Thermal Dynamics Auto-Cut 200 XT Operating Manual

®

AUTO-CUT 200 XT

PLASMA CUTTING SYSTEM

™

Operating

Manual

Revision:

AF

Issue Date:

January 14, 2016

Manual No.:

0-5284

ThermalDynamics.com

400V

®

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 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 ® 200 XT™

Operating Manual No. 0-5284

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 47x1925.

Publication Date: April 17, 2013

Revision Date: May 27, 2015

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!

This Page Intentionally Blank

Declaration of Conformity

We

Thermal Dynamics Corporation.

of

2800 Airport Road

Denton, TX 76207 U.S.A.

in accordance with the following Directive(s)

:

2006/95/EC The Low Voltage Directive

2004/108/EC The Electromagnetic Compatibility Directive

hereby declare that

:

Equipment: Plasma Cutting Controller

Model Name/Number: Auto-Cut 200 XT

Market Release Date: April 17, 2013

is in conformity with the applicable requirements of the following harmonized standards

:

CENELEC EN61010-1 Ed:3 Safety Requirements for Electrical Equipment for Measurement, Control, and

Laboratory Use Part 1: General Requirements

Classification: The equipment described in this document is Class A and intended for industrial use.

!

WARNING

This Class A equipment is not intended for use in residential locations where the electrical power is provided by the public low-voltage supply system. There may be potential difficulties in ensuring electromagnetic compatibility in those locations, due to conducted as well as radiated disturbances.

Manufacturer’s Authorized Representative

Steve Ward V.P. Europe and General Manager

Address:Victor Technologies International Inc.

Building

Chorley N Industrial Park

Lancashire,

England PR6 7BX

Date: April 8, 2015

(Signature)

Steve

Full Name

V.P. Europe and General Manager

(Position)

!

WARNING

This Class A equipment is not intended for use in residential locations where the electrical power is provided by the public low-voltage supply system. There may be potential difficulties in ensuring electromagnetic compatibility in those locations, due to conducted as well as radiated disturbances.

TABLE OF CONTENTS

SECTION 1: SAFETY...............................................................................................................1-1

1.01 Safety Precautions - ENGLISH ...................................................................1-1

1.02 Précautions de sécurité - FRENCH CANADIAN ........................................1-6

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

2.01 General Description Of The System ...........................................................2-1

2.02 Plasma Power Supply .................................................................................2-1

2.03 Plasma Cutting Torch .................................................................................2-1

2.04 System Component Layout ........................................................................2-1

2.05 Power Supply Specifications & Electrical Requirements ............................2-2

2.06 Power Supply Dimensions ..........................................................................2-3

2.07 Power Supply Rear Panel Features ...........................................................2-4

2.08 Gas Requirements ......................................................................................2-5

2.09 Gas Applications .........................................................................................2-5

2.10 XT TM -301 Torch Specifications ...................................................................2-6

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

3.01 Installation Requirements ...........................................................................3-1

3.02 Cables and Leads Identification ..................................................................3-2

3.03 Cables & Leads Identification .....................................................................3-2

3.04 Position the Power Supply ..........................................................................3-3

3.05 Primary Power Connections .......................................................................3-4

3.06 Ground Connections ...................................................................................3-6

3.07 Connect Work Cable ...................................................................................3-9

3.08 Connect Gas Supply Lines .......................................................................3-10

3.09 Connect CNC Cable ................................................................................3-11

3.10 Height Control Connections ......................................................................3-12

3.11 Connect Torch Leads to the Arc Starter ...................................................3-12

3.12 Torch Head Installation and Connection ..................................................3-15

3.13 Install Consumable Torch Parts ................................................................3-16

3.14 Voltage Divider for iHC Torch Height Control ...........................................3-20

3.15 Fill Cooling System ...................................................................................3-22

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

4.01 Power Supply Indicators .............................................................................4-1

4.02 Control Console Features ...........................................................................4-2

4.03 Operating Set-up ........................................................................................4-4

4.04 System Operation .......................................................................................4-5

4.05 Gas Selection .............................................................................................4-8

4.06 Power Supply Status Codes .......................................................................4-9

4.07 Cut Quality ................................................................................................4-15

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

5.01 General Maintenance .................................................................................5-1

5.02 Coolant Filter Cleaning Procedure ..............................................................5-1

5.03 Coolant Replacement Procedure ................................................................5-2

5.04 Arc Starter Service ......................................................................................5-3

5.05 Arc Starter Spark Gap Adjustment .............................................................5-4

TABLE OF CONTENTS

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

6.01 Replacement Power Supply .......................................................................6-1

6.02 Leads and Cables .......................................................................................6-1

6.03 Power Supply External Replacement Parts ...............................................6-2

6.04 Power Supply Replacement Parts - Lower Right Side ...............................6-3

6.05 Power Supply Replacement Parts - Upper Right Side ...............................6-4

6.06 Power Supply Replacement Parts - Lower Left Side .................................6-5

6.07 Power Supply Replacement Parts - Upper Left Side ..................................6-6

6.08 Power Supply Replacement Parts - Rear Panel .........................................6-7

6.09 Power Supply Replacement Parts - Front ..................................................6-8

6.10 Recommended Gas Supply Hose ..............................................................6-8

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

7.01 Consumable Removal ................................................................................7-1

7.02 O-Ring Lubrication ......................................................................................7-2

7.03 Parts Wear ..................................................................................................7-2

7.04 Torch Consumables Installation .................................................................7-3

APPENDIX 1: CNC CONTROL MODULE .............................................................................. A-1

Control PCB Connections ........................................................................................ A-1

CNC functions. ........................................................................................................ A-2

APPENDIX 2: CCM CPU PCB LAYOUT .............................................................................. A-10

APPENDIX 3: CCM I/O PCB LAYOUT ................................................................................. A-12

APPENDIX 4: PILOT PCB LAYOUT .................................................................................... A-14

APPENDIX 5: RELAY AND INTERFACE PCB LAYOUT ..................................................... A-16

APPENDIX 6: DISPLAY PCB LAYOUT ............................................................................... A-18

APPENDIX 7: SYSTEM BIAS PCB LAYOUT ....................................................................... A-20

APPENDIX 8: MAIN INVERTER BOTTOM PCB LAYOUT .................................................. A-22

APPENDIX 9: MAIN INVERTER TOP PCB LAYOUT .......................................................... A-24

APPENDIX 10: CONTROL AND FAULT PCB LAYOUT ...................................................... A-26

APPENDIX 11: CAP BIAS BOTTOM PCB LAYOUT ............................................................ A-28

APPENDIX 12: CAP BIAS TOP PCB LAYOUT .................................................................... A-29

APPENDIX 13: SUPPRESSOR PCB LAYOUT .................................................................... A-30

APPENDIX 14: WMS GAS BOX LAYOUT ........................................................................... A-31

APPENDIX 15: COOLING DIAGRAM .................................................................................. A-32

APPENDIX 16: SYSTEM SCHEMATIC PG 1 ...................................................................... A-34

TABLE OF CONTENTS

APPENDIX 17: SYSTEM SCHEMATIC PG2 ....................................................................... A-36

APPENDIX 18: ADVANCED TROUBLESHOOTING ........................................................... A-38

APPENDIX 19: PUBLICATION HISTORY ........................................................................... A-76

STATEMENT OF WARRANTY .................................................................INSIDE BACK COVER

INTERNATIONAL CONTACT INFORMATION ........................................................ BACK COVER

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TABLE OF CONTENTS

AUTO-CUT 200 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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AUTO-CUT 200 XT

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 200 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 200 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

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AUTO-CUT 200 XT

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AUTO-CUT 200 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 200 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.

0-5284 SAFETY INSTRUCTIONS 1-7

AUTO-CUT 200 XT

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 0-5284

AUTO-CUT 200 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.

0-5284 SAFETY INSTRUCTIONS 1-9

AUTO-CUT 200 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.

Art# A-12736

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.

1-10 SAFETY INSTRUCTIONS 0-5284

SECTION 2: SPECIFICATIONS

AUTO-CUT 200 XT

2.01 General Description Of The System

A typical Auto-Cut 200 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

CNC CNC Cable P

Primary power

Ground

Cable

F1

Auto-Cut XT

Power Supply

G: Torch Lead Set, Shielded

- Coolant Supply w/ Negative

- Coolant Return

- Pilot Return

- Plasma Gas

- Shield Gas

Positioning

Tube

Torch

Work Cable O Work

Art # A-11687_AB

0-5284 SPECIFICATIONS 2-1

AUTO-CUT 200 XT

2.05 Power Supply Specifications & Electrical Requirements

Auto-Cut 200 XT™Power Supply Specifications

Max OCV (U0)

Max Output Current

425 vdc

200 Amps

Output Voltage

Duty Cycle Rating

60 - 170 vdc

100% @ 200A @ 200V (40 kW)

Operating range

Power Factor

Cooling

14°F to 122°F (-10°C to + 50°C)

0.94 @ 200 ADC Output

Forced Air (Class F) and Liquid Cooled

!

Input

Voltage

(Volts)

400

Freq.

(Hz)

50/60

3-Ph

(kVA)

41

Auto-Cut 200 XT™Power Supply

Power Input Current

3-Ph

(Amps)

60

Suggested Sizes (See Note)

Fuse (Amps)

3-Ph

100

Wire (AWG)

3-Ph

#6

Wire (mm

3-Ph

16

* 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 )

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.

2-2 SPECIFICATIONS 0-5284

2.06 Power Supply Dimensions

47.77 inch

1213 mm

27.6 inch

701 mm

35.97 inch

914 mm

Art # A-11460_AB

490 lb / 222 kg

AUTO-CUT 200 XT

0-5284 SPECIFICATIONS 2-3

AUTO-CUT 200 XT

2.07 Power Supply Rear Panel Features

Customer

Optional

Ports

Circuit Breakers

CNC

Connector

C.C.M.

USER INPUT

HEIGHT CONTROL

J15 - CNC

N 2

PLASMA

CB2 - 5A 120 VAC

CB3 - 5A 24 VAC

CB4 - 5A 120 VAC

F1 - 8A SB 230 VAC F2 - 8A SB 230 VAC

Fuses

Coolant Filter

Plasma Gas Port

Shield Gas Port

Optional Water

Mist Port

Torch Leads Port

Torch Leads

Ground Terminal

Work Cable Port

Two Stage

Air Filter

Input Power

Ground Terminal on inside

Art # A-12837

2-4 SPECIFICATIONS 0-5284

2.08 Gas Requirements

AUTO-CUT 200 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.

Auto-Cut 200 XT™BASIC Power Supply: Gas Pressures, Flows, and Quality Requirements

Gas Quality Minimum Pressure Flow

O

2

(Oxygen)

99.5% Purity

(Liquid recommended)

120 psi

8.3 bar / 827 kPa

200 scfh (95 lpm)

N

2

(Nitrogen)

99.5% Purity

(Liquid recommended)

<1000 ppm O

2 ppm H

2

O)

, <32

120 psi

8.3 bar / 827 kPa

300 scfh (141.6 lpm)

Compressed

Air

Clean, Dry,

Free of Oil (see Note 1)

120 psi

8.3 bar / 827 kPa

400 scfh (188.8 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)

For systems with optional H

2

See Note 2

O water mist

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.

2.09 Gas Applications

Material

Operation

55A CUT

Mild Steel

Plasma Shield

Air Air

O

2

Air

Air Air

100A CUT

O

2

Air

Air

200A CUT

Air

O

2

Air

Stainless Steel

Plasma Shield

Air Air

Air

N

2

H35

Air

N

2

H35

Air

H

2

O

N2

Air

H

2

O

N2

Aluminum

Plasma Shield

Air Air

Air

N

2

H35

Air

N

2

H35

Air

H

2

O

N2

Air

H

2

O

N2

0-5284 SPECIFICATIONS 2-5

AUTO-CUT 200 XT

2.10 XT

TM

-301 Torch Specifications

A. Torch Dimensions

19"

482.7 mm

End Cap

Art # A-11538

2.25"

57.15 mm

Mounting Tube

15.5"

393.8 mm

B. Torch Leads Lengths

6.3"

160.1 mm

3.98"

101.1 mm

2.7"

69.6 mm

1.6"

40. mm

Torch Lead Assembly

Lengths

Feet Meters

10

15

25

50

75

100

3.05

4.6

7.6

15.2

22.8

30.4

2.0"

50.8 mm

2.4"

61 mm

1.49"

37.8 mm

2-6 SPECIFICATIONS 0-5284

C. Torch Parts (Generic Parts Shown)

Art # A-04741_AB

Shield Gas

Distributor

Plasma Gas

Distributor

AUTO-CUT 200 XT

Shield Cap Tip Electrode

Shield Cup Cartridge

D. Parts - In - Place (PIP)

The torch is designed for use with a power supply which senses coolant return flow to confirm that torch parts are in place. If coolant return flow to the power supply is absent or insufficient the power supply will not provide power to the torch. Coolant leakage from the torch also indicates that torch parts are absent or installed improperly.

