4928 9-4929
F1
G
K
O
P
Ground Cable
Ground Cable, Gas to Earth
Torch Lead Assembly
Control Cable, Power Supply to GCM 1000 XT
Work Cable
Control Cable, CNC
to Power Supply
9-4931
9-4907
9-4932 9-4933 9-4934
4-3044 4-3045 4-3046
9-4908 9-4909 9-9332 9-4910
9-7350 9-7351 9-7352
9-7368 9-7369
9-4935 9-4936 9-4937
4-3047 4-3048
9-4911 9-4912 9-4913
9-7353
9-7370 9-7371 9-7372
0-5261
NOTE!
Supply lead set includes Pilot Return Cable, Negative Cable, Coolant
Supply & Return Hoses, and Control Cable.
PARTS LIST 6-1
AUTO-CUT 300 XT
A
#8 AWG Cable
2/0 (70 mm ) Cable
F
F1
B
C
D
E 14
G
Green
Red
Green
Red
Green / Yellow #4 AWG
K 37
O
P 37
Pilot Return, Power Supply to Arc Starter
Negative Lead, Power Supply to Arc Starter
Coolant Leads, Power Supply to Arc Starter
Control Cable, Power Supply to Arc Starter
Ground Cable
Ground Cable,
Arc Starter
To Earth Ground
Torch Lead Set
Control Cable,
Power Supply to
Gas Control Module
Work Cable
CNC Cable (28 Wire)
Art # A-11903
6-2 PARTS LIST 0-5261
6.03 Power Supply External Replacement Parts
Item # Qty
5
6
3
4
1
2
1
1
1
1
1
1
Description
GCM 1000 XT Top Cover
Power and Leads Cable Covers
Lifting Eye, Cable
Upper Side Covers (2 total)
Lower Left Side Cover
Lower Right Side Cover
1
AUTO-CUT 300 XT
Catalog #
9-7345
9-7346
9-7347
9-7301
9-7304
9-7344
2
2
3
4
5
Art # A-11933
4
6
0-5261 PARTS LIST 6-3
AUTO-CUT 300 XT
6.04 Power Supply Replacement Parts - Lower Right Side
Item # Qty Description Catalog #
1 1 Coolant Tank, Cap
5
3
4
1
1
1
1
Sensor, Coolant level
Pump, Coolant, Assembly (with motor)
Pump, Coolant, Assembly (no motor)
Motor, Pump (motor only)
6 1 Heat Exchanger Fan FAN1
7 1 Radiator
8 1 Flow, Switch (Not shown, behind cooling fan)
8-5142
9-7306
9-7307
9-7309
9-7422
9-7424
9-7348
9-7349
9-7310
Art # A-11984_AB
1
3
2
4
7
5
6
8
6-4 PARTS LIST 0-5261
6.05 Power Supply Replacement Parts - Upper Right Side
Item # Qty Description Ref. Des.
AUTO-CUT 300 XT
Catalog #
1
2
1
1
Relays, Pump / Fan MC3 / MC2 9-7314
Relay, Inrush Control K1 9-7336
3 1 Relay, MC1 9-7337
4 1 Resistor, R2
5
6
7
1
1
1
Auxilliary Transformer T1
Display PCB
On/Off Switch Breaker CB1
9-7376
9-7315
9-9252
9-7316
9
10
11
1
1
1
Relay and Interface PCB
Pilot PCB
CCM Assembly
9-9253
9-9251
9-9250
9-7324
8
7 9
6 10
5
4
3
2
1
11
Art # A-11935
0-5261 PARTS LIST 6-5
AUTO-CUT 300 XT
6.06 Power Supply Replacement Parts - Left Side
Item # Qty Description Ref. Des.
2
3
4
6
1
1
1
1
Main Contactor (2 total) W1, W2
Full Inverter Block (2 total) 380-415 VAC
Partial Inverter Block 380-415 VAC
Current Transducer, 300A HCT1
Catalog #
9-9254
9-7318
9-7317
9-7319
W7005324
1
3
2
4
3
Art # A-11936
6-6 PARTS LIST 0-5261
6.07 Power Supply Replacement Parts RAS - GCM 1000 XT
AUTO-CUT 300 XT
Item # Qty Description Ref. Des. Catalog #
1
2
5 1
1
1
Gas Solenoid (3 required per unit)
Water Filter Assembly
PCB, RAS1000 RF Cap Board
9-6319
8-3460
9-4959
9-6318
9-9423
1
2
3
5
4
1
Art # A-11937-AB
0-5261 PARTS LIST 6-7
AUTO-CUT 300 XT
6.08 Power Supply Replacement Parts - Rear Panel
Item # Qty Description Breaker Rating Cicuit Rating Ref. Des. Catalog #
1 1
3
4
1
1
*5 1
* Not Shown
Coolant Filter Assy.
Gas Selection Switch
Fuse, 8A SB 500V (2 total)
Air Filter Assembly AC200-XT
- First Stage Filter Element only
-Second Stage Filter Element only
9-7320
9-7322
9-3325
9-7377
9-7527
9-1021
9-1022
3
1
J55 - GCM
USER INPUT
J15 - CNC
HEIGHT CONTROL
2
J54 - TSC /COMM
J59 - RAS
J70 - HE
F1 - 8A SB 500 VAC
CB2 - 5A 120 VAC
CB3 - 5A 24 VAC
CB4 - 5A 120 VAC
F2 - 8A SB 500 VAC
4
Art # A-011938_AB
6-8 PARTS LIST 0-5261
AUTO-CUT 300 XT
6.09 Power Supply Replacement Parts - Front of GCM1000 XT
Item # Qty Description Catalog #
1
3
4
5
1
1
1
1
Pressure Gauge
Run/Set Selector Switch
Potentiometer with Knob
Shield Gas Selector Switch
8-6800
9-9509
9-3426
9-2685
9-3427
9-7762
Art # A-11939_AB
1
3
RUN
SET
4
SHIELD GAS
CUT
OUT
A
GCM 1000 XT
GAS CONTROL MANAGEMENT SYSTEM
H20 MIST
5
PLASMA
2
SHIELD
2
1
H20 MIST
6
0-5261 PARTS LIST 6-9
AUTO-CUT 300 XT
6.10 Recommended Gas Supply Hose
Item #
1
Qty
1
Description Catalog #
3/8”Gray Synflex Hose. No fittings included. Catalog number per foot 9-3616
6-10 PARTS LIST 0-5261
AUTO-CUT 300 XT
SECTION 7: TORCH MAINTENANCE
7.01 Consumable Removal
1. Use the removal tool to hold the Shield Cup & Cartridge Assembly stationary. Turn the Shield Cup to remove it from the Cartridge Assembly
Cartridge Tool
Assembled Cartridge
Art # A-04344_AB
Shield Cup
2. Take the Removal Tool off the back of the Cartridge Assembly Use the removal tool to push the consumable parts out of the Cartridge.
Cartridge Tool Cartridge Assembly
Art # A-04345_AB
0-5261 TORCH INFORMATION 7-1
AUTO-CUT 300 XT
7.02 O-Ring Lubrication
Lubricate all three O-Rings on the Cartridge Assembly and all three O-Rings on the Torch Head periodically with O-Ring Lubricant supplied. Remove the snap ring on the cartridge assembly and slide the locking ring downward for access to the O-Ring under the locking ring.
O-Rings Torch Head
Inner O-Ring (Cat. No. 9-3030)
Location (Under Locking Ring)
Cat. No. 9-9041
!
O-Ring, Cat. No. 9-3029
O-Ring, Cat. No. 9-3028
Cat. No. 8-0524
Cat. No. 9-3026
Cat. No. 9-3025
Cartridge Assembly
Cat. No. 9-9429
Snap Ring
Art # A-04071_AC
Art # A-04066_AE
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-04861
7-2 TORCH INFORMATION 0-5261
7.04 Torch Consumables Installation
1. Install the consumables as follows:
AUTO-CUT 300 XT
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
Shield
Retainer
NOTE!
For 200-Amp consumables, when replacing the shield retainer or the shield cup, assemble these two parts first before assembling the other consumables.
Cartridge
Shield Cap ibutor
Shield Gas
Tip ibutor
Plasma Gas Electrode
Assemble First
Art # A-11915
0-5261 TORCH INFORMATION 7-3
AUTO-CUT 300 XT
1: Stack Parts 2: Press Cartridge onto Stacked Parts
Electrode
Plasma Gas
Distributor
Tip
O-Ring on Tip
Shield Gas
Distributor
Shield Cap
3: Thread Shield Cup onto Cartridge
No Gaps
Between Parts
4: Check Shield Cap Protrusion
Cartridge Covers
O-Ring on Torch Tip
Shield Cup
Shield Cap
Shield Cap Protrudes
0.063-0.083" (1.6 - 2.1 mm)
Art # A-04873
7-4 TORCH INFORMATION 0-5261
AUTO-CUT 300 XT
2. Remove the Removal 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
Ohmic Clip
Art # A-07202_AB
Art # A-03393_AB
Installing Assembled Cartridge Onto Torch Head
3. Slide the ohmic clip over the shield cup if using ohmic torch height control sensing.
NOTE!
Ohmic height sensing is not recommended with water shield. Water on the plate interferes electrically with the ohmic sensing circuit.
4. Connect the wire lead from the height finder to the ohmic clip.
0-5261 TORCH INFORMATION 7-5
AUTO-CUT 300 XT
E. Coolant Leak Trouble-Shooting
Never operate the system if coolant leaks from 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
Consumable Parts
Installed?
No
Yes
Are Parts New or Used?
New
Used
Leaking from
Coolant Supply or
Coolant Return?
Return
Order Coolant
Check Valve
Kit 9-4846
Supply
Order Coolant
Tube Replacement Kit
The parts probably are worn out.
See chart for approximate life expectancy.
The torch may be damaged. See page to determine if head damage has occurred.
Are Parts fully assembled into the Torch?
Yes Is the Torch Damaged?
No
Remove and Lubricate all O-rings on Torch Head,
Consumables Cartridge, and Consumables.
Re-assemble Torch.
Still leaks?
Yes
Unsure?
Disassembly fully and re-assemble the Torch Properly.
See Installation Manual.
Yes
Replace Torch Head Yes
Replace Consumable
Cartridge and Shield Cup.
Torch still leaks?
Amperage Plasma Gas Recommended Wear Depth
for Replacement
50
O
2
Air
Inch mm
0.04
0.08
1
2
100
200
300
O
2
Air
O
2
Air
Air
0.04
0.08
0.08
0.08
0.08
1
2
2
2
2
Art # A-11955_AB Torch
Electrodes
7-6 TORCH INFORMATION 0-5261
A1.01
APPENDIX 1: CNC Control Module
AUTO-CUT 300 XT
Control PCB Connections
TB1
10K
(LV) OK To Move 2
High +10V
Analog Current Control
Wiper / Input
Low (-)
Divided Arc Volts
Output
Start/Stop Input
Stop (NC)
(LV) OK To Move 2
CNC Plasma Enable
(
(
(+)
)
12
11
10
9
8
(+)
)
7
6
5
4
3
(
(+)
)
2
1
TB2
(+)
DC
OK To Move
SW6
Pilot On Output
(Contacts)
Preflow On
Hold Start
(+)
( )
(+)
( )
12
11
10
9
8
7
6
3
2
5
4
1
TB3
Spare #2 Output
Normally Open Contacts
Spare #2 Output
Normally Closed Contacts
Spare #1 Output
Normally Open Contacts
Expanded
Metal
Corner Current
Reduction
Remote
Plasma Marking
6
5
8
7
4
3
12
11
10
9
2
1
( )
(+)
( )
+
( )
(+)
Art # A-11512_AB
0-5261 APPENDIX A-1
AUTO-CUT 300 XT
A1.02 CNC functions
CNC I/O circuits provide at least 1000V galvanic isolation from the plasma power supply.
While the CNC circuits are isolated from the power supply, many of the signal returns on J15 and TB1, TB2 & TB3 are common to each other. J15 pins 1, 4, 5, 10, 17, and TB1-1, 5, 7, 9, and TB2-1 & 3 are all common. J15 pin 12 and
TB2-10 are also connected to the others when SW6 (OK to Move select) is set for voltage.
Rear Panel CNC Connector J15:
37 Circuit (Amp CPC) Remote Standard:
These are also duplicated on TB1, TB2 & TB3 use one or the other not both.
Chassis gnd (for SC-11 cable shield)
Start/Stop
Ok to Move (contacts or voltage 1)
Divided Arc volts (selectable ratio
50:1; 40:1; 30:1; 16.6:1, 25:1)
PreFlow ON
Corner Current Reduction
Isolated Circuit Comm (for SC-11)
1
3 (+); 4 (-)
12(-); 14 (+)
5 (-); 6 (+)
7 (+); 9 (-)
10 (+); 11 (-)
8
Hold Start
Plasma Mark
Cut Expanded Metal
CNC Plasma Enable2
Remote Analog Current Control 3
Stop (Latched) SW4
Pilot is ON (contacts)
16(+); 17 (-)
21 (+); 22 (-)
23 (+); 24 (-)
25 (+); 26 (-)
29 (+); 30 (signal); 31 (-)
32 (+); 33 (-)(comm.)
34; 35
A-2 APPENDIX 0-5261
Internal CNC connections. TB1, TB2 & TB3 on CCM module.
AUTO-CUT 300 XT
Connections are provided on the CCM module TB1, TB2 & TB3 terminal blocks including most of the rear panel functions plus some additional features. All these signals are isolated from the plasma power supply but signals marked (comm.) and (-) are common to each other.
Users are expected to install their own CNC cable to these connections. Knockout hole is provided in rear panel of
CCM module. User shall provide strain relief / cord grip for user installed cable.
TB1
CNC Enable/Disable
OK to Move 2
Stop Latched (NC) 4
Start/Stop Ret 4
or Start Latched (NO)
Divided Arc Voltage
4
Remote Analog Current Control
TB2
Hold Start
Preflow ON
Pilot is ON (contacts)
OK to Move (contacts or DC Volts)5
TB3
TB1-2 (+), TB1-1(-)(comm.)
TB1-3 &TB1-12 Contacts only, rated 1A @ 28 VAC/DC
TB1-4 (+) & TB1-5 (-) (comm.) used with Start Latched
TB1-6 (+), TB1-5 (-) (comm.)
TB1-6 (+), TB1-5 (-) (comm.) used with Stop Latched
TB1-8 (+), TB1-7 (-) comm.
TB1-9 Analog Comm. (-) or 10K CC Pot low
TB1-10 Analog in (+) or CC Pot Wiper
TB1-11 10K CC Pot Hi (+10V @ 1 ma. Supply)
TB2-2 (+),TB2-1 (-) (comm. )
TB2-4 (+), TB2-3 (-) (comm.)
TB2-6, TB2-8 rated 1A @ 120 VAC or 28 VDC
TB2-12 (+), TB2-10 (-)
Plasma Marking
Corner Current Reduction
Cut Expanded Metal
Spare NO Contact
Spare NC Contact
Spare NO Contact
TB3-2(+), TB3-1(-) (comm.)
TB-4(+), TB3-3(-)(comm.)
TB3-6(+), TB3-5(-)(comm.)
TB3-7, TB3-8
TB3-9, TB3-10
TB3-11, TB3-12
1 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
2 Remove factory installed jumper from TB1-1 & 2 if using CNC Plasma Enable in J15.
3-5 See below.
0-5261 APPENDIX A-3
AUTO-CUT 300 XT
CNC Input / Output Descriptions
All inputs except the Analog Current Control are digital active low (contact or SW closure).
CNC Enable / Disable ( input)
— Requires closed connection rated for 10 ma. @ 20VDC for unit to operate.
Factory installed jumper between TB1-1&2 must be removed when connecting user supplied Enable/Disable circuit.
4 Start/Stop (input)—Switch (momentary or sustained) rating 35ma. @ 20 VDC
Start / Stop circuit configuration. Momentary Start / Stop (Latched) is only available at TB1.
SUSTAINED START / STOP
START / STOP
TB1-5
TB1-6
MOMENTARY START / STOP
STOP
TB1-4
START
TB1-5
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 5A. User is responsible for setting correct analog voltage to maintain at least 5A 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 by some height controls to flow gas while finding height. Also 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. Used with CNC START. Apply START to begin gas flow. Same time apply
HOLD to delay ignition until height is found. Remove HOLD to ignite pilot, initiate arc transfer.
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. PREFLOW ON should remain active for at least 1 second after CNC START is applied. It is OK if it remains on until the end of the cut.
Need to recycle it to begin a new preflow prior to applying START for the next 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.
5 OK to Move2 – Provides a second set of N.O. contacts that close when arc transfer is detected. Contacts are rated for maximum of 24 VAC/DC @ 1A. Simplified CNC Circuit.
A-4 APPENDIX 0-5261
AUTO-CUT 300 XT
5 +10V @ 10ma. For Remote CC Pot – Previously CCM versions if one wanted to use a potentiometer for the Remote
Analog Current Control (CC) input an external 10 V supply was required for Pot High.. Now an isolated (from main plasma circuits) 10V supply is provided. Recommended value of the pot is 5K or 10K.
Ext. +10V TB1
11
10
9
+10V
WIPER
Art # A-09246
Plasma Marking (input) --- Plasma marking is available only with Ultra-Cut XT systems with Auto Gas Box.
Corner Current Reduction (input) --- When activated, normally from a table controller’s corner or height control inhibit signal, signaling that the cutting speed is being reduced to navigate a corner or small radius, the cutting current is reduced at a fixed rate to a predetermined level to provide an improved cut at the lower speed.
Cut Expanded Metal (input) ---Normally the plasma supply is optimized for pierce cutting, high pierce height directly above the metal to be cut, short pilot time, etc. Activating this input adjusts the plasma supply to optimize it’s parameters for cutting expanded metal, perforated metal, running edge starting, etc. Among other changes the transfer height is reduced to same as cut height. In addition to activating the Cut Expanded Metal input CCM switch SW1-1 should be turned on automatically restart the pilot and SW8-1 set on for longer pilot time.
Spare contacts --- These are not currently active but are reserved for possible future use.
0-5261 APPENDIX A-5
AUTO-CUT 300 XT
Simplified CNC Circuit
Autocut 300 XT Simplified CNC
OK2 (cont act)
+10V (CC Pot Hi )
CC Pot W iper
CC Pot L ow
Di v Arc V (+)
Di v Arc V (-)
/Start - Stop (+)
/Start - Stop (-)
Stop Mo m NC
OK2 (cont act)
/ CNC Enabl e (+)
/ CNC Enabl e (-)
TB1
8
7
6
5
4
3
2
1
12
11
10
9
OK to M OV E (+)
OK to M OV E (-)
PILOT is ON
PILOT is ON
Prefl ow ON (+)
Prefl ow ON (-)
Hol d Start (+)
Hol d Start (-)
TB2
8
7
6
5
4
3
2
1
12
11
10
9
Spare Input
Reserved
Spare #1b NO
Reserved
{
/ Plasma M arki ng (-)
/ Plasma M arki ng (+)
TB3
8
7
6
5
4
3
2
1
12
11
10
9
Art # A-11931_AB
+18VDC
D C VO LT S
SW6A
C ONTA CT S
SW6B
OK
3
B
+
4
-
VOLTAGE DIVIDER
5
+10V
GND
PSR
ALL SW OFF f or 50: 1 ( def aul t )
SW12A ( 1) ON = 16. 7: 1 ( SC- 11)
SW12B ( 2) ON = 30: 1
SW12C ( 3) ON = 40: 1
SPA RE #1a
GND
13
14
15
16
10
9
11
12
17
18
7
8
5
6
3
4
1
2
J21
13
14
15
16
10
9
11
12
17
18
19
20
7
8
5
6
3
4
1
2
J22
(133)
(134)
(137)
(139)
(138)
(143)
(140)
(141)
(136)
(135)
(132)
(153)
(142)
(144)
(145)
(146)
(147)
(148)
(149)
(150)
(151)
(152)
(154)
(155)
(156)
(157)
(158)
(159)
J15-1 to chassis used for
SC-11 cable shield
The COMM Ref at pin
8 is also for the SC-11
Harness to Relay PCB
Harness to CPU PCB
(115)
(116)
(117)
(118)
(119)
(120)
J54 - Rem ote HM I & CN C CO M M
(100)
(101)
(102)
(109)
(108)
9
10
11
12
13
14
7
8
5
6
3
4
1
2
RS 485
/ 422
Comm
C hassi s
(133)
(134)
(135)
(136)
(137)
(138)
(139)
(140)
(141)
(142)
(143)
(144)
(145)
J15-13 connects SC-11 chassis to PS chassis.
(146)
(147)
(148)
(149)
(150)
(151)
(132)
(152)
(153)
(154)
(155)
(156)
(157)
(158)
(159)
J15-CNC
29
30
31
32
25
26
27
28
33
34
35
36
37
21
22
23
24
17
18
19
20
13
14
15
16
9
10
11
12
7
8
5
6
3
4
1
2
3- / CNC Start (+)
4- / CNC Start (-)
5- Divided A rc V (-)
6- Divided A rc V (+)
7- / Preflow ON (+)
8- COMM Ref (1K Ohm)
9- / Preflow ON (-)
12- OK to M ove (-)
14- OK to M ove (+)
15 - K ey Plug
16- / Hold Start (+)
17- / Hold Start (-)
21- / Plasma M ark (+)
22- / Plasma M ark (-)
23-
24-
}
Reserved
25- / CNC Plasma Enable (+)
26- / CNC Plasma Enable (-)
29- Remote CC Pot High
30- Remote CC (analog)
31- Remote CC Pot Low
32- Stop SW (momentary) *
33- Stop SW Ret
34- Pilot is ON (a)
35- Pilot is ON (b)
36- Spare OUT #1 (a)
37- Spare OUT #1 (b)
* Used with Mom en tary CNC St art SW
Art # A-11931_AB
A-6 APPENDIX 0-5261
Autocut 300 XT Simplified CNC
OK2 (cont act)
+10V (CC Pot Hi )
CC Pot W iper
CC Pot L ow
Di v Arc V (+)
Di v Arc V (-)
/Start - Stop (+)
/Start - Stop (-)
Stop Mo m NC
OK2 (cont act)
/ CNC Enabl e (+)
/ CNC Enabl e (-)
TB1
8
7
6
5
4
3
2
1
12
11
10
9
OK to M OV E (+)
OK to M OV E (-)
PILOT is ON
PILOT is ON
Prefl ow ON (+)
Prefl ow ON (-)
Hol d Start (+)
Hol d Start (-)
TB2
8
7
6
5
4
3
2
1
12
11
10
9
Spare Input
Reserved
Spare #1b NO
Reserved
{
/ Plasma M arki ng (-)
/ Plasma M arki ng (+)
TB3
8
7
6
5
4
3
2
1
12
11
10
9
Art # A-11931_AB
+18VDC
D C VO LT S
SW6A
C ONTA CT S
SW6B
OK
3
B
+
4
-
VOLTAGE DIVIDER
5
+10V
GND
PSR
ALL SW OFF f or 50: 1 ( def aul t )
SW12A ( 1) ON = 16. 7: 1 ( SC- 11)
SW12B ( 2) ON = 30: 1
SW12C ( 3) ON = 40: 1
AUTO-CUT 300 XT
SPA RE #1a
GND
13
14
15
16
10
9
11
12
17
18
7
8
5
6
3
4
1
2
J21
13
14
15
16
10
9
11
12
17
18
19
20
7
8
5
6
3
4
1
2
J22
(133)
(134)
(137)
(139)
(138)
(143)
(140)
(141)
(136)
(135)
(132)
(153)
(142)
(144)
(145)
(146)
(147)
(148)
(149)
(150)
(151)
(152)
(154)
(155)
(156)
(157)
(158)
(159)
J15-1 to chassis used for
SC-11 cable shield
The COMM Ref at pin
8 is also for the SC-11
Harness to Relay PCB
Harness to CPU PCB
(115)
(116)
(117)
(118)
(119)
(120)
J54 - Rem ote HM I & CN C CO M M
(100)
(101)
(102)
(109)
(108)
9
10
11
12
13
14
7
8
5
6
3
4
1
2
RS 485
/ 422
Comm
C hassi s
(133)
(134)
(135)
(136)
(137)
(138)
(139)
(140)
(141)
(142)
(143)
(144)
(145)
J15-13 connects SC-11 chassis to PS chassis.
(146)
(147)
(148)
(149)
(150)
(151)
(132)
(152)
(153)
(154)
(155)
(156)
(157)
(158)
(159)
J15-CNC
29
30
31
32
25
26
27
28
33
34
35
36
37
21
22
23
24
17
18
19
20
13
14
15
16
9
10
11
12
7
8
5
6
3
4
1
2
3- / CNC Start (+)
4- / CNC Start (-)
5- Divided A rc V (-)
6- Divided A rc V (+)
7- / Preflow ON (+)
8- COMM Ref (1K Ohm)
9- / Preflow ON (-)
12- OK to M ove (-)
14- OK to M ove (+)
15 - K ey Plug
16- / Hold Start (+)
17- / Hold Start (-)
21- / Plasma M ark (+)
22- / Plasma M ark (-)
23-
24-
}
Reserved
25- / CNC Plasma Enable (+)
26- / CNC Plasma Enable (-)
29- Remote CC Pot High
30- Remote CC (analog)
31- Remote CC Pot Low
32- Stop SW (momentary) *
33- Stop SW Ret
34- Pilot is ON (a)
35- Pilot is ON (b)
36- Spare OUT #1 (a)
37- Spare OUT #1 (b)
* Used with Mom en tary CNC St art SW
Art # A-11931_AB
0-5261 APPENDIX A-7
AUTO-CUT 300 XT
CNC Connections
Cutting Machine
START/STOP
*
(1)
3
4
6
7
CNC Cable
Start Motion
(OK-To-Move)
{
(16)
(17)
(21)
(22)
(23)
(24)
(25)
(26)
10 K
**
(29)
(30)
(31)
(32)
(33)
(34)
(35)
(36)
(37)
Shield
Represents switch, relay, open collector transistor, etc.
