Thermal Dynamics AUTO-CUT 300 XT Operating Manual Download Page 83

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AUTO-CUT 300 XT

Manual 0-5300

TORCH INFORMATION

7-3

7.04 Torch Consumables Installation

1. Install the consumables as follows:

Art # A-03887

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.

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 Cap

Shield Gas

Distr

ibutor

Tip

Plasma Gas

Distr

ibutor

Electrode

Cartridge

Art # A-11915

Assemble First

Summary of Contents for AUTO-CUT 300 XT

Page 1: ...ThermalDynamics com 480V AUTO CUT 300 XT PLASMA CUTTING SYSTEM Operating Manual Revision AE Issue Date May 27 2015 Manual No 0 5300...

Page 2: ...ncern 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...

Page 3: ...in this Manual whether such error results from negligence accident or any other cause Publication Date April 22 2013 Revision Date May 27 2015 Record the following information for Warranty purposes Wh...

Page 4: ...hereof 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 perio...

Page 5: ...nform ment la description contenue dans ce manuel les tiquettes d accompagnement et ou les feuillets d information si l quipement est install op r entretenu et r par selon les instructions fournies Vo...

Page 6: ...This Page Intentionally Blank...

Page 7: ...3 06 Connect Work Cable to Power Supply 3 6 3 07 Ground Connections 3 6 3 08 Ground Connections 3 7 3 09 Connect Gas and Coolant Supply Lines 3 10 3 10 Cables for CNC Arc Starter Gas Control 3 11 3 1...

Page 8: ...h Consumables Installation 7 3 APPENDIX 1 CNC CONTROL MODULE A 1 Control PCB Connections A 1 CNC functions A 2 CNC Cable Color Code A 9 APPENDIX 2 CCM CPU PCB LAYOUT A 10 APPENDIX 3 CCM I O PCB LAYOUT...

Page 9: ...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...

Page 10: ...posure 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...

Page 11: ...o 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...

Page 12: ...ion 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 mark...

Page 13: ...AUTO CUT 300 XT Manual 0 5300 SAFETY INSTRUCTIONS 1 5 This Page Intentionally Blank...

Page 14: ...lier ininflammable afin de vous prot ger des tincelles et de la chaleur par rayonnement 4 Les tincelles et les projections de m tal incandescent risquent de se loger dans les manches retrouss es les r...

Page 15: ...e restreint ou humide ne tenez vous pas directement sur le m tal ou sur la terre tenez vous sur des planches s ches ou une plate forme isol e et portez des chaussures semelles de caoutchouc 8 Avant de...

Page 16: ...u cylindre de la soupape ou du dispositif de surpression peut causer des blessures graves ou mortelles Par cons quent 1 Utilisez toujours le gaz pr vu pour une op ration et le d tendeur appropri con u...

Page 17: ...rc 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...

Page 18: ...r s il est plac sur une surface dont la pente d passe 15 Vous pourriez vous blesser ou endommager l quipement de fa on importante 15 Art A 12726 Art A 12736 MISE EN GARDE Soulevez l aide de la m thode...

Page 19: ...em 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 ar...

Page 20: ...rrent Suggested Sizes See Note Voltage Freq 3 Ph 3 Ph Fuse Amps Wire AWG Wire mm2 Volts Hz kVA Amps 3 Ph 3 Ph 3 Ph 480 50 60 63 77 150 4 25 IEC 480 50 60 72 88 150 4 25 NOTE Suggested wire size based...

Page 21: ...AUTO CUT 300 XT Manual 0 5300 SPECIFICATIONS 2 3 2 06 Power Supply Dimensions Art A 11918 40 6 inch 1031 2 mm 27 5 inch 698 5 mm 55 inch 1397 mm 610 lb 277 kg...

Page 22: ...cuit Breakers Customer Port Input Power Coolant Return Coolant Supply Customer Optional Port Pilot Lead Work Lead Fuses J56 Gas Control J58 Arc Starter J15 To CNC Control J59 To Arc Starter J55 To Gas...

Page 23: ...See Note 2 55 psi 3 8 bar 10 gph 0 6 lpm Note 1 The air source must be adequately filtered to remove all oil or grease Oil or grease contamination from compressed or bottled air can cause fires in co...