E. Type Cooling

Combination of gas stream through torch and liquid cooling.

0-5284 SPECIFICATIONS 2-7

AUTO-CUT 200 XT

F. XT TM -301 Torch Data (with Auto-Cut 200 XT™ Power Supply)

XT TM -301 Torch Ratings

(when used with Auto-Cut 200 XT™Power Supply)

Ambient

Temperature

Duty Cycle

104° F

40° C

100% @ 200 Amps

Maximum Current

Voltage (V peak

)

Arc Striking Voltage

Current

200 Amps

500V

10kV

Up to 200 Amps, DC,

Straight Polarity (See Note)

XT TM -301 Torch Gas Specifications

Plasma Gases:

Compressed Air, Oxygen,

Nitrogen, H35, F5

Shield Gases:

Compressed Air,

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

Auto-Cut 200 XT

2-8 SPECIFICATIONS 0-5284

AUTO-CUT 200 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

(Volts)

400

Freq.

(Hz)

50/60

Auto-Cut 200 XT™Power Supply

Power Input Current Suggested Sizes (See Note)

3-Ph

(kVA)

41

3-Ph

(Amps)

60

Fuse (Amps)

3-Ph

100

Wire (AWG)

3-Ph

#6

Wire (mm

3-Ph

16

* 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 )

!

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

Protects To

10° F / -12° C

7-3581 ‘Ultra-Cool TM ’

7-3582 ‘Extreme Cool

TM

’

50 / 50 27° F / -33° C

Concentrate* -65° F / -51° C

* For mixing with D-I Cool TM 7-3583

0-5284 INSTALLATION 3-1

AUTO-CUT 200 XT

3.02 Cables and Leads Identification

Refer to section 3.05 and 3.06 for ground connections and ground cables.

CNC CNC Cable P

Primary power

Ground

Cable

F1

Auto-Cut XT

Power Supply

G: Torch Lead Set, Shielded

- Coolant Supply w/ Negative

- Coolant Return

- Pilot Return

- Plasma Gas

- Shield Gas

Positioning

Tube

Torch

Work Cable O Work

Art # A-11687_AB

3.03 Cables & Leads Identification

F1

G

Ground Cable,

Arc Starter

To Earth Ground

Torch Lead Set

O

Work Cable

P

CNC Cable (14 Wire)

Art # A-11688

3-2 INSTALLATION 0-5284

3.04 Position the Power Supply

AUTO-CUT 200 XT

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-11503

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.

0-5284 INSTALLATION 3-3

AUTO-CUT 200 XT

3.05 Primary Power Connections

The primary power cable and through hole cable grip must be supplied by the end user and connected to the power supply. Refer to local and national electrical codes for suggested cable and fuse sizes.

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.

USER INPUT

HEIGHT CONTROL

J15 - CNC

AIR / O2

PLASMA

N2 / H35

PLASMA

CB2 - 5A 120 VAC

CB3 - 5A 24 VAC

CB4 - 5A 120 VAC

F1 - 8A SB 230 VAC F2 - 8A SB 230 VAC

3-4

Input Power

INSTALLATION

Art # A-11949

0-5284

AUTO-CUT 200 XT

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.

Auto-Cut XT CE System

Cutting Machine / Gantry Torch

Cutting Table

CNC

Device

Auto-Cut

Power Supply

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

1/0 Work Cable

1/0 Ground Cable

(F1)

‘Star’

Ground

Art # A-11950_AB

0-5284 INSTALLATION 3-5

AUTO-CUT 200 XT

3.06 Ground Connections

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.

3-6 INSTALLATION 0-5284

C. Creating An Earth Ground

AUTO-CUT 200 XT

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.

0-5284 INSTALLATION 3-7

AUTO-CUT 200 XT

F

Triad N-68X

R = 1.2K, 15W

(2.2K, 25W for 220 VAC)

Triad N-68X

F

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.

3-8 INSTALLATION 0-5284

3.07 Connect Work Cable

AUTO-CUT 200 XT

1. Refer to the illustration below. Pass the end of the work cable through the cord grip at the back of the power supply rear panel, then through the bottom opening in the bulkhead panel.

2. Refer to the illustration below. Connect the lead to the bolt in the first hole on the bus bar as shown. Tighten securely. Do not overtighten.

WARNING

Ensure that lead attachment hardware is properly sized. Excess length may cause damage if hardware contacts other parts of the system.

Art # A11951_AB

0-5284 INSTALLATION 3-9

AUTO-CUT 200 XT

3.08 Connect Gas Supply Lines

1. Connect the gas supply lines to the appropriate input ports shown below. The first view shows factory default for using shop air. All other gasses to use the second view, bypassing the two stage air filter.

NOTE!

When using shop air, connection must be made through the two stage air filter located in the center of the rear panel. Do not use the two stage air filter for other gases.

Factory Default Air/Air Using Shop Air All Gases Except Air

USER INPUT

HEIGHT CONTROL

J15 - CNC

AIR / O2

PLASMA

N2 / H35

PLASMA

CB2 - 5A 120 VAC

CB3 - 5A 24 VAC

CB4 - 5A 120 VAC

F1 - 8A SB 230 VAC F2 - 8A SB 230 VAC

IN OUT

Plasma Gas Port

Shield Gas Port

Optional Water

Mist Port

Torch Leads Port

Torch Leads

Ground Terminal

Work Cable Port

Shop Air Input

USER INPUT

HEIGHT CONTROL

J15 - CNC

CB2 - 5A 120 VAC

CB3 - 5A 24 VAC

CB4 - 5A 120 VAC

F1 - 8A SB 230 VAC F2 - 8A SB 230 VAC

Plasma Gas Port

Shield Gas Port

Optional Water

Mist Port

Torch Leads Port

Torch Leads

Ground Terminal

Work Cable Port

Art # A-11952

Art # A-11953

3-10 INSTALLATION 0-5284

3.09 Connect CNC Cable

1. Connect one end of the CNC cable to the power supply receptacle marked ‘CNC’.

2. Connect the other end of the cable to the CNC device .

3. The CNC cable shield must be attached to ground.

AUTO-CUT 200 XT

To CNC

USER INPUT

HEIGHT CONTROL

J15 - CNC

N / H35

CB2 - 5A 120 VAC

CB3 - 5A 24 VAC

CB4 - 5A 120 VAC

F1 - 8A SB 230 VAC F2 - 8A SB 230 VAC

Art # A-11527_AC

0-5284 INSTALLATION 3-11

AUTO-CUT 200 XT

3.10 Height Control Connections

The terminal strip provides connections to negative Arc Volts (Torch or electrode), Tip Volts (Pilot) and Work.

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. The allowable current draw is 100ma @ 120VAC and 1Amp @ 24 VAC.

TB4 1 2 3 4 5 6

Art # A-11900

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..

3.11 Connect Torch Leads to the Arc Starter

1. Remove the top cover.

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 but do not secure until all leads have been connected.

3-12 INSTALLATION 0-5284

AUTO-CUT 200 XT

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

Outer Leads Shield

1

Clamp * (Clamp type may vary)

2

3

Art # A-11528

0-5284

Coolant Return

Connection (Tagged Red)

Torch Leads

INSTALLATION

Coolant Supply

Connection (Tagged Green)

Plasma Gas

Connection

Shield Gas

Connection

Art # A-11529

3-13

AUTO-CUT 200 XT

5. Fold the end of the leads outer webbed shielding jacket back and over the connection ring inside the module.

Slide the leads clamp over the jacket and fasten the clamp and jacket to the connection ring.

6. Re-install the side cover(s) cover.

4

Clamp

Art # A-11530

3-14 INSTALLATION 0-5284

3.12 Torch Head Installation and Connection

AUTO-CUT 200 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.

End Cap

Shown to illustrate assembly order only; parts must remain secured tightly.

O-Ring

Insulating Paper

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

0-5284 INSTALLATION 3-15

AUTO-CUT 200 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. Use protective gloves when handling the leads. Do not kink or bend the leads.

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.

3.13 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.

NOTE!

For 200-Amp consumables, when replacing the shield retainer or the shield cup, assemble these two parts first before assembling the other consumables.

Art # A-08303

Shield

Retainer

Shield Cup

Tip Plasma Gas

Electrode

Cartridge

A

1 - Assemble “A” 200 A only.

2 - Assemble “B”.

B

3 - Assemble “B” to “C”.

C

4 - Assemble “A” to “B-C” assembly.

3-16 INSTALLATION 0-5284

AUTO-CUT 200 XT

3. Stack the consumable parts together.

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

0-5284 INSTALLATION 3-17

AUTO-CUT 200 XT

5. Use the removal tool to hold the cartridge assembly, while turning the shield cup 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

3-18 INSTALLATION 0-5284

7. Confirm proper parts assembly as shown.

Torch Head

AUTO-CUT 200 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.

0-5284 INSTALLATION 3-19

AUTO-CUT 200 XT

3.14 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.

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

V-D Board shown with optional wire harness for iHC controller

Art # A-12079

3-20 INSTALLATION 0-5284

Control Cable.

AUTO-CUT 200 XT

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

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.

TB4 1 2 3 4 5 6 7

24 VAC

@ 1A

120 VAC

@ 100 ma.

Work

Tip Volts

(Pilot)

Arc Volts

(Torch)

Art # A-11954

“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.

0-5284 INSTALLATION 3-21

AUTO-CUT 200 XT

3.15 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 ’ 25 / 75

7-3581 ‘Ultra-Cool TM ’ 50 / 50

Protects To

10° F / -12° C

27° F / -33° C

7-3582 ‘Extreme Cool

TM

’ Concentrate* -65° F / -51° C

* For mixing with D-I Cool TM 7-3583

Coolant Tank

Fill Range

Art # A-11463

3. 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.

4. 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.

3-22 INSTALLATION 0-5284

SECTION 4: OPERATION

4.01 Power Supply Indicators

AC Indicator Gas Indicator

Temp Indicator DC Indicator

A/ Status Indicator

AUTO-CUT 200 XT

A/

Art # A-11467

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 Status Code Section for details.

Rear Panel AC Power Lamp

Indicates AC power is present inside the unit

0-5284 OPERATION 4-1

AUTO-CUT 200 XT

4.02 Control Console Features

Standard System

PLASMA SHIELD

RUN

SET

A

Plasma Gas

Pressure Gauge

PLASMA

Art # A-11468

SHIELD

Shield Gas

Pressure Gauge

Plasma Gas Pressure

Control Knob

Shield Gas Pressure

Control Knob

Run / Set Selector

RUN

SET

A

Amperage /

Current

Selector

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.

Amperage Selector: Continuously adjustable from 5 to 200 Amps. Visible here:

A/

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 0-5284

Optional System with Water Mist (H

2

O)

PLASMA SHIELD

RUN

SET

SHIELD GAS

H20 MIST

H20 MIST

A

Plasma Gas

Pressure Gauge PLASMA

Art # A-11468

SHIELD

Shield Gas

Pressure Gauge

AUTO-CUT 200 XT

Plasma Gas Pressure

Control Knob

Shield Gas Pressure

Control Knob

RUN

SET

SHIELD GAS

H

2

0 MIST

H

2

0 MIST

Run / Set Selector

A

Amperage / Current

Selector

Shield

Selector

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 H

2

O Mist (water).

Water Shield Mist (H

2

O) Flowmeter and Control Knob:

Shield Selector : Selects shield fluid, gas or H2O Mist (water).

Water Shield Flowmeter and Control Knob: Controls flow rate of shield water supply.

Amperage Selector: Continuously adjustable from 5 to 200 Amps. Visible here:

A/

Plasma Gas Type Selector (rear panel): Selects proper operating voltage for either Air & O2 or N2 & H35. Also use N2/H35 setting for F5.

0-5284 OPERATION 4-3

AUTO-CUT 200 XT

4.03 Operating Set-up

Follow this set-up procedure each time the system is operated:

WARNING

Disconnect primary power at the source before assembling or disassembling power supply, torch parts, torch and leads assemblies or adding coolant.