Power Supply
J15
14
15
16
17
18
19
20
21
22
23
24
25
26
27
31
32
33
28
29
30
34
35
36
37
1
2
10
11
3
4
5
6
7
8
9
12
13
*
NC
..........
..........
..........
Source, 16 VDC, 10 ma.
... Divided Arc V (-)
Divided Arc V (+)
Pre Flow ON (+)
*
..........
..........
...
..........
..........
Pre Flow ON (-)
Corner Current Reduction (+)
Corner Current Reduction (-)
SW6
(+)
DC
/Hold Start(+)
/Hold Start(-)
OK-To-Move
Relay DCV (-)
Contact or
(1A @ DCV (+)
120 VAC ( 15 - 18 VDC @ or 28 VDC) up to 100 ma.)
..........
..........
..........
..........
..........
..........
..........
..........
..........
..........
..........
..........
..........
..........
..........
/Plasma Mark (+)
/Plasma Mark (-)
/Cut Expanded Metal (+)
/Cut Expanded Metal (-)
/CNC Plasma Enable (+)
/CNC Plasma Enable (-)
Remote CC Pot High (+10VDC)
Remote CC 0-10V Signal or Pot Wiper
Remote CC Pot Low (-)
Stop SW (momentary)
Stop SW Ret
Pilot is ON (a)
Pilot is ON (b)
Spare OUT #1 (a)
Spare OUT #1 (b)
Relay contact 1A @
120 VAC or 28
* Power Supply Gnd not used for CNC cable
Do not connect wire #1 to anything.
** Cable Shield drain wire must be
connected to ground at cutting machine.
Art # A-11901
A-8 APPENDIX 0-5261
PIN
LOCATION
3
4
5
25
26
29
22
23
24
16
17
21
9
10
11
12
14
6
7
8
33
34
35
30
31
32
36
37
CNC Cable Color Code
AUTO-CUT 300 XT
TABLE 1: CABLE ITEM#4 COLOR CODE TABLE
COLOR
WHITE/BLUE
WHITE/VIOLET
WHITE/BROWN/VIOLET
WHITE/BROWN
YELLOW
GREEN
WHITE/BLACK/BROWN
WHITE/BROWN/BLUE
WHITE/BLACK
BLACK
BLUE
WHITE/BROWN/YELLOW
WHITE/BROWN/GREEN
WHITE/BLACK/ORANGE
WHITE/BLACK/RED
WHITE/BROWN/ORANGE
ORANGE
RED
BROWN
WHITE/BROWN RED
WHITE
GRAY
VIOLET
WHITE/BLACK/YELLOW
WHITE/BLACK/GRAY
WHITE/BLACK/VIOLET
WHITE/BLACK/BLUE
WHITE/BLACK/GREEN
SIGNAL DESCRIPTION
START CNC (+)
START CNC (-)
DIV ARC (-)
DIV ARC(+)
PREFLOW ON (+)
COMM 1K
PREFLOW ON (-)
CORNER CR (+)
CORNER CR (-)
OK TO MOVE (-)
OK TO MOVE (+)
/HOLD START (+)
/HOLD START (-)
/PLASMA MARK (+)
/PLASMA MARK (-)
/CUT EXPANDED METAL (+)
/CUT EXPANDED METAL (-)
/CNC PLASMA ENABLE (+)
/CNC PLASMA ENABLE (-)
REMOTE CC POT HIGH
REMOTE CC (ANALOG)
REMOTE CC POT LOW
STOP SW (MOMENTARY)
STOP SW RETURN
PILOT IS ON (A)
PILOT IS ON (B)
SPARE OUT #1 (A)
SPARE OUT #1 (B)
PIN 1
Art # A-12757
0-5261 APPENDIX A-9
AUTO-CUT 300 XT
APPENDIX 2: CCM CPU PCB Layout
= Test Point
A-10 APPENDIX
Art # A-11675_AC
0-5261
CCM CPU PCB
Test Points
TP1 GND
TP2
TP3
TP4
TP5
ISO +5.0V
+24V
+3.3V
ISO GND
TP6
TP7
+5.0V
TOTAL DEMAND 3.3V=400A
TP9 /WR
TP10 /RD
TP11 CPU TEMP SENSE
TP12 +3.3VA
TP13 -15VDAC
TP14 PC2
TP15 +15VDAC
TP16 CLKO
TP18 OSC_CLOCK
LED Reference
D2
D3
D4
D7
D11
D17
Red RXD
Red TXD
Red Fiber Out 2
Red Fiber Out 1
Green Future Use
Green Future Use
AUTO-CUT 300 XT
0-5261 APPENDIX A-11
AUTO-CUT 300 XT
APPENDIX 3: CCM I/O PCB Layout
= Test Point
A-12 APPENDIX 0-5261
CCM I/O PCB
Test Points
D20
D25
D33
D37
D41
D43
D8
D12
D13
D18
D2
D3
D4
D6
TP1
TP2
TP3
TP4
GND
/COOLANT FANS ON
/TORCH PUMP ON
LOW COOLANT FLOW (SW)
TP5
TP6
TP7
TP8
COOLANT FLOW SIGNAL (PULSE)
+15V ISOLATED
-15V ISOLATED
+18V ISOLATED
ANALOG CURRENT CONTROL TP9
0-3.3V
TP10 GND ISOLATED
TP11 /PILOT ENABLE
TP12 +5VDC
TP13 -15VDC
TP14 +15VDC
TP15 24VDC
TP18 +5V ISOLATED
TP19 WORK CURRENT
LED Reference
Green PLASMA ENABLE
Green E-STOP_PS
Green GAS ON
Green CNC START
Green HOLD START
Green PREFLOW ON
Green CSD
Green MARK
Green SPARE1
Green EXP METAL
Green OK TO MOVE
Green PSR
Green SPARE FIELD OUT 2
Green SPARE FIELD OUT 1
AUTO-CUT 300 XT
J Connectors
J25
J26
J28
J29
J21
J22
J23
J24
BASIC CNC
EXTENDED CNC
RELAY - INTERFACE BOARD
ARC / TIP VOLTS
TEST
GAS BOX
TO CPU
TO CPU
0-5261 APPENDIX A-13
AUTO-CUT 300 XT
APPENDIX 4: Pilot PCB Layout
= Test Point
A-14 APPENDIX
Art # A-11677_AB
0-5261
Pilot PCB Test Points
TP1
TP2
TP3
TP4
GND
PILOT GATE
+5V
TIP
LED Reference
D2 Green PILOT ENABLE
D11 Green +5V
AUTO-CUT 300 XT
0-5261 APPENDIX A-15
AUTO-CUT 300 XT
APPENDIX 5: Relay and Interface PCB Layout
= Test Point
A-16 APPENDIX
Art # A-11678_AB
0-5261
Relay and Interface PCB Test Points
D7
D11
D12
D22
D23
D24
D25
D26
D27
TP1
TP2
TP3
TP4
TP5
TP6
GND
-15V
+5VDC
+12V
+24V
+15V
TP7 +5VDC
LED Reference
D2 Green 1 TORCH GAS ON
Green PILOT ENABLE
Green PILOT CURRENT DETECTED
Green WORK CURRENT DETECTED
Green CONTACTORS ON
Green RF ON
Green FANS ON
Green PLASMA ENABLED
Green 1 TORCH ON
Green TORCH COOLANT ON
AUTO-CUT 300 XT
0-5261 APPENDIX A-17
AUTO-CUT 300 XT
APPENDIX 6: Display PCB Layout
= Test Point
A-18
Art # A-11679
APPENDIX 0-5261
Display PCB Test Points
TP1
TP2
TP3
GND
+5VDC
+24VDC
AUTO-CUT 300 XT
0-5261 APPENDIX A-19
AUTO-CUT 300 XT
APPENDIX 7: System Bias PCB Layout
= Test Point
A-20
Art # A-11680_AB
APPENDIX 0-5261
System Bias PCB Test Points
D26
D27
D30
D44
D3
D4
D14
D15
TP5
TP6
TP7
TP8
TP1
TP2
TP3
TP4
GND
24VDC
DC INPUT POSITIVE
Vcc1
Vcc2
GATE
PRIMARY GND
+12V PRIMARY
TP9
TP10
LED Reference
P_ISOL_GND
DC SENSE POSITIVE
Red MISSING PHASE
Red AC V HIGH
Red AC V LOW
Green VAC_IDA
Green +12V PRIMARY
Green VAC_IDB
Green 24VDC
Green TRANSFORMER ON
AUTO-CUT 300 XT
0-5261 APPENDIX A-21
AUTO-CUT 300 XT
APPENDIX 8: Main Inverter Bottom PCB Layout
= Test Point
A-22 APPENDIX 0-5261
Main Inverter Bottom PCB Test Points
TP1 GND
TP6
TP7
TP8
TP9
TP2
TP3
TP4
TP5
GATE 2A
GATE 1A
GATE 3A
GATE 4A
GATE 2B
GATE 1B
GATE 4B
GATE 3B
TP10 +12VP
TP11 +12VDC
TP12
TP13
THERMISTOR SIDE A
THERMISTOR SIDE B
TP14 +5VDC
TP15 PGND
LED Reference
D3 Red CAP IMBALANCE
D4 Green READY
AUTO-CUT 300 XT
0-5261 APPENDIX A-23
AUTO-CUT 300 XT
APPENDIX 9: Main Inverter Top PCB Layout
= Test Point
A-24 APPENDIX 0-5261
Main Inverter Top PCB Test Points
TP5
TP6
TP7
TP8
TP1
TP2
TP3
TP4
GND
GATE 2A
GATE 1A
GATE 3A
GATE 4A
GATE 2B
GATE 1B
GATE 4B
TP9 GATE 3B
TP10 +12VP
TP11 +12VDC
TP12 THERMISTOR SIDE A
TP13 THERMISTOR SIDE B
TP14 +5VDC
TP15 PGND
LED Reference
D3
D4
Red CAP IMBALANCE
Green READY
AUTO-CUT 300 XT
0-5261 APPENDIX A-25
AUTO-CUT 300 XT
APPENDIX 10: Control and Fault PCB Layout
= Test Point
Art # A-11683_AC
A-26 APPENDIX 0-5261
Control and Fault PCB Test Points
TP1 GND
TP22 +12VDC
TP23 +5VDC
TP24 GATE 1+
TP25 A_OUT1
TP26 B_OUT1
TP27 GATE 1-
TP28 I_SNS1
TP29
TP30
GATE 2+
I_DMD1 0.5V-6.7V
TP31 GATE 2-
TP32 -12VDC
TP33 START 2
TP34 SHDN
TP35 ENABLE
TP36 READY IN
TP37 READY OUT
LED Reference
D1 Red INV FLT
D14
D24
D32
Red OVER TEMP
Green PWM ON
Red PRI OC
AUTO-CUT 300 XT
0-5261 APPENDIX A-27
AUTO-CUT 300 XT
APPENDIX 11: Cap Bias Bottom PCB Layout
A-28 APPENDIX
Art # A-11685_AC
0-5261
AUTO-CUT 300 XT
APPENDIX 12: Cap Bias Top PCB Layout
0-5261 APPENDIX
Art # A-11686_AC
A-29
AUTO-CUT 300 XT
APPENDIX 13: Suppressor PCB Layout
A-30 APPENDIX
Art # A-11684_AC
0-5261
APPENDIX 14: Cooling Diagram
AUTO-CUT 300 XT
0-5261 APPENDIX A-31
AUTO-CUT 300 XT
APPENDIX 15: System Schematic pg 1
1 2
A
(1)
(2)
(3)
W2A
W2B
W2C
(7)
(8)
(9)
3
(7)
(8)
(9)
J105B
1
2
J104B
1
2
J103B
1
2
AC INPUT
(7)
(8)
(9)
J105A
1
2
J104A
1
2
J103A
1
2
019X502700
AC INPUT
019X502000
4 5
INVERTER MODULE (IM) #3 (top)
IM #3 Section B (upper)
J100 -- 30 CKT RIBBON
IM #3 Section A (lower)
J100 -- 30 CKT RIBBON
B
(1)
(2)
(3)
J50
9
10
11
12
13
14
7
8
5
6
3
4
1
2
AC LINE
AC
SUPPRESSION
PCB
019X504000
J51
3
4
1
2
GND
J52
3
4
1
2
(10)
(11)
(12)
(13)
LT1
LT2
INTERNAL AC INDICATOR
CHASSIS GND
LT1 & LT2
INPUT POWER
NEON INDICATORS
Rear Panel & Internal
(23)
(24)
(25)
J105A
1
2
J104A
1
2
J103A
1
2
INVERTER MODULE (IM) #2 half module (middle position)
AC INPUT
019X502000
IM #2 Section A (lower)
J100 -- 30 CKT RIBBON
C
L1
L2
L3
Earth
1
1
1
1
(1)
(2)
(3)
W1A
W1B
W1C
(23)
(24)
(25)
(23)
(24)
(25)
J105B
1
2
J104B
1
2
J103B
1
2
AC INPUT
MAIN PCB LEDS
D3, RED, CAP
IMBALANCE
D4, GREEN, READY
INVERTER MODULE (IM) #1 (bottom)
IM #1 Section B (upper)
J100 -- 30 CKT RIBBON
CAP BIAS PCB LEDS
D6, GREEN, -12V
D11, GREEN, +12VP
D13, GREEN, +12V
CONTROL PCB LEDS
D1, RED, INV FLT
D14, RED, OVER TEMP
D24, GREEN, PWM ON
D32, RED, PRI OC
019X502700
AC INPUT
IM #1 Section A (lower)
J100 -- 30 CKT RIBBON
D
CHASSIS GND
CB1
ON / OFF
16 A
(1-20)
(2-21)
(3-22)
18 AWG wire both in and out of
CB1
(23)
(24)
(25)
J105A
J104A
1
2
J103A
1
2
1
2
019X502000
E
F
FRONT PANEL
To J27 on CCM I/O PCB
F1
8A, 500V, SB
J63 = Mini-Fit Jr goes to
J12 on T1 primary
400 VAC -- Single 18 AWG
in pins 1 & 12
480 VAC -- Single 18 AWG
in pins 1 & 12
230 VAC -- 18 AWG
wires in pins
1, 6, 7, 12
F2
8A, 500V, SB
(86A)
(27A)
(85A)
(86B)
(27B)
(85B)
AC INPUT
13
14
15
16
9
10
11
12
17
18
7
8
5
6
3
4
1
2
J60
J63
SYSTEM BIAS SUPPLY PCB
019X501900
(43A)
K1A
TO J12
(Sht 2, A1)
K1B
1 2 3 4 5 6 7 8 9 10 11 12
TO AUX TRANSFORMER
(44A)
+ V
GND
+24VDC
(Sht 2, E3)
J62
8
9
6
7
3
4
1
2
5
10
11
12
13
14
24 VDC
24 VDC
MISSING PHASE a
MISSING PHASE b
AC V HIGH a
AC V HIGH b
AC V LOW a
24 VDC_RET
24 VDC_RET
AC V LOW b
VAC_IDA a
/ VAC_IDA b
VAC_IDB a
/ VAC_IDB b
230V 400V 480V ERR
/VAC_IDAb 0 1 0 1
/VAC_IDBb 0 0 1 1
(37)
(38)
(39)
(40)
(41)
(42)
(29)
(30)
(31)
(32)
(33)
(34)
(35)
(36)
(48)
Measure relative to TP1 (24VDC_RET)
"0" = 10-12V "1" = 24V
J61
VOLTAGE SELECTION
Wire #48 from J61-1 to:
J61-2 for 208-230 VAC
J61-3 for 400 VAC
J61-4 for 480 VAC
System Bias LEDs & Test Points
LEDS
D3, RED, MISSING PHASE
D4, RED, AC V HIGH
D14, RED, AC V LOW
D26, GREEN, +12V PRI
D30, GREEN, 24VDC
D44, GREEN, T1 ON
TEST POINTS
TP1 SECONDARY GND
TP2 24VDC
TP3 DC INPUT POSITIVE
TP4 VCC1
TP5 VCC2
TP6 GATE
TP7 PRIMARY GND
TP8 +12V PRIMARY
TP9 P ISOL GND
Art # A-11927_AC
1 2 3
Component Locations (not including PCB components)
C4 Capacitor, fan starting, 8uf 440VAC (Sht 2, D2)
CB1 Circuit Breaker /ON/OFF SW, 15A 480V
(Sht 1, E1)
CB2-4 Circuit Breaker, 5A, 250V (Sht 2, B3)
F1, 2 Fuse, 8A, 500V, S.B. (Sht 1,E1)
FAN1 Fan, Heat Exchanger , 230 VAC (Sht 2, D2)
FL1 Flow meter, pulse output (Sht 2, B2)
FS1
HCT1
Flow SW, 0.5 GPM (3.8 lpm), N.O. (Sht 2, A2)
Current Sensor, Hall Effect 200A, Work Lead
(Sht 1, C8)
K1 Relay, 24VAC, Inrush Control, (Sht2, B9)
L1 Inductor, (Sht 1, B7)
L3-9 Toriod Core Common Mode Ind (Sht1 B8, A-D3)
LS1 Level Switch, Coolant Tank (Sht 2, A3)
LT1, LT2 Indicator, Neon, 250V, AC Volts Present
(Sht 1, B2 & C2)
M1 Motor, Pump, ½ hp 230VAC, 50/60 Hz, 1Ph
(Sht 2, C2)
MC1 Relay, 120VAC, Inrush, coil (Sht2, B9)
contact (Sht2, A1)
MC2 Relay, 120 VAC, Fan Control, coil
(Coil at Sht 2, A7)(Contacts at Sht 2, D1)
MC3 Relay, 120 VAC, Pump Motor Control, coil
(Coil at Sht 2, A7)(Contacts at Sht 2, C1)
R2 Inrush, 4.7 Ohm, 30W (Sht2, A1)
R3,4 Ext RC, 100 ohm 55W (Sht1, A7)
SA1-4 Snubber, Contactor & Relay coils
(Sht 2, A8 & A9)
T1
TB4
Aux Transformer (Sht 2, B2)
Terminal Block (Sht 1, C9)
TS1 Temperature Sensor, NTC, Coolant Return
(Sht 2, A5)
TS2 Temperature Sensor, NTC, Ambient (Sht 2, A5)
W1 Contactor , Input (Coil Sht 2, A8), (Contacts C2)
W2 Contactor , Input (Coil Sht 2, A8), (Contacts A2)
4 5
A-32 APPENDIX 0-5261
6
TO CCM
(Sht 2, C3)
7 8 9 10
ELECTRODE (-)
WORK (+)
OUTPUT
5
4
3
2
1
(49F)
(51F)
J102B
TO CCM
(Sht 2, C3)
ELECTRODE (-)
WORK (+)
OUTPUT
5
4
3
2
1
J102A
(49E)
(51E)
TO CCM
CPU PCB J33
(Sht 2, C3)
ELECTRODE (-)
WORK (+)
OUTPUT
5
4
3
2
1
J102A
(49C)
(51C)
TO CCM
(Sht 2, C3)
ELECTRODE (-)
WORK (+)
OUTPUT
5
4
3
2
1
J102B
(49B)
(51B)
TO CCM
(Sht 2, C3)
ELECTRODE (-)
WORK (+)
OUTPUT
5
4
3
2
1
J102A
(49A)
(50)
PILOT BOARD
LED'S
D2 PILOT ENABLE
D11 +5V
(50)
R3 & R4
TEST POINTS
TP1 GND
TP2 PILOT GATE
TP3 +5V
J58A
(49)
TORCH
1
(49)
J43
ELECTRODE
PILOT PCB
J44
EARTH GROUND
1
(52)
PILOT
1
J58C
(51F)
5
4
3
2
1
J40
INVERTER
019X501600
J42
TO RELAY BOARD
1 2 3 4 5 6 7 8 9 10
CHASSIS GND
J41
TIP
2
1
1 2 3 4 5 6 7 8
J45
TO I/O BOARD
(51)
10 ckt Ribbon
TO J3 on RELAY PCB
(Sht 2, A5)
TIP VOLTS
To J24 on I-O PCB
(Sht 2, D3)
WORK
ARC VOLTS
(51)
(51)
HCT1
Hall Effect Sensor
(53)
(55)
WORK
1
Rev Revision
00 Initial Design
0 1 A d d F 2
02 Add T1 Inrush Ckt
03 Misc updates & corrections
0 4 More updates & corrections
By Date
DAT 10/03/2012
D A T 1 1 / 2 1 / 2 0 1 2
DAT
DAT
D A T
2/18/2013
6/27/2013
9 / 1 2 / 2 0 1 3
Rev
6 10
SHIELD
Sheet
(+)
J46-M
J46-F
TO J1 on RELAY PCB
(Sht 2, B9)
J16
(56)
(57)
(58)
(59) g w o b
RIBBON CABLE 30 ckt.
CCM (J31-36) - INVERTER (J100)
1 READY +
2 READY -
3 INVERTER_FLT +
4 INVERTER_FLT -
5 OVERTEMP_FLT +
6 OVERTEMP_FLT -
7 PWR_PRESENT +
8 PWR_PRESENT -
9 OUT_COM (+3 to 5VDC)
10 VAC_SELA
11 VAC_SELB
12 IS_IDA
13 IS_IDB
14 IS_IDC
15 ENABLE +
16 ENABLE -
17 START2 +
18 START2 -
19 SPARE
20 SYNC_IN +
21 SYNC_IN -
22 NC
23 NC
24 47 OHM to COMM
25 DEMAND +
26 DEMAND -
27 47 OHM to COMM
28 CURRENT +
29 CURRENT -
30 47 OHM to COMM
AC 120V- TB4-4
AC 120V- Ret- TB4-3
AC 24V-TB4-2
AC 24V- Ret -TB4-1
(J10 Sht 2, B8)
(49)
(52)
(51)
(60)
(61)
(62)
(63)
TB4
7
6
5
4
3
2
1
ARC VOLTS (TORCH)
TIP VOLTS (PILOT)