Page 24: ...38 2 25 57 15 mm 2 0 50 8 mm 2 4 61 mm 1 49 37 8 mm 19 482 7 mm 15 5 393 8 mm 2 7 69 6 mm 1 6 40 mm 3 98 101 1 mm 6 3 160 1 mm Mounting Tube End Cap XT 301 Basic 100 Amp B Torch Leads Lengths Torch Le...

Page 25: ...t r o d e Cartridge Art A 11915 Assemble First 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 coola...

Page 26: ...ature 104 F 40 C Duty Cycle 100 300 Amps Maximum Current 300 Amps Voltage Vpeak 500V Arc Striking Voltage 10kV Current Up to 300 Amps DC Straight Polarity See Note XTTM 301 Torch Gas Specifications Pl...

Page 27: ...nd national codes that apply to your region for final determination of correct wire type and size CAUTION Fuse and wire sizes are for reference only The installation must conform to national and local...

Page 28: ...le O Primary power Work Torch Auto Cut 300XT Power Supply Arc Starter Gas Control Module GCM 1000XT Pilot Return Negative Coolant Supply Coolant Return Control Cable CNC Positioning Tube Control Cable...

Page 29: ...B C D E F F1 K 37 14 Coolant Leads Power Supply to Arc Starter Pilot Return Power Supply to Arc Starter Negative Lead Power Supply to Arc Starter Control Cable Power Supply to Arc Starter Ground Cabl...

Page 30: ...e 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 i...

Page 31: ...Port at the bottom of the panel There are 2 extra plates included at the cable entrance Discarding one or both allows changing the opening size for larger cable strain relief 3 Install stripped end o...

Page 32: ...shown Tighten securely Do not overtighten Art A 11533 Pilot Work Cable Torch 4 Reinstall the cover on the power supply Secure with two screws removed earlier Do not overtighten 3 07 Ground Connections...

Page 33: ...ame 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 Th...

Page 34: ...is tance 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 Al...

Page 35: ...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...

Page 36: ...Coolant Supply Lines 1 Connect the gas supply lines to the appropriate input ports as shown upper left NOTE Coolant lines are factory installed If attaching optional HE400 see subsection 3 14 COOLANT...

Page 37: ...supply Some cables shown are options and may not apply to your system 2 Connect the other end of the CNC cable to the CNC device NOTE The CNC cable shield must be attached to ground at the CNC end CO...

Page 38: ...2 ON 3 ON 4 OFF 0 4 Seconds 2 OFF 3 OFF 4 ON 0 8 Seconds 2 ON 3 OFF 4 ON 1 0 Seconds 2 OFF 3 ON 4 ON 1 5 Seconds 2 ON 3 ON 4 ON 2 0 Seconds SW 4 Postflow Time 1 OFF 2 OFF 10 Seconds Factory default se...

Page 39: ...ntact closure 120VAC 1A Factory default setting or DC Volts 16 18vdc up to 100 ma SW 11 Set B position up for default SW 11 Set A position down for remote analog current control SW 8 2 must be set to...

Page 40: ...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 Art A 11905 TB4 24 VAC 1A TB4 1 2 3 4 5 6 7 120 VAC 100 ma Wor...

Page 41: ...lides into the port CAUTION Use protective gloves when handling the leads Do not kink or bend the leads 3 Inside the module slide the leads clamp over the leads 4 Connect the leads to the module in th...

Page 42: ...gged Red Art A 04832 Plasma Gas Connection Shield Gas Connection Torch Leads 5 Fold the end of the leads outer jacket back over the connection ring inside the module Slide the leads clamp over the jac...

Page 43: ...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...

Page 44: ...that the end cap engages the O ring at the top of the positioning tube 8 Install the shield cup and cartridge assembly including consumables onto the torch head 3 15 Install Consumable Torch Parts 1...

Page 45: ...ring protrudes from the cartridge the parts are not seated properly Cartridge Covers O Ring on Torch Tip Shield Cap Protrudes 0 063 0 083 1 6 2 1 mm Electrode Plasma Gas Distributor Tip Shield Gas Di...