A. Coolant Level Inspection

Check the coolant level in the coolant tank at the front of the unit. If the tank is below 3/4 full, add coolant.

B. Torch Parts Selection

Check the torch for proper assembly. Install proper torch parts for the application per the Torch section of the manual..

C. Input Power

Check the power source for proper input voltage. Close main disconnect switch or plug unit in to supply primary power to the system.

D. Work Cable Connection

Check for a solid and clean work cable connection to the workpiece or cutting table. The connection area must be free from paint and rust.

E. Torch Connection

Check that the torch is properly connected.

F. Gas Supplies

Connect desired plasma and shield gases. Make sure gas sources meet requirements. Check connections and turn gas supply on. Set Gas Selection Switch on rear panel to the correct plasma gas being used.

With H2O Mist option: Select the desired shield gas as follows:

1. If gas shield is desired, set shield selector switch to GAS position.

2. If Water Mist shield is desired, set shield mode selector switch to ‘H

2 nected to the rear panel H

2

O connection.

O MIST’ position. Water must be con-

NOTE!

Tap water should only be used for shield gas.

If tap water pressure is over 100 psi (6.9 bar) there must be a Water Regulator (Catalog

No. 8-6118) installed between the water source and the Power Supply.

G. Plasma Gas Purge

Move the Power Supply ON/OFF switch to the ON position.

An automatic gas purge will remove any condensation that may have accumulated in the torch and leads while the system was shut down. After the purge is complete, if the RUN/SET switch is in SET position, gases will flow.

H. Amperage Selection

Select the desired current output amperage.

I. Pressure and Flow Settings

1. Refer to the Torch manual for pressure and flow details according to the material being cut. Move the RUN/

SET switch to SET position. (Gas will flow through the torch). Set gas pressures and flows as follows:

4-4 OPERATION 0-5284

2. To set the Plasma Gas pressure:

AUTO-CUT 200 XT a. Pull out the knob on the Plasma Gas pressure control knob.

c. Turn the knob to adjust gas pressure.

d. Push the knob back in to lock the pressure setting.

3. To set the Shield Gas pressure:

For Gas Shield: a. Set the Shield Mode Selector switch to the GAS position b. Pull out the Shield Gas Pressure Control Knob.

c. Turn the knob to adjust gas pressure.

d. Push the knob back in to lock the pressure setting.

For H

2

O MIST Shield: a. Set the Shield Mode Selector switch to the H

2

O MIST position b. Turn the Water Mist Control Knob to adjust pressure.

NOTE!

Unless the installation includes gas selection equipment between the gas supplies and the control console, switching between gases requires disconnecting the gas supply line(s) from the control console rear panel and connecting the appropriate input gases.

Water input can remain connected permanently because the shield selector switch disables and enables the flow of water for H

2

O Mist shield.

4.04 System Operation

This section contains operating information which is specific to the power supply.

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. Fans start. 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”.

0-5284 OPERATION 4-5

AUTO-CUT 200 XT

• The coolant pump 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: “200”

• Once coolant flow is detected, usually within 5 seconds after the pump starts, the W1 input contactor closes 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.

I

POWER

OFF

O

OFF

O

OFF

O

ON

OFF

4-6

Art # A-11461

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

(refer to cut chart manual for required pressure/flow.)

2

O Mist option. 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 (arcstarter 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.

OPERATION 0-5284

AUTO-CUT 200 XT

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 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.

Operational Suggestions

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.

0-5284 OPERATION 4-7

AUTO-CUT 200 XT

4.05 Gas Selection

A. Plasma Gases

1. Air Plasma

• Most often used on ferrous or carbon base materials for good quality at faster cutting speeds.

• Air plasma is normally used with air shield.

• Only clean, dry air is recommended for use as plasma gas. Any oil or moisture in the air supply will 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.

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.

4-8 OPERATION 0-5284

4.06 Power Supply Status Codes

NOTE!

See the Appendix for Advanced Troubleshooting

AUTO-CUT 200 XT

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

Code

101

102

103

104

Message

Plasma Disabled

Pilot Ignition Failure

Lost Pilot

Transfer Lost

CCM Status Code

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

0-5284 OPERATION 4-9

AUTO-CUT 200 XT

Code Message

201 Missing AC Phase

202 Not used

203 Not used

204 Not used

205 DC Output Low

206 Not used

207

Unexpected current in work lead

208

Unexpected current in pilot circuit

209 Not used

210

Output Current Too

High

211

212

213

214

Output Current Too

Low

Inverter 1A Output

Current Low

Inverter 1B Output

Current Low

Inverter 2A Output

Current Low

215 Not used

216 Not used

217 Not used

218

219

Inverter 1A Output

Current High

Inverter 1B Output

Current High

220

Inverter 2A Output

Current High

221 Not used

222 Not used

223 Not used

CCM Status Code

Group 2 -- Plasma Power Supply

Remedy / Comments

Blown wall fuse, Blown unit fuse F1 or F2 or rear panel, Bad power cable connection; Defective System Bias PCB.

Reserved for legacy product

Reserved for legacy product

Reserved for legacy product

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);

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 models with additional inverter sections.

Reserved for other models with additional inverter sections.

Reserved for other models with additional inverter sections.

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 models with additional inverter sections.

Reserved for other models with additional inverter sections.

Reserved for other models with additional inverter sections.

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

4-10 OPERATION 0-5284

Code

227

Message

Inverter 2A Incompatible Revision

228 Not used

229 Not used

230 Not used

231

Inverter 1A VAC

Mismatch

232

Inverter 1B VAC

Mismatch

233

Inverter 2A VAC

Mismatch

234 Not used

235 Not used

236 Not used

237

Too Few Inverters

Found

238 BIAS VAC Invalid

239 AC Voltage High

240 AC Voltage Low

241

242

243

Inverter 1A Input

Voltage Error

Inverter 1B Input

Voltage Error

Inverter 2A Input

Voltage Error

244 Not used

245 Not used

246 Not used

247

248

249

Inverter 1A Circuit

Fault

Inverter 1B Circuit

Fault

Inverter 2A Circuit

Fault

250 Not used

251 Not used

AUTO-CUT 200 XT

Remedy / Comments

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 models with additional inverter sections.

Reserved for other models with additional inverter sections.

Reserved for other models with additional inverter sections.

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 models with additional inverter sections.

Reserved for other models with additional inverter sections.

Reserved for other models with additional inverter sections.

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 models with additional inverter sections.

Reserved for other models with additional inverter sections.

Reserved for other models with additional inverter sections.

Inverter Module 1 Section A detected a circuit fault; Damaged Inverter Module 1

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 models with additional inverter sections.

Reserved for other models with additional inverter sections.

0-5284 OPERATION 4-11

AUTO-CUT 200 XT

Code Message

252 Not used

253

Inverter 1A Over

Temp

Remedy / Comments

Reserved for other models with additional inverter sections.

Inverter Module 1 Section A detected an over temperature fault; Check for restricted air flow, clogged radiator; Defective fan; If problem persists replace inverter module.

254

259

Inverter 1B Over

Temp

255

Inverter 2A Over

Temp

256 Not used

257 Not used

258 Not used

Inverter 1A Over

Temp Ambient

260

Inverter 1B Over

Temp Ambient

Inverter Module 1 Section B detected an over temperature fault; Check for restricted air flow, clogged radiator; Defective fan; If problem persists replace inverter module.

Inverter Module 2 Section A detected an over temperature fault; Check for restricted air flow, clogged radiator; Defective fan; If problem persists replace inverter module.

Reserved for other models with additional inverter sections.

Reserved for other models with additional inverter sections.

Reserved for other models with additional inverter sections.

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.

261

Inverter 2A Over

Temp Ambient

262 Not used

263 Not used

264 Not used

265

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.

Reserved for other models with additional inverter sections.

Reserved for other models with additional inverter sections.

Reserved for other models with additional inverter sections.

Inverter 1A No Input

Power

Inverter section may have no input power. Contactor not closed; Defective contactor or CB4 tripped; Inverter section input not connected; Defective Inverter.

266

Inverter 1B No Input

Power

Inverter section may have no input power. Contactor not closed; Defective contactor or CB4 tripped; Inverter section input not connected; Defective Inverter.

267

271

Inverter 2A No Input

Power

268 Not used

269 Not used

270 Not used

Inverter ID reading fault

Inverter section may have no input power. Contactor not closed; Defective contactor or CB4 tripped; Inverter section input not connected; Defective Inverter.

Reserved for other models with additional inverter sections.

Reserved for other models with additional inverter sections.

Reserved for other models with additional inverter sections.

CCM found ID values inconsistent during reading. CCM to an Inverter section ribbon damaged or disconnected; Improper ribbon cable routing.

4-12 OPERATION 0-5284

AUTO-CUT 200 XT

Code

301

303

Message

Not used

302 Reserved

Gas Supply Pressure out of range.

Reserved for other models.

Remedy / Comments

No information available; Contact customer service

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

CCM Status Code

Group 3 -- Gas Controller Status & Protocol

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

Code Message

401 Coolant Level low

402

403

404

Low coolant flow

Coolant overheated

Coolant System not ready.

405

Low Coolant Level

Warning

406 Not used

407

CCM Status Code

Group 4 -- Torch Coolant System

Remedy / Comments

Check coolant level, add as needed.

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 supply temperature exceeded 75 degrees Celcius (167 ℉ ). Operating with either lower side panel loose or removed; Coolant fan failed; radiator fins clogged with dirt.

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.

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

0-5284 OPERATION 4-13

AUTO-CUT 200 XT

CCM Status Code

Group 6 -- CCM

Remedy / Comments Code Message

601 Analog Voltage Error Defective CCM, replace.

602 ADC or DAC error Defective CCM, replace.

603 Reserved

604 Data Memory error

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.

4-14 OPERATION 0-5284

4.07 Cut Quality

AUTO-CUT 200 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.

0-5284 OPERATION 4-15

AUTO-CUT 200 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.

4-16 OPERATION 0-5284

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 200 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.

0-5284 OPERATION 5-1

AUTO-CUT 200 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 3:14

Fill Cooling System on the procedure for this.

MAINTENANCE 0-5284

5.04 Arc Starter Service

AUTO-CUT 200 XT

Symptom

Arc Starter Service Chart

Cause

Coolant has become conductive

Check

Use conductivity meter

No Pilot ignition:

Spark in Arc Starter but no ignition

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)

Visual inspection

Check with feeler gauge

Use capacitance meter

Visual inspection

Visual inspection

No Pilot ignition:

No Spark in Arc Starter

No cooling or insufficient cooling:

Leaks coolant

Spark gap bus caps

(C1, C2, C3) broken or defective

Negative supply not connected correctly

Spark gap set too large

Faulty transformer

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).

Capacitance meter

Visual inspection

Check with feeler gauge

Resistance measurement

Check input voltage at EMI filter

Visual inspection

Voltage/ Resistor measurement

Visual inspection

Visual inspection

Visual inspection

No cooling or insufficient cooling:

No Coolant Flow

Erratic System

Behavior

(EMI Interference)

Supply & return hose reversed

Blockage in coil or supply/return hoses

Loose or missing connection from Torch Lead Shield. F1 ground not connected

Missing or loose ground connection

Cap C5 not connected, open or loose

Remedy

Flush system, replace coolant.

Connect Wire.

Set to 0.063” ±0.002”

Reconnect or replace.

Replace.

Remove short; increase coil gaps.

Replace.

Reconnect.

Set to 0.063” ±0.002”

Replace.

Make connections; replace harness.

Reconnect.

Replace.

Tighten fittings.

Replace HF Coil.

Replace coolant line(s).

Visual Inspection of color-coded connections

Match coolant connection colors to arc starter fitting colors.

Loosen fitting slightly and check for coolant flow

Flush system.

Visual inspection of lead attachment to Arc Starter

Visual inspection of ground wire to Arc Starter

Visual inspection / capacitor measurement

Reconnect / tighten lead connectors.

Make or tighten connections to good ground.

Replace PCB.

0-5284 OPERATION 5-3

AUTO-CUT 200 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-11464

5-4 MAINTENANCE 0-5284

AUTO-CUT 200 XT

SECTION 6: REPLACEMENT ASSEMBLIES & PARTS

6.01 Replacement Power Supply

Complete Unit / Component Catalog Numbers

Auto-Cut 200 XT™ Power Supply, 400VAC +10 -15% CE

6.02 Leads and Cables

Refer to section 3.05 for ground connections and ground cables.