WORK
120 VAC @ 100 ma.
24 VAC @ 1A
RIBBON CABLE 40 ckt CCM (J23) - RELAY PCB (J4)
1 COMMON
2 /1TORCH START *
3 NA
4 /1TORCH GAS SOL ON *
5 /MAIN TORCH IDLE *
6 /1TORCH PRESS OK *
7 FLOW SENSOR (pulses)
8 LOW COOLANT FLOW
9 COOLANT LEVEL OK
10 COMMON
11 NA
12 /PLASMA ENABLE-HMI
13 /COOLANT PUMP ON
14 COMMON
15 /PILOT ENABLE
16 /RAS ON
17 /CONTACTORS ON
18 COMMON
19 /COOLANT FANS ON
20 /1TORCH CONTACTOR ON *
21 /PLASMA ENABLE RELAY
22 COMMON
23 PILOT CURRENT SIG-
24 NC
25 PILOT CURRENT SIG+
26 COMMON
27 WORK CURRENT SIG-
28 WORK CURRENT SIG+
29 NC
30 AMBIENT TEMP
31 COOLANT TEMP
* Used with 1 Torch Option
32 COMMON
33 -15 VDC
34 COMMON
35 24 VDC
36 COMMON
37 24 VDC
38 COMMON
39 24 VDC
40 COMMON
RIBBON CABLE 16 ckt
CCM ( J37) - DISPLAY
PCB (J17)
1,3,5,7
2,4,6,8
9,10 NC
11-16
RIBBON CABLE 10 ckt
RELAY PCB (J3) – PILOT PCB (J42)
1,2
24 VDC
COMMON
SERIAL DATA
24 VDC
3,4,7,10 COMMON
5 PILOT ENABLE +
6 PILOT ENABLE –
8 PILOT CURRENT SIG –
9 PILOT CURRENT SIG +
Art # A-11927_AC
7
Revision By Date
C
GCM1000XT
8
Title SCHEMATIC
Auto-Cut XT 300A 380-415 VAC
9
CHASSIS GND
(+)
(-)
Tip
Work
Date Printed
9/30/2013
Drawn
DAT
Size C
Drawing Number
Date Revised
9/16/2013
Date 10/04/2012
1
042X1355 of 2
A
B
C
D
E
F
A
1
(1)
(2)
(3)
2
W2A
W2B
W2C
(7)
(8)
(9)
3
(7)
(8)
(9)
J105B
1
2
J104B
1
2
J103B
1
2
AC INPUT
(7)
(8)
(9)
J105A
1
2
J104A
1
2
J103A
1
2
019X502700
AC INPUT
019X502000
4 5
INVERTER MODULE (IM) #3 (top)
IM #3 Section B (upper)
J100 -- 30 CKT RIBBON
IM #3 Section A (lower)
J100 -- 30 CKT RIBBON
B
(1)
(2)
(3)
J50
9
10
11
12
13
14
7
8
5
6
3
4
1
2
AC LINE
AC
SUPPRESSION
PCB
019X504000
J51
3
4
1
2
GND
J52
3
4
1
2
(10)
(11)
(12)
(13)
LT1
LT2
INTERNAL AC INDICATOR
CHASSIS GND
LT1 & LT2
INPUT POWER
NEON INDICATORS
Rear Panel & Internal
(23)
(24)
(25)
J105A
1
2
J104A
1
2
J103A
1
2
INVERTER MODULE (IM) #2 half module (middle position)
AC INPUT
019X502000
IM #2 Section A (lower)
J100 -- 30 CKT RIBBON
C
L1
L2
L3
Earth
1
1
1
1
(1)
(2)
(3)
W1A
W1B
W1C
(23)
(24)
(25)
(23)
(24)
(25)
J105B
1
2
J104B
1
2
J103B
1
2
AC INPUT
MAIN PCB LEDS
D3, RED, CAP
IMBALANCE
D4, GREEN, READY
INVERTER MODULE (IM) #1 (bottom)
IM #1 Section B (upper)
J100 -- 30 CKT RIBBON
CAP BIAS PCB LEDS
D6, GREEN, -12V
D11, GREEN, +12VP
D13, GREEN, +12V
CONTROL PCB LEDS
D1, RED, INV FLT
D14, RED, OVER TEMP
D24, GREEN, PWM ON
D32, RED, PRI OC
019X502700
AC INPUT
IM #1 Section A (lower)
J100 -- 30 CKT RIBBON
D
CHASSIS GND
CB1
ON / OFF
16 A
(1-20)
(2-21)
(3-22)
18 AWG wire both in and out of
CB1
(23)
(24)
(25)
J105A
J104A
1
2
J103A
1
2
1
2
019X502000
E
F
FRONT PANEL
To J27 on CCM I/O PCB
F1
8A, 500V, SB
J63 = Mini-Fit Jr goes to
J12 on T1 primary
400 VAC -- Single 18 AWG
in pins 1 & 12
480 VAC -- Single 18 AWG
in pins 1 & 12
230 VAC -- 18 AWG
wires in pins
1, 6, 7, 12
F2
8A, 500V, SB
(86A)
(27A)
(85A)
(86B)
(27B)
(85B)
AC INPUT
13
14
15
16
9
10
11
12
17
18
7
8
5
6
3
4
1
2
J60
J63
SYSTEM BIAS SUPPLY PCB
019X501900
(43A)
K1A
TO J12
(Sht 2, A1)
K1B
1 2 3 4 5 6 7 8 9 10 11 12
TO AUX TRANSFORMER
(44A)
+ V
GND
+24VDC
(Sht 2, E3)
J62
8
9
6
7
3
4
1
2
5
10
11
12
13
14
24 VDC
24 VDC
MISSING PHASE a
MISSING PHASE b
AC V HIGH a
AC V HIGH b
AC V LOW a
24 VDC_RET
24 VDC_RET
AC V LOW b
VAC_IDA a
/ VAC_IDA b
VAC_IDB a
/ VAC_IDB b
230V 400V 480V ERR
/VAC_IDAb 0 1 0 1
/VAC_IDBb 0 0 1 1
(37)
(38)
(39)
(40)
(41)
(42)
(29)
(30)
(31)
(32)
(33)
(34)
(35)
(36)
(48)
Measure relative to TP1 (24VDC_RET)
"0" = 10-12V "1" = 24V
J61
VOLTAGE SELECTION
Wire #48 from J61-1 to:
J61-2 for 208-230 VAC
J61-3 for 400 VAC
J61-4 for 480 VAC
System Bias LEDs & Test Points
LEDS
D3, RED, MISSING PHASE
D4, RED, AC V HIGH
D14, RED, AC V LOW
D26, GREEN, +12V PRI
D30, GREEN, 24VDC
D44, GREEN, T1 ON
TEST POINTS
TP1 SECONDARY GND
TP2 24VDC
TP3 DC INPUT POSITIVE
TP4 VCC1
TP5 VCC2
TP6 GATE
TP7 PRIMARY GND
TP8 +12V PRIMARY
TP9 P ISOL GND
Art # A-11927_AC
1 2 3
Component Locations (not including PCB components)
C4 Capacitor, fan starting, 8uf 440VAC (Sht 2, D2)
CB1 Circuit Breaker /ON/OFF SW, 15A 480V
(Sht 1, E1)
CB2-4 Circuit Breaker, 5A, 250V (Sht 2, B3)
F1, 2 Fuse, 8A, 500V, S.B. (Sht 1,E1)
FAN1 Fan, Heat Exchanger , 230 VAC (Sht 2, D2)
FL1 Flow meter, pulse output (Sht 2, B2)
FS1
HCT1
Flow SW, 0.5 GPM (3.8 lpm), N.O. (Sht 2, A2)
Current Sensor, Hall Effect 200A, Work Lead
(Sht 1, C8)
K1 Relay, 24VAC, Inrush Control, (Sht2, B9)
L1 Inductor, (Sht 1, B7)
L3-9 Toriod Core Common Mode Ind (Sht1 B8, A-D3)
LS1 Level Switch, Coolant Tank (Sht 2, A3)
LT1, LT2 Indicator, Neon, 250V, AC Volts Present
(Sht 1, B2 & C2)
M1 Motor, Pump, ½ hp 230VAC, 50/60 Hz, 1Ph
(Sht 2, C2)
MC1 Relay, 120VAC, Inrush, coil (Sht2, B9)
contact (Sht2, A1)
MC2 Relay, 120 VAC, Fan Control, coil
(Coil at Sht 2, A7)(Contacts at Sht 2, D1)
MC3 Relay, 120 VAC, Pump Motor Control, coil
(Coil at Sht 2, A7)(Contacts at Sht 2, C1)
R2 Inrush, 4.7 Ohm, 30W (Sht2, A1)
R3,4 Ext RC, 100 ohm 55W (Sht1, A7)
SA1-4 Snubber, Contactor & Relay coils
(Sht 2, A8 & A9)
T1
TB4
Aux Transformer (Sht 2, B2)
Terminal Block (Sht 1, C9)
TS1 Temperature Sensor, NTC, Coolant Return
(Sht 2, A5)
TS2 Temperature Sensor, NTC, Ambient (Sht 2, A5)
W1 Contactor , Input (Coil Sht 2, A8), (Contacts C2)
W2 Contactor , Input (Coil Sht 2, A8), (Contacts A2)
4 5
0-5261
AUTO-CUT 300 XT
6
TO CCM
(Sht 2, C3)
7 8 9 10
ELECTRODE (-)
WORK (+)
OUTPUT
5
4
3
2
1
(49F)
(51F)
J102B
TO CCM
(Sht 2, C3)
ELECTRODE (-)
WORK (+)
OUTPUT
5
4
3
2
1
J102A
(49E)
(51E)
TO CCM
CPU PCB J33
(Sht 2, C3)
ELECTRODE (-)
WORK (+)
OUTPUT
5
4
3
2
1
J102A
(49C)
(51C)
TO CCM
(Sht 2, C3)
ELECTRODE (-)
WORK (+)
OUTPUT
5
4
3
2
1
J102B
(49B)
(51B)
TO CCM
(Sht 2, C3)
ELECTRODE (-)
WORK (+)
OUTPUT
5
4
3
2
1
J102A
(49A)
(50)
PILOT BOARD
LED'S
D2 PILOT ENABLE
D11 +5V
(50)
R3 & R4
TEST POINTS
TP1 GND
TP2 PILOT GATE
TP3 +5V
J58A
(49)
TORCH
1
(49)
J43
ELECTRODE
PILOT PCB
J44
EARTH GROUND
1
(52)
PILOT
1
J58C
(51F)
5
4
3
2
1
J40
INVERTER
019X501600
J42
TO RELAY BOARD
1 2 3 4 5 6 7 8 9 10
CHASSIS GND
J41
TIP
2
1
1 2 3 4 5 6 7 8
J45
TO I/O BOARD
(51)
10 ckt Ribbon
TO J3 on RELAY PCB
(Sht 2, A5)
TIP VOLTS
To J24 on I-O PCB
(Sht 2, D3)
WORK
ARC VOLTS
(51)
(51)
HCT1
Hall Effect Sensor
(53)
(55)
WORK
1
Rev Revision
00 Initial Design
0 1 A d d F 2
02 Add T1 Inrush Ckt
03 Misc updates & corrections
0 4 More updates & corrections
By Date
DAT 10/03/2012
D A T 1 1 / 2 1 / 2 0 1 2
DAT
DAT
D A T
2/18/2013
6/27/2013
9 / 1 2 / 2 0 1 3
Rev
6 10
SHIELD
Sheet
(+)
J46-M
J46-F
TO J1 on RELAY PCB
(Sht 2, B9)
J16
(56)
(57)
(58)
(59) g w o b
RIBBON CABLE 30 ckt.
CCM (J31-36) - INVERTER (J100)
1 READY +
2 READY -
3 INVERTER_FLT +
4 INVERTER_FLT -
5 OVERTEMP_FLT +
6 OVERTEMP_FLT -
7 PWR_PRESENT +
8 PWR_PRESENT -
9 OUT_COM (+3 to 5VDC)
10 VAC_SELA
11 VAC_SELB
12 IS_IDA
13 IS_IDB
14 IS_IDC
15 ENABLE +
16 ENABLE -
17 START2 +
18 START2 -
19 SPARE
20 SYNC_IN +
21 SYNC_IN -
22 NC
23 NC
24 47 OHM to COMM
25 DEMAND +
26 DEMAND -
27 47 OHM to COMM
28 CURRENT +
29 CURRENT -
30 47 OHM to COMM
AC 120V- TB4-4
AC 120V- Ret- TB4-3
AC 24V-TB4-2
AC 24V- Ret -TB4-1
(J10 Sht 2, B8)
(49)
(52)
(51)
(60)
(61)
(62)
(63)
TB4
7
6
5
4
3
2
1
ARC VOLTS (TORCH)
TIP VOLTS (PILOT)
WORK
120 VAC @ 100 ma.
24 VAC @ 1A
RIBBON CABLE 40 ckt CCM (J23) - RELAY PCB (J4)
1 COMMON
2 /1TORCH START *
3 NA
4 /1TORCH GAS SOL ON *
5 /MAIN TORCH IDLE *
6 /1TORCH PRESS OK *
7 FLOW SENSOR (pulses)
8 LOW COOLANT FLOW
9 COOLANT LEVEL OK
10 COMMON
11 NA
12 /PLASMA ENABLE-HMI
13 /COOLANT PUMP ON
14 COMMON
15 /PILOT ENABLE
16 /RAS ON
17 /CONTACTORS ON
18 COMMON
19 /COOLANT FANS ON
20 /1TORCH CONTACTOR ON *
21 /PLASMA ENABLE RELAY
22 COMMON
23 PILOT CURRENT SIG-
24 NC
25 PILOT CURRENT SIG+
26 COMMON
27 WORK CURRENT SIG-
28 WORK CURRENT SIG+
29 NC
30 AMBIENT TEMP
31 COOLANT TEMP
* Used with 1 Torch Option
32 COMMON
33 -15 VDC
34 COMMON
35 24 VDC
36 COMMON
37 24 VDC
38 COMMON
39 24 VDC
40 COMMON
RIBBON CABLE 16 ckt
CCM ( J37) - DISPLAY
PCB (J17)
1,3,5,7
2,4,6,8
9,10 NC
11-16
RIBBON CABLE 10 ckt
RELAY PCB (J3) – PILOT PCB (J42)
1,2
24 VDC
COMMON
SERIAL DATA
24 VDC
3,4,7,10 COMMON
5 PILOT ENABLE +
6 PILOT ENABLE –
8 PILOT CURRENT SIG –
9 PILOT CURRENT SIG +
Art # A-11927_AC
7
Revision By Date
C
GCM1000XT
8
Title SCHEMATIC
Auto-Cut XT 300A 380-415 VAC
9
CHASSIS GND
(+)
(-)
Tip
Work
Date Printed
9/30/2013
Drawn
DAT
Size C
Drawing Number
Date Revised
9/16/2013
Date 10/04/2012
1
042X1355 of 2
A
B
C
D
E
F
APPENDIX A-33
AUTO-CUT 300 XT
APPENDIX 16: System Schematic pg2
A
1
J12 = Mini-Fit Jr
400 VAC -- Single 18 AWG in pins 1 & 4
480 VAC -- Single 18 AWG in pins 1 & 8
230 VAC -- 18 AWG wires in pins 1,5,2,6
From Sys Bias J63
(Sht 1, F2)
(43A) (44A)
MC1A
B
C
D
E
1 2 3 4
5 6 7 8
J12
J13 to CB5 and to MC2
& MC3, also
J14, J16
all 18 AWG
J13
2
FS1
COOLANT
0.7 GPM
J74
1
2
3
LS1
COOLANT LEVEL
4
J71
1
2
3
(84)
(83)
4
(90)
(89)
5
AMBIENT
TS2
COOLANT
TS1
(92) (93)
(94)
(95)
(87)
460V
400V
220V
(65A)
(64A)
0 V
MC3A
MC3B
MC2B
T1
24V
120V_2 RET
CHASSIS GND
MC2A
(67)
(69)
(70)
(69)
(70)
24V RET
120V_2
120V-1 RET
(66)
120V_1
Torch Coolant Pump
J73
1
2
3
J16
1
2
3
BLUE
RED
YELLOW
BLUE
RED
YELLOW
4
3
6
5
2
1
J14
Gas Selection
From Gas Sel SW in
GCM 1000 XT via
J55-27 & 28
GAS_SEL_RET
(Sht2, D9)
GAS_SEL
(Sht2, D9)
(166)
(167)
(79)
(77)
CB2 5 A
(78)
(76)
(74)
CB3 5 A
(75)
(73)
(71)
CB4 5 A
(72)
To J100 of IM #1B
(Sht 1, C,D6)
J6
3
4
1
2
J9
8
7
6
5
4
3
2
1
12
11
10
9
J5 J7 J1 J2
COOLANT FLOW SW
+5VDC
120VAC_2
24VAC
LEVEL SENSORS WORK CURRENT SENSOR TEMP SENSOR
RELAY & INTERFACE PCB
D2, GREEN, 1TORCH GAS ON
D7, GREEN, PILOT ENABLED
D11, GREEN, PILOT CURRENT
D12, GREEN, WORK CURRENT
D22, GREEN, CONTACTORS ON
D23, GREEN, RF ON
D24, GREEN, FANS ON
D25, GREEN, PLASMA ENABLED
D26, GREEN, 1TORCH ON
D27, GREEN, COOLANT ON
Test Points
TP1, GND
TP2, -15V
TP3, +5VDC
TP4, +12V
TP5, +24V
TP6, +15V
TP7, +5VDC
120VAC_1
BIAS TRANSFORMER 019X501700
J15
1 TORCH INTERFACE
To J100 of IM #2A
(Sht 1, B,C6)
J31 - 30 CKT RIBBON J32 - 30 CKT RIBBON
CCM
CPU
PCB
J33 - 30 CKT RIBBON
N/C
J34 - 30 CKT RIBBON
To J100 of IM #3B
To J100 of IM #3A
(Sht 1, A,B6)
M1
J35 - 30 CKT RIBBON J36 - 30 CKT RIBBON
J28 30 CKT RECEPTACLE - BOTTOM ENTRY
19X501100
(69)
R
1
2
3
J72 C4
BN
230 VAC _ SW _ RET
BK
(A9)
FAN1
BL
R
Harness from Pilot PCB J45
(Sht 1, B8)
(55)
(51)
(53)
7
8
5
6
3
4
1
2
J24
CCM I-O PCB
I / O PCB LEDS
J28 30 CKT PIN HEADER
----------------------------------------------
D2 CNC PLASMA ENABLE
D3 E-STOP_PS
D4 GAS ON (Auto-cut, PAK)
D6 CNC START
D8 HOLD START
D12 PREFLOW ON
D13 CSD (corner current reduction)
D18 MARK
D20 SPARE
D25 EXP METAL
D33 OK_CNC
D37 PSR
D41 SPARE OUT 2
D43 SPARE OUT 1
CHASSIS GND
(70)
230 VAC _ SW
(A9)
230 VAC_SW goes to J70
for HE 400
24 VDC
24 VDC
MISSING PHASE a
MISSING PHASE b
AC V HIGH a
AC V HIGH b
AC V LOW a
24 VDC_RET
24 VDC_RET
AC V LOW b
VAC_IDA a
/ VAC_IDA b
VAC_IDB a
/ VAC_IDB b
(37)
(38)
(39)
(40)
(41)
(42)
(29)
(30)
(31)
(32)
(33)
(34)
(35)
(36)
8
9
6
7
10
11
3
4
1
2
5
12
13
14
J27
. 230V 400V 480V ERR
J62-12 (/VAC_IDAb) 0 1 0 1
J62-14 (/VAC_IDBb) 0 0 1 1
Measure relative to TP1 (24VDC_RET)
"0" = 10-12V "1" = 24V
I / O PCB TEST POINTS
-------------------------------------
TP1 PCB COMMON
TP2 COOLANT FANS ON
TP3 PUMP ON
TP4 LOW FLOW (SW)
TP5 FLOW SIGNAL (pulse, Ultracut only)
TP6 +15VDC_ISO (ref to TP10)
TP7 -15VDC_ISO (ref to TP10)
TP8 +16-18 VDC_ISO (ref to TP10)
TP9 ANALOG CURRENT SIGNAL
(remote & Autocut only)
TP10 ISOLATED VOLTAGE COMMON
TP11 1 TORCH CONTACTOR ON
TP12 +5 VDC
TP13 -15 VDC
TP14 +15 VDC
TP15 +24 VDC
TP18 +5 VDC_ISO (ref to TP10)
19X501200
I / O PCB DIP SW
---------------------------------------------
SW6 OK TO MOVE
(CONTACTS, VOLTS)
SW11 ANALOG CC SOURCE
SW12 DIVIDED ARC VOLTAGE
(50:1, 16.7:1, 30:1, 40:1, 25:1)
F
Art # A-11928_AC
1 2 3 4
A-34 APPENDIX 0-5261
5
PCB1
TDYN SILK
ESD SILK
114Xabcd
6 7 8 9 10
TO PILOT PCB
J29 30 CKT PIN HEADER
CPU PCB LEDs
----------------------------
D2 RXD (red)
D3 TXD (red)
D4 CAN BUS (slave)
D7 CAN BUS (MAIN)
D11 5 VDC POWER
D17 STATUS CODE
D18 INITIALIZING /
PROGRAMMING (red)
SA3
MC2 Fan Control
ARC_SUPPRESSOR MC3 Pump Motor Control
SA1
ENABLE
PLAS_ENABLE SW
PLAS_ EN_SW_RET
/ GAS PRESS OK
/ BASIC ID
(96)
13
14
15
16
9
10
11
12
17
18
7
8
5
6
3
4
1
2
J21
230 VAC _ SW
(D2)
230 VAC _ SW _ RET
SA2
(D2)
(130)
(131)
(112)
(114)
(121)
(122)
(124)
(129)
(128)
(70)
( 6 9 )
230 VAC to HE 400
230 VAC Ret
(70)
( 6 9 )
(166)
(167)
(106)
(113)
CHASSIS GND
(133)
(134)
(135)
(136)
(137)
(138)
(139)
(140)
(141)
(142)
J70 - HE
5
6
7
3
4
1
2
W1 W2
SA4
CHASSIS GND
ARC_SUPPRESSOR
(96)
(98)
(99)
(97)
ARC_SUPPRESSOR
(97)
ARC_SUPPRESSOR
120 VAC to RAS
120 VAC Ret
(60)
MC1
J3 J8 (107)
J38
PILOT PCB
GND
1 2 3 4 5 6 7 8 9
24 VDC
CONTROL OUTPUTS
RS 232 D-SUB
SERIAL PROG
PORT
3
4
1
2
5
6
J18
PROG
USB IC
7
8
5
6
3
4
1
2
9
10
11
12
J19
J29 30 CKT RECEPTACLE - BOTTOM ENTRY
24 VAC 120 VAC_1
120 VAC_2
J4 -- 40 CKT RIBBON CABLE
HMI/GCM
18
17
16
15
14
13
12
11
10
9
8
7
6
5
4
3
2
1
J10
(100)
(101)
(102)
(103)
(104)
(62)
(106)
(108)
(109)
(110)
(111)
(63)
(113)
(61)
AC 24V GCM2
AC 120V - GCM
AC 24V - RET - GCM2
AC 120V- Ret- GCM
AC 120V- Ret- TB4-3
J39
USB
PORT
1 2 3 4
7
8
5
6
3
4
1
2
9
10
11
12
J20
USB Cable to Front Panel
GND
GND
Rx-
Tx+
Tx-
3
4
1
2
5
6
J30
3
4
1
2
J47
(116)
(117)
(120)
(115)
(119)
(118)
J37
(62)
(60)
(63)
Harness
AC 24V GCM1
AC 24V-TB4-2
AC 120V- TB4-4
AC 24V Ret- GCM1
AC 24V- Ret -TB4-1
(62) 1
K1
(63) 5
120VAC
2
4
3
(107)
(61)
INRUSH CONTROL
16 CKT RIBBON
Harness
J17
(99)
(98)
J59 - RAS
9
10
11
12
13
14
7
8
5
6
3
4
1
2
3 - Key Plug
J54 - Remote HMI & CNC COMM
(100)
(101)
(102)
(109)
(108)
(115)
(116)
(117)
(118)
(119)
(120)
9
10
11
12
13
14
7
8
5
6
3
4
1
2
3- Jumper to 24 VAC
5-HMI Plasma Enable SW
6-HMI Plasma Enable SW
12 - Tx-
14 - Rx-
RS 485
/ 422
Comm
Display PCB
019X501800
(121)
(122)
(123)
(124)
(125)
(126)
(127)
(128)
(129)
(130)
(131)
CPU PCB TEST POINTS
--------------------------------------------
TP1 GND (PCB common)
TP2 +5V_ISO (REF TP5)
TP3 +24 VDC
TP4 +3.3V
TP5 GND_ISO
TP6 +5.0 V
TP7 TOTAL DEMAND
(3.3V = 400A)
TP9 /WR
TP10 /RD
TP11 CPU TEMP SENSE
TP12 +3.3VA
TP13 -15VDAC
TP14 PC2
TP15 +15VDAC
TP16 CLKO
TP18 OSC_CLOCK
J23- 40 ckt ribbon cable
OK2 (contact)
+10V (CC Pot Hi)
CC Pot Wiper
CC Pot Low
Div Arc V (+)
Div Arc V (-)
/Start - Stop (+)
/Start - Stop (-)
Stop Mom NC
OK2 (contact)
/ CNC Enable (+)
/ CNC Enable (-)
TB1
8
7
6
5
4
3
2
1
12
11
10
9
OK to MOVE (+)
OK to MOVE (-)
PILOT is ON
PILOT is ON
Preflow ON (+)
Preflow ON (-)
Hold Start (+)
Hold Start (-)
TB2
8
7
6
5
4
3
2
1
12
11
10
9
CPU PCB DIP SW
---------------------------------------------
SW1 AUTO PILOT RESTART
SW3 PREFLOW TIME
SW4 POSTFLOW TIME
SW5 FUNCTION
SW8 SYSTEM CONTROL
(pilot time, etc.)
SW9 RESERVED (future)
SW10 ADDRESS (default = 0)
SW13 UNIT TYPE (AC / UC)
SW14 LINE TERMINATION
(serial comm.)
Spare #2 NO
Spare #2 NC
Spare #1b NO
/ Cut Expanded Metal (-)
/ Cut Expanded Metal (+)
/ Corner Current Reduction (-)
/ Corner Current Reduction (+)
/ Plasma Marking (-)
/ Plasma Marking (+)
TB3
8
7
6
5
4
3
2
1
12
11
10
9
OK
+10V
GND
PSR
GAS ON
SPARE #1a
GND
GND
13
14
15
16
9
10
11
12
17
18
19
20
7
8
5
6
3
4
1
2
J22
13
14
15
16
9
10
11
12
7
8
5
6
3
4
1
2
J26
(123)
(125)
(126)
(127)
(142)
(133)
(134)
(137)
(139)
(138)
(143)
(140)
(141)
(136)
(135)
(132)
(153)
(144)
(145)
(146)
(147)
(148)
(149)
(150)
(151)
(152)
(154)
(155)
(156)
(157)
(158)
(159)
GAS_SEL_RET
GAS_SEL
(166)
(167)
AC 24V-GCM1
AC 24V Ret - GCM1
AC 24V-GCM2
AC 24V Ret-GCM2
J69
2
1
AC 120V - GCM
AC 120V- Ret- GCM
(111)
(132)
(152)
(153)
(154)
(155)
(156)
(157)
(158)
(159)
(146)
(147)
(148)
(149)
(150)
(151)
(112)
(114)
(103)
(110)
(143)
(144)
(145)
29
30
31
32
25
26
27
28
33
34
35
36
37
21
22
23
24
17
18
19
20
13
14
15
16
9
10
11
12
7
8
5
6
3
4
1
2
J55 - GCM
1- PLAS_ENABLE SW *
2- PLAS_ EN_SW_RET
3- GAS PRESS OK RET
4- / GAS PRESS OK
5- POT HIGH (GCM 1000)
6- POT WIPER (GCM 1000)
7- POT LOW (GCM 1000)
8- BASIC ID RET
9- / BASIC ID **
10-
11-
GCM 1000 XT
Jumper
14-
15- 24 VAC - RET
* Plasma Enable SW
in GCM 2010.
Jumpered in
GCM 1000 XT
and DMC 3000.