Page 46: ...Art A 04344_AB 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...

Page 47: ...rotrusion 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 inter feres electrically with...

Page 48: ...nel 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...

Page 49: ...ive 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 shi...

Page 50: ...ugh 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 Protects To 7 3580 Extr...

Page 51: ...l 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 Depe...

Page 52: ...This Page Intentionally Blank...

Page 53: ...come ON when the internal temperature sensors detect tempera tures above normal limits Let the unit cool before continuing operation GAS Lamp Flashing during start up gas purge pump priming then stead...

Page 54: ...ust 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...

Page 55: ...2 Turn ON OFF switch to ON up position System goes through the Start up Sequence For about 10 seconds the decimal points of the 4 digit display blink from right to left Next the 4 rectangular LED ind...

Page 56: ...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...

Page 57: ...als 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 n...

Page 58: ...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...

Page 59: ...ctive ribbon cable If problem persists replace Inverter Module 1 214 Inverter 2A Output Current Low Plasma work current low during cutting and attributed to Inverter Module 2 Section A output low Inve...

Page 60: ...h Inverter AC Voltage rating incompatible with Power Supply voltage rating Ribbon cable CCM J35 to Inverter Module 3 Section A damaged or loose Wrong voltage Inverter Module 2 installed Defective Inve...

Page 61: ...power supply cutting Duty Cycle Reduce ambient air temperature Add auxiliary cooler 256 Not used Reserved for other model with another inverter section 257 Inverter 3A Over Temp Ambient Inverter circu...

Page 62: ...r 271 Inverter ID reading fault CCM found ID values inconsistant during reading CCM to an Inverter section ribbon damaged or disconnected Inproper ribbon cable routing CCM Status Code Group 3 Gas Cont...

Page 63: ...oose or removed Coolant fan failed radiator fins clogged with dirt 404 Coolant System not ready Proper coolant flow of 0 7 gpm as measured by flow switch FS1 was not obtained dur ing up to 4 minutes o...

Page 64: ...FW USF not found Add proper files to Flash Drive for Firmware updating 616 DPC Update Fault Fault occurred attempting to update DPC firmware Add proper files to USB Flash drive for Firmware updating R...

Page 65: ...to the RUN position 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...

Page 66: ...t 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 U...

Page 67: ...ion Replace as needed Clean water filter if using H2 O Mist Six Months Replace coolant filter Clean coolant tank Vacuum out any dust buildup inside power supply 5 02 Coolant Filter Cleaning Procedure...

Page 68: ...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 cau tion must be used when perfo...

Page 69: ...heck input voltage at EMI filter Make connections replace harness No loose connection to spark gap Visual inspection Reconnect Faulty EMI filter Voltage Resistor measurement Replace No cooling or insu...

Page 70: ...XT MAINTENANCE Manual 0 5300 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 Art A 11913 0 063 0 002...

Page 71: ...2 m 60 ft 18 3 m 75 ft 22 8 m 100 ft 30 5 m 125 ft 38 1 m A B C D E Supply Lead Set 4 3096 4 3097 4 3098 4 3099 4 3100 4 3101 4 3105 4 3102 4 3103 4 3104 A Pilot Return Cable 4 ft 1 2 m 9 4890 9 4891...

Page 72: ...ellow 1 0 50 mm A Green Red 8 AWG Cable B C D E F F1 K 37 14 Coolant Leads Power Supply to Arc Starter Pilot Return Power Supply to Arc Starter Negative Lead Power Supply to Arc Starter Control Cable...

Page 73: ...eplacement Parts Item Qty Description Catalog 1 1 GCM 1000 XT Top Cover 9 7345 2 1 Power and Leads Cable Covers 9 7346 3 1 Lifting Eye Cable 9 7347 4 1 Upper Side Covers 2 total 9 7301 5 1 Lower Left...

Page 74: ...ant Tank 9 7306 3 1 Sensor Coolant level 9 7307 4 1 Pump Coolant Assembly with motor 9 7309 1 Pump Coolant Assembly no motor 9 7422 5 1 Motor Pump motor only 9 7424 6 1 Heat Exchanger Fan FAN1 9 7348...