Catalog Number

3-9112-4

CNC CNC Cable P

Primary power

Ground

Cable

F1

Auto-Cut XT

Power Supply

G: Torch Lead Set, Shielded

- Coolant Supply w/ Negative

- Coolant Return

- Pilot Return

- Plasma Gas

- Shield Gas

Positioning

Tube

Torch

Work Cable O Work

Art # A-11687_AB

Key

F1

G

O

P

Leads Catalog Numbers; Auto-Cut 200 XT Power Supply

Leads Length

Description

Ground Cable, Power

Supply to Earth

Torch Lead Assembly

Work Cable

Control Cable, CNC

to Power Supply

10 ft

3.05 m

15 ft

4.5 m

25 ft

7.6 m

9-4932 9-4933

4-3044 4-3045 4-3046 4-3047 4-3048

9-7350 9-7351 9-7352 9-7353

9-7368

35 ft

10.6 m

50 ft

15.2 m

75 ft

22.8 m

100 ft

30.5 m

125 ft

38.1 m

9-4934 9-4935 9-4936 9-4937

9-7369 9-7370 9-7371 9-7372

NOTE!

Supply lead set includes Pilot Return Cable, Negative Cable, Coolant Supply & Return Hoses, and Control Cable.

0-5284 PARTS LISTS 6-1

AUTO-CUT 200 XT

F1

G

O

P

6.03 Power Supply External Replacement Parts

Item # Qty Description

3

4

1

2

5

1

1

1

1

1

Power Supply Top Panel

Power Supply Upper Right and Left Side

Power Supply Lower Right Side

Power Supply Lower Left Side

Input Power Cover

1

Ground Cable,

Arc Starter

To Earth Ground

Torch Lead Set

Work Cable

CNC Cable (14 Wire)

Art # A-11688

Catalog #

9-7300

9-7301

9-7302

9-7304

9-7346

2 2

5

4

3

Art # A-11947

6-2 PARTS LISTS 0-5284

6.04 Power Supply Replacement Parts - Lower Right Side

Item # Qty

AUTO-CUT 200 XT

Description Ref. Des. 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

7 1 Radiator

8 1 Flow, Switch (Not shown, behind cooling fan)

8-5142

9-7306

9-7307

9-7309

9-7422

9-7424

9-7415

9-7311

FS1 9-7310

Art # A-11984_AB

1

3

2

4

7

5

6

8

0-5284 PARTS LISTS 6-3

AUTO-CUT 200 XT

6.05 Power Supply Replacement Parts - Upper Right Side

Item # Qty Description Ref. Des. Catalog #

1

2

6

8

1

1

1

1

Pump Motor Control Relay

Inrush Control Relay

On/Off Switch Breaker

Relay and Interface PCB

MC3

K1

9-7314

9-7337

MC1 9-7336

T1 9-7315

9-9252

CB1 9-7316

9-9253

9-9251

9-7324

7

6 8

5

4

3

2

1

9

Art # A-11567_AB

6-4 PARTS LISTS 0-5284

6.06 Power Supply Replacement Parts - Lower Left Side

Item # Qty Description

1 1 AC Suppressor PCB

3

4

6

1

1

1

Half Inverter Block

Full Inverter Block

EMI Filter PCB (2 total)

AUTO-CUT 200 XT

Ref. Des. Catalog #

9-9254

9-9255

9-7319

9-7317

W1 9-7318

9-9264

1

2

3

5

6

4

Art # A-11946

0-5284 PARTS LISTS 6-5

AUTO-CUT 200 XT

6.07 Power Supply Replacement Parts - Upper Left Side

Item # Qty Description

3

4

1

2

5

1

1

1

1

1

Gas Solenoid (2 required 3 with H2O Mist option)

Water Filter Assembly (Optional. Requires 3rd gas solenoid)

PCB, RAS1000 RF Cap Baord

HF Coil Assy, Arc Starter

Current Transducer, 300A

Ref. Des. Catalog #

SOL 1, 2, 3 9-6319

8-3460

9-9423

9-4959

HCT1 W7005324

PS1 9-6318

2

3 4

5 6

1

Art # A-12814

6-6 PARTS LISTS 0-5284

6.08 Power Supply Replacement Parts - Rear Panel

Item # Qty

AUTO-CUT 200 XT

Description Breaker Rating Cicuit Rating Ref. Des. Catalog #

1

3

4

1

1

1

Coolant Filter Assy.

Gas Selection Switch

Air Filter Assembly AC200-XT

- First Stage Filter Element only

-Second Stage Filter Element only

9-7320

9-7322

9-3325

9-7527

9-1021

9-1022

1

USER INPUT

HEIGHT CONTROL

3

2

J15 - CNC

AIR / O2

PLASMA

N2 / H35

PLASMA

CB2 - 5A 120 VAC

CB3 - 5A 24 VAC

CB4 - 5A 120 VAC

F1 - 8A SB 500 VAC F2 - 8A SB 500 VAC

4 5

Art # A-11948_AB

0-5284 PARTS LISTS 6-7

AUTO-CUT 200 XT

6.09 Power Supply Replacement Parts - Front

Item # Qty Description

1 1 Pressure Gauge

3 1 Run/Set Selector Switch

4 1 Potentiometer

6 1 Shield Gas Selector Switch

Catalog #

8-6800

9-9509

9-3427

9-2685

9-3426

6.10 Recommended Gas Supply Hose

Item # Qty

1

Description

3/8”Gray Synflex Hose. No fittings included. Catalog number per foot

Catalog #

9-3616

6-8 PARTS LISTS 0-5284

AUTO-CUT 200 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

0-5284 TORCH INFORMATION 7-1

AUTO-CUT 200 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 0-5284

7.04 Torch Consumables Installation

1. Install the consumables as follows:

AUTO-CUT 200 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

NOTE!

For 200-Amp consumables, when replacing the shield retainer or the shield cup, assemble these two parts first before assembling the other consumables.

Shield

Retainer

Shield Cup

Tip Plasma Gas

Electrode

Art # A-08303

Cartridge

A

1 - Assemble “A” 200 A only.

2 - Assemble “B”.

B

3 - Assemble “B” to “C”.

C

4 - Assemble “A” to “B-C” assembly.

0-5284 TORCH INFORMATION 7-3

AUTO-CUT 200 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 0-5284

AUTO-CUT 200 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.

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.

0-5284 TORCH INFORMATION 7-5

AUTO-CUT 200 XT

Torch leaks

Are Torch

Consumable Parts

Installed?

No

Yes

Are Parts New or Used?

New

Used

Leaking from

Coolant Supply or

Coolant Return?

Return

Supply

Order Coolant

Check Valve

Kit 9-4846

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?

Unsure?

Disassembly fully and re-assemble the Torch Properly.

See Installation Manual.

Yes Is the Torch Damaged?

No

Yes

Replace Torch Head Yes

Remove and Lubricate all O-rings on Torch Head,

Consumables Cartridge, and Consumables.

Re-assemble Torch.

Still leaks?

Yes

Replace Consumable

Cartridge and Shield Cup.

Torch still leaks?

Torch

Electrodes

Amperage Plasma Gas Recommended Wear Depth

for Replacement

30

50

Inch mm

O2 0.04

1

Air 0.04

2

O2 0.04

1

70

100

Air 0.08

2

O2 0.04

1

Air 0.08

2

O2 0.04

1

H35 0.08

2

Art # A-04704_AB

7-6 TORCH INFORMATION 0-5284

APPENDIX 1: CNC Control Module

AUTO-CUT 200 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

0-5284 APPENDIX A-1

AUTO-CUT 200 XT

CNC functions.

CNC I/O circuits provide at least 1000V galvanic isolation from the plasma power supply.

While the CNC circuits are isolated from the power supply, many of the signal returns on J15 and TB1 & 2 are common to each other. J15 pins 1, 4, 5 & 10 and TB1-1, 5, 7, 9, and TB2-1 & 3 are all common. J15 pin 12 and TB2-10 are also connected to the others when SW6 (OK to Move select) is set for voltage.

Rear Panel CNC Connector J15:

14 Circuit (Amp CPC) Remote Standard:

1

Chassis gnd (for SC-11 cable shield)

Start/Stop

1 Ok to Move (contacts or voltage 2 )

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

1 These are also duplicated on TB1, TB2 & TB3 use one or the other not both. Additional functions are only available on TB1, TB2 & TB3.

2 SW6 on CCM I/O PCB selects OK to Move for isolated contact closure or DC Volts (15-18V) at <100ma. When set for contacts, OK to Move circuit is rated for 120 VAC / 28 VDC @ 1A.

Internal CNC connections. TB1, TB2 & TB3 on CCM module.

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) 4

Divided Arc Voltage

Remote Analog Current Control

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)

A-2 APPENDIX 0-5284

AUTO-CUT 200 XT

TB2

Hold Start

Preflow ON

Pilot is ON (contacts)

OK to Move (contacts or DC Volts)5

TB3

Plasma Marking

Corner Current Reduction

Cut Expanded Metal

Spare NO Contact

Spare NC Contact

Spare NO Contact

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 (-)

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

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

0-5284 APPENDIX A-3

AUTO-CUT 200 XT

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.

Remote Selection of Plasma Marking (input) --- Plasma marking is not available with the Auto-cut.

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.

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

Remote Selection of Plasma Marking (input) --- Plasma marking is not available with the Auto-cut.

The following functions may not yet be available on your system. *

*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 --- .

A-4 APPENDIX 0-5284

AUTO-CUT 200 XT

This Page Intentionally Blank

0-5284 APPENDIX A-5

AUTO-CUT 200 XT

Simplified CNC Circuit

Auto-Cut XT CCM Simplified CNC & Gas Control

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

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 TO MOVE SELECT

18 VDC or Contacts

SW6A

+18VDC

DC VOLTS

CONTACTS

SW6B

3

B

+

4

-

VOLTAGE DIVIDER

5

OK

ALL SW OFF f or 50: 1 ( defaul t )

SW12A ( 1) ON = 16. 7: 1 ( SC- 11)

SW12B ( 2) ON = 30: 1

SW12C ( 3) ON = 40: 1

SW12D ( 4) ON = 25: 1

PSR

Art # A-11578

GAS ON

+10V

GND

ENABLE

PLAS_ENABLE SW

PLAS_ EN_SW_RET

/ GAS PRESS OK

/ BASIC ID

13

14

15

16

9

10

11

12

7

8

5

6

3

4

1

2

J26

GND

/ CNC Plasma Enable (+)

/ CNC Plasma Enable (-)

GND

13

14

15

16

9

10

11

12

17

18

7

8

5

6

3

4

1

2

J21

SPARE #1

13

14

15

16

9

10

11

12

17

18

19

20

7

8

5

6

3

4

1

2

J22

(142)

(133)

(134)

(137)

(139)

(138)

(143)

(140)

(141)

(136)

(135)

(130)

(131)

(104)

(121)

(124)

(129)

(123)

(125)

(126)

(127)

AC 24V-GCM2 (B8)

(124)

PS1 PLASMA (51 PSI)

(123)

(131)

SW 1

(126)

(125)

(127)

R?

10K

CURRENT

CONTROL

AC 24V Ret-GCM2 (B8)

(130)

(130)

(130)

GAS

SW 2

H2O

SOL1

PLASMA

SOL2

SHIELD

(165) (164)

SOL3

H2O Mist

(111) (111)

H2O Mist Option

Installing H2O Mist Option

------------------------------------------------------------------

Remove #130 from Shield SOL, connect #165 in it's place.

Connect #111 with other #111 on Shield SOL.

Connect #130 from SW2 with other #130 on SW1.

J15-1 to chassis used for

SC-11 cable shield

The COMM Ref at pin 8 is also for the SC-11

J15-13 connects SC-11 chassis to PS chassis.