** Jumper in
GCM 1000 XT
27- GAS SEL SW RET
28- GAS SEL SW
J15-1 to chassis used for
SC-11 cable shield
J15-13 connects SC-11 chassis to PS chassis.
J15-CNC
29
30
31
32
25
26
27
28
33
34
35
36
37
21
22
23
24
17
18
19
20
13
14
15
16
9
10
11
12
7
8
5
6
3
4
1
2
The COMM Ref at pin 8 is also for the SC-11
3- / CNC Start (+)
4- / CNC Start (-)
5- Divided Arc V (-)
6- Divided Arc V (+)
7- / Preflow ON (+)
8- COMM Ref (1K Ohm)
9- / Preflow ON (-)
10- / Corner Current Reduction (+)
11- / Corner Current Reduction (-)
12- OK to Move (-)
14- OK to Move (+)
15 - Key Plug
16- / Hold Start (+)
17- / Hold Start (-)
21- / Plasma Mark (+)
22- / Plasma Mark (-)
23- / Cut Expanded Metal (+)
24- / Cut Expanded Metal (-)
25- / CNC Plasma Enable (+)
26- / CNC Plasma Enable (-)
29- Remote CC Pot High
30- Remote CC (analog)
31- Remote CC Pot Low
32- Stop SW (momentary) *
33- Stop SW Ret
34- Pilot is ON (a)
35- Pilot is ON (b)
36- Spare OUT #1 (a)
37- Spare OUT #1 (b)
Art # A-11928_AC
* Used with Momentary CNC Start SW
Rev
00
0 1
Revision
Initial Design
A d d F 2
02 Add T1 Inrush Ckt
03 Misc updates & corrections
0 4 More updates & corrections
6
By Date
DAT 10/03/2012
D A T 1 1 / 2 1 / 2 0 1 2
DAT
DAT
D A T
2/18/2013
6/27/2013
9 / 1 2 / 2 0 1 3
Rev
7
Revision By Date
8
Title SCHEMATIC
Auto-Cut XT 300A 380-415 VAC
9
Date Printed
9/30/2013
Drawn
DAT
Size
C
Drawing Number
Date Revised
9/12/2013
Date
10/4/2012
Sheet
2 of 2
042X1355
10
A
B
C
D
E
F
A
1
J12 = Mini-Fit Jr
400 VAC -- Single 18 AWG in pins 1 & 4
480 VAC -- Single 18 AWG in pins 1 & 8
230 VAC -- 18 AWG wires in pins 1,5,2,6
From Sys Bias J63
(Sht 1, F2)
(43A) (44A)
MC1A
B
C
D
E
1 2 3 4
5 6 7 8
J12
J13 to CB5 and to MC2
& MC3, also
J14, J16
all 18 AWG
J13
2
FS1
COOLANT
0.7 GPM
J74
1
2
3
LS1
COOLANT LEVEL
4
J71
1
2
3
(84)
(83)
4
(90)
(89)
5
AMBIENT
TS2
COOLANT
TS1
(92) (93)
(94)
(95)
(87)
460V
400V
220V
(65A)
(64A)
0 V
MC3A
MC3B
MC2B
T1
24V
120V_2 RET
CHASSIS GND
MC2A
(67)
(69)
(70)
(69)
(70)
24V RET
120V_2
120V-1 RET
(66)
120V_1
Torch Coolant Pump
J73
1
2
3
J16
1
2
3
BLUE
RED
YELLOW
BLUE
RED
YELLOW
4
3
6
5
2
1
J14
Gas Selection
From Gas Sel SW in
GCM 1000 XT via
J55-27 & 28
GAS_SEL_RET
(Sht2, D9)
GAS_SEL
(Sht2, D9)
(166)
(167)
(79)
(77)
CB2 5 A
(78)
(76)
(74)
CB3 5 A
(75)
(73)
(71)
CB4 5 A
(72)
To J100 of IM #1B
(Sht 1, C,D6)
J6
3
4
1
2
J9
8
7
6
5
4
3
2
1
12
11
10
9
J5 J7 J1 J2
COOLANT FLOW SW
+5VDC
120VAC_2
24VAC
LEVEL SENSORS WORK CURRENT SENSOR TEMP SENSOR
RELAY & INTERFACE PCB
D2, GREEN, 1TORCH GAS ON
D7, GREEN, PILOT ENABLED
D11, GREEN, PILOT CURRENT
D12, GREEN, WORK CURRENT
D22, GREEN, CONTACTORS ON
D23, GREEN, RF ON
D24, GREEN, FANS ON
D25, GREEN, PLASMA ENABLED
D26, GREEN, 1TORCH ON
D27, GREEN, COOLANT ON
Test Points
TP1, GND
TP2, -15V
TP3, +5VDC
TP4, +12V
TP5, +24V
TP6, +15V
TP7, +5VDC
120VAC_1
BIAS TRANSFORMER 019X501700
J15
1 TORCH INTERFACE
To J100 of IM #2A
(Sht 1, B,C6)
J31 - 30 CKT RIBBON J32 - 30 CKT RIBBON
CCM
CPU
PCB
J33 - 30 CKT RIBBON
N/C
J34 - 30 CKT RIBBON
To J100 of IM #3B
To J100 of IM #3A
(Sht 1, A,B6)
M1
J35 - 30 CKT RIBBON J36 - 30 CKT RIBBON
J28 30 CKT RECEPTACLE - BOTTOM ENTRY
19X501100
(69)
R
1
2
3
J72 C4
BN
230 VAC _ SW _ RET
BK
(A9)
FAN1
BL
R
Harness from Pilot PCB J45
(Sht 1, B8)
(55)
(51)
(53)
7
8
5
6
3
4
1
2
J24
CCM I-O PCB
I / O PCB LEDS
J28 30 CKT PIN HEADER
----------------------------------------------
D2 CNC PLASMA ENABLE
D3 E-STOP_PS
D4 GAS ON (Auto-cut, PAK)
D6 CNC START
D8 HOLD START
D12 PREFLOW ON
D13 CSD (corner current reduction)
D18 MARK
D20 SPARE
D25 EXP METAL
D33 OK_CNC
D37 PSR
D41 SPARE OUT 2
D43 SPARE OUT 1
CHASSIS GND
(70)
230 VAC _ SW
(A9)
230 VAC_SW goes to J70
for HE 400
24 VDC
24 VDC
MISSING PHASE a
MISSING PHASE b
AC V HIGH a
AC V HIGH b
AC V LOW a
24 VDC_RET
24 VDC_RET
AC V LOW b
VAC_IDA a
/ VAC_IDA b
VAC_IDB a
/ VAC_IDB b
(37)
(38)
(39)
(40)
(41)
(42)
(29)
(30)
(31)
(32)
(33)
(34)
(35)
(36)
8
9
6
7
10
11
3
4
1
2
5
12
13
14
J27
. 230V 400V 480V ERR
J62-12 (/VAC_IDAb) 0 1 0 1
J62-14 (/VAC_IDBb) 0 0 1 1
Measure relative to TP1 (24VDC_RET)
"0" = 10-12V "1" = 24V
I / O PCB TEST POINTS
-------------------------------------
TP1 PCB COMMON
TP2 COOLANT FANS ON
TP3 PUMP ON
TP4 LOW FLOW (SW)
TP5 FLOW SIGNAL (pulse, Ultracut only)
TP6 +15VDC_ISO (ref to TP10)
TP7 -15VDC_ISO (ref to TP10)
TP8 +16-18 VDC_ISO (ref to TP10)
TP9 ANALOG CURRENT SIGNAL
(remote & Autocut only)
TP10 ISOLATED VOLTAGE COMMON
TP11 1 TORCH CONTACTOR ON
TP12 +5 VDC
TP13 -15 VDC
TP14 +15 VDC
TP15 +24 VDC
TP18 +5 VDC_ISO (ref to TP10)
19X501200
I / O PCB DIP SW
---------------------------------------------
SW6 OK TO MOVE
(CONTACTS, VOLTS)
SW11 ANALOG CC SOURCE
SW12 DIVIDED ARC VOLTAGE
(50:1, 16.7:1, 30:1, 40:1, 25:1)
F
Art # A-11928_AC
1 2 3 4
AUTO-CUT 300 XT
0-5261
5
PCB1
TDYN SILK
ESD SILK
114Xabcd
6 7 8 9 10
TO PILOT PCB
J29 30 CKT PIN HEADER
CPU PCB LEDs
----------------------------
D2 RXD (red)
D3 TXD (red)
D4 CAN BUS (slave)
D7 CAN BUS (MAIN)
D11 5 VDC POWER
D17 STATUS CODE
D18 INITIALIZING /
PROGRAMMING (red)
SA3
MC2 Fan Control
ARC_SUPPRESSOR MC3 Pump Motor Control
SA1
ENABLE
PLAS_ENABLE SW
PLAS_ EN_SW_RET
/ GAS PRESS OK
/ BASIC ID
(96)
13
14
15
16
9
10
11
12
17
18
7
8
5
6
3
4
1
2
J21
230 VAC _ SW
(D2)
230 VAC _ SW _ RET
SA2
(D2)
(130)
(131)
(112)
(114)
(121)
(122)
(124)
(129)
(128)
(70)
( 6 9 )
230 VAC to HE 400
230 VAC Ret
(70)
( 6 9 )
(166)
(167)
(106)
(113)
CHASSIS GND
(133)
(134)
(135)
(136)
(137)
(138)
(139)
(140)
(141)
(142)
J70 - HE
5
6
7
3
4
1
2
W1 W2
SA4
CHASSIS GND
ARC_SUPPRESSOR
(96)
(98)
(99)
(97)
ARC_SUPPRESSOR
(97)
ARC_SUPPRESSOR
120 VAC to RAS
120 VAC Ret
(60)
MC1
J3 J8 (107)
J38
PILOT PCB
GND
1 2 3 4 5 6 7 8 9
24 VDC
CONTROL OUTPUTS
RS 232 D-SUB
SERIAL PROG
PORT
3
4
1
2
5
6
J18
PROG
USB IC
7
8
5
6
3
4
1
2
9
10
11
12
J19
J29 30 CKT RECEPTACLE - BOTTOM ENTRY
24 VAC 120 VAC_1
120 VAC_2
J4 -- 40 CKT RIBBON CABLE
HMI/GCM
18
17
16
15
14
13
12
11
10
9
8
7
6
5
4
3
2
1
J10
(100)
(101)
(102)
(103)
(104)
(62)
(106)
(108)
(109)
(110)
(111)
(63)
(113)
(61)
AC 24V GCM2
AC 120V - GCM
AC 24V - RET - GCM2
AC 120V- Ret- GCM
AC 120V- Ret- TB4-3
J39
USB
PORT
1 2 3 4
7
8
5
6
3
4
1
2
9
10
11
12
J20
USB Cable to Front Panel
GND
GND
Rx-
Tx+
Tx-
3
4
1
2
5
6
J30
3
4
1
2
J47
(116)
(117)
(120)
(115)
(119)
(118)
J37
(62)
(60)
(63)
Harness
AC 24V GCM1
AC 24V-TB4-2
AC 120V- TB4-4
AC 24V Ret- GCM1
AC 24V- Ret -TB4-1
(62) 1
K1
(63) 5
120VAC
2
4
3
(107)
(61)
INRUSH CONTROL
16 CKT RIBBON
Harness
J17
(99)
(98)
J59 - RAS
9
10
11
12
13
14
7
8
5
6
3
4
1
2
3 - Key Plug
J54 - Remote HMI & CNC COMM
(100)
(101)
(102)
(109)
(108)
(115)
(116)
(117)
(118)
(119)
(120)
9
10
11
12
13
14
7
8
5
6
3
4
1
2
3- Jumper to 24 VAC
5-HMI Plasma Enable SW
6-HMI Plasma Enable SW
12 - Tx-
14 - Rx-
RS 485
/ 422
Comm
Display PCB
019X501800
(121)
(122)
(123)
(124)
(125)
(126)
(127)
(128)
(129)
(130)
(131)
CPU PCB TEST POINTS
--------------------------------------------
TP1 GND (PCB common)
TP2 +5V_ISO (REF TP5)
TP3 +24 VDC
TP4 +3.3V
TP5 GND_ISO
TP6 +5.0 V
TP7 TOTAL DEMAND
(3.3V = 400A)
TP9 /WR
TP10 /RD
TP11 CPU TEMP SENSE
TP12 +3.3VA
TP13 -15VDAC
TP14 PC2
TP15 +15VDAC
TP16 CLKO
TP18 OSC_CLOCK
J23- 40 ckt ribbon cable
OK2 (contact)
+10V (CC Pot Hi)
CC Pot Wiper
CC Pot Low
Div Arc V (+)
Div Arc V (-)
/Start - Stop (+)
/Start - Stop (-)
Stop Mom NC
OK2 (contact)
/ CNC Enable (+)
/ CNC Enable (-)
TB1
8
7
6
5
4
3
2
1
12
11
10
9
OK to MOVE (+)
OK to MOVE (-)
PILOT is ON
PILOT is ON
Preflow ON (+)
Preflow ON (-)
Hold Start (+)
Hold Start (-)
TB2
8
7
6
5
4
3
2
1
12
11
10
9
CPU PCB DIP SW
---------------------------------------------
SW1 AUTO PILOT RESTART
SW3 PREFLOW TIME
SW4 POSTFLOW TIME
SW5 FUNCTION
SW8 SYSTEM CONTROL
(pilot time, etc.)
SW9 RESERVED (future)
SW10 ADDRESS (default = 0)
SW13 UNIT TYPE (AC / UC)
SW14 LINE TERMINATION
(serial comm.)
Spare #2 NO
Spare #2 NC
Spare #1b NO
/ Cut Expanded Metal (-)
/ Cut Expanded Metal (+)
/ Corner Current Reduction (-)
/ Corner Current Reduction (+)
/ Plasma Marking (-)
/ Plasma Marking (+)
TB3
8
7
6
5
4
3
2
1
12
11
10
9
OK
+10V
GND
PSR
GAS ON
SPARE #1a
GND
GND
13
14
15
16
9
10
11
12
17
18
19
20
7
8
5
6
3
4
1
2
J22
13
14
15
16
9
10
11
12
7
8
5
6
3
4
1
2
J26
(123)
(125)
(126)
(127)
(142)
(133)
(134)
(137)
(139)
(138)
(143)
(140)
(141)
(136)
(135)
(132)
(153)
(144)
(145)
(146)
(147)
(148)
(149)
(150)
(151)
(152)
(154)
(155)
(156)
(157)
(158)
(159)
GAS_SEL_RET
GAS_SEL
(166)
(167)
AC 24V-GCM1
AC 24V Ret - GCM1
AC 24V-GCM2
AC 24V Ret-GCM2
J69
2
1
AC 120V - GCM
AC 120V- Ret- GCM
(111)
(132)
(152)
(153)
(154)
(155)
(156)
(157)
(158)
(159)
(146)
(147)
(148)
(149)
(150)
(151)
(112)
(114)
(103)
(110)
(143)
(144)
(145)
29
30
31
32
25
26
27
28
33
34
35
36
37
21
22
23
24
17
18
19
20
13
14
15
16
9
10
11
12
7
8
5
6
3
4
1
2
J55 - GCM
1- PLAS_ENABLE SW *
2- PLAS_ EN_SW_RET
3- GAS PRESS OK RET
4- / GAS PRESS OK
5- POT HIGH (GCM 1000)
6- POT WIPER (GCM 1000)
7- POT LOW (GCM 1000)
8- BASIC ID RET
9- / BASIC ID **
10-
11-
GCM 1000 XT
Jumper
14-
15- 24 VAC - RET
* Plasma Enable SW
in GCM 2010.
Jumpered in
GCM 1000 XT
and DMC 3000.
** Jumper in
GCM 1000 XT
27- GAS SEL SW RET
28- GAS SEL SW
J15-1 to chassis used for
SC-11 cable shield
J15-13 connects SC-11 chassis to PS chassis.
J15-CNC
29
30
31
32
25
26
27
28
33
34
35
36
37
21
22
23
24
17
18
19
20
13
14
15
16
9
10
11
12
7
8
5
6
3
4
1
2
The COMM Ref at pin 8 is also for the SC-11
3- / CNC Start (+)
4- / CNC Start (-)
5- Divided Arc V (-)
6- Divided Arc V (+)
7- / Preflow ON (+)
8- COMM Ref (1K Ohm)
9- / Preflow ON (-)
10- / Corner Current Reduction (+)
11- / Corner Current Reduction (-)
12- OK to Move (-)
14- OK to Move (+)
15 - Key Plug
16- / Hold Start (+)
17- / Hold Start (-)
21- / Plasma Mark (+)
22- / Plasma Mark (-)
23- / Cut Expanded Metal (+)
24- / Cut Expanded Metal (-)
25- / CNC Plasma Enable (+)
26- / CNC Plasma Enable (-)
29- Remote CC Pot High
30- Remote CC (analog)
31- Remote CC Pot Low
32- Stop SW (momentary) *
33- Stop SW Ret
34- Pilot is ON (a)
35- Pilot is ON (b)
36- Spare OUT #1 (a)
37- Spare OUT #1 (b)
Art # A-11928_AC
* Used with Momentary CNC Start SW
Rev
00
0 1
Revision
Initial Design
A d d F 2
02 Add T1 Inrush Ckt
03 Misc updates & corrections
0 4 More updates & corrections
6
By Date
DAT 10/03/2012
D A T 1 1 / 2 1 / 2 0 1 2
DAT
DAT
D A T
2/18/2013
6/27/2013
9 / 1 2 / 2 0 1 3
Rev
7
Revision By Date
8
Title SCHEMATIC
Auto-Cut XT 300A 380-415 VAC
9
Date Printed
9/30/2013
Drawn
DAT
Size
C
Drawing Number
Date Revised
9/12/2013
Date
10/4/2012
Sheet
2 of 2
042X1355
10
A
B
C
D
E
F
APPENDIX A-35
AUTO-CUT 300 XT
APPENDIX 17: Advanced Troubleshooting
System Overview
The Auto-Cut 200 & 300 XT & Ultra-Cut 100, 200, 300 & 400
XT power supplies include one, two or three inverter modules (IM). Each IM may have either 1 or 2 inverter sections designated A or B sections. The IMs are mounted one over the other numbered from bottom to top. The sections are also designated from bottom to top with section A being on the bottom of each module. An IM with one section is considered to be a ½ or “partial” module with the upper or “B” section missing. ½ modules are used with the 200A & 300A power supplies and will always be in the middle position.
IMs with 2 sections are considered to be “full” modules.
Each inverter section can supply up to 67A but does not do so in all configurations:
A 400A unit uses 6 sections. 400A / 6 = 66.67A per section.
A 300A unit uses 5 sections. 300A / 5 = 60A per section.
A 200A unit uses 3 sections. 200/3 = 66.67A per section.
A 100A unit uses 2 sections. 100/2=50A per section.
Unit configurations.
With the exception of the AC 200 XT all other units have the same chassis with room for up to 3 IMs. The unused areas have blank panels filling the empty locations which are required for proper air flow. A 100A system uses 1 full IM;
200A uses 1 and ½ modules with a full module in the bottom location and a ½ module in the middle position. A 300A unit has full modules top and bottom with the ½ module in the middle location. The AC 200 XT has only the bottom and middle locations for IMs. An internal Arc Starter and
Gas Control are located in the place of the 3rd or upper IM.
Inverter module cooling.
The power semiconductors of the inverter modules are liquid cooled allowing us to get more power in a smaller area and at lower cost. Each IM has a liquid cooled heatsink or
“cold plate” shared by the 2 inverter sections. The magnetic components, transformers and inductors, are air cooled and mounted on the back side of the IMs where they are exposed to high volumes of air flow from the cooling fans whose air also cools liquid coolant in the radiator or heat exchanger.
It is important that lower right side panel be in place or the air flow will not be proper for cooling the magnetics.
Inverter control.
The inverter sections are operated as separate inverters whose outputs are connected in parallel. They are controlled independently from the Command and Control Module
(CCM) which is the “brains” of the system. Each inverter section has a separate ribbon cable connected to it coming from the CCM which has 6 connectors, J31 – J36 corresponding to the inverter sections 1A through 3B. The ribbon cables are labeled on the inverter ends as INV with the number and
Art # 12299
Art # 12300
A-36 APPENDIX 0-5261
AUTO-CUT 300 XT section (INV 1A, INV 1B, etc.). A 100A unit will only have ribbon cables in J31 & J32; a 200A will have J31-J33 filled with the others empty. 300A will have J34 missing with the others filled.
Other boards in the system include the System Bias Supply, the Relay & Interface PCB, Display PCB, Pilot PCB and AC Suppression PCB.
The CCM has 2 boards, the I/O (input/output) and the CPU (central processing unit) board. The CE units will also have one or more EMI Filter boards on the input power.
System Bias supply PCB is powered from the 3 phase AC input and works from about 150V to over 600V covering all the normal voltage ranges. It can operate from 2 phases (single phase) so it still provides bias power and can report a fault if a phase is missing. The supply’s output is 24 VDC which powers the Relay board, the Display, the
Pilot board and the 2 boards in the CCM. System Bias also contains circuits to detect missing phase and determine if the AC voltage is within the correct range, not too high or too low. It also signals to the CCM what voltage the unit is configured for. The System Bias supply PCB includes a relay, K1, which only applies voltage to Auxiliary transformer, T1, primary when the input voltage is in the correct range.
The Relay and Interface PCB Accepts and distributed the output of the Aux Transformer. It has relay to control the pump, fans, input contactors, the Arc Starter and the Inrush relays. A circuit on the Relay board accepts input from the Work current sensor, HCT1, and Pilot current sensor (on the Pilot PCB) and sends the Enable signal to the Pilot boards IGBT switches via the J3 to J42 ribbon cable. Other inputs on the Relay board include those from the Negative Temperature Coefficient (NTC) ambient and coolant temperature sensors. Coolant tank level switch and coolant flow switch, which determines if the flow is above the required minimum rate, also send signals to the
Relay Board. Ultra-Cut units include a flow sensor whose output to the Relay Board is a series of pulses whose frequency indicates the flow rate and can detect the presence of gas bubbles in the coolant. All these signals pass to the CCM via a 40 conductor ribbon cable going to the CCM I/O board.
The Display Board Has LEDs for AC, TEMP, GAS & DC. It also has a 4 digit 7 segment display for status and fault information. AC LED indicates the input contactors to the inverters have been commanded to close, but does not mean they are closed. TEMP means one or more inverters or the coolant has exceeded the allowed temperature.
GAS means gas is flowing and coolant flow is OK. DC means the inverters output voltage is above 60 VDC.
The first digit of the 7 segment display shows the letter, “C”; “E”; “L” or is blank. During the initial power up sequence the letter “C” followed by the other 3 digits, indicates the CCM code revision. Status or Fault codes which may occur during the power up sequence or any time thereafter are preceded by letters “E” for an active fault or
“L” for a “latched” or “last” fault that stopped the process but is no longer active. When there is no Fault or active
Status code, the output current setting is displayed with the first digit blank. If the system is an Ultra-Cut XT using the Auto Gas Control, DFC 3000, the display will show “0” until a process has been loaded. If there is a fault or other status showing the display will alternate between the current setting and the fault.
The Pilot PCB contains a pair of parallel IGBT transistors working as an electronic switch to connect and disconnect the torch tip from the 1st inverter section.
When the pilot electronic switch is closed and the pilot is ignited by the Arc Starter, current from the 1st section flows between electrode and tip. Then as transfer begins, a small current from the 2nd inverter flows from electrode to work. When transfer is detected the pilot switch is opened and current from the 1st section is free to flow to the work through the diode which is also on the Pilot board. The Pilot PCB also contains a pilot current sensor to detect and measure the level of pilot current. Additional resistor/capacitor (RC) circuits on the pilot PCB assist and stabilize the pilot and transferred arcs.
Art # 12301
2nd INVERTER SECTION
(INV 1 B)
1st INVERTER SECTION
(INV 1 A)
PILOT SW (IGBT)
(+)
TIP
WORK (+)
0-5261 APPENDIX A-37
AUTO-CUT 300 XT
The AC Suppression PCB has capacitors and other transient suppression components to protect the system from transients on the AC lines. It also provides power for the neon AC present indicators which illuminate when AC power is connected even with ON-OFF switch, CB1, off.
Differences between various models.
Auto-Cut 200 or 300 XT units use the basic gas control/arc start circuits consisting of single gas inlets, one for Plasma, one for Gas Shield and one for water inlet, optional for AC 200 XT, for H2O Mist shield. There is a pressure regulator and gauge for each gas inlet and water flow meter/control when the H2O Mist option is used. All 3 are turned on/off with control solenoids. Changing gas types requires connecting different gasses to the rear panel and setting the gas switch on the rear panel to match the plasma gas type. There is no separate pilot (Preflow) gas at this time.
The Auto-Cut Arc starter is the conventional spark gap type with water cooled coil that we’ve used for several years.
This arc starter injects the HF onto the torch electrode via the negative lead with the return via the tip and pilot lead.
The Ultra-Cut XT units use the remote arc starter, RAS 1000 XT. In place of the spark gap the RAS 1000 XT uses a solid state ignition module to create the HF pulses which are injected onto the tip and return via the electrode, the opposite direction of that used in the Auto-Cut, Auto-Cut XT and the older RAS 1000 used with the Ultra-Cut units.
The AC 200 XT had the gas control and arc starter built into the main enclosure in the area that is used for the top inverter module in other units of this family. The AC 300 XT has a separate gas control/Arc Starter that sits on top of the main enclosure very similar to the GCM 1000 of our earlier Auto-Cut models. It is in fact called a GCM 1000
XT .