Page 75: ...Fan MC3 MC2 9 7314 2 1 Relay Inrush Control K1 9 7336 3 1 Relay Inrush MC1 9 7337 4 1 Resistor Inrush R2 9 7376 5 1 Auxilliary Transformer T1 9 7315 6 1 Display PCB 9 9252 7 1 On Off Switch Breaker CB...

Page 76: ...wer Supply Replacement Parts Left Side Item Qty Description Ref Des Catalog 1 1 Suppressor PCB 9 9254 2 1 Main Contactor 2 total W1 W2 9 7318 3 1 Inverter Module Full 2 total 480 VAC 9 7330 4 1 Invert...

Page 77: ...ly Replacement Parts RAS GCM 1000 XT Item Qty Description Ref Des Catalog 1 1 Gas Solenoid 3 required per unit 9 6319 2 1 Water Filter Assembly 8 3460 3 1 HF Transformer 9 4959 4 1 Pressure Switch 9 6...

Page 78: ...1 Coolant Filter 9 7322 3 1 Gas Selection Switch 9 3325 4 1 Fuse 8A SB 500V 2 total 9 7377 5 1 Air Filter Assembly AC200 XT 9 7527 First Stage Filter Element only 9 1021 Second Stage Filter Element o...

Page 79: ...Catalog 1 1 Pressure Gauge 8 6800 2 1 Gas Regulator 9 9509 3 1 Run Set Selector Switch 9 3426 4 1 Potentiometer with Knob 9 2685 5 1 Shield Gas Selector Switch 9 3427 6 1 Flowmeter H2 O 9 7762 GCM 10...

Page 80: ...AUTO CUT 300 XT REPLACEMENT PARTS Manual 0 5300 6 10 Recommended Gas Supply Hose Item Qty Description Catalog 1 3 8 Gray Synflex Hose No fittings included Catalog number per foot 9 3616...

Page 81: ...eld Cup CartridgeAssembly stationary Turn the Shield Cup to remove it from the Cartridge Assembly Assembled Cartridge Cartridge Tool Shield Cup Art A 04344_AB 2 Take the Removal Tool off the back of t...

Page 82: ...tion Under Locking Ring O Ring Cat No 9 3028 Art A 04071_AC Snap Ring Cartridge Assembly Art A 04066_AC O Rings Cat No 9 3027 Cat No 9 3026 Cat No 9 3025 Torch Head Cat No 9 9041 CAUTION Use only Ther...

Page 83: ...materials out of the consumables and Cartridge Handle all parts carefully to avoid damage which may affect torch performance NOTE For 200 Amp consumables when replacing the shield retainer or the shi...

Page 84: ...ap Protrudes 0 063 0 083 1 6 2 1 mm Electrode Plasma Gas Distributor Tip Shield Gas Distributor Shield Cap O Ring on Tip 1 Stack Parts 2 Press Cartridge onto Stacked Parts 4 Check Shield Cap Protrusio...

Page 85: ...the torch head with a wire brush Apply oxygen compatible lubricant supplied with the torch to the threads Torch Head O Ring Torch Head Art A 07202 0 063 0 083 1 6 2 1 mm Protrusion Ohmic Clip Art A 03...

Page 86: ...or Used Are Parts fully assembled into the Torch Unsure Disassembly fully and re assemble the Torch Properly See Installation Manual Replace Torch Head Is the Torch Damaged Replace Consumable Cartrid...

Page 87: ...emote Plasma Marking Corner Current Reduction Expanded Metal Spare 1 Output Normally Open Contacts Spare 2 Output Normally Open Contacts Hold Start CNC Plasma Enable LV OK To Move 2 Preflow On Start S...

Page 88: ...the other not both Chassis gnd for SC 11 cable shield 1 Start Stop 3 4 Ok to Move contacts or voltage 1 12 14 Divided Arc volts selectable ratio 50 1 40 1 30 1 16 6 1 25 1 5 6 PreFlow ON 7 9 Corner C...

Page 89: ...omm OK to Move 2 TB1 3 TB1 12 Contacts only rated 1A 28 VAC DC Stop Latched NC 4 TB1 4 TB1 5 comm used with Start Latched Start Stop