(133)

(134)

(135)

(136)

(137)

(138)

(139)

(140)

(141)

(142)

(143)

Chassis

9

10

11

12

13

14

7

8

5

6

3

4

1

2

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 (+)

J15-CNC

Art # A-11578

A-6 APPENDIX 0-5284

Auto-Cut XT CCM Simplified CNC & Gas Control

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

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 TO MOVE SELECT

18 VDC or Contacts

SW6A

+18VDC

DC VOLTS

CONTACTS

SW6B

3

B

+

4

-

VOLTAGE DIVIDER

5

OK

ALL SW OFF f or 50: 1 ( defaul t )

SW12A ( 1) ON = 16. 7: 1 ( SC- 11)

SW12B ( 2) ON = 30: 1

SW12C ( 3) ON = 40: 1

SW12D ( 4) ON = 25: 1

PSR

Art # A-11578

AUTO-CUT 200 XT

GAS ON

+10V

GND

ENABLE

PLAS_ENABLE SW

PLAS_ EN_SW_RET

/ GAS PRESS OK

/ BASIC ID

13

14

15

16

9

10

11

12

7

8

5

6

3

4

1

2

J26

GND

/ CNC Plasma Enable (+)

/ CNC Plasma Enable (-)

GND

13

14

15

16

9

10

11

12

17

18

7

8

5

6

3

4

1

2

J21

SPARE #1

13

14

15

16

9

10

11

12

17

18

19

20

7

8

5

6

3

4

1

2

J22

(142)

(133)

(134)

(137)

(139)

(138)

(143)

(140)

(141)

(136)

(135)

(130)

(131)

(104)

(121)

(124)

(129)

(123)

(125)

(126)

(127)

AC 24V-GCM2 (B8)

(124)

PS1 PLASMA (51 PSI)

(123)

(131)

SW 1

(126)

(125)

(127)

R?

10K

CURRENT

CONTROL

AC 24V Ret-GCM2 (B8)

(130)

(130)

(130)

GAS

SW 2

H2O

SOL1

PLASMA

SOL2

SHIELD

(165) (164)

SOL3

H2O Mist

(111) (111)

H2O Mist Option

Installing H2O Mist Option

------------------------------------------------------------------

Remove #130 from Shield SOL, connect #165 in it's place.

Connect #111 with other #111 on Shield SOL.

Connect #130 from SW2 with other #130 on SW1.

J15-1 to chassis used for

SC-11 cable shield

The COMM Ref at pin 8 is also for the SC-11

J15-13 connects SC-11 chassis to PS chassis.

(133)

(134)

(135)

(136)

(137)

(138)

(139)

(140)

(141)

(142)

(143)

Chassis

9

10

11

12

13

14

7

8

5

6

3

4

1

2

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 (+)

J15-CNC

Art # A-11578

0-5284 APPENDIX A-7

AUTO-CUT 200 XT

CNC Connections

Cutting Machine

START/STOP

Corner

Start Motion

(OK-To-Move)

{

**

Shield

CNC Cable Power Supply

J15

1

2

3

*

NC

..........

Source, 16 VDC, 10 ma.

4

5

... Divided Arc V (-)

6 ..........

Divided Arc V (+)

7

..........

Pre Flow ON (+)

8

9

..........

Pre Flow ON (-)

10

11

12

13

*

14

..........

Corner Current Reduction (+)

...

Corner Current Reduction (-)

(+)

DC

OK-To-Move

Relay DCV (-)

Contact or

(1A @ DCV (+)

120 VAC ( 15 - 18 VDC @ or 28 VDC) up to 100 ma.)

SW6

* 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-11502

*

(1)

A-8 APPENDIX 0-5284

AUTO-CUT 200 XT

This Page Intentionally Blank

0-5284 APPENDIX A-9

AUTO-CUT 200 XT

APPENDIX 2: CCM CPU PCB Layout

= Test Point

A-10 APPENDIX

Art # A-11675_AC

0-5284

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 200 XT

0-5284 APPENDIX A-11

AUTO-CUT 200 XT

APPENDIX 3: CCM I/O PCB Layout

= Test Point

A-12 APPENDIX 0-5284

CCM I/O PCB

D13

D18

D20

D25

D4

D6

D8

D12

D33

D37

D41

D43

Test Points

TP1

TP2

TP3

TP4

TP5

TP6

TP7

TP8

TP9

GND

/COOLANT FAN ON

/TORCH PUMP ON

LOW COOLANT FLOW (SW)

COOLANT FLOW SIGNAL (PULSE)

+15V ISOLATED

-15V ISOLATED

TP10

TP11

+18V ISOLATED

ANALOG CURRENT CONTROL 0-3.3V

GND ISOLATED

/PILOT ENABLE

TP12 +5VDC

TP13 -15VDC

TP14 +15VDC

TP15 24VDC

TP18

TP19

+5V ISOLATED

WORK CURRENT

LED Reference

D2

D3

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 200 XT

J Connectors

J21 BASIC CNC

J22

J23

J24

J25

J26

J28

J29

EXTENDED CNC

RELAY - INTERFACE BOARD

ARC / TIP VOLTS

TEST

GAS BOX

TO CPU

TO CPU

0-5284 APPENDIX A-13

AUTO-CUT 200 XT

APPENDIX 4: Pilot PCB Layout

= Test Point

A-14 APPENDIX

Art # A-11677_AB

0-5284

Pilot PCB Test Points

TP1 GND

TP2

TP3

PILOT GATE

+5V

TP4 TIP

LED Reference

D2 Green PILOT ENABLE

D11 Green +5V

AUTO-CUT 200 XT

0-5284 APPENDIX A-15

AUTO-CUT 200 XT

APPENDIX 5: Relay and Interface PCB Layout

= Test Point

A-16 APPENDIX

Art # A-11678_AB

0-5284

Relay and Interface PCB Test Points

TP1 GND

TP2

TP3

TP4

TP5

-15V

+5VDC

+12V

+24V

TP6

TP7

LED Reference

+15V

+5VDC

D22

D23

D24

D25

D2

D7

D11

D12

D26

D27

Green 1 TORCH GAS ON

Green PILOT ENABLE

Green PILOT CURRENT DETECTED

Green WORK CURRENT DETECTED

Green CONTACTORS ON

Green RF ON

Green FAN ON

Green PLASMA ENABLED

Green 1 TORCH ON

Green TORCH COOLANT ON

AUTO-CUT 200 XT

0-5284 APPENDIX A-17

AUTO-CUT 200 XT

APPENDIX 6: Display PCB Layout

= Test Point

A-18

Art # A-11679

APPENDIX 0-5284

Display PCB Test Points

TP1 GND

TP2

TP3

+5VDC

+24VDC

AUTO-CUT 200 XT

0-5284 APPENDIX A-19

AUTO-CUT 200 XT

APPENDIX 7: System Bias PCB Layout

= Test Point

A-20

Art # A-11680_AB

APPENDIX 0-5284

System Bias PCB Test Points

TP1 GND

D26

D27

D30

D44

D3

D4

D14

D15

TP6

TP7

TP8

TP9

TP2

TP3

TP4

TP5

24VDC

DC INPUT POSITIVE

Vcc1

Vcc2

GATE

PRIMARY GND

+12V PRIMARY

P_ISOL_GND

TP10 DC SENSE POSITIVE

LED Reference

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 200 XT

0-5284 APPENDIX A-21

AUTO-CUT 200 XT

APPENDIX 8: Main Inverter Bottom PCB Layout

= Test Point

A-22 APPENDIX 0-5284

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 200 XT

0-5284 APPENDIX A-23

AUTO-CUT 200 XT

APPENDIX 9: Main Inverter Top PCB Layout

= Test Point

A-24 APPENDIX 0-5284

Main Inverter Top 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

D4

Red CAP IMBALANCE

Green READY

AUTO-CUT 200 XT

0-5284 APPENDIX A-25

AUTO-CUT 200 XT

APPENDIX 10: Control and Fault PCB Layout

= Test Point

Art # A-11683_AC

A-26 APPENDIX 0-5284

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 GATE 2+

TP30

TP31

I_DMD1 0.5V-6.7V

GATE 2-

TP32 -12VDC

TP33 START 2

TP34 SHDN

TP35 ENABLE

TP36

TP37

LED Reference

READY IN

READY OUT

D1

D14

D24

D32

Red INV FLT

Red OVER TEMP

Green PWM ON

Red PRI OC

AUTO-CUT 200 XT

0-5284 APPENDIX A-27

AUTO-CUT 200 XT

APPENDIX 11: Cap Bias Bottom PCB Layout

A-28 APPENDIX

Art # A-11685_AC

0-5284

AUTO-CUT 200 XT

APPENDIX 12: Cap Bias Top PCB Layout

0-5284 APPENDIX

Art # A-11686_AC

A-29

AUTO-CUT 200 XT

APPENDIX 13: Suppressor PCB Layout

A-30 APPENDIX

Art # A-11684_AC

0-5284

AUTO-CUT 200 XT

APPENDIX 14: WMS gas box layout

PRESSURE SWITCH

PRESSURE GAUGE PRESSURE GAUGE

0-5284 APPENDIX

Dimensions are in inches. Machined corners and edges to be 0.010 All diameters on same axis to be concentric within 0.005 TIR. Machined surfaces to be 125 µi surface finish or better. Chamfer thread starts 45° to root. * O-ring surface finish 32-64 µi. Radius corners 0.010 Decimals Angular .XX

A-31

AUTO-CUT 200 XT

APPENDIX 15: Cooling Diagram

A-32 APPENDIX 0-5284

AUTO-CUT 200 XT

This Page Intentionally Blank

0-5284 APPENDIX A-33

AUTO-CUT 200 XT

APPENDIX 16: System Schematic pg 1

A-34

1 2 3 4 5

INVERTER 1/2 MODULE (IM) #2 (top)

A

B

L1

1

(1)

(2)

(3)

(1)

(2)

(3)

1

2

IN1

EMI

FIL-

TER

PCB

OUT1

2

1

1

2

1

2

IN2

OUT2

GND2B

IN3 OUT3

2

1

2

1

CHASSIS GND

1

2

IN1

EMI

FIL-

TER

PCB

OUT1

2

1

1

2

1

2

IN2

OUT2

GND2B

IN3 OUT3

2

1

2

1

(20)

(21)

(22)

W1A

W1B

W1C

(7)

(8)

L6

(9)

Toriod Core

(7)

(8)

(9)

L5

Toriod Core

J105B

1

2

J104B

1

2

J103B

1

2

(7)

(8)

(9)

L4

Toriod Core

J105A

1

2

J104A

1

2

J103A

1

2

J105A

1

2

J104A

1

2

J103A

1

2

AC INPUT

019x502000

AC INPUT

019x502700

AC INPUT

IM #2 Section A (lower)

INVERTER MODULE (IM) #`1 (bottom)

MAIN PCB LEDS

D3, RED, CAP

IMBALANCE

D4, GREEN, READY

CAP BIAS PCB LEDS

D6, GREEN, -12V

D11, GREEN, +12VP

D13, GREEN, +12V

IM #1 Section B (upper)

CONTROL PCB LEDS

D1, RED, INV FLT

D14, RED, OVER TEMP

D24, GREEN, PWM ON

D32, RED, PRI OC

IM #1 Section A (lower)

L2

1

CHASSIS GND

019x502000

C

D

E

F

L3

Earth

1

1

CHASSIS GND

380-415

VAC

INPUT

(Customer supplied power cord must pass through ferrite core assembly.)

CB1

ON / OFF

(1)

(2)

(3)

18 AWG wire both in and out of

CB1 to J60

J50

9

10

11

12

13

14

7

8

5

6

3

4

1

2

AC LINE

AC

SUPPRESSION

PCB PANEL AC INDICATOR

(10)

3

4

1

2

(11) LT1

J51

INTERNAL AC INDICATOR

(12)

GND

J52

3

4

1

2

(13) LT2

019X504000

CHASSIS GND

LT1 & LT2

INPUT POWER

NEON INDICATORS

Rear Panel & Internal

Component Locations (not including PCB components)

T1

T2

TB4

TS1

TS2

W1

C1-3 Capacitor, 1900 pf, 15Kv. (Sht 1, A10)

C4 Capacitor, fan starting, 8uf 440VAC (Sht 2, E1)

CB1

CB2-4

Circuit Breaker /ON/OFF SW, 15A 480V (Sht 1, D1)

Circuit Breaker, 5A, 250V (Sht 2, B3)

F1, 2 Fuse, 8A, 500V, S.B. (Sht 1, E1)

FAN1, 2 Fan, Heat Exchanger , 230 VAC (Sht 2, D2)

FS1

HCT1

Flow SW, 1.0 GPM (3.8 lpm), N.O. (Sht 2, A2)

Current Sensor, Hall Effect 200A, Work Lead (Sht 1, D9)

K1 Relay, 24VAC, Inrush Control (Sht 2, B9)

L2 Inductor, HF, 400A, Water Cooled (Sht 1, A10)

L3-6 Toriod Core Common Mode Ind (Sht1 B9, B&C3)

LS1 Level Switch, Coolant Tank (Sht 2, A3)

LT1, LT2 Indicator, Neon, 250V, AC Volts Present (Sht 1, C3)

M1 Motor, Pump, ½ hp 230VAC, 50/60 Hz, 1Ph (Sht 2, C2)