Both Auto-Cut XT models have an analog current control (Potentiometer). On the front panel of the main unit for the AC 200 XT and in the upper box, the GCM 1000 XT, for the AC 300 XT version. In either case the amperage setting is displayed on the front panel digital display.
Both Auto-Cut models have the gas mode switch on the rear, for the AC 300 XT next to the gas inlets of the GCM
1000 XT. On the AC 200 XT it’s near the connectors, fuses & circuit breakers. The switch should be set according to the type of gas, AIR/O2 or N2, H35 or other non-oxidizing gas, being used for the plasma.
In the AC 200 XT the Pilot board is mounted on the upper section of the second inverter module (IM#2) the ½ module, in the place of the second or “B” section if it was a full module. The AC 300 XT and all Ultra-Cut XT models have the Pilot board on the opposite side from the inverters, the “circuit breaker” side, in the upper rear behind the
CCM module. Refer to the Replacement Parts section of the manual for illustrations showing the locations.
Ultra-Cut XT units, 100, 200, 300 & 400A units all can use either the GCM 2010 “manual” Gas control or the DFC
3000 Auto Gas Control.
These gas controls remain unchanged from earlier Ultra-Cut units.
Ultra-Cut XT units use the same flow switch, FS1, as the Auto-Cut XT units to detect and prevent operation when coolant flow is below the minimum of 0.75 GPM (2.8 l/m). However, the Ultra-Cut XTs include a coolant flow sensor, FL1, which also measures the flow and can detect if there are gas bubbles in the coolant which can reduce consumable part life. Detecting bubbles or low flow from FL1 will NOT prevent cutting but will show a code as a warning that something is not right. The code is E406.
Ultra-Cut XTs have standard consumables for cutting currents lower than those used for Auto-Cut XT, 15A vs. 55A as well as marking at lower currents. To improve operation at these lower currents an additional output inductor,
L1, is added in series with the 1st inverter section (IM#1A).
Status codes.
The codes for the power supply are displayed on the Display PCB 4 digit numerical display. Some codes refer to the Gas Controls but more detailed Gas Control codes will be found on the individual gas controls. The gas controls used with the XT family of plasma supplies have not changed. They have their own set of status codes which should be covered in another section. This guide assumes you have first considered the Status Code Tables in the
Operation Section of the unit manual. Individual codes will point to different inverter sections while this guide groups similar codes together. For example code E (or L) 249 indicates an inverter fault in Inverter 2A. This guide covers codes 247-252 in one section as they are all the same, varying only by which inverter and section they refer to.
A-38 APPENDIX 0-5261
AUTO-CUT 300 XT
The codes are separated into 6 groups.
Group 1
Group 2
Group 3
Group 4
Group 5
Plasma Process -- Relating to pilot, transfer, torch voltages, etc.
Plasma Power Supply -- Primarily the Inverter Sections
Interface to Gas controls -- Mainly the DFC 3000
Cooling System -- The liquid cooling system for the torch and inverters
CCM -- Communications port to the gas controls
For the XT units we are using a 3 digit code with group 1 codes in the 100’s, group 2 in the 200s etc. These correspond to the older codes used in previous units, where 1-1 is now 101. For the most part the codes have the same meaning. Where an older code no longer applies to the XT system we don’t use it over again and have left it reserved to avoid confusion. For example the code 204 (2-4) which meant the inverter module wasn’t ready. We now detect that error in a different way that has a somewhat different meaning so we have reserved the 204 Code.
While most of the codes indicate a fault has occurred, a few of them, such as 304 (formerly 3-4), simply refer to the current status. 304 indicates either “priming” where the pump is filling the system with coolant or more often
“purging” where the gas is flowing to dry the consumables after replacing them or purging the gas lines when a different gas type has been selected.
Troubleshooting (General)
In many cases where the cause may be listed as a cable or wire disconnected but also includes loose or broken.
All Ribbon cables have an extra receptacle near one end for measuring signals on the cable.
A number of the measurements will require probing of some small connectors or measuring signal on ribbon cables.
For probing the small connectors, standard meter probes are usually too big. We suggest making a couple probes using steel wire. Copper buss wire isn’t stiff enough. A paper clip is a little too big. One idea is take a socket from an Amp mate-n-loc or similar connector into which your meter probe will fit and crimp a small piece of steel wire,
(0.020 to 0.025” dia.; (0.5-0.6 mm) works best), into where wire would normally be crimped. The wire should be soldered and crimped. The steel wire may be found in hobby stores that cater to model building.
Art # 12302 Art # 12303
Insulate all but the end of the wire and slide these onto your meter probe. If your meter has alligator clip adaptors you could hold the wire in these as well, be sure they don’t short together.
Problems that do not set Status or Fault codes:
1. At power on GAS LED blinks continuously, no code set. Real problem is no or low coolant flow but it takes
4 minutes before code is set and people don’t wait that long.
Power Supply Status Codes
Group 1, Process Codes
101 Plasma Enable Is Disabled
Code 101 is activated by either an open circuit between TB1-1 & 2 on CCM I/O PCB or Plasma Enable switched off on the GCM 2010 or on the TSC 3000. TB1-1 & 2 comes from the factory with a jumper installed. An installer may remove the jumper and connect a separate Plasma Enable switch or use the Plasma Enable wires included in the 37 pin CNC cable used with the Ultra-Cut XT & Auto-Cut 300XT. The Auto-Cut 200XT which uses a 14 pin CNC does not have the Plasma Enable in the cable. These may be used to connect to the cutting table E-Stop switch. In either case the jumper would be removed from TB1-1 & 2. 101 is not a latched code, it clears as soon as the condition is fixed.
0-5261 APPENDIX A-39
AUTO-CUT 300 XT
Causes for 101 code other than one of the Enable switches being off (see detailed descriptions below):
• Gas Control Cable from J55 to gas control not connected.
• Ribbon cable from Relay board to I/O board not connected.
• CNC cable not connected (if using a Plasma Enable switch or output from the cutting table or robot).
• Defective Relay PCB
• Defective CCM I/O PCB
Special case: Display alternates between E101 and ----. This happens when there is both a missing phase and
Plasma enable is off. It is probably a bug in the code, it should be showing E101 & E201 (missing phase code).
We will likely fix this in a later code release but be aware of it for now.
External or CNC Plasma Enable D2, CNC PLASMA ENABLE LED, is not on.
• LED D2 on the CCM will be on if this input is satisfied either with the jumper on TB1- 1 & 2 or an external or CNC switch. If the jumper is in place and the LED is not on, the CCM is most likely defective.
• If the jumper at CCM TB1-1 & 2 has been removed to use an external switch, install a jumper as a test. If
D2 illuminates the problem is with the switch or it’s wiring.
• If Plasma Enable is wired through the CNC cable remove the cable and jumper J15 pins 25 & 26. If D2 still not on there may be a problem in the wiring inside the power supply.
Plasma Enable from Gas Control or TSC 3000
If the External or CNC Plasma Enable is satisfied, D2 is on, a relay K7 on the CCM I/O PCB energizes supplying +15V to another relay K1 on the I/O board. An active low signal, /Plasma Enable-HMI, comes from TSC
3000 Plasma Enable switch via the Relay PCB or if TSC 3000 is not installed the signal originates on the Relay
PCB. This signal applies ground to the K1 relay energizing it and lighting the LED, D3 on the I/O board. K1’s contacts go back to the Relay board and the Gas control connector J55 to allow turning on relays and solenoids on those devices. The AC 200 XT does not use the separate Gas Control or the TSC 3000.
Simplified schematic, all connectors are not shown.
Refer to unit schematics for details.
CCM I/O PCB
XT Power Supply
When the circuit between J54-1 & 3 is closed (jumper, etc.) K7 is energized and requires a Plasma Enable SW or equivlant to enable the plasma.
With J54-1 & 3 open K7 is denergized and it's NC contacts complete the Plasma Enable-HMI circuit.
D2
GREEN
1
K6
5
2
4
3
+15VDC
RELAY PCB
24 VAC
24 VAC
J54
-1
-3
J61
-1
-3
TSC 3000
J54
-1
-3
J25 iCNC
XT 2 &
XT 242
J54
-1
-3
J30 iCNC
XT 211
PLASMA ENABLE - CNC
D3
GREEN
PS_ENABLE
1
8
K1
2
3
4
5
6
To
Relay
PCB
7
PLASMA ENABLE
To Gas
Control
1
K7
GND
2
4
3
5
HMI PLASMA
ENABLE BYPASS
/PLASMA ENABLE - HMI
-6
-5
-6
-5
Plasma
Enable
SW
-6
-5
GCM 2010
(or jumper in other gas controls)
Plasma Enable SW
-22
-15
-6
-5
GCM 1000 XT
(AC 300 XT
DMC 3000)
-25
-20
J26-6
J26-7 -2 -2 -2
Jumper in
AC 200 XT Art # 12304
If a TSC 3000 is not connected or unit is an Auto-Cut, K7 on the Relay PCB is de-energized and GND is connected through its normally closed contacts. If the TSC is connected, 24 VAC through a jumper in the TSC 3000 energizes K7, opening its NC contacts and now GND connects through the TDC 3000 Plasma Enable switch.
The GND obtained by either path passes through the GCM 2010 Plasma Enable switch or through a jumper
(J56-1 to J56-2) present in the other gas controls (GCM 1000 XT or DMC 3000) and is connected to the coil of K1 on the I/O PCB. If the CNC Plasma Enable is also active (D2 is on) +15V will be connected to K1’s coil through the relay K7 on the I/O PCB. This energizes K1 and turns on D3, Plasma Enable LED. The contacts of K1 go back to the Relay board and to the Gas control to enable power to connect to relays and solenoids in those items.
A-40 APPENDIX 0-5261
AUTO-CUT 300 XT
Troubleshooting:
1. If both D2 and D3 are on and you still have 101 fault replace the CCM. Otherwise go to step 2 except if it’s an AC 200 XT skip to step 4.
2. If D3 is not on and there is a TSC 3000 in use remove its cable from J54. K7 on the Relay board will deenergize and satisfy the Plasma Enable to K1. If D3 is now on problem was in the TSC 3000 or its cable.
Otherwise reconnect the cable.
3. For an Ultra-Cut with DFC 3000 or GCM 2010 or an Auto-Cut 300 with a GCM 1000 XT remove the cable from J55 the gas control connector and jumper pins 1 & 2. If D3 is on now problem is in the Gas Control or its cable. If D3 still not on replace the Gas Control cable.
4. If neither of the above steps works, on the CCM I/O board, jumper J26-7 to GND (TP1 on I/O). If D2 is on and D3 still does not light then replace the CCM.
5. If D3 does light in the above step find the 40 pin ribbon cable plugged in to the top of the CCM. Confirm that it is plugged in to both the CCM and the Relay board and the connector tabs are locked in place.
Now using the spare receptacle measure voltage between GND (TP1 on I/O) and the ribbon cable pin 12.
It should be zero V. If not, if it’s something like 10-15VDC, the ribbon cable is open or the Relay board is defective.
GCM 2010 PLASMA ENABLE / E-STOP SIMPLIFIED CIRCUIT
XT PLASMA SUPPLY
RELAY BOARD
AC24V GCM1 15
GCM 2010 GAS CONTROL
AC24V Ret - GCM1
CCM I/O BOARD
7
J10
3
(103)
(112)
16
14
GAS
CONTROL
CABLE
16
14
(56)
(58)
12
15
GCM 2010 CONTROL BOARD
F20
1A
K1
PLASMA ENABLE
4
J26
(110)
(114)
17
15
J55
13
15
J56
(57)
(59)
13
J5
16
D13
GREEN
1
K?
2
E-STOP
4
5
Art # 12306
102 Pilot Ignition Failure
Code 102 is activated when there is no pilot current after 15 seconds of firing the Arc Starter. Pilot ignition requires the Pilot board to be enabled, pilot switch (IGBT) turned on and high voltage pulses (HF) from the arc
Starter (either the Remote Arc Starter RAS 1000 XT or GCM 1000 XT or the arc starter built in to the AC 200 XT) applied between the tip and the electrode of the torch.
Possible Causes for 102 code:
• No HF to the torch due to broken pilot wire connection in the torch leads.
• No HF to the torch due to defective Arc Starter.
• Arc Starter not receiving power.
• Pilot board not enabled.
• Pilot board defective.
• Relay board defective.
• Work lead current sensor defective.
• CCM defective.
0-5261 APPENDIX A-41
AUTO-CUT 300 XT
Troubleshooting:
1. Determine if the problem is a lack of HF (Arc Starter) or if it’s due to the pilot circuit.
Auto-cut XT Arc Starter (inside main chassis for AC200 XT; in the GCM1000XT for AC300XT) has open spark gap. If the spark gap is firing it is receiving power. A few early Ultra-Cut XT units were shipped with the
RAS1000 Arc Starter. Troubleshoot them the same as the GCM1000XT below. Most Ultra-Cut XT units now use the RAS1000XT Arc Starter which doesn’t use a spark gap and is covered in the next section.
Arc starter with Spark Gap (Auto-Cut)
No spark at spark gap
1. Check that spark gap is set for 0.062” +/- 0.002”. If gap is too high there may not be enough voltage from
T1 to fire the gap.
2. Check for power to the high frequency (HF) transformer (T2 in AC 200 XT; T1 in GCM1000XT) during the 15 seconds following prefow (ignition phase). Arc starter power comes through the rear panel circuit breaker
CB4, make sure it isn’t tripped. a. For the GCM1000XT (AC300XT) 120 VAC from J59-7 & 9 on the power supply rear panel connects to
J58-7 & 9 on the GCM 1000XT. See diagram below. From J58 on the GCM1000XT it goes directly to the line filter and passes through the filter to primary of T1. During the ignition phase, check for 120 VAC on the T1 side of the line filter. b. For AC200XT the HF transformer T2 has insulated Faston (also known as push on , stab-on, spade, etc.) on its primary wires. Disconnect these and measure for 120 VAC on the harness side during ignition phase.
3. If 120 VAC not present go to step 4.
a. If 120 VAC is present and still no spark, T1 (T2 in AC200XT) may be bad. Remove power and measure resistance of T1 (T2 in AC200XT) primary and secondary. The primary should measure about 3-7 ohms.
The secondary about 25-35 K ohms. If either measurement not correct replace T1 (T2 in AC200XT).
b. If T1 (T2 in AC200XT) measures OK, check for shorted capacitors C1-C3 (very unlikely).
4. No 120 VAC to T1 (T2 in AC200XT) primary during the ignition phase (15 seconds following Preflow) check for 120 VAC into the line filter (GCM1000XT only). If it’s there replace the filter. If 120 VAC isn’t present at the line filter or if this is an AC 200XT go to step 5 in section Either Arc Starter below.
Arc starter without Spark Gap (Ultra-Cut)
1. Check for power to the RAS 1000XT’s Ignition Module during the 15 seconds following preflow (ignition phase). Arc starter power comes through the rear panel circuit breaker CB4, make sure it isn’t tripped.
a. During the ignition phase, measure for 120 VAC at the input terminals marked 120 VAC on the Ignition module, a gray rectangular box with screw terminals on one side.
WARNING
Do not let the meter probes (or your hands) come in contact with the other terminals marked
Hb and Ho or the other end of the wires connected to them. These can have 10,000 volt pulses which can cause physical harm and will damage your meter.
2. If 120 VAC is not present go to step 3.
a. If 120 VAC is present and still no spark, the Ignition Module may be bad.
3. 120 VAC to the remote Arc Starter comes from J59-7 & 9 on the power supply rear panel and connects to
J58-7 & 9 on the RAS1000XT. Remove the cable from J59 and during the ignition phase measure for 120 VAC between pins 7 & 9.
a. If 120 VAC is present problem is in the cable to the RAS 1000 XT or the J58 connector and internal harness in the Arc Starter.
A-42 b. If 120 VAC is present proceed to the next step.
APPENDIX 0-5261
AUTO-CUT 300 XT
4. 120 VAC to J59 comes from the relay board J8-3 with return on pin 11. On the Relay board, RF ON LED,
D23, should be on during the igniting phase. If it is not skip to the next step.
a. If D23 is on and there is not 120 VAC at J8-3 & 11 then the Relay board is bad.
Either Arc Starter
5. /RAS ON signal not on. CCM sends active low signal “ /RAS ON” over the 40 pin ribbon cable on pin
16 to the Relay & Interface board. On the relay board RAS Control relay (K2) closes (RF ON LED, D23 on) sending 120 VAC to J8-3 with return on J8-11. From here it either goes to the HF transformer T2 (AC200XT) or to J59 as described above. a. Measure the signal “/RAS ON” on pin 16 of the 40 pin ribbon cable relative to TP1 on either the CCM
I/O board or the Relay board. If it is low (less than 1V) skip to step 6. Otherwise continue this step.
NOTE!
If the CCM thinks there is already a pilot it would not enable the HF. Pilot board has a current sensor that sends a differential analog pilot current level signal to the Relay board which in turn passes that signal to the CCM. On the Relay board D11 LED
“Pilot Current Detected” or just “PILOT” lights if it sees a signal from the pilot board.
Reasons why RAS Control relay would not close:
6. Pilot current flowing. There actually is pilot current flowing somewhere. Unlikely as it would normally set the 208 fault but we have to rule it out. a. Disconnect J41 on the Pilot board, if HF still doesn’t fire and the Relay board Pilot LED, D11, is still on, it’s due to a fault in the detection circuits.
7. Faulty detection circuit. There isn’t any pilot current but a fault in the circuits measuring pilot current is indicating there is current.
a. Measure between pins 8 (-) and 9 (+) on the Pilot ribbon cable from Relay board J3 to Pilot board J42. If there is no pilot current it should be zero. Anything else indicates the Pilot board current sensor is faulty causing the Relay board D11 to be on. Replace the Pilot board assembly.
b. If the Pilot current signal on the pilot ribbon cable was zero, measure between pins 23 (-) and 25 (+) on the 40 pin ribbon cable between the Relay board and the CCM. This would also normally be zero if there is no pilot current. Anything else would indicate the Relay board is faulty.
CCM I/O Board
TO RELAY BOARD
/ RAS ON
TP1
GND
J23
29
30
31
32
25
26
27
28
21
22
23
24
17
18
19
20
37
38
39
40
33
34
35
36
13
14
15
16
9
10
11
12
7
8
5
6
3
4
1
2
J4
29
30
31
32
25
26
27
28
21
22
23
24
17
18
19
20
37
38
39
40
33
34
35
36
13
14
15
16
9
10
11
12
7
8
5
6
3
4
1
2
Relay & Interface Board
From I/O PCB
24VDC_SW
120 VAC_1
From J9-1
120 VAC_RET
From J9-7
D21
1
K2
D23
GREEN
5
RF ON
3
4 120 VAC to RAS
RAS CONTROL
16
15
14
13
12
11
10
9
8
7
6
5
4
3
2
1
J8
TP1
GND
(99)
(98)
(99)
(98)
AC200XT only
T2
6.5K 1W
6.5K 1W
120 / 6000 VAC
Art # 12307
9
10
11
12
13
14
7
8
5
6
3
4
1
2
0-5261 APPENDIX A-43
AUTO-CUT 300 XT
8. If “ /RAS ON” signal is low on pin 16 of the 40 pin ribbon cable, relative to TP1 on the CCM I/O board, during the ignition time then we need to determine if the Relay board is defective. If /RAS ON signal is not low the CCM or the 40 pin ribbon cable may be defective.
a. If the Relay board RF ON LED, D23, is not on while the /RAS ON signal is low, then the Relay board is defective.
b. Is D23 is on, measure for 120 VAC on J8-3 to J8-11. If not present the Relay board is defective. c. If 120 VAC is present at J8 during the ignition time go back and perform steps 2-4.
Troubleshooting Pilot Board problems.
1. The Pilot board is behind the CCM in the AC 300 XT and all Ultra-Cut XTs or on the upper section of the second inverter module in an AC 200 XT and has two LEDs. The first one, D11, a green LED, indicates the board has bias power and should be on all the time when the unit is turned on. The second LED, D2, also green, is on when the pilot is enabled, that is the pilot IGBT switch is turned on. The pilot is enabled near the end of preflow time and remains on until the transfer is established or for 15 seconds after which a 102 code is displayed. If D2 performs as expected you know the CCM, Relay board and work current sensor are not causing the problem.
2. If D11 on the Pilot board is not on check if the 10 pin ribbon cable is connected between the Pilot board (J42) and the Relay board (J3). Measure for 24 VDC on the Pilot ribbon cable test connector pin 2 (+) and pin 10
(-). If 24V is present and neither D11 nor D2 lights then the Pilot board may be defective. Pilot board end of the ribbon cable could also be the cause.
What should happen on the Relay board is LEDs D12, work Current Detected & D11, Pilot Current Detected should both be off. When you apply START after 2 seconds (Preflow time) D7, Pilot Enable, should come on.
Also D23, RF ON, should come on indicating the Arc Starter is being enabled. Normally D23 would only be on for a moment until pilot current is detected. Then D11 would be on (and D23 off) until arc transfer or pilot timeout (15 sec.) Since a pilot has not been detected D11 should not come on.
3. If the work current sensor is defective it could be telling the relay board (and thus the CCM) that there is already a transferred arc so no need for pilot. D12, a green LED on the Relay board, is on if work current is detected. If D12 is not on skip to step 5, otherwise disconnect J1, the work sensor connector. If D12 is still on the Relay board is defective.
4. If D12 goes out when J1 is disconnected, plug it back in and measure voltage from TP1 (common) to J1-1, should be positive 12-15VDC. Now measure J1-2, should be negative 12-15VDC. Now measure J1-3, should be 0 +/- 0.05V. If any of these are wrong disconnect J1 and measure again (on the relay board, not the harness). If still wrong the relay board is defective. Otherwise it’s the work sensor.
5. Pilot Enable signal comes from the CCM on pin 15 of the 40 pin ribbon cable between the Relay board (J4) and the CCM (J23). It should be low, less than 2V relative to TP1 on either the CCM I/O board or the Relay board. You can also measure this on TP11 of the I/O board. If the signal does not go low when the pilot should be enabled at the end of preflow time then the CCM is probably defective. You can also jumper
TP11 on the CCM I/O board to TP1, also on the I/O, to see if that will light D7, the Pilot Enable LED, on the
Relay board. If it does, that further confirms the CCM is bad. If jumping TP11 to TP1 does not light D7 on the Relay board, the problem is likely the Relay board or possibly the ribbon cable.
A-44 APPENDIX 0-5261
103 Lost Pilot
AUTO-CUT 300 XT
Code 103 occurs when Pilot has ignited as sensed by the pilot current sensor on the Pilot board , but went out on its own while CNC Start is still active before the pilot timeout (85 ms. or 3 sec.).
Possible causes:
• Preflow gas pressure too high, for manual gas controls check cut charts for proper setting. For DFC 3000 check that the process is correct for the consumables.
• Cutting current set too low for the torch parts being used. Pilot current level is automatically set based on the cutting current. A low cutting current results in a lower pilot current that may not be able to sustain a pilot for higher current torch parts.
• Remote Analog Current Control switches set wrong can also result in lower than normal pilot current setting. See section on these switch settings under next section for code 104.
• Broken torch pilot wire.
• Defective Inverter module puts out less current than it’s set for.
104 Transfer Lost
Arc transferred to metal for at least 50 ms. then went out.
Causes for 104 code:
• Cut demand set much lower than recommended for torch parts, i.e. 100A consumables in torch but cut current set for 30 or 50A (or zero). Current may be too low to keep arc on.
• Torch standoff too high for cutting process being used.
• Plasma gas flow too low due to a leak somewhere between the plasma regulator or the DPC 3000 and the torch. Check for leaks.
• Remote analog current control switches set wrong. o If remote analog current control is being used, SW8-2 (CCM CPU PCB) is on and SW11 (CCM I/O
PCB) is set to “A” (down) position, but no analog voltage connected to TB1-10 or J15-30 (CNC cable) then cut demand will be zero, pilot will be weak, depending on torch height it may still transfer but will immediately go out. o If remote analog current control is not being used but either SW11 is set to the down position or SW8-2 is on also results in zero cut demand.
o If system is Auto-Cut XT, current control is an analog voltage from the GCM 1000 XT or the AC 200
XT front panel pot. The current control setting will be shown on the front panel 4 digit display. SW8-
2 should be off and SW11 set to up position. With pot at max, check for 3.3V on CCM I/O PCB TP9
(TP1 common). While turning the pot toward minimum TP9 voltage should vary linearly to zero V.
GCM 1000 XT
(AC 300 XT)
R1
10K
J56
13
14
15
16
9
10
11
12
7
8
5
6
3
4
1
2
J55
13
14
15
16
9
10
11
12
7
8
5
6
3
4
1
2
(125)
(126)
(127)
AC 200 XT
R1
10K
J26
16
15
14
13
12
11
10
9
8
7
6
5
4
3
2
1
Auto-Cut XT Power Supply
+10.0V
Divide
by 3.
CCM
1
SW11
2
3
TP9
0-3.3VDC
TP1 GND
GND
From Remote analog Current
Control GND
Art # 12309
105 Not Used. This is one of the reserved codes from the earlier product.
0-5261 APPENDIX A-45
AUTO-CUT 300 XT
106 Pilot Timeout, no Transfer
Pilot time is limited to either 0.085 seconds (85 ms.) with CCM SW8-1 off (default for pierce starting) or 3 seconds with SW8-1 on (used for cutting over holes, expanded metal, etc.). Arc must transfer before pilot time ends.