MC1 Relay, 120 VAC, Inrush, Coil (Sht 2, B9), Contact (Sht2, A1)

MC3 Relay, 120 VAC, Pump Motor Control

(Coil at Sht 2, A7) (Contacts at Sht 2, C2)

PS1 Pressure Switch, Plasma Gas, N.O. , 51 PSI (Sht 2, C9)

R1 Current Control 10K (sht 2, D9)

R2 Inrush, 4.7 ohm 30W (Sht2, A1)

SA1, 2

SG1

SOL1

SOL2

SOL3

Snubber, Contactor & Relay coil (Sht 2, A7)

Spark Gap (Sht 1, A9)

Solenoid, Plasma Gas, 24 VAC (Sht 2, D9)

Solenoid, Shield Gas, 24 VAC (Sht 2, D9)

SW1

SW2

Solenoid, H2O Mist (water shield), 24 VAC (Sht 2, D10)

Switch, RUN / SET, DPDT (Sht 2, D10)

Switch, Shield Mode, SPDT (Sht 2, D10)

SW3 Switch, Gas Mode, SPST, rear panel (Sht 2, B2)

Aux Transformer (Sht 2, B2)

Transformer, HV, 120/6000V (Sht 1, A9)

Terminal Block (Sht 1, C9)

Temperature Sensor, NTC, Coolant Return (Sht 2, A5)

Temperature Sensor, NTC, Ambient (Sht 2, A5)

Contactor , Input (Coil at Sht 2, A8) (Contacts at Sht 1, B2)

F1

8A, 500V, SB

(86A)

(27A)

(85A)

(86B)

(27B)

(85B)

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

(43A)

TO AUX TRANSFORMER

TO J12

(Sht 2, A1)

(44A)

T1 PRIMARY

Art # A-11944_AC

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

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

K1A K1B

1 2 3 4 5 6 7 8 9 10 11 12

019X501900

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

GND

+24VDC

+ V

12

13

14

10

9

11

7

8

1

4

5

2

3

6

J61

J62

VOLTAGE SELECTION

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)

To J27 on CCM I/O PCB

230V 400V 480V ERR

/VAC_IDAb 0 1 0 1

/VAC_IDBb 0 0 1 1

(Sht 2, E3)

(48)

Wire #48 from J61-1 to:

J61-2 for 208-230 VAC

J61-3 for 400 VAC

J61-4 for 480 VAC

Measure relative to TP1 (24VDC_RET)

"0" = 10-12V "1" = 24V

1 2 3 4 5

WORK (+)

APPENDIX 0-5284

6 7 8 9 10

TO CCM

CPU PCB J33

(Sht 2, C3)

AC 120V (Sht 2, A8)

AC 120V_RET (Sht 2, A8)

(99)

(98)

T2

6.5K 1W

6.5K 1W

120 / 6000 VAC

J100 -- 30 CKT RIBBON

ELECTRODE (-)

WORK (+)

OUTPUT

J102A

(49C)

5

4

3

2

1

(51C)

J100 -- 30 CKT RIBBON

ELECTRODE (-)

WORK (+)

OUTPUT

J100 -- 30 CKT RIBBON

ELECTRODE (-)

WORK (+)

OUTPUT

TO CCM

CPU PCB

J32

(Sht 2, B3)

J102B

5

4

3

2

1

(49B)

(51B)

TO CCM

CPU PCB

J31

(Sht 2, B3)

5

4

3

2

1

J102A

(49A)

(50)

PILOT BOARD LED'S

D2 PILOT ENABLE

D11 +5V

TEST POINTS

TP1 GND

TP2 PILOT GATE

TP3 +5V

J58A

(49)

J43

(51A)

J58B

J58C

5

4

3

2

1

J40

INVERTER

J42

TO RELAY BOARD

1 2 3 4 5 6 7 8 9 10

ELECTRODE

PILOT PCB

TO I/O BOARD

1 2 3 4 5 6 7 8

J45

J44

1

J41

2

1

TIP

NEG

(49)

CGND PLT

CHASSIS GND

(52)

(52)

TO J3 on RELAY PCB

(Sht 2, A6)

(53)

To J24 on I-O PCB

(Sht 2, D3)

(51)

(55)

10 ckt Ribbon

TIP VOLTS

WORK

ARC VOLTS

SG1

0.062"

(49)

Toriod Core

AC 120V- TB4-4 (Sht 2, B8)

AC 120V- Ret- TB4-3 (Sht 2, B8)

AC 24V-TB4-2 (Sht 2, B8)

AC 24V- Ret -TB4-1 (Sht 2, B8)

(51)

(60)

(61)

(62)

(63)

(49)

TB4

7

6

5

4

3

2

1

ARC VOLTS (TORCH)

WORK

120 VAC @ 100 ma.

24 VAC @ 1A

L3

(49)

RIBBON CABLE 30 ckt.

CCM (J31-33) - INVERTER (J100)

(Sht 2, C4) (Sht 1, A6, B6) (51A)

(51)

HCT1 Hall Effect Sensor

C2

C1

C3

L2

HF COIL_WC

PILOT

1

CHASSIS GND

WORK

1

(-)

(+)

Tip

SHIELD

Work

TORCH

(+)

C

A

B

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

TO J1 on RELAY PCB

(Sht 2, A5)

J16

(56)

(57)

(58)

(59) g w o b

+15 VDC

-15 VDC

SIG (+)

COMMON

RIBBON CABLE 40 ckt CCM (J23 (Sht 2, C7)) - RELAY PCB (J4 (Sht 2, B7))

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 *

* Used with 1 Torch Option

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

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 (Sht 2, C8)) -

DISPLAY PCB (J17 (Sht 2, C9))

1,3,5,7

2,4,6,8

9,10 NC

11-16

RIBBON CABLE 10 ckt

RELAY PCB (J3 (Sht 2, A6)) -

PILOT PCB (J42 (Sht 1, C8))

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 +

D

E

Art # A-11944_AC

00

0 1

Initial Design

Added MC3 Pump Control

0 2 Added R1, K1, MC1 inrush

03 Misc updates & corrections

0 4 More updates & corrections

DAT

D A T

D A T

DAT

D A T

4/18/2012

8 / 3 1 / 2 0 1 2

1 / 1 6 / 2 0 1 3

6/27/2013

9 / 1 2 / 2 0 1 3

6 7 8

SCHEMATIC

Auto-Cut XT 200A CE 380-415 VAC

9

Date Printed

9/30/2013

DAT

C

Date Revised

9/16/2013

04/18/2012

1 of 2

F

042X1350

10

1 2 3 4 5

INVERTER 1/2 MODULE (IM) #2 (top)

A

B

L1

1

(1)

(2)

(3)

(1)

(2)

(3)

1

2

IN1

EMI

FIL-

TER

PCB

OUT1

2

1

1

2

1

2

IN2

OUT2

GND2B

IN3 OUT3

2

1

2

1

CHASSIS GND

1

2

IN1

EMI

FIL-

TER

PCB

OUT1

2

1

1

2

1

2

IN2

OUT2

GND2B

IN3 OUT3

2

1

2

1

(20)

(21)

(22)

W1A

W1B

W1C

(7)

(8)

L6

(9)

Toriod Core

(7)

(8)

(9)

L5

Toriod Core

J105B

1

2

J104B

1

2

J103B

1

2

(7)

(8)

(9)

L4

Toriod Core

J105A

1

2

J104A

1

2

J103A

1

2

J105A

1

2

J104A

1

2

J103A

1

2

AC INPUT

019x502000

AC INPUT

019x502700

AC INPUT

IM #2 Section A (lower)

INVERTER MODULE (IM) #`1 (bottom)

MAIN PCB LEDS

D3, RED, CAP

IMBALANCE

D4, GREEN, READY

CAP BIAS PCB LEDS

D6, GREEN, -12V

D11, GREEN, +12VP

D13, GREEN, +12V

IM #1 Section B (upper)

CONTROL PCB LEDS

D1, RED, INV FLT

D14, RED, OVER TEMP

D24, GREEN, PWM ON

D32, RED, PRI OC

IM #1 Section A (lower)

L2

1

CHASSIS GND

019x502000

C

D

E

F

L3

Earth

1

1

CHASSIS GND

380-415

VAC

INPUT

(Customer supplied power cord must pass through ferrite core assembly.)

CB1

ON / OFF

(1)

(2)

(3)

18 AWG wire both in and out of

CB1 to J60

J50

9

10

11

12

13

14

7

8

5

6

3

4

1

2

AC LINE

AC

SUPPRESSION

PCB PANEL AC INDICATOR

(10)

3

4

1

2

(11) LT1

J51

INTERNAL AC INDICATOR

(12)

GND

J52

3

4

1

2

(13) LT2

019X504000

CHASSIS GND

LT1 & LT2

INPUT POWER

NEON INDICATORS

Rear Panel & Internal

Component Locations (not including PCB components)

T1

T2

TB4

TS1

TS2

W1

C1-3 Capacitor, 1900 pf, 15Kv. (Sht 1, A10)

C4 Capacitor, fan starting, 8uf 440VAC (Sht 2, E1)

CB1

CB2-4

Circuit Breaker /ON/OFF SW, 15A 480V (Sht 1, D1)

Circuit Breaker, 5A, 250V (Sht 2, B3)

F1, 2 Fuse, 8A, 500V, S.B. (Sht 1, E1)

FAN1, 2 Fan, Heat Exchanger , 230 VAC (Sht 2, D2)

FS1

HCT1

Flow SW, 1.0 GPM (3.8 lpm), N.O. (Sht 2, A2)

Current Sensor, Hall Effect 200A, Work Lead (Sht 1, D9)

K1 Relay, 24VAC, Inrush Control (Sht 2, B9)

L2 Inductor, HF, 400A, Water Cooled (Sht 1, A10)

L3-6 Toriod Core Common Mode Ind (Sht1 B9, B&C3)

LS1 Level Switch, Coolant Tank (Sht 2, A3)

LT1, LT2 Indicator, Neon, 250V, AC Volts Present (Sht 1, C3)

M1 Motor, Pump, ½ hp 230VAC, 50/60 Hz, 1Ph (Sht 2, C2)

MC1 Relay, 120 VAC, Inrush, Coil (Sht 2, B9), Contact (Sht2, A1)

MC3 Relay, 120 VAC, Pump Motor Control

(Coil at Sht 2, A7) (Contacts at Sht 2, C2)

PS1 Pressure Switch, Plasma Gas, N.O. , 51 PSI (Sht 2, C9)

R1 Current Control 10K (sht 2, D9)

R2 Inrush, 4.7 ohm 30W (Sht2, A1)

SA1, 2

SG1

SOL1

SOL2

SOL3

Snubber, Contactor & Relay coil (Sht 2, A7)

Spark Gap (Sht 1, A9)

Solenoid, Plasma Gas, 24 VAC (Sht 2, D9)

Solenoid, Shield Gas, 24 VAC (Sht 2, D9)

SW1

SW2

Solenoid, H2O Mist (water shield), 24 VAC (Sht 2, D10)

Switch, RUN / SET, DPDT (Sht 2, D10)

Switch, Shield Mode, SPDT (Sht 2, D10)

SW3 Switch, Gas Mode, SPST, rear panel (Sht 2, B2)

Aux Transformer (Sht 2, B2)

Transformer, HV, 120/6000V (Sht 1, A9)

Terminal Block (Sht 1, C9)

Temperature Sensor, NTC, Coolant Return (Sht 2, A5)

Temperature Sensor, NTC, Ambient (Sht 2, A5)

Contactor , Input (Coil at Sht 2, A8) (Contacts at Sht 1, B2)

F1

8A, 500V, SB

(86A)

(27A)

(85A)

(86B)

(27B)

(85B)

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

(43A)

TO AUX TRANSFORMER

TO J12

(Sht 2, A1)

(44A)

T1 PRIMARY

Art # A-11944_AC

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

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

K1A K1B

1 2 3 4 5 6 7 8 9 10 11 12

019X501900

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

GND

+24VDC

+ V

12

13

14

10

9

11

7

8

1

4

5

2

3

6

J61

J62

VOLTAGE SELECTION

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)

To J27 on CCM I/O PCB

230V 400V 480V ERR

/VAC_IDAb 0 1 0 1

/VAC_IDBb 0 0 1 1

(Sht 2, E3)

(48)

Wire #48 from J61-1 to:

J61-2 for 208-230 VAC

J61-3 for 400 VAC

J61-4 for 480 VAC

Measure relative to TP1 (24VDC_RET)