Code 106 is set if no arc transfer (current in work lead) was sensed before pilot timed out. If the unit does not detect pilot current the arc starter will operate up to 15 seconds then set the 102 code. If you are getting 106 there is pilot current somewhere. If it’s not visible perhaps it’s inside the consumables or following some other part.
Causes for 106 code:
No Pilot Visible:
• Pilot inside the consumables
Visible Pilot:
• First the obvious, make sure the work lead is connected both to the work and the power supply. Also make sure the work itself is making good electrical contact with cutting table. If rusty or painted metal, you may need to clean a spot and attach the work lead directly to the metal.
• Torch too far from work.
• Cut current set too low for torch parts being used. Pilot current is set based on cut current. If cut current is too low pilot current will be lower and may not transfer at the height used for higher current consumables.
• Preflow pressure/flow too low.
• Remote Analog Current Control switches set wrong can also result in lower than normal pilot current setting. See section on these switch settings under section for code 104.
• Defective work lead current sensor circuit. If transfer is not sensed cut current remains at the lower starting level and pilot timer (85 ms. or 3 sec) will time out.
107 Not Used. This is one of the reserved codes from the earlier product.
108 Tip to Electrode Voltage Fault
The Pilot voltage, measured between tip and electrode varies with different current and gas type, flow rate and consumable design.
Once the arc is transferred the pilot switch opens leaving the tip basically floating. The voltage then is determined by how much of a cold gas barrier surrounds the arc. Too much current or too little gas and the arc starts to contact the tip reducing the voltage difference between tip and electrode and leading to a double arc that destroys the consumables.
The CCM measures both electrode and tip voltage and calculates the difference. If the difference between tip and electrode is found to be less than a minimum voltage we stop cutting and set a fault for the 108 code. The normal tip to electrode voltage is different for different processes so the min value for each process is embedded in the cut charts when using the DFC 3000 or in the CCM code if using the GCM 2010 or for Auto-Cut XT gas controls (GCM 1000XT or the built in one in the AC 200 XT).
New for the Auto-Cut XT units is a switch on the rear of the power supply that needs to be set according to the plasma gas. If using an oxidizing gas (O2 or Air) set it as indicated for those gasses (left if AC 200 XT or up for
AC300XT) or if using a non-oxidizing gas (N2, H35 or other inert gas) set it to the right or down as indicated for those gas types.. This switch adjusts the range of voltage for the gas type to better protect the torch. A wrong setting could result in false setting of the 108 code.
During piloting and ramping (the time from transfer until the current reaches full cut current), we lower the allowed tip to electrode voltage to about 80% of that allowed during cutting because the current is lower and the gas flow is lower during that time.
A-46 APPENDIX 0-5261
AUTO-CUT 300 XT
Causes for 108 code:
• Gas Flow/pressure too low for consumable parts being used. o If gas source pressure is not well regulated it is possible pressure may be OK at times and drop too low at other times such as during a cut.
o A leak of the preflow/plasma gas after the pressure/flow control (GCM 2010, DPC, GCM 1000 XT) can reduce the pressure/flow to the torch because some if it is bypassing the torch, while seeming to have enough pressure/flow at the gas control.
• Cut current set too high for consumable parts being used.
• With DFC 3000 a faulty component would be expected to set a fault code in either the DPC or DMC.
However, if a wrong process is selected which doesn’t match the consumable type or if using a custom process where pressure has been set too low or current too high that could cause 108 without setting any faults in the DFC 3000.
• A broken pilot wire in the torch lead making intermittent contact can allow piloting or sometimes the torch can transfer using only HF (high frequency). This intermittent connection will upset the tip voltage measurement and can result in the 108 code. Symptom is - it may cut for a short time then fault. Check for an open/broken torch lead pilot wire.
• Physically shorted torch body between anode (tip) and cathode (electrode).
The fault resulting in a 108 code is measured while cutting. It is more likely a shorted torch body, depending on the resistance of the short, it will set code 208 (Unwanted Current) as that is measured prior to starting cut
However, it must be considered as a last resort.
109 Part Process not Configured.
This represents a status, not a fault. This is used with the DFC 3000 only. It means the operator hasn’t loaded the cutting process from either the TSC 3000 or from the program embedded in the cutting table CNC controller. The solution is to load a process. The code will continue to be displayed until the CNC Start is applied at which time the code will clear.
110 Not Used. This is one of the reserved codes from the earlier product.
Group 2 – Plasma Power Supply codes
General:
LEDS
Several LEDs are used as indicators on the different inverter module boards. RED LEDs indicate faults. Green
LEDs should be on for the most part. Green LEDs are: On the main board, D4-READY; On the Cap Bias Board,
D6, -12V, D11 +12VP (primary referenced), D13, +12V; On the Control board D24, PWM will only be on when the inverter is enabled and its brightness varies with the duty cycle of the PWM.
Signals:
General description of some Inverter Signals passed to the CCM that can generate fault codes in Group 2.
“Ready” also called AC IN FLT (D4, READY LED, green, on Main Inverter board)
On the inverter main board we measure the input voltage. The 3 phases are rectified and lightly filtered to achieve an average voltage. Due to the light filtering a missing phase will also lower the average voltage so it will be detected. Voltage in the correct range turns on the READY LED D4 (on the far left of the main boards, in the upper part of the “B” section or lower part of the “A” section). Voltage outside the correct range or missing phase will turn D4 off.
An AC Input Fault by itself (no other faults occurring at the same time) will set codes in the 241-246 group depending on which inverter sees the problem.
INV FLT (D1, INV FLT LED, red, on the Inverter Control and Fault board)
0-5261 APPENDIX A-47
AUTO-CUT 300 XT
Several things can cause Inv Flt (Inverter Fault). Inverter fault is indicated by an LED, D1 on the Inverter Control and Fault board. Inverter Fault, when it occurs, is latched on. The latch is reset next time the inverter is enabled unless it is still active in which case it is immediately latched again. Inverter Fault will set the codes
247-252 unless it’s in conjunction with another fault in which case that fault code may be set.
Things that can set the inverter fault:
• The local (to the inverter) + 12V & -12V bias supplies out of tolerance. There are LEDs on the Cap/Bias board that light indicating these bias supplies are present but don’t verify they are in tolerance. It’s not likely this would happen. More likely that fault related to the +/-12V the supply would be missing and it’s LED not on.
• Capacitor imbalance. In a cap imbalance condition D3, red Led on the main board (lower left corner of bottom or “A” section and upper left corner of the upper or “B” section), will latch on.
• Primary over current. This is an over current condition in main switching transformer’s primary. This will latch on but is cleared when the inverter is enabled unless it is still active in which case it is immediately latched again.
• Inverter over temperature sets the Fault signal and LED but has its own fault signal to the CCM. See OT
Flt below.
OT FLT (D14, OT FLT, Inverter Control and Fault board)
• Inverter over temperature lights LED D14 on the Inverter Control and Fault board and will latch the fault signal and it’s LED but also has its own separate fault so that will be reported as a code in the range of
253-258 or 259-264.
PWR Present
• When power is first applied to the inverter (contactor closed) CCM checks for presence of the +12V bias on the Inverter Control and Fault board. If not present will set codes in the range of 265-270.
IS_ID (A, B, or C)
VAC_SEL (A or B)
201 Missing AC Phase
The System Bias Supply board contains circuits to detect if one of the 3 AC input phases is missing. Along with that it can also detect if the AC voltage is too low or too high. Three phase voltage is supplied from the input terminals through the ON/OFF Switch / circuit breaker CB1 to the System Bias board. The System Bias can operate on any 2 of the 3 phases to supply control power and fault detection.
I/O PCB
SYSTEM BIAS PCB
3 phase AC
CB1
ON / OFF
F1
F2
J60-9,18
J60-5,14
J60-1,10
+V
GND
J62
9
10
11
12
13
14
7
8
5
6
3
4
1
2 Missing Phase a
Missing Phase b
J27
9
10
11
12
13
14
7
8
5
6
3
4
1
2 1
U?
2
HCPL-817
4
3
GND
Missing Phase
To CPU PCB
J29-16
Art # 12310
Normally when the phase is not missing the transistor is on which turns on the opto-isolator making the signal
“Missing Phase” low.
Causes for 201, missing phase code. Codes are displayed two different ways, with an “L” meaning “Latched” or “Last”, before the number meaning it was a problem but isn’t right now or with an “E” meaning the problem exists now.
L201 :
Most likely cause is an intermittent problem with the incoming power or possibly a loose connection on the power cord at the back or the Ultra-Cut or Auto-Cut plasma supply.
A-48 APPENDIX 0-5261
E201:
AUTO-CUT 300 XT
• Phase missing from the wall fuse box, blown fuse.
• F1 or F2, 8A 500V slow blow fuses blown.
• CB1 one phase open.
• System Bias board defective.
• I/O board defective.
Troubleshooting:
1. System Bias board has a red LED, D3, that lights if it detects a missing phase. If D3 is on, check J60 for all 3 phases.
a. If all 3 phases are not present at J60 check for incoming power, then the F1 & F2 fuses. Finally the CB1. b. If all 3 phases present and about equal voltage then change the System Bias board.
2. If D3, Missing Phase LED, is not on check for voltage at J27-3 & 4 on the CCM. Normal voltage, with no missing phase, at J27 (or J62 on the System Bias board) pin 3 and pin 4, relative to I/O PCB ground. (TP1) should be between 10-14VDC with pin 3 being a couple volts higher than pin 4. If this is normal, problem may be in the CCM.
3. If the voltage at J27-3 & 4 is higher than 10-14VDC and up to 20-24VDC, make the same measurement at
J62 pin 4. If still high there and you have confirmed all 3 phases are present at J60 then the System Bias is defective.
4. If the voltage at J62-4 is not high the wires between J27 and J62 may be broken.
202-204 Not used. Reserved codes from the earlier product.
205 DC Output Low
DC output (voltage) low means one or more inverter sections are enabled but the output voltage is below a preset voltage. Shortly after receiving the Start signal from the CNC, but before the end of preflow, both sections of IM#1 are enabled and CCM measures the power supply output voltage between negative (Torch) to positive
(Work) at the output terminals. If this is less than a set value during preflow or if at any time during piloting or cutting it drops to below that value for a short time, the inverters are shut off and code 205 is set. 205 will almost always be indicated as an “L”, not an “E” fault because as soon as it’s detected the inverters are shut off and so no longer have the fault of low output voltage. Currently the low voltage value is -60VDC.
Causes of 205 code can include shorts outside the plasma power supply, shorts inside the plasma power supply and measurement errors.
a. Short external to the plasma power supply:
• The negative lead goes from the rear of the power supply to the remote arc starter or to the GCM 1000 XT in the case of the AC 3000 XT. o Cable pinched in or exiting the power track o Short inside the Arc Starter such as a wire coming loose and grounding to the chassis. o Short inside the torch mounting tube.
• Trouble shoot for external negative lead shorts by removing the lead from the rear of the power supply and try to start. It won’t start but if you get the same 205 code the problem is inside the unit. b. Short inside the supply:
• All the inverters outputs except that of IM1A are in parallel. If any inverter’s output is shorted it will appear as a short across the power supply output.
Troubleshoot by removing all (or one at a time) of the inverter output connectors except those on IM1A.
Then apply Start to the unit. If it starts now one of the other inverters had shorted output. To find the defective one reconnect one at a time until the fault reappears.
206 Not used. Reserved codes from the earlier product.
0-5261 APPENDIX A-49
AUTO-CUT 300 XT
207 Unexpected Current in the Work Lead.
HCT1, a Hall Effect current sensor on the positive (work buss bar) measures the work lead current. Inverter section 1A is enabled during preflow time but there should be no current in the work lead before the pilot is ignited and before the arc is transferred to the work. If current greater than 8A is detected before or during preflow something is wrong.
1. 207 code before START applied:
• Defective work current sensor, HCT1.
• Defective Relay PCB
• Defective CCM
Defective Sensor
• The work current sensor, HCT1, receives power, +15VDC and -15VDC from the Relay PCB. Both must be present for the sensor to work properly. Measure between Relay PCB TP1 (or J1-4) to J1-1 for +15VDC and to J1-2 for -15VDC.
• If either + or – 15VDC not present remove the J1 connector and repeat the measurement at J1-1 & 2 on the
Relay board. If the voltage is now present the sensor is defective or shorted (the harness may be shorted).
If voltages still not present, the Relay board is defective.
Relay PCB
• Relay board LED D12, Work Current Detected, will light if the current sensor signal exceeds 0.05V. If
D12 is on, measure the sensor output signal at J1-3 with signal common on J1-1. This signal should be
0V +/- 0.04VDC. If greater than +/- 0.04VDC with no work lead current, the sensor is defective. If the signal voltage is within the limits and D12 is on, then the Relay board is defective.
• If D12 is not on and the 207 code is still active, either the Relay board or the CCM is defective.
CCM or ribbon cable
• The work current signal leaving the relay board is on the 40 pin ribbon cable (Relay J4 to CCM J23) pins
27 (-) & 28 (+). If the voltage here exceeds 0.1VDC with no work current the Relay board is likely defective. Another possibility is in the 40 pin ribbon cable either pin 27 or 28 is shorted to an adjacent pin.
Otherwise the CCM is defective.
2. 207 code after START applied (during preflow):
• Short between power supply negative output and Work circuit.
• Short between power supply negative output and earth ground.
• Defective or incorrectly installed user supplied equipment such as torch height controls that make connections to power supply output.
Shorts are more likely to cause DC output voltage low (code 205). However, if the short has enough resistance it is possible to show code 207. To test, remove negative output cable and reapply Start. If 207 code does not appear problem is a short somewhere outside the power supply.
User Installed Equipment
For user installed equipment to cause 207 code it would have to be connected on the output (to the rear) of the current sensors. To test, disconnect user equipment and apply CNC START. If code 207 is gone user equipment was defective or connected incorrectly.
208 Unexpected current in Pilot Circuit
The Pilot board includes a current sensor to measure the pilot current. There should not be any pilot current until the inverters and the pilot board are enabled and the arc starter has fired to ignite the pilot. Pilot current or the signal indicating pilot current should not be present until the arc starter has fired.
A-50 APPENDIX 0-5261
AUTO-CUT 300 XT
Unwanted current signal due to defective sensor or defective circuit boards will most likely be present as soon as the power up sequence completes and will be indicated as an active fault, E208. An actual short allowing real current to flow in the pilot circuit will not occur until the inverter and pilot board are enabled near the end of preflow. This will result in the inverters immediately being shut off and displaying a “last” or “latched” fault,
L208. An LED, D2, on the Pilot board lights when the Pilot Board is enabled.
1. 208 code before START applied:
• Defective Pilot board (current sensor circuit).
• Defective Relay PCB
• Defective CCM
Pilot PCB
Pilot current signal is on the 10 pin ribbon cable (Pilot J42, Relay PCB J3) between pins 8 (-) and 9 (+). With no current, the signal should be zero +/- 0.05 V. Also the Relay board has an LED, D11, “Pilot Current Detected”, which will light if the pilot current signal exceeds 0.15V. If the signal is not zero V.Pilot PCB is likely the cause.
To be sure, disconnect the Pilot board ribbon cable from the Relay board at J3. If D11 goes out, the Pilot board was the cause. Double check by measuring pin 8 & 9 again. If it’s zero V. now, the Pilot board is defective. If
D11 is still on or pin 8 & 9 voltage still high check the Relay board.
Relay Board or CCM
If D11 on the Relay PCB is still on after the previous tests, measure the output to the CCM on the 40 pin ribbon cable (Relay J4 to CCM J23) between pins 23 (-) and 25 (+). It should be less than 0.1V. If not, the Relay board is bad. If voltage is zero then the CCM is defective.
2. 208 code comes on during preflow:
IM#1 and the Pilot board are enabled near the end of preflow. To have unwanted current there must be a path
(short) for current to flow between the inverter negative output (negative cable/torch electrode) and the Pilot return/tip before the arc starter is enabled for pilot ignition.
Possible causes are:
• Short between electrode and tip due to mismatch of consumables, damaged consumables or foreign matter between tip and electrode. An electrode at the end of its life may lose material that can short between electrode and tip.
• Defective or incorrectly installed user supplied equipment such as torch height controls that make connections to power supply output.
• Short between power supply negative output cable and pilot cable.
• Shorted torch body.
Troubleshooting:
1. Remove and insulate (may have voltage on it) the pilot cable from the rear of the unit. Attempt to pilot. If no 208 code shows, it confirms problem is outside the power supply.
2. Remove and check consumable for damage, cleanliness and missing (gas dist, etc.) or wrong components.
3. Disconnect user supplied equipment and see if fault still exists.
4. Inspect Arc Starter for broken/disconnected wires or burnt components.
5. Inspect inside the torch mounting tube for shorts.
6. If all else fails disconnect the pilot wire from the back of the torch head. Insulate it well or keep it away from any metal, it may have HF (high frequency) on it when you try to start. Try to start, if the 208 is gone now the torch head is shorted.
209 Not used. Reserved codes from the earlier product.
210–211 Output current, measured by the work lead current sensor, is too high (210) or too low (211).
These are warnings and do not shut down the process but may explain poor cut quality or poor parts life.
0-5261 APPENDIX A-51
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Individual inverter sections have their own current sensors and the work lead has a current sensor whose signal should equal the sum of the individual inverter sections. Each section is set to output a certain current based on its ”demand” signal. If the current differs from the total “demand”, sum of the individual demands, the individual sections are checked to determine if their output is correct compared with their demand signals.
If the individual sections are correct but the work current sensor signal differs from the total demand by more than 16% code 210 (too high) or 211 (too low) is displayed.
If an individual inverter section was found to be in error causing the total current to be wrong, a different code would be displayed in the range of 212 to 223 depending on which section was at fault.
Possible causes for work current signal too high:
• HCT1 Work Current Sensor
• Relay PCB
• CCM
Possible cause for work current to low.
• All the above plus a short to chassis caused by: o User installed equipment connect behind the current sensor that makes a connection to work or earth allowing current flow to bypass work sensor.
o Inverter + output shorted to chassis.
Troubleshooting:
1. For current too low due to a short disconnect work lead from back of unit. Check for continuity to chassis, there should be none. Inspect for incorrectly connected user equipment.
2. If no shorts were found or if fault was current signal too high see section on code 207 for detailed description of the power and signal paths for the work lead current sensor.
3. In the section on code 207 for Relay PCB it describes measuring the work current sensor signal when there is no current. The signal should be zero and we assume it is or else you should have gotten the 207 code. If the zero current signal is correct but there is an error while cutting, measure the signal on the 40pin ribbon cable (Relay board J4 to CCM J23) pins 27 (-) & 28 (+). The signal voltage should equal the cutting current
* 0.0266. For example for 100A (100*0.0266) =2.66V.
• If this signal is correct the fault is the CCM
• If it’s not correct the error may be in the Relay board or sensor. Follow the instructions for code 207 to measure the voltage to and signal from the current sensor at J1 on the Relay board. The signal voltage should equal the cutting current * 0.0133. For example for 100A (100*0.0133) =1.33V. For 400A would be
400*0.013 3= 5.33V.
• If power and signal are correct Relay board is faulty. If not correct the HCT1 work current sensor is bad.
212-223 Incorrect output from an inverter section.
Work current high or low due to wrong output from one inverter section. Individual code indicates which section.
Causes may be:
• The named inverter section output connector, J102 A or B, is not plugged in or is damaged.
• Ribbon cable with bad connection, perhaps not fully locked in place at either the inverter or the CCM.
• Defective inverter section.
Troubleshooting:
1. If it reports the current of an individual inverter section is too high, the problem is the inverter.
2. If the report is current too low (which included no current) check the connections.
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3. The ribbon cable for the first inverter section (IM#1A) must connect to that section only but if there are 2 additional sections, unit is 200A or greater, swap the ribbon cable going into those sections.
a. If it now reports a different section as bad, the one whose cable was moved, then the original section was bad. b. If it still reports the original section the ribbon cable or the CCM is bad (unlikely). c. Swap both ends of the ribbon cable with one next to it. If still reports the original section then the problem is with the CCM if not then it’s the ribbon cable.
4. If it’s the first inverter section or it’s a 100A unit so there’s no other inverter to swap cables with, replace the inverter.
Additional hint: Inverter control PCBs have a green LED, D24, PWM ON, that lights when that section is enabled and has a demand signal. The LED brightness is relative to the output so may be very dim if output is low. If that LED doesn’t light may indicate a defective inverter (control board).
224 Inverter 1 not found.
There must be an inverter connected in the 1st section, 1A, to be able to pilot. During the power up sequence, before power is connected to the inverters, the CCM does a continuity test to see if its section 1A ribbon cable
(J31 on CCM) is connected.
Causes & troubleshooting:
• As this is just a continuity test it is very unlikely to be a bad inverter. Most likely a poor connection or defective ribbon cable. o Check ribbon cable connections at both ends of INV1A to CCM J31 (1A) cable. Make sure it is plugged into J31, the top connector, on the CCM.
o Plug a different inverter cable into J31, doesn’t matter which one for this test as long as it’s plugged into an inverter on the other end. If still gives 224, “Inverter 1 not found” fault, it’s a bad CCM. Otherwise it’s the ribbon cable.
225-230 Inverter Revision and CCM incompatible.
If sometime in the future we should make a change to the inverter making it incompatible with older CCM we have included a hardware key that would change to indicate this. During the power up sequence, before power is connected to the inverters, the CCM does a continuity test to determine what is the hardware key configuration. The key uses 3 lines of the CCM to inverter ribbon cable which are named IS_ID_A, IS_ID_B, IS_ID_C (on pins 12, 13 & 14) and checks for continuity to a 4th line OUTCOM (pin 9). The test consists of applying voltage to OUTCOM and looking for that voltage coming back on the 3 ID pins. The present configuration has all 3 lines connected to OUTCOM so all 3 should be high.
To get the 225-230 code now when we don’t have any incompatible revisions would most likely be a bad connection in the ribbon cable between the CCM and the inverter or a defective CCM (unlikely).
• On the inverter section swap the ribbon cable with that of a different inverter section. If fault remains unchanged, still calls out the original inverter section, the problem is with either ribbon cable or CCM.
• On the inverter end put the ribbon cables back in their original positions. Now swap suspect ribbon cable with another one on the CCM. If the fault now moves to a different section it’s the ribbon cable. If it remains with the original section the problem is the CCM.
231-236 Inverter VAC Mismatch.
Different inverter modules are manufactured for 480VAC, 380-415VAC & 208-230VAC operation voltages. There is a key, called inverter ID, read through the inverter’s ribbon cable, to identify which voltage range the inverter is designed for. The unit itself is wired differently for the different input voltages and part of that includes a jumper at J61 on the System Bias board that indicates to the System Bias board what voltage the unit is wired to accept.
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At power on, the System Bias board measures the incoming voltage, determines what input voltage range it fall into and sends that range information to the CCM. Before Appling power to the inverters by turning on the input contactors, the CCM checks that each connected inverter is of the correct voltage matching that of the
System Bias board. The inverter ID’s are read from the lowest section to the highest so in all cases if it truly is a wrong voltage inverter it should call out the A section whose code is read first. A VAC mismatch of a B section is likely another problem.
Possible causes:
• Wrong voltage inverter (very unlikely but easy to check).
• System Bias board wrong J61 jumper (unlikely but easy to check)
• Defective inverter.
• Ribbon Cable
• CCM
• System Bias board defective.
Troubleshooting:
1. If System Bias board has either the wrong jumper or is defective it will call out the first inverter section, code
231, because all the inverters won’t match the incorrect signal and 1A is checked first.
a. For the jumper Wire #48 should be connected from J61-1 to: i. J61-2 for 208-230 VAC ii. J61-3 for 400 VAC iii. J61-4 for 480 VAC
Check for proper connection and continuity.
b. System Bias may be defective reporting the wrong voltage ID. On the output of the System Bias board at J62 measure relative to TP1 or ( J62-8, 24VDC_RET) to J62-12 for signal /VAC_IDAb and J62-14 for signal /VAC_IDBb. The 2 signals should read according to this table. “0” = 10-12V; “1” = 24V.
signal
/VAC_IDAb
/VAC_IDBb
230V 400V 480V ERR
0
0
1
0
0
1
1
1
2. Defective inverter, ribbon cable or CCM.
a. On the inverter section swap the ribbon cable of the inverter section whose fault was indicated with that of a different inverter section. If fault remains unchanged, still calls out the original inverter section, the problem is with either ribbon cable or CCM. If fault changes to the different section, the one the ribbon cable was swapped with, then it’s the inverter that’s defective.
b. If the fault remained unchanged in Step A, on the inverter end, put the ribbon cables back in their original positions. Now swap suspect ribbon cable with another one on the CCM. If the fault now moves to a different section it’s the ribbon cable. If it remains with the original section the problem is the CCM.
237 Too Few Inverters Found
There must be a minimum of 2 inverter sections present to operate. We know the ribbon cable for inverter section 1A is connected or else we would have code 224. During the power up sequence, before power is connected to the inverters, the CCM does a continuity test through the ribbon cable to see if an inverter is connected. If it doesn’t see continuity with at least one other inverter it assumes none are connected.
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Possible causes:
• Ribbon cable disconnected or defective.
• Inverter defective
• CCM defective.