"0" = 10-12V "1" = 24V

1 2 3 4 5

WORK (+)

AUTO-CUT 200 XT

0-5284

6 7 8 9 10

TO CCM

CPU PCB J33

(Sht 2, C3)

AC 120V (Sht 2, A8)

AC 120V_RET (Sht 2, A8)

(99)

(98)

T2

6.5K 1W

6.5K 1W

120 / 6000 VAC

J100 -- 30 CKT RIBBON

ELECTRODE (-)

WORK (+)

OUTPUT

J102A

(49C)

5

4

3

2

1

(51C)

J100 -- 30 CKT RIBBON

ELECTRODE (-)

WORK (+)

OUTPUT

J100 -- 30 CKT RIBBON

ELECTRODE (-)

WORK (+)

OUTPUT

TO CCM

CPU PCB

J32

(Sht 2, B3)

J102B

5

4

3

2

1

(49B)

(51B)

TO CCM

CPU PCB

J31

(Sht 2, B3)

5

4

3

2

1

J102A

(49A)

(50)

PILOT BOARD LED'S

D2 PILOT ENABLE

D11 +5V

TEST POINTS

TP1 GND

TP2 PILOT GATE

TP3 +5V

J58A

(49)

J43

(51A)

J58B

J58C

5

4

3

2

1

J40

INVERTER

J42

TO RELAY BOARD

1 2 3 4 5 6 7 8 9 10

ELECTRODE

PILOT PCB

TO I/O BOARD

1 2 3 4 5 6 7 8

J45

J44

1

J41

2

1

TIP

NEG

(49)

CGND PLT

CHASSIS GND

(52)

(52)

TO J3 on RELAY PCB

(Sht 2, A6)

(53)

To J24 on I-O PCB

(Sht 2, D3)

(51)

(55)

10 ckt Ribbon

TIP VOLTS

WORK

ARC VOLTS

SG1

0.062"

(49)

Toriod Core

AC 120V- TB4-4 (Sht 2, B8)

AC 120V- Ret- TB4-3 (Sht 2, B8)

AC 24V-TB4-2 (Sht 2, B8)

AC 24V- Ret -TB4-1 (Sht 2, B8)

(51)

(60)

(61)

(62)

(63)

(49)

TB4

7

6

5

4

3

2

1

ARC VOLTS (TORCH)

WORK

120 VAC @ 100 ma.

24 VAC @ 1A

L3

(49)

RIBBON CABLE 30 ckt.

CCM (J31-33) - INVERTER (J100)

(Sht 2, C4) (Sht 1, A6, B6) (51A)

(51)

HCT1 Hall Effect Sensor

C2

C1

C3

L2

HF COIL_WC

PILOT

1

CHASSIS GND

WORK

1

(-)

(+)

Tip

SHIELD

Work

TORCH

(+)

C

A

B

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

TO J1 on RELAY PCB

(Sht 2, A5)

J16

(56)

(57)

(58)

(59) g w o b

+15 VDC

-15 VDC

SIG (+)

COMMON

RIBBON CABLE 40 ckt CCM (J23 (Sht 2, C7)) - RELAY PCB (J4 (Sht 2, B7))

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 *

* Used with 1 Torch Option

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

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 (Sht 2, C8)) -

DISPLAY PCB (J17 (Sht 2, C9))

1,3,5,7

2,4,6,8

9,10 NC

11-16

RIBBON CABLE 10 ckt

RELAY PCB (J3 (Sht 2, A6)) -

PILOT PCB (J42 (Sht 1, C8))

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 +

D

E

Art # A-11944_AC

00

0 1

Initial Design

Added MC3 Pump Control

0 2 Added R1, K1, MC1 inrush

03 Misc updates & corrections

0 4 More updates & corrections

DAT

D A T

D A T

DAT

D A T

4/18/2012

8 / 3 1 / 2 0 1 2

1 / 1 6 / 2 0 1 3

6/27/2013

9 / 1 2 / 2 0 1 3

6 7 8

SCHEMATIC

Auto-Cut XT 200A CE 380-415 VAC

9

Date Printed

9/30/2013

DAT

C

Date Revised

9/16/2013

04/18/2012

1 of 2

F

042X1350

10

APPENDIX A-35

AUTO-CUT 200 XT

APPENDIX 17: System Schematic pg2

A

B

C

D

E

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 J63 (Sht 1, F2)

(43A)

(44A)

MC1A

2

LS1

3

J71

3

4

1

2

(90)

(89)

4 5

AMBIENT

TS2

COOLANT

TS1

COOLANT LEVEL

J74

1

2

(84)

(83)

(92)

(93) (94)

(95)

Mini-Fit Jr

J12

1 2 3 4

5 6 7 8

Mini-Fit

J13

R2

4.7 30W

(87)

FS1

460V

400V

220V

T1

SW3 AIR / O2

N2, H35, OTHER

Gas Selection

24V RET

24V

120V_2 RET

120V_2

120V-1 RET

BLUE

RED

YELLOW

BLUE

RED

YELLOW

4

3

6

5

2

1

J14

(166)

(167)

(79)

(77)

(74)

(78)

CB2 5 A

(76)

(75)

CB3 5 A (73)

(71)

CB4 5 A

(72)

120V_1 To J100 of IM #1A

(Sht 1, B6)

0 V

MC3A

(66)

CHASSIS GND

MC3B

(64B) (67)

To J100 of IM #1B

(Sht 1, B6)

To J100 of IM #2A

(Sht 1, A6)

J16

1

2

3

M1

Torch Coolant Pump

Harness from Pilot PCB J45

(Sht 1, C8)

J5 J7 J1 J2

J6

3

4

1

2

8

7

6

5

4

3

2

1

12

11

10

9

COOLANT FLOW SW LEVEL SENSORS

+5VDC

SIGNAL

120VAC_2

24VAC

120VAC_1

J9 BIAS TRANSFORMER

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

019X501700

WORK CURRENT SENSOR

J15

TEMP SENSOR

1 TORCH INTERFACE

J31 - 30 CKT RIBBON

J32 - 30 CKT RIBBON

J33- 30 CKT RIBBON

N/C

J34 - 30 CKT RIBBON

N/C

J34 - 30 CKT RIBBON

N/C

J34 - 30 CKT RIBBON

CCM

CPU

PCB

(65A)

(64A)

(65C)

(64C)

CHASSIS GND

Alternate fan.

100 & 200A units may use either this single larger fan (same as 300 & 400A units) or the 2 smaller fans shown above.

BK R

1

2

3

J72 C4

BN

R

FAN1

BL

J72

1

2

3

J73

1

2

3

FAN1

FAN2 (55)

(51)

Harness from System Bias PCB

(Sht 1, E4)

(53)

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)

11

12

13

7

8

9

10

14

J27

3

4

1

2

5

6

. 230V 400V 480V ERR

J62-12 (/VAC_IDAb) 0 1 0 1

J62-14 (/VAC_IDBb) 0 0 1 1

Measured relative to TP1 (24VDC_RET)

"0" = 10-12V "1" = 24V

7

8

5

6

3

4

1

2

J24

J28 30 CKT RECEPTACLE - BOTTOM ENTRY

019X501100

CCM I-O PCB

J28 30 CKT PIN HEADER

I / O PCB LEDS

----------------------------------------------

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

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)

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)

19X501200

F

Art # A-11945_AC

1 2 3 4 5

A-36 APPENDIX 0-5284

J3

6

TO PILOT PCB J42

(Sht 1, C7)

10 CKT RIBBON

PILOT PCB

GND

7

MC3

Pump Motor Control

(96)

W1

Input Contactor

(97)

SA2 SA1

8 9

ARC_SUPPRESSOR ARC_SUPPRESSOR

(98)

(99)

120 VAC Ret

120 VAC to RAS

24 VDC

J8

CONTROL OUTPUTS

120 VAC_RET

24 VAC 120 VAC_1

120 VAC_2

HMI/GCM

J4 -- 40 CKT RIBBON CABLE

18

17

16

15

14

13

12

11

10

9

8

7

6

5

4

3

2

1

J10

(104)

(62)

(60)

(111)

(63)

(61)

AC 120V_RET (Sht 1, A8)

AC 120V (Sht 1, A8)

MC1

(60)

AC 24V-GCM2 (D9)

(62)

AC 24V-TB4-2 (Sht 1, C9)

1

120VAC

(107)

K1

2

AC 120V- TB4-4 (Sht 1, C9)

4

3

AC 24V Ret-GCM2 (D9)

(63)

5

INRUSH

AC 24V- Ret -TB4-1 (Sht 1, C9)

(61)

AC 120V- Ret- TB4-3 (Sht 1, C9)

10

J38

1 2 3 4 5 6 7 8 9

RS 232 D-SUB

SERIAL PROG

PORT

3

4

1

2

5

6

PROG

USB IC

7

8

5

6

3

4

1

2

9

10

11

12 J18

J19

J29 30 CKT RECEPTACLE - BOTTOM ENTRY

J39

USB

PORT

1 2 3 4

7

8

5

6

3

4

1

2

9

10

11

12

J20

GND

GND

Rx-

Tx+

Tx-

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)

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

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 (-)

OK to MOVE (+)

OK to MOVE (-)

PILOT is ON

PILOT is ON

Preflow ON (+)

Preflow ON (-)

Hold Start (+)

Hold Start (-)

TB1

8

7

6

5

4

3

2

1

12

11

10

9

TB2

8

7

6

5

4

3

2

1

12

11

10

9

GAS ON

J23- 40 ckt ribbon cable

ENABLE

PLAS_ENABLE SW

PLAS_ EN_SW_RET

/ GAS PRESS OK

/ BASIC ID

GND

OK

+10V

GND

/ CNC Plasma Enable (+)

/ CNC Plasma Enable (-)

13

14

15

16

9

10

11

12

17

18

7

8

5

6

3

4

1

2

J21

GND

13

14

15

16

9

10

11

12

7

8

5

6

3

4

1

2

J26

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

PSR

SPARE #1

13

14

15

16

9

10

11

12

17

18

19

20

7

8

5

6

3

4

1

2

J22

3

4

1

2

5

6

J30

J37

16 CKT RIBBON

J17

019X501800

Display PCB

C

(133)

(134)

(137)

(139)

(138)

(143)

(140)

(141)

(136)

(135)

(124)

PS1 PLASMA (51 PSI)

(130)

(131)

(104)

AC 24V-GCM2 (B8)

(121)

(124)

(129)

(123)

(125)

(126)

(127)

(125)

(126)

(127)

(142)

CURRENT

CONTROL

AC 24V Ret-GCM2 (B8)

(130)

(123)

(131)

(130)

SOL1

PLASMA

SW 1

GAS

(165)

RUN

SET

(130)

SW 2

H2O

(164)

SOL3

H2O Mist

(111) (111)

H2O Mist Option

Installing H2O Mist Option

------------------------------------------------------------------

Remove #130 from Shield SOL, connect #165 in it's place.

Connect #111 with other #111 on Shield SOL.

Connect #130 from SW2 with other #130 on SW1.

D

J15-1 to chassis used for SC-11 cable shield

J15-13 connects SC-11 chassis to PS chassis.