Troubleshooting:
1. Check that all cables are connected, latches locked down, at both the inverter and CCM ends.
2. If this fault occurs it’s most likely on a 100A unit which only has one section (1B) in addition to the 1A section. If there were 2 or more additional sections it’s extremely unlikely all ribbon cables or CCM connectors would be defective. a. Swap the ribbon cables of the inverter section 1A and 1B. If fault remains unchanged, still 237, problem is with either ribbon cable or the CCM. If fault changes from 237 to 224 indicating inverter 1A missing, then it’s the inverter that’s defective.
b. If the fault remained unchanged in step a., on the inverter end put the ribbon cables back in their original positions. Now swap suspect ribbon cables on the CCM. If the fault now changes it’s the ribbon cable.
If it remains the same it is the CCM.
c. If there are 2 or more ribbon cables in addition to the one on section 1A then CCM is seeing none of them connected which indicates the CCM is faulty.
238 System Bias voltage identification is invalid.
At power up the System Bias board measures the input voltage and sends signals to the CCM indicating which range of voltage it has detected. See section 231-236 for details. If one of the 3 voltage ranges, 208-230V, 380-
415V or 480V isn’t identified then both ID signals are high resulting in an invalid signal.
Possible causes:
• Unit is connected to voltage below the 208-230V range or above the 480V range. (unlikely unless there is a problem with the incoming voltage.)
• Defective System Bias board
• Bad connection between System Bias output J62 and CCM input J27 on the I/O board.
• Defective CCM
Troubleshooting:
1. Measure all 3 phases of the input voltage and confirm they are within the tolerance specified in the unit manual.
2. Refer to section 231-236 Inverter VAC Mismatch and perform troubleshooting in step 1.b. If the 2 signals don’t match the incoming voltage, if both are high, then the System Bias is defective.
3. If step 2 was OK make the same measurement at J27 on the CCM I/O PCB. If OK here the CCM is defective.
Otherwise inspect the connections at J62 and J27.
239 AC Voltage High
Voltage OK -- At power up the System Bias board measures the input voltage and determined if it is within the range of voltage set by the J16 jumper. See section 231-236 Inverter VAC Mismatch Troubleshooting step 1.a for details of the jumper. Normally when the input voltage is OK the System Bias board turns on a relay K1 on the left die of the board to apply power to the T1 Auxiliary transformer. D44, a green “Transformer ON”
LED, will light when K1 is energized. T1 provides power to the gas controls and the TSC 3000 as well as the pumps and fans.
Voltage High -- If the AC voltage is determined to be too high it lights D4, ACV HIGH, a red LED on the System
Bias board, and sets the signal “AC V HIGH b” on J62-6 to a “high” about 24VDC (normal for a “low” here is
10-14VDC). To prevent the possibility of excessive voltage applied to several items (gas controls, pumps, fans etc.) K1 is opened removing power from T1 and D44 goes off. If it’s more than a momentary glitch the gas controls and the TSC 3000 (if used) will reset. Communication with the cutting table may be interrupted. With the DFC 3000 Auto Gas Control and perhaps the cutting table control, the process will have to be reloaded.
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D4 is on and the signal “AC V HIGH b” is high only while the voltage is actually high. The signal “AC V HIGH b” does not latch on.
If the fault is E239 that means it is currently active, that is, currently detected as being too high. If it’s L239 that means the voltage too high previously but it is not too high now. Applying START will clear the fault unless it becomes active again.
The voltage that triggers an AC Voltage High fault is above 550V for 480VAC line; above 470V for a 380, 400 or
415V nominal line; above 270V for a 208 or 230VAC line.
Possible causes:
• Incoming voltage is or was too high.
• Bad connection at J62 or J27
• Bad connection at J61 jumper
• System Bias board defective
• CCM defective.
Troubleshooting:
1. If the fault is L239 applying START will clear the fault unless it becomes active again. An occasional problem may be due to incoming voltage swells (voltage increases lasting from ½ cycle to as much as a minute).
Usually, if the plasma is at fault the problem will be present all the time.
2. It is unlikely that an open connection on the J61 jumper would result in a 239 fault, more likely to be a Voltage Mismatch fault. However, if it’s intermittent at exactly the right time, perhaps not fully plugged in, it could possibly show up as 239. Check J61.
3. If the incoming voltage is OK and the problem persists it may be the System Bias board, the CCM or the connection between J62 and J27.
a. If the incoming voltage is OK and D4 is on or signal “AC V HIGH b” on J62-6 is “high” (about 24VDC, relative to TP1 or J62-8 ) the System Bias board is defective. b. If D4 is not on and the signal “AC V HIGH b” on J62-6 is “low” (about 10-14VDC, relative to TP1 or J62-
8) then System Bias is OK and problem is in the CCM.
c. If J62-6 is near zero volts there may be bad connection between J62-6 and J27-6 or J62-7 and J27-6.
240 AC Voltage Low
Refer to the first paragraph for code 239 for explanation of what should happen when the input voltage is correct.
Voltage Low -- If the System Bias board determines AC voltage is too low it lights a red LED, D14, ACV LOW, and sets the signal “AC V LOW b” on J62-10 to a “high”, about 24VDC (normal for a “low” here is 10-14VDC).
Power is not removed from T1 as low voltage won’t damage anything, However, if it’s too low for too long, some things like contactors, AC solenoids, the gas controls or TSC 3000 may stop working. A low voltage, if it’s low enough, may also light D3, the red Missing Phase LED. This does not indicate the phase is actually missing.
The voltage that triggers an AC Voltage Low fault is 380V for a 480VAC nominal line; 300V for a 380, 400 or
415VAC nominal line; 175V for a 208 or 230 VAC line.
Possible cause:
• Incoming voltage is now, or was previously, too low. o Power distribution wires or power cord too small for the load.
o Loose or high resistance connection somewhere in the power distribution or power cord connection.
• Bad connection at J62 on the System Bias board or J27 on the CCM.
• Bad connection at J61 jumper on the System Bias board.
• System Bias board defective.
• CCM defective.
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Troubleshooting:
1. If the fault is L240, applying START will clear the fault unless it becomes active again. An occasional problem may be due to incoming voltage dips or sags (voltage drops lasting from ½ cycle to as much as a minute).
Usually, if the plasma is at fault, the problem will be present all the time. After ruling out everything else we may have to attach a monitor to the power input to determine if this is the problem.
2. Voltage can be OK when not cutting or cutting at lower currents but at higher current too much voltage may be lost due to undersize power cord or distribution wires.
a. Measure the voltage while cutting at higher current to determine if the drop is excessive.
b. Verify all power connections are clean and secure.
c. Verify correct wires size for the current draw per the recommendations in our manual as well as the local electrical codes.
3. It is unlikely that an open connection on the J61 jumper would result in a 240 fault, it is more likely to cause a Voltage Mismatch fault. However, if it’s intermittent at exactly the right time, perhaps not fully plugged in, it possibly could show up as 240. Check the jumper at J61.
4. If the incoming voltage is OK and the problem persists it may be System Bias, CCM or connection between
J62 and J27. a. If the incoming voltage is OK and D14, ACV LOW, is on or the signal “AC V LOW b” on J62-10 is “high”
(about 24VDC, relative to TP1 or J62-8 ) the System Bias board is defective. b. If D14 is not on and signal “AC V HIGH b” on J62-10 is “low” (about 10-14VDC, relative to TP1 or J62-8) then System Bias is OK and problem is in the CCM.
c. If J62-10 is near zero volts there may be a bad connection between J62-10 and J27-10 or J62-7 and J27-7.
241-246 Inverter Section Input Voltage Error.
The System Bias board checks for input voltage high, low or missing a phase from the power coming in from the power cord. It is unlikely but not impossible that a problem with the incoming power could result in 241-246 codes. The 241-246 codes more likely point to problems with the power into or within a single inverter section or in the case of missing phase it may be the contactor that supplies up to 3 inverter sections.
Once the input contactors close, applying voltage to the inverters, they test for input too high or too low and for missing phase. When the input voltage is in the correct range, a green LED, D4, named READY, lights on the left side of the main inverter board. If D4 is not on, either the input voltage is out of range or the inverter is defective.
You can still get the 241-246 code with a missing phase with the READY LED on. The LED will be going on and off rapidly but appears to the eye to be on. In this case you can measure the signal on the ribbon cable.
The signal previously called READY is now called AC_INPUT_FLT. It is a differential signal on pins 1(+) &
2(-) of the inverters 30 pin ribbon cable. If the AC input is correct you should read 5-6V between the pins. If
AC_INPUT_FLT is true voltage on pins 1 & 2 will be less than 2V.
Some of the other faults such as Inverter Fault and Over Temperature also set the AC_INPUT_FLT (not Ready).
However, they will latch on associated LEDs or set different fault codes. In the event of an Input Voltage Fault the CCM does not remove power from the inverter.
Things that can cause Input Voltage Fault codes:
1. Intermittently having the power drop out on one or more phases for at least 1 ms. a longer term loss would more likely trigger a different fault. If it’s the incoming power it would be likely not always be the same inverter.
2. Phase missing or intermittent to a specific inverter the fault would always call out that inverter.
3. Intermittent connections on the fault signal internal to the inverter.
247-252 Inverter Fault
Once the input contactors close applying voltage to the inverters several tests are performed. The Inverter Fault signal latches on so even if the cause has gone away you can see that there was a fault as indicated by red LED
D1, INV FLT on the inverter Control & Fault PCB. It is reset by applying start signal or cycling power. If the fault is still present it will come back on.
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Things that cause an inverter fault:
• One or more of the local bias supplies (+/-12VDC) failed or out of spec. Green LEDs on Cap Bias board labeled +12V (D13) & -12V (D6) indicate the supplies are present but not necessarily that they are in tolerance.
• Input capacitor voltage imbalance indicated by D3 CAP IMBALANCE LED (red) on left side of main inverter board. Applies to units with series connected capacitors (380-480V units).
• Too much current in the main transformer (switching transformer) primary, D32, PRI OC LED (red), on inverter control board.
INV_FLT is a differential signal on pins 3(+) & 4(-) of the inverters 30 pin ribbon cable. If there is not a fault you should read 5-6V between the two pins. If INV_FLT is true voltage on pins 3 & 4 will be less than 2V.
253-258 Inverter Over Temperature.
Each inverter section (IS) contains one or more temperature sensors. If any of these detect an over temperature condition it activates the signal “OVERTEMP_FLT going to the CCM over the inverter sections ribbon cable.
Inverters semiconductors (transistors and diodes) are liquid cooled. Anything that increases the coolant temperature too high can cause overheating of the inverters. The inverters magnetics (transformer & inductors) are air cooled by the same fan(s) that cool(s) the liquid.
Possible causes:
• Cooling fan(s) not operating.
• Disrupted air flow.
• Defective inverter module.
• Inverter Ribbon cable bad connection.
• Defective CCM.
Originally 100 and 200A units had 2 smaller fans while 300 & 400A used a single larger fan along with a larger radiator. More recently, the single larger fan may be used in the 100 & 200A as well.
Troubleshooting:
1. Confirm that air is exhausting from both the top (top fan)and bottom (bottom fan of units with 2 fans) of the opening in the right side panel. As the fan(s) are behind the radiator it’s hard to see them to confirm they are turning but perhaps you can use an inspection mirror. Refer to section for code 403 for troubleshooting defective fans.
!
WARNING
Fan blades can be moving and accidental contact with a mirror or other inspection devise can cause personal injury or damage to the machine.
2. Leaving the side panels and cover off, especially the left lower side or the top cover will reduce the air flow.
Also if the radiator fins become clogged with dust it will reduce air flow. Clean the radiator periodically by blowing air into it to clear dirt from the fins.
259-264 Inverter Over Temperature due to high Ambient.
The CCM measures the ambient temperature where the cooling air enters the louvers on the left side of the front panel. If an inverter goes over temperature and we have determined that the ambient exceeds 40 deg C we will get one or more of the high ambient codes, 252-264. The sensor, TS2, is a NTC (Negative Temperature
Coefficient) resistor whose resistance varies with temperature. It is mounted on the inside of the front panel next to the louvers on the left. To access it requires removing one or more of the inverter modules. If the ambient is high but no inverter is too hot there is no fault.
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Possible causes:
• Ambient is too high.
• Cooling fan(s) not operating.
• Disrupted air flow.
• TS2, Ambient temperature sensor, shorted (very unlikely) or otherwise defective.
• Defective Relay board.
• Defective CCM.
• Defective Relay board.
Troubleshooting:
1. If room temperature exceeds 40 deg C, cool the room, or operate the unit at reduced duty cycle or lower current.
2. Confirm that air is exhausting from opening in the right side panel. As the fan(s) are behind the radiator it’s hard to see them to confirm they are turning but perhaps you can use an inspection mirror. Be careful not to get the mirror or your hands into the blades. 100 & 200A units have 2 smaller fans, 300 & 400A have one larger one.
3. It is unlikely these high ambient temperature codes would be set before some other temperature related code but just in case we’ll note that leaving the side panels and cover off, especially the left lower side or the top cover will reduce the air flow. Also the radiator fins clogged with dust will reduce air.
4. To test TS2 remove J2 from the Relay board and measure the resistance between pins 4 & 6 of the J2 harness connector. The resistance varies from about 33K ohms at 0 degrees C to about 12K ohms at 20C to 5.3K ohms at 40C.
5. If TS2 is within the correct range the problem may be with the Relay board or the CCM.
a. The output from the relay board going to the CCM is on pin 30 of the 40 pin ribbon cable (J4 of Relay board to J23 of the CCM I/O board). It is an analog voltage that should range between 0.44V at 0 deg
C to 1.6V at 40C. If it is confirmed that the room ambient is not above 40C and Ambient temperature signal at pin 30 is higher than 1.6V then the Relay board is defective.
b. If Ambient temperature signal at pin 30 is OK, less than 1.6V, and the room ambient is not above 40C then the CCM is bad.
265-270 Inverter No Input Power
There are several digital signals on the ribbon cables between the inverter sections and the CCM that involve some level of voltage. These include AC_INPUT_FLT\, INVERTER _FLT\, OVERTEMP_FLT\ and POWER_
PRESENT. Normally all of these should be high. Before power is applied to the inverter modules the CCM has already performed a continuity check to see if that section is in place and it’s ribbon cable connected (code
224 & 237). As soon as power is applied to the inverter modules the CCM checks these 4 signals and, having already confirmed there is an inverter whose ribbon cable is connected. If it finds none of the signals have voltage, it assumes there is no power into the section or something is wrong with that inverter section’s bias power.
Possible causes:
• The 3 input phases, J103-105 to that inverter section not connected.
• The circuit breaker CB2 providing the 120 VAC to the contactor (and Remote Arc Starter) has tripped.
• The contactor powering that section (and others) defective.
• Relay board defective.
• Inverter defective.
• CCM defective.
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Troubleshooting:
1. Check that the input power cables are connected to the inverters.
2. Check if the contactor for that section (W1 for 1A, 1B, 2A; W2 for 2B, 3A, 3B) is energized.
a. There is a rectangular section in the middle of each contactor top that can be used to attach auxiliary contacts. This can also be an indicator of contactor operation as it pulls in when the contactor is energized. b. Check for CB2 on the rear panel being tripped. The white button marked “5” indicating it’s 5 amps, will pop out if tripped. Reset it and if it pops out again something (contactor coil?) may be shorted.
c. Measure for 120 VAC on the contactor coil. If present, but the contactor isn’t pulled in, it’s probably a defective contactor.
3. On the Relay board D22, CONTACTOR ON LED (green) next to relay K1 lights if K1 is being told to energize.
a. If it’s on check for 120 VAC between J8-1 and J8-9. If present the relay board is OK.
b. If D22 is on but 120 VAC is not present at J8-1 and J8-9 (make sure meter is set for ACV) then the relay board is defective. c. D22 is not on, go to the 40 pin ribbon cable test connector and measure voltage on pin 17 (relative to
TP1 on either the Relay board or the CCM I/O Board). It should be low, less than 1 volt. If it is the relay board is likely bad. If it’s high, about 24VDC then the CCM may be bad, not telling the contactor to turn on.
4. The inverter section may be defective with a bad bias supply. Swap the inverter end of the ribbon cable with one next to it. a. If it now reports a different code, that of the inverter that was swapped with, then the original section is bad. b. If it still reports the same section even though the ribbon cable was swapped then the CCM is bad.
271 Inverter ID Reading Fault.
Refer to section for codes 225-230 for a description of the ID signals. If this code appears it means one of these
ID signals has gone false some time after power up.
Possible causes:
• An intermittent ribbon cable or one not fully latched in place.
• EMI interference.
Troubleshooting:
1. First recycle power to see if the fault is still there. It may now show up as one of the 225-230 codes which will indicate which inverter.
2. Determine when the code shows up. If it is EMI it may not happen every time but if, when it happens, it is always at the beginning of piloting, it may be EMI interference. Check the system ground cables and if an
AC200XT check the torch shield connection to the unit rear panel.
3. If it happens intermittently during cutting or idling it might be an intermittent ribbon cable. This code does not say which inverter section so you have to check each ribbon cable for proper connection on each end. It’s highly unlikely for a ribbon cable to be intermittent but if you have more than 2 sections try disconnecting one section at a time and cut at lower current. See if you find one that causes the problem and if so replace that ribbon cable.
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Group 3 codes relate to the GAS Controls Status and Communication Protocol
Also refer to GCM 2010 Status Codes at the end of this Group 3 codes section.
301 Gas Control Communication Fault
No signal detected over the fiber-optic link from the gas control. In the case where there are additional devices other than Gas Control connected to the CANBUS this code would indicate the Gas Control is having communication problems while the other CANBUS devices are OK. We don’t currently have any other devices on the
CANBUS so it is more likely that code 501 will be what is set. In any case troubleshooting is the same as for 501.
Possible cause:
• Most likely cause is dirty or defective fiber-optic cable or connector.
• Cable to GCM 2010, DMC or DPC not connected or broken.
• Defective control board or power supply in the Gas Control
• Defective CCM
Troubleshooting:
1. Check that the fiber-optic cable is fully plugged in to both sockets. Clean the cable ends with a soft cloth and blow out the sockets with air.
2. Check gas control cables. If any of the gas control cables are not connected there will be no communication as there will be no power to the control. This may show up as a 301 or 501 code. Also if the cable is broken or defective such that the gas control is not enabled it may have power but in the case of the DMC or DPC its fault light will blink error 101 while the CCM will only detect that there is no communication and it will show 301 or possibly 501.
302 Gas Control communications reply fault
Communication has been established but Gas Control did not reply to a request from the CCM in the time allowed. Likely cause is Fiber-optic problems (see code 501) or if problem persists defective Gas Control main PCB.
303 Gas Pressure fault
Gas pressure faults only show up when you try to start the torch, not during purging or setting flows .
With the Auto-Cut 200 XT and the Auto-Cut 300 XT (GCM 1000 XT), the gas pressure sensor is only on the plasma gas and is in series with Run/Set switch. A 303 code here indicates either plasma gas missing or very low pressure, less than 50 PSI, or RUN/SET switch is in SET position.
Starting with GCM2010 revision AG we measure inlet pressure of both plasma and shield gas at the inlet of the gas selection manifold. If pressure is either too low or too high it sets 303 code. Earlier revision should not display 303 code. GCM2010 will display which gas is the problem and its actual pressure. The pressure at the point where it is measured should be in the range of 100-135 PSI. Exception is for shield gas if the Gas switch is set to Pressure then the min pressure can be 85 PSI.
In the GCM 2010 Gas Control, on the main PCB, measure between test points TP1 (ground) and TP18 (shield) and TP19 (plasma) to measure the output of the pressure sensors. Voltage should be between 2.6V to 3.5V for
100-135 PSI. With shield switch set to pressure low limit is 2.1V. Whichever gas is outside those limits will be the one causing the fault. Remember the pressure may drop during operation, set the code, then recover displaying L303 when you are measuring it.
• To test for faulty pressure sensor or inadequate gas supply with too much restriction. On the GCM 2010 place the Mode switch to SET Plasma & Shield, turn the mechanical pressure regulators to max pressure and compare mechanical gauges with the pressure display. If the pressure display doesn’t approximately match the gauge the sensor is likely defective. If the gauge and the pressure display both show low pressure the supply to the gas control has too much restriction. Perhaps the hose is too long or too small.
0-5261 APPENDIX A-61
AUTO-CUT 300 XT
304 Gas Control not ready
This is the normal code when the gas control is conducting a purge at start up or when the process is loaded or changed or when the plasma system has been disabled and is returned to “Enable”. If it is a GCM 2010 the
Mode switch may not be set to the RUN mode.
Code 304 combined with 204 & 402 when the Plasma Enable on the GCM 2010 gas control is set to disable can indicate a fault in the CCM I/O PCB. When switching back to Enabled the pump will not restart so continues to display 4-2 indicating no coolant flowing.
Normally the code during a disable should be 101. Circuits on the I/O PCB detect the Plasma Enable is disabled and send signal to the microcontroller in the CCM. If a fault in the CCM prevents that signal from getting sent to the microcontroller it doesn’t know the system is disabled so it sets these other 3 codes.
305 Gas Control Protocol Error
Application error or firmware incompatibility fault. Consult factory for latest firmware update. Possible electromagnetic interference from the Arc Starter; inspect grounding, bonding, and isolation.
306 Not Used. This is one of the reserved codes from the earlier product.
307 Gas Control returns wrong command sequence.
Firmware incompatibility. Consult factory for latest firmware update. Possible electromagnetic interference from the Arc Starter; inspect grounding; bonding; and isolation.
308 Mismatch between the CCM and gas control type.
The Auto-Cut XT CCM is designed to work with the GCM 1000 (AC 300 XT) or the built in gas control of the AC
200 XT. Attempting to use a GCM 2010 or DFC 3000 Auto Gas Control on an Auto-Cut will result in a 308 code.
Similarly attempting to use a CCM from an Auto-Cut XT in an Ultra-Cut XT supply will also result in a 308 code.
309 Gas Control Communication reply fault.
Relay doesn’t match what was requested. Possible firmware incompatibility. Consult factory for latest firmware update.
Possible electromagnetic interference from the Arc Starter; inspect grounding; bonding; and isolation.
310-313 DFC 3000 Auto Gas Faults.
These different codes displayed on the power simply indicate one of the Auto Gas modules (DPC for codes
310 or 311; DMC for 312 and 313 could be either) is reporting a fault. You need to refer to the specific modules blinking red LED status indicator and the Status code tables for more information.
GCM 2010 Status Codes
GCM 2000 has an LED on the front panel which blinks various codes.
GCM 2010 has LCD display which displays many of the Status messages. However, there are a few relating to communications that aren’t clear.
When there is a communication error it will be displayed but once it has recovered the display will show what the error was by displaying:
^E4 – Low level CAN bus error where the CCM did not acknowledge receiving a message from the Gas Control.
^E5 – Low level CAN bus error where the bus is off.
^E6 – CAN bus communication (the fiber-optic) has timed out.
A-62 APPENDIX 0-5261
Group 4 codes relate to the Liquid Cooling System
AUTO-CUT 300 XT
Cooling system description. System includes a reservoir, a pump, one or more heat exchangers, flow switch, level switch and flow sensor on some models. Also included are a filter and various fittings and hoses. New coolant is installed into the reservoir or “tank” from an opening in the unit’s front panel where there is a visual level indicator. Coolant flows to the pump inlet from the bottom of the tank, is pumped through a pressure relief or “bypass” valve which limits MAX pressure to 150 PSI bypassing excess flow back into the reservoir.
The coolant temperature sensor, TS1, a linear NTC sensor, is mounted on the bypass valve.
From the bypass valve, in most systems, coolant is plumbed to the rear panel coolant supply fitting where it goes to the torch via the RAS 1000 XT, the remote arc starter.
Exceptions are the Ultra-Cut 400 XT which has an additional external heat exchanger and the Auto-Cut 200 XT which has an internal arc starter.
For the Ultra-Cut 400 XT the HE 400 XT external heat exchanger is placed between the plasma power supply and the RAS 1000 XT with the supply coolant passing through the radiator for extra cooling.
In the Auto-Cut 200 XT coolant goes to the water cooled HF (high frequency) coil and then to the torch supply lead attached to the internal torch connection bulkhead.
For the coolant return in most systems the return from the Torch goes to the RAS 1000 XT and on to the return fitting on the rear of the power supply. In the Ultra-Cut 400 XT the return from the RAS1000XT first passes through the HE 400 XT then to the rear panel of the power supply. For the Auto-Cut 200 XT the coolant returns from the torch to the torch bulkhead inside the unit.
Coolant returning from the torch is routed through the rear panel filter then through the radiator (internal heat exchanger) and through the flow switch. Ultra-Cut models also have a flow sensor in series with the flow switch that can detect bubbles in the coolant. Upon leaving the radiator, coolant goes into the bottom inverter “cold plate” or liquid cooled heat sink. It flows through the inverters in series and returns to the tank.
401 Coolant Level Low
The coolant reservoir (tank) has a normally open (tank dry) float type level switch, LS1. When the coolant level in the tank is below about ½ full this fault will signal the need to add coolant. It will not stop the process during a cut but will instead show the 405 fault as a warning. As soon as the cut stops it will not allow another to start until the issue is corrected.
Possible causes:
• Coolant is low
• Level switch defective, disconnected or installed upside down.
• Relay board defective or J7 disconnected.
• CCM defective.
Troubleshooting:
1. Confirm visually that the level switch float is below the coolant, if not add more coolant to the tank.
2. Check J7 on the Relay board.
a. If properly connected remove J7 and check continuity between pins 2 and 4 (pins 2 & 3 of J71 on the switch itself). b. If no continuity at J71 on the switch, if it is still open, replace the switch.