The COMM Ref at pin 8 is also for the SC-11

(133)

(134)

(135)

(136)

(137)

(138)

(139)

(140)

(141)

(142)

(143)

CHASSIS GND

9

10

11

12

13

14

7

8

5

6

3

4

1

2

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 (+)

J15-CNC

Art # A-11945_AC

E

0 0

0 1

I N I T I A L

Added MC3 Pump Control

0 2 Added R1, K1, MC1 inrush

03 Misc updates & corrections

0 4 More updates & corrections

D A T

D A T

D A T

DAT

D A T

4 / 1 8 / 2 0 1 2

8 / 3 1 / 2 0 1 2

1/16/2013

6/27/2013

9 / 1 2 / 2 0 1 3

6 7 8

Title SCHEMATIC

Auto-cut XT 200A CE 380-415 VAC

9

Date Printed

9/30/2013

Drawn

DAT

Size C

Drawing Number

Date Revised

9/12/2013

Date

04/18/2012

Sheet

2 of 2

042X1350

10

F

A

B

A

B

C

D

E

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 J63 (Sht 1, F2)

(43A)

(44A)

MC1A

2

LS1

3

J71

3

4

1

2

(90)

(89)

4 5

AMBIENT

TS2

COOLANT

TS1

COOLANT LEVEL

J74

1

2

(84)

(83)

(92)

(93) (94)

(95)

Mini-Fit Jr

J12

1 2 3 4

5 6 7 8

Mini-Fit

J13

R2

4.7 30W

(87)

FS1

460V

400V

220V

T1

SW3 AIR / O2

N2, H35, OTHER

Gas Selection

24V RET

24V

120V_2 RET

120V_2

120V-1 RET

BLUE

RED

YELLOW

BLUE

RED

YELLOW

4

3

6

5

2

1

J14

(166)

(167)

(79)

(77)

(74)

(78)

CB2 5 A

(76)

(75)

CB3 5 A (73)

(71)

CB4 5 A

(72)

120V_1 To J100 of IM #1A

(Sht 1, B6)

0 V

MC3A

(66)

CHASSIS GND

MC3B

(64B) (67)

To J100 of IM #1B

(Sht 1, B6)

To J100 of IM #2A

(Sht 1, A6)

J16

1

2

3

M1

Torch Coolant Pump

Harness from Pilot PCB J45

(Sht 1, C8)

J5 J7 J1 J2

J6

3

4

1

2

8

7

6

5

4

3

2

1

12

11

10

9

COOLANT FLOW SW LEVEL SENSORS

+5VDC

SIGNAL

120VAC_2

24VAC

120VAC_1

J9 BIAS TRANSFORMER

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

019X501700

WORK CURRENT SENSOR

J15

TEMP SENSOR

1 TORCH INTERFACE

J31 - 30 CKT RIBBON

J32 - 30 CKT RIBBON

J33- 30 CKT RIBBON

N/C

J34 - 30 CKT RIBBON

N/C

J34 - 30 CKT RIBBON

N/C

J34 - 30 CKT RIBBON

CCM

CPU

PCB

(65A)

(64A)

(65C)

(64C)

CHASSIS GND

Alternate fan.

100 & 200A units may use either this single larger fan (same as 300 & 400A units) or the 2 smaller fans shown above.

BK R

1

2

3

J72 C4

BN

R

FAN1

BL

J72

1

2

3

J73

1

2

3

FAN1

FAN2 (55)

(51)

Harness from System Bias PCB

(Sht 1, E4)

(53)

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)

11

12

13

7

8

9

10

14

J27

3

4

1

2

5

6

. 230V 400V 480V ERR

J62-12 (/VAC_IDAb) 0 1 0 1

J62-14 (/VAC_IDBb) 0 0 1 1

Measured relative to TP1 (24VDC_RET)

"0" = 10-12V "1" = 24V

7

8

5

6

3

4

1

2

J24

J28 30 CKT RECEPTACLE - BOTTOM ENTRY

019X501100

CCM I-O PCB

J28 30 CKT PIN HEADER

I / O PCB LEDS

----------------------------------------------

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

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)

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)

19X501200

F

Art # A-11945_AC

1 2 3 4 5

0-5284

AUTO-CUT 200 XT

J3

6

TO PILOT PCB J42

(Sht 1, C7)

10 CKT RIBBON

PILOT PCB

GND

7

MC3

Pump Motor Control

(96)

W1

Input Contactor

(97)

SA2 SA1

8 9

ARC_SUPPRESSOR ARC_SUPPRESSOR

(98)

(99)

120 VAC Ret

120 VAC to RAS

24 VDC

J8

CONTROL OUTPUTS

120 VAC_RET

24 VAC 120 VAC_1

120 VAC_2

HMI/GCM

J4 -- 40 CKT RIBBON CABLE

18

17

16

15

14

13

12

11

10

9

8

7

6

5

4

3

2

1

J10

(104)

(62)

(60)

(111)

(63)

(61)

AC 120V_RET (Sht 1, A8)

AC 120V (Sht 1, A8)

MC1

(60)

AC 24V-GCM2 (D9)

(62)

AC 24V-TB4-2 (Sht 1, C9)

1

120VAC

(107)

K1

2

AC 120V- TB4-4 (Sht 1, C9)

4

3

AC 24V Ret-GCM2 (D9)

(63)

5

INRUSH

AC 24V- Ret -TB4-1 (Sht 1, C9)

(61)

AC 120V- Ret- TB4-3 (Sht 1, C9)

10

J38

1 2 3 4 5 6 7 8 9

RS 232 D-SUB

SERIAL PROG

PORT

3

4

1

2

5

6

PROG

USB IC

7

8

5

6

3

4

1

2

9

10

11

12 J18

J19

J29 30 CKT RECEPTACLE - BOTTOM ENTRY

J39

USB

PORT

1 2 3 4

7

8

5

6

3

4

1

2

9

10

11

12

J20

GND

GND

Rx-

Tx+

Tx-

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)

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

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 (-)

OK to MOVE (+)

OK to MOVE (-)

PILOT is ON

PILOT is ON

Preflow ON (+)

Preflow ON (-)

Hold Start (+)

Hold Start (-)

TB1

8

7

6

5

4

3

2

1

12

11

10

9

TB2

8

7

6

5

4

3

2

1

12

11

10

9

GAS ON

J23- 40 ckt ribbon cable

ENABLE

PLAS_ENABLE SW

PLAS_ EN_SW_RET

/ GAS PRESS OK

/ BASIC ID

GND

OK

+10V

GND

/ CNC Plasma Enable (+)

/ CNC Plasma Enable (-)

13

14

15

16

9

10

11

12

17

18

7

8

5

6

3

4

1

2

J21

GND

13

14

15

16

9

10

11

12

7

8

5

6

3

4

1

2

J26

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

PSR

SPARE #1

13

14

15

16

9

10

11

12

17

18

19

20

7

8

5

6

3

4

1

2

J22

3

4

1

2

5

6

J30

J37

16 CKT RIBBON

J17

019X501800

Display PCB

C

(133)

(134)

(137)

(139)

(138)

(143)

(140)

(141)

(136)

(135)

(124)

PS1 PLASMA (51 PSI)

(130)

(131)

(104)

AC 24V-GCM2 (B8)

(121)

(124)

(129)

(123)

(125)

(126)

(127)

(125)

(126)

(127)

(142)

CURRENT

CONTROL

AC 24V Ret-GCM2 (B8)

(130)

(123)

(131)

(130)

SOL1

PLASMA

SW 1

GAS

(165)

RUN

SET

(130)

SW 2

H2O

(164)

SOL3

H2O Mist

(111) (111)

H2O Mist Option

Installing H2O Mist Option

------------------------------------------------------------------

Remove #130 from Shield SOL, connect #165 in it's place.

Connect #111 with other #111 on Shield SOL.

Connect #130 from SW2 with other #130 on SW1.

D

J15-1 to chassis used for SC-11 cable shield

J15-13 connects SC-11 chassis to PS chassis.

The COMM Ref at pin 8 is also for the SC-11

(133)

(134)

(135)

(136)

(137)

(138)

(139)

(140)

(141)

(142)

(143)

CHASSIS GND

9

10

11

12

13

14

7

8

5

6

3

4

1

2

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 (+)

J15-CNC

Art # A-11945_AC

E

0 0

0 1

I N I T I A L

Added MC3 Pump Control

0 2 Added R1, K1, MC1 inrush

03 Misc updates & corrections

0 4 More updates & corrections

D A T

D A T

D A T

DAT

D A T

4 / 1 8 / 2 0 1 2

8 / 3 1 / 2 0 1 2

1/16/2013

6/27/2013

9 / 1 2 / 2 0 1 3

6 7 8

Title SCHEMATIC

Auto-cut XT 200A CE 380-415 VAC

9

Date Printed

9/30/2013

Drawn

DAT

Size C

Drawing Number

Date Revised

9/12/2013

Date

04/18/2012

Sheet

2 of 2

042X1350

10

F

A

B

APPENDIX A-37

AUTO-CUT 200 XT

APPENDIX 18: 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-38 APPENDIX 0-5284

AUTO-CUT 200 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 (+)

0-5284 APPENDIX A-39

AUTO-CUT 200 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).

A-40 APPENDIX 0-5284

Status codes.

AUTO-CUT 200 XT

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.

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.

0-5284 APPENDIX A-41

AUTO-CUT 200 XT

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.

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

K1

1

8

2

3

4

5

To

Relay

PCB

6

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)

-22

-15

-6

-5

GCM 1000 XT

(AC 300 XT

DMC 3000)

-25

-20

Plasma Enable SW

J26-6

J26-7 -2 -2 -2

Jumper in

AC 200 XT

Art # 12304

A-42 APPENDIX 0-5284

AUTO-CUT 200 XT

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.

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 7

J10 GAS

CONTROL

CABLE

GCM 2010 CONTROL BOARD

F20 1A

CCM I/O BOARD

3

(103)

(112)

16

14

16

14

(56)

(58)

12

15

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

0-5284 APPENDIX A-43

AUTO-CUT 200 XT

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.

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.

A-44 APPENDIX 0-5284

Arc starter without Spark Gap (Ultra-Cut)

AUTO-CUT 200 XT

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.

b. If 120 VAC is present proceed to the next step.

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.

0-5284 APPENDIX A-45

AUTO-CUT 200 XT

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

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.

A-46 APPENDIX 0-5284

AUTO-CUT 200 XT

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.

103 Lost Pilot

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.

0-5284 APPENDIX A-47

AUTO-CUT 200 XT

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.

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.

A-48 APPENDIX 0-5284

AUTO-CUT 200 XT

• 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.

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.

0-5284 APPENDIX A-49

AUTO-CUT 200 XT

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)

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.

A-50 APPENDIX 0-5284

PWR Present

AUTO-CUT 200 XT

• 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.

E201:

• 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.

0-5284 APPENDIX A-51

AUTO-CUT 200 XT

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.

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.

A-52 APPENDIX 0-5284

AUTO-CUT 200 XT

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.

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.

0-5284 APPENDIX A-53

AUTO-CUT 200 XT

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.

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

A-54 APPENDIX 0-5284

AUTO-CUT 200 XT

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.

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.

0-5284 APPENDIX A-55

AUTO-CUT 200 XT

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.

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.

A-56 APPENDIX 0-5284

AUTO-CUT 200 XT

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 1 0 1

0 0 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.

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.

0-5284 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.

APPENDIX A-57

AUTO-CUT 200 XT

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.

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.

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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.

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.

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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.

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.

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253-258 Inverter Over Temperature.

AUTO-CUT 200 XT

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.

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.

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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.

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.

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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.

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

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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.

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.

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307 Gas Control returns wrong command sequence.

AUTO-CUT 200 XT

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.

Group 4 codes relate to the Liquid Cooling System

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

0-5284 APPENDIX A-65

AUTO-CUT 200 XT 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.

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.

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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.

• 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.

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.

0-5284 APPENDIX A-67

AUTO-CUT 200 XT

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

J72

1

2

3

R

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.

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.

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AUTO-CUT 200 XT

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.

0-5284 APPENDIX A-69

AUTO-CUT 200 XT 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.

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

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).

A-70 APPENDIX 0-5284

AUTO-CUT 200 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:

• 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.

0-5284 APPENDIX A-71

AUTO-CUT 200 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.

A-72 APPENDIX 0-5284

AUTO-CUT 200 XT

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.

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.

0-5284 APPENDIX A-73

AUTO-CUT 200 XT

613 USB Log File Creation Fault

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.

A-74 APPENDIX 0-5284

AUTO-CUT 200 XT

This Page Intentionally Blank

0-5284 APPENDIX A-75

AUTO-CUT 200 XT

APPENDIX 19: Publication History

Cover Date Rev

Apr 17, 2013 AA

Change(s)

First issue.

July 2, 2013 AB Updated section 3 with information about V-D Board installation for height controller

ECOB2488

Jan. 16, 2014 AC

May 29, 2014 AD

Updated many items, text and art throughout the manual. Added Advanced Trouble shooting and plumbing diagrams to Appendix per ECOB2552.

Updated Sect. 6 Leads Catalog Numbers. ECO-B2664

Insert Sect. 3 ‘Ground rod tester’ info. ECO-B2676

Update DoC. ECO-B2680

Add Sect. 6 ‘Current transducer’. ECO-B2681

Updated Sect. 6 Radiator # / fan art. ECO-B2689

May 27, 2015 AE Returned to Thermal Dynamics trade dress. New Read Me pages and DOC.Added new safety section. New safety icons throughout. Updated Gas Requirement chart. Updated art for upper left side showing toroid. 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 and change radiator number in Sec. 6. ECOB2713.

Jan. 14, 2016 AF 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 8-5124 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-65, added Warranty Statement inside rear

VCR-01537

A-76 APPENDIX 0-5284

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

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Denton, TX USA

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Ph: 1-800-279-2628 (tollfree)

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