3. If there was continuity at J7 plug it back in and measure voltage on pin 9 of the 40 pin ribbon cable (Relay board J4 to CCM J23). Common is TP1 on either the Relay or the I/O board.
a. Pin 9 should be high, about +10 to +15V. If it’s not the relay board is bad or the ribbon cable is shorted. b. To test the ribbon cable remove both ends, J4 on the Relay board and J23 on the I/O board and measure from pin 9 of the ribbon cable to both pin 8 and pin 10 of the cable. Both should be open. If not replace the ribbon cable. Otherwise it’s the Relay board.
4. If pin 9 of the 40 pin ribbon cable was high in step 3.a the CCM is defective.
0-5261 APPENDIX A-63
AUTO-CUT 300 XT
402 Low coolant Flow
The flow switch FS1 is positioned in series with the radiator where it measures the flow returning from the torch. The flow switch serves two purposes, one to insure there is adequate flow for cooling needs and two, it insures the torch consumables are in place so the negative output of the power supply is not exposed. This function is called “Parts in Place” or PIP. The output cannot be enabled if parts are not in place. The normally open flow switch requires 0.7 GPM (2.65 liter/min.) +/- about 10% to close.
When the system is turned on and enabled and fails to achieve proper coolant flow after 4 minutes code 404 will be set. Getting code 402 means it initially had enough flow but something has caused the flow to be reduced. Listed here are things that might happen during cutting to cause reduced flow. For other causes like component failures refer to code 404.
Possible causes for low flow:
• Coolant filter clogged.
• Flow bypass valve incorrect adjustment or defective. Call the factory for instructions.
• Defective pump.
• Coolant supply or return hose twisted or pinched reducing flow.
If coolant flow is not low but code is being set, possible causes:
• Flow switch disconnected or defective.
• Relay PCB.
• CCM.
Troubleshooting:
1. First note whether the fault is an “E” meaning it’s currently low or an “L” meaning it was low but isn’t now.
Flow that remains low could indicate a failed component or a blockage such as clogged filter or pinched hose. It also means you should be able to measure the flow to determine if it is really low or the sensor has a problem.
2. First recycle power. If flow is still low or a component is defective the code should change to 404. Go to that section for further troubleshooting.
3. If after recycling power there is no code, continue cutting to see if it occurs again. Take note of when it occurs, for example if it’s with the torch at one end of the table, perhaps the leads get pinched there? In any case go to code 404 section for more information.
403 Coolant overheated
TS1 is a linear negative temperature coefficient (NTC) resistor sensor attached to the brass fitting at the exit of the bypass valve. Here we determine the coolant being supplied to the torch is below the required temperature which is currently 75 deg C (167F). The radiator is on the lower right side of the unit. The fan(s) are behind it and blow out through the radiator. 100A & 200A units may either have 2 smaller fans or one larger one. The
300 & 400A units have one larger one.
Fans operate during cutting and for 4 minutes after last cut then shut off. Exception is AC 200 XT where the fans are on whenever power is on. The external heat exchanger, HE400, fan is thermostatically controlled so it only comes on when coolant is over 60 deg C. It will shut off when the other fans shut off.
Possible reasons for coolant overheated:
Coolant fan(s) failed or defective fan control relay MC2.
A-64
• Radiator fins clogged with dirt.
• Duty cycle exceeded (ambient temperature above 40 deg C and operating at high duty cycle).
• Operating with an object placed in close proximity to the air outlet (right side of the unit) or the front panel inlet openings.
• Operating for extended time with right lower side panel removed.
• Defective Relay board.
• Defective CCM.
APPENDIX 0-5261
AUTO-CUT 300 XT
Troubleshooting:
1. Check for air blowing out of the unit. Remember, except for the AC 200 XT, the fans only run when CNC
START is applied and for 4 minutes after cutting, you may have to apply start again to restart the 4 minute time. Fans may be forced on by jumping TP2 on the CCM I/O board to TP1 (ground).
a. If using the external HE400XT heat exchanger, optional for 300A, standard for 400A, check for air blowing out of it. Note that the HE400XT fan, controlled by a thermal switch in the HE400XT, only runs if the coolant is over 60 deg C and the internal fans are operating. With the 100 & 200A if it has 2 fans make sure both fans are operating by checking for air both top and bottom of the opening. The fans are difficult to see, perhaps you can use an inspection mirror. Be careful not to get the mirror or your hands into the blades.
2. Fans are powered by 230 VAC. The 230 VAC for the fan(s) is switched by the MC2 control relay (except the
AC 200 XT where the fan(s) is powered directly from the T1 transformer at J13).
CCM I/O PCB
To test fan relay jump TP2 to TP1.
TP2 TP1
J4-19
Relay PCB
24 VAC
+24
1
K4
D24
5
Fan Bias Control
2
4
3
J8
13
14
15
16
9
10
11
12
7
8
5
6
3
4
1
2
230 VAC from T1
J13
(65A)
MC2A
(64A)
MC2B
(161)
SA3
MC2
Fan Control
ARC_SUPPRESSOR
(160)
(69)
(70)
(69)
(70)
CHASSIS GND
To J70-3
R
1
2
3
J72 C4
BN
R
J73
1
2
3
(70)
BK
To J70-2
FAN1
BL
Art # 12311
3. Check for 230 VAC at either of the fan connectors, J72 & J73. It may also be measured at the rear panel connector J70 for the HE400XT fan.
a. If the fans are not getting 230 VAC, measure for 24 VAC on the coil of MC2. If present and the relay contacts aren’t closed the relay is defective. Note, the coil is rectified so you won’t measure continuity of even a good coil. b. If 24 VAC is not on the MC2 coil check for D24 on the relay board being ON. If it’s on, the Relay board should be providing the 24 VAC so if it’s not the Relay board must be defective.
c. If D24 is not on, measure on the CCM I/O board between TP2 and the common at TP1. It should be low, near zero volts. If not the CCM is probably defective. Jumper TP2 (I/O board) to TP1. If the fans now come on replace the CCM. d. If jumping TP2 to TP1 does not turn the fans on then the Relay board or the 40 pin ribbon cable pin 19 is at fault.
404 Coolant System Not Ready
When power is applied to the system with External Plasma Enable satisfied and Plasma Power Supply Enabled
(switch on 2010 or TSC 3000), assuming there is enough coolant in the tank, after some initial tests taking about
15-20 seconds (see manual section 4 for details of the Start-Up Sequence) the pump will start. Coolant will be pumped through the system. Flow is measured by the FS1 flow switch placed in the torch coolant return path just before the radiator (see plumbing diagram). If the flow doesn’t reach at least 0.75 GPM (2.8 lpm) within
4 minutes it will set the 404 fault. The reason for the 4 minutes is a new dry system especially one with long torch leads will take some time before the leads, hoses, radiator and cold plates are full of coolant. More coolant may have to be added. On a system that has been run before it normally takes only a few seconds to establish proper flow. In any case the pump will run for 4 minutes before setting the 404 fault.
0-5261 APPENDIX A-65
AUTO-CUT 300 XT
First determine if the pump motor is running and if so is there any coolant flowing. With the right lower side panel removed touch the pump and feel for vibration to indicate if the motor is running. Observe the clear coolant hoses to see if they are full of coolant. There are two hose fittings on the back of the tank. The upper one is the coolant return. Remove the tank filler cover. You should see a fairly strong stream of coolant from that fitting. The lower fitting is from the pump bypass valve. If the pump is operating some coolant may be exiting that fitting as well. If these fittings are below the coolant level you may have to drain out some of the coolant to see this. If a strong stream is exiting the bypass (lower) fitting but nothing from the upper fitting, you probably have some kind of blockage.
Reasons for 404 faults (Coolant not flowing):
• In new installation, coolant has not circulated all the way through the leads. Add more coolant if necessary and recycle the power to restart the pump and 4 minute timer.
• Coolant supply & return leads are reversed, check valve in torch coolant return prevents reverse flow.
• Torch parts removed or are wrong style so torch check valve shuts off flow.
• Torch coolant tube damaged or the tube extension (if required) missing.
• No power to pump motor.
• Pump/motor failure.
• Bypass valve defective or adjusted incorrectly.
Damaged Coolant Tube
Coolant tube includes a check valve at its upper end. When cartridge with consumables is not installed the spring loaded coolant tube is fully extended closing the check valve preventing coolant from leaking out.
When consumables are in place they push the tube inward, opening the check valve, allowing coolant to flow.
The coolant tube has fingers on the end to contact the inside of the electrode and allow coolant to flow through the openings between the fingers.
The fingers can be bent over or broken if reasonable care is not taken when the cartridge is not in place. If the fingers are bent or broken it shortens the tube so the consumables may not push the tube in enough to open the check valve resulting in no coolant flow. The coolant tube assembly may be replaced separately from the torch head.
Some consumables use an extension on the coolant tube. A missing extension will not allow the check valve to open.
Internal Check Valve
Fingers
Coolant Tube Extension
Art # 12312
No Power to the Pump Motor
The pump motor is powered by 230 VAC controlled by the MC3 control relay. During the 4 minutes after turning on power, before the 404 fault code is displayed, measure for 230 VAC at the motor connector J16 pin 1 to pin 3.
a. If the pump motor is not getting 230 VAC, measure for 24 VAC on the coil of MC3. If present and the relay contacts aren’t closed the relay is defective. Note, the coil is rectified so you won’t measure continuity of even a good coil. b. If 24 VAC is not on the MC3 coil check for D27 on the relay board being ON. If it’s on the Relay board should be providing the 24 VAC so if it’s not the Relay board may be defective. Measure for 24 VAC at J9-6 to J9-12 on the Relay board. If 24 VAC is present and D27 is on, the Relay board or the wire harness is defective.
c. If D27 is not on, measure on the CCM I/O board between TP3 and the common at TP1. It should be low, near zero volts. If not the CCM is probably defective. Jumper TP3 (I/O board) to TP1. If the pump comes on now replace the CCM. d. If jumping TP3 to TP1 does not turn the fans on then the Relay board or the 40 pin ribbon cable pin 13 is at fault.
A-66 APPENDIX 0-5261
CCM I/O PCB
To test Pump relay jump TP3 to TP1.
TP3 TP1
J4-13
Relay PCB
24 VAC
+24
1
K5
D27
5
Coolant Pump Control
2
4
3
J8
13
14
15
16
9
10
11
12
7
8
5
6
3
4
1
2
AUTO-CUT 300 XT
J13
230 VAC from T1
MC3A
(65B)
(64B)
MC3B CHASSIS GND
(67)
(162)
SA4
MC3
Coolant pump Control
(66)
J16
1
2
3
M1
Torch Coolant Pump
ARC_SUPPRESSOR
(163) Art # 12313
Coolant flows but flow is less than the required minimum:
Test and adjust the pump/bypass valve:
This test measures the “dead head” or blocked flow pressure at the rear panel coolant supply fitting. Perform this test only after the coolant system is fully primed, that is after the coolant is circulated throughout the system and is mostly free of bubbles. It requires a pressure gauge with #6 JIC fitting.
The gauge needs to be able to read at least 173 PSI. Remove the coolant supply hose and connect the pressure gauge in its place. For the Auto-Cut 200 XT connect the gauge in place of the torch coolant supply hose on the torch connection bulkhead. This is a #5 JIC fitting.
NOTE!
Do not put the gauge in-line and attempt to pinch off the hose to block the flow. It is very difficult to totally block the flow and failure to do so will result in incorrect setting of the bypass.
Turn the on the unit. You will have 4 minutes to perform the test/adjustment before the system times out with a coolant flow fault. If that happens recycling the power gives you another 4 minutes.
1. The pressure on the gauge should be close to 173 (170-175) PSI. If it is the pump and the bypass are OK.
2. If the pressure is less than 173 PSI adjust the bypass screw clockwise to raise the pressure. If you can change the pressure with the bypass screw but cannot reach 173 PSI it is likely the pump is worn out or damaged. If the pressure does not change using the bypass screw it is likely the bypass is defective.
3. If the pressure is above 173 reduce the pressure by adjusting the bypass valve screw counter clockwise.
Coolant flow test:
In addition to the pressure test or in place of it if you don’t have a gauge, determine if the flow returning from the torch (the flow that passes through the FS1), is greater than the required minimum. With the unit switched off remove the return hose from the back of the power supply. Place it in a container of a known volume. Turn the unit on and let the pump run exactly 30 seconds. It should pump at least 3/8 gal. (1.4 l). Use a larger container in case the flow is greater and it overflows.
If the flow is lower than 0.75 GPM:
• Look for restrictions such as sharp bends or something pinching the coolant hoses or torch leads.
• Other possibilities are the bypass valve has been adjusted wrong (someone may have turned the adjustment screw) see pressure test/adjustment above
• The pump is worn out (may be the case with an older unit).
0-5261 APPENDIX A-67
AUTO-CUT 300 XT
Coolant flow is correct but system doesn’t detect it due to defective components:
• Defective or disconnected FS1 flow switch.
• Relay board.
• CCM.
Flow Switch FS1 disconnected – FS1 comes with wire about 1 ft. long and a connector that connects to a 3 wire harness. This could be disconnected at either end, J74 or J5 on the relay board.
Defective FS1– The flow switch, normally open, closes when flow through it exceeds 0.75 GPM, could be open.
Easiest place to measure the switch is at the J5 harness connector that plugs into the Pilot board. Assuming you have previously determined flow is sufficient, disconnect J5 from the Pilot board, start the unit so the coolant is flowing and measure continuity between the 2 pins of J5.
• If there is no continuity either the switch is open or the harness between J5 and J74 at FS1 is open.
• If there is continuity between the J5 pins with sufficient coolant flow then either relay board or the CCM is faulty.
• Relay board
• CCM
405 Low Coolant Level Warning
If the coolant level becomes low while cutting it is not necessary to immediately stop the cut as there is still enough coolant to continue so we display E405 as a warning. Once the cut stops if the coolant is still low the display changes to E401 and prevents starting another cut. Refer to the section for code 401 for troubleshooting.
406 Coolant Flow Low Warning
Ultra-Cut XT units, in addition to a coolant flow switch, include a turbine flow sensor FL1, referred to in the plumbing diagram as a “bubble sensor”, with a pulse output that accurately measures coolant flow and in addition can detect the presence of gas bubbles in the coolant. Gas bubbles from leaking seals in the torch or hose fittings have been proven to reduce consumable life. This code is a warning, it does not prevent cutting but if it persists the cause should be investigated.
407 Coolant Overheated due to High Ambient
As described in the section for codes 259-264 the CCM measures the ambient temperature using sensor TS2 and, like with the inverters, if the coolant is over temperature we first check the ambient and if it is above 40 deg C we attribute the cause of the coolant over temperature to high ambient and of course the solution is to lower the ambient or reduce the duty cycle.
The other possibility is the ambient measuring circuit is defective and the coolant is overheated. In that case you would have to go to the section for code 403 to find the cause of the coolant overheating and go to section for codes 259-264 to determine what is wrong with the TS2 circuit.
The 5 Group relates to CANBUS (Fiber optic) communication errors
501 CANBUS Failure to Acknowledge fault
The CCM communicates with the gas controls (except GCM 1000 XT) over a fiber-optic cable using the CANBUS protocol. The CCM is looking for a signal from the gas control (GCM 2010 or DMC) over the fiber-optic link.
No signal has been detected. Communication with the DPC which is relayed through the DMC sets a different code, 301, if there is a problem with it.
Possible causes:
A-68
• Gas control is GCM 1000 XT (Auto-Cut 300XT) which has no fiber-optic, with Basic ID problem.
• CANBUS / Fiber-optic problem to either the GCM 2010 or the DMC (part of DFC 3000).
• Control Cable to DMC or GCM 2010 defective.
• Gas control (DMC or GCM 2010) main PCB blown fuse or defective.
• DMC power supply PCB blown fuse or defective.
• CCM defective.
APPENDIX 0-5261
AUTO-CUT 300 XT
Troubleshooting:
1. GCM 1000XT (also called a Basic Gas Control) does not use CANBUS (fiber-optic) communication. A jumper in the gas control connector J56 pins 8 & 9, gives the signal “Basic ID” telling the CCM not to expect any
CANBUS. If somewhere this circuit is open, in the Gas Control cable, connector pins, connection from the rear panel GCM connector, J55, to the CCM (J26) CCM will expect to see a CANBUS connection and report this error because there is no CANBUS connected.
2. DFC 3000. If the gas control does not have power it will not communicate. Check for power to the gas control boards. a. When using Auto Gas (DFC3000) with DMC & DPC if there is no power to the DMC main board, the green power light on the DMC front panel will not be lighted. The main board receives several voltages from its separate power supply board. For communication it needs +5VDC. There is a green LED, D17
(first on the left of the row of LEDs.) that lights when the main board has +5V power. b. The DMC power supply board has several blue LEDs that light when it has power. If none of these are on check for the control cable being connected or the circuit breaker, CB2, on the plasma supply rear panel may be tripped in which case there is probably a short somewhere. c. The DMC power supply which supplies several voltages could be missing one or more and still have some blue LEDs lighted. Check for voltages.
3. GCM 2010.
4. CANBUS / Fiber-optic communication errors can be difficult to troubleshoot, especially when they are intermittent. See “Test the Fiber” below. Things to look for are: a. The connectors not locked in place at either end of the fiber.
b. The fiber is damaged or bent sharply. This should not be the case if the fiber is inside the protective hose and the hose properly secured in the strain relief but that is not always the case.
c. Dirt on the ends of the fiber or in the receiver/transmitter where the fiber plugs in. Blow out gently with clean dry air such as is used to clean a camera lens. d. Excessive electrical interference. While the fiber is immune to EMI it can bother circuits at either end.
Check that all the grounding connections are connected per the manual and are clean and tight. Check the resistance of the ground rod (with all wires disconnected from it). It may have increased due to dryer weather conditions. See the instructions in the Plasma Installation manual. e. Defective receiver/transmitter or other circuits on either CCM or Gas Control main board. Otherwise replace either (or both) Gas Control main board or CCM.
Transmitter / Receiver Tests. The transmitter/receiver pair on the PCB and the fiber cable looks like this:
Art # 12314
Test the fiber:
Note that the fiber goes from black on one end to blue on the other. Shine a bright light into one end and you should be able to see light from the other end. This tells you the light is getting through but doesn’t prove it is strong enough.
The CCM is the communication master. It transmits then expects a reply from the Gas Control Module (GCM).
The GCM does not transmit on its own, only in response to a request from the CCM.
The black end of the fiber cable is inserted into the transmitter which is the gray housing on the PCB. The other end of the transmitting fiber is blue and goes into the receiver with the black housing.
A few seconds after power is turned on and when the pump has started up the CCM will try to transmit continuously for a while. You can unplug the fiber from the CCM and should see the transmitter red LED on the CCM
PCB blinking. It may stop after a while so recycle power before deciding it isn’t working. If no light, check one of the other transmitter/receiver pairs. If none of them blink the problem is in the CCM.
0-5261 APPENDIX A-69
AUTO-CUT 300 XT
If at least one transmitter blinks plug the fiber back into that one then at the Gas Control end of the fiber (unplugged) you should see the red light coming out of the blue end.
The Gas Control transmitter does not transmit except in response to a request from the CCM so you will not see any light from the GCM transmitter with the cable unplugged. However, if you turn the connector 90 deg and insert the blue end into the receiver (black housing), leaving transmitter open, then the GCM should receive the requests from the CCM and should blink it’s transmitter (gray housing) in response. If not, problem is likely on the GCM board assuming it has power.
It is still possible even though you see the red light coming out the GCM end of the fiber that dirt in the transmitter or receiver or on the fiber ends or the fiber is damaged so the light even though visible is not strong enough for the GCM board. If all else fails replace the fiber cable and both CCM and GCM PCB.
502 CANBUS off due to excessive errors
See 501 code for troubleshooting CANBUS faults.
503 CANBUS Data Error Warning
This is a warning, does not shut the system down but is an indication that it probably will shut down soon (502 code). Troubleshooting is same as for 501.
504 Reserved for future use.
Should not get this but if it happens may be due to EMI. Contact customer service.
Group 6 codes relate to the CCM and program updates. One exception is 619 which is a coolant flow switch FS1 fault.
601-611 Various CCM CPU board internal faults.
For most of these faults try recycling the power but if the problem returns only thing to do is replace the CCM.
Exceptions are:
1. 603 This is one of the reserved codes from the earlier product. Not used so it should never appear, if it does contact customer service.
2. 607 Processor over temperature could occur if the ambient in the area of the CCM is too high. Try opening the upper right side panel, perhaps blow some air to cool it off. If that doesn’t help or the ambient was not too hot to begin with, replace the CCM.
3. 611 Code has various causes most of which require replacing the CCM. However, one possible cause is the programming jumper on the CPU board (under the Static suppression PCB) has been left in the PROG position. This is a factory setting used during initial programming and should never be found in the field.
It is NOT used for application code updates However, if someone did move it 611 will be the result.
612 USB port power fault
USB port supplies +5V to power some USB devices such as the flash drive (thumb drive, memory stick), used for program updates. A flash drive is the only device currently being used with this USB port. This fault detected no or low voltage to the port. This could be a shorted flash drive or some other device that draws too much current exceeding the limits of the USB power supply.
Try another flash drive or if you know this one is OK (it works with a computer), then replace the CCM.
A-70 APPENDIX 0-5261
613 USB Log File Creation Fault
AUTO-CUT 300 XT
When updating the CCM, DMC and DPC programs from a flash drive, a log file called CCM_LOG.TXT is created on the flash which reports on the results of the update including any problems. If that log file can’t be created you get 613. This may be a problem with the flash drive having too many other files on it or a problem with its format that may not be compatible with the CCM.
1. Try putting the update files on a different, preferably empty, flash drive.
2. Or save all the flash drive files in another place on your computer, then delete all the files on the flash drive.
Now copy onto the flash drive only the files required for program updates.
3. If the above doesn’t work, making sure you still have copies of the files, format your flash drive which erases everything on it. Now load only the files required for program update.
614 No USF File
The file VTCCMFW.USF is required on the flash drive along with the program files when performing a program update. If it’s either missing or corrupted the display will show b614. The “b” indicates the fault is generated by the Bootloader program rather than the normal application program code. Note that each new revision of the program files is supplied with a new VTCCMFW.USF. Even though the name is the same it requires the new version of this file that is supplied with the application code.
1. Install the correct VTCCMFW.USF on the flash drive.
2. If you already have the correct version of VTCCMFW.USF perhaps the flash drive is the problem. Follow the instructions for code 613.
615-617 No Update File for CCM, DPC or DMC found
Program files for the CCM, DMC & DPC may be updated through the plasma supply’s USB port. The GCM2010 is updated by other means. For a unit with GCM 2010 the CCM may still be updated using the USB. Program update files are in the format Cx_x_0.S (CCM); Mx_x_0.S (DMC) and Px_x_0.S (DPC).
If the Bootloader finds there are 3 devices, CCM, DMC & DPC on the CANBUS but the flash drive doesn’t have all 3 update files it will go ahead and update those it has but will show a code indicating that one or more are missing (615 for CCM; 616 for DMC; 617 for DPC).
Try another flash drive or if you know this one is OK (it works with a computer), then replace the CCM.
This completes the Advanced Troubleshooting information.
0-5261 APPENDIX A-71
AUTO-CUT 300 XT
APPENDIX 18: Publication History
Cover Date Rev
April 17, 2013 AA
May 14, 2013 AB
Change(s)
First Release
Per ECOB2455 update gas application chart showing Air for shield gas under Mild
Steel and warranty statement showing XT and not XT300 torch
July 2, 2013 AC Updated section 3 with information about V-D Board installation for height controller
ECOB2488
Jan. 16, 2014 AD Updated many items, text and art throughout the manual. Added Advanced Trouble shooting and plumbing diagrams to Appendix per ECOB2552.
Oct. 30, 2014 AE
May 27, 2015 AF
Update Sect. 6 Leads Catalog Numbers. ECO-B2664
Remove Appx. ‘Serial Communications’. ECO-B2675
Insert Sect. 3 ‘Ground Rod Tester’ info. ECO-B2676
Remove DoC. ECO-B2680
Add Section 6 ‘Current transducer’. ECO-B2681
Returned to Thermal Dynamics trade dress. Added new safety section. New safety icons throughout. Updated Gas Requirement chart. Added note to grounding art Sec. 3 and weekly maint. check Sec. 5. Updated spark gap specs sec. 5. Updated pump and motor spare parts list in Sec. 6. ECOB2713.
Jan. 14, 2016 AG Added Water Spec Section 2.08 pg. 2-5, corrected spelling mistakes Section 4, corrected part number for items line G “Torch Leads Assembly” Sec 6.02 pg. 6-1, corrected coolant tank cap catalog number from 9-7305 to 8-5142 pg. 6-4, updated art A-04066 pg. 7-2 (o- ring p/n changed from 9-3027 to 8-0524), corrected CNC Enable/ Disable text pg. A-4, updated Advanced Troubleshooting text pg. A-63, added Warranty Statement inside rear
VCR-01537
A-72 APPENDIX 0-5261
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
Auto-Cut XT™ and Ultra-Cut XT™ Power Supplies and Components 2 Years 1 Year
Torch And Leads
XT TM 300 / XT TM -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 October 23, 2012
THE AMERICAS
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Ph: 1-800-279-2628 (tollfree)
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Fax: 1-940-483-8178
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800-588-1714
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940-483-8178
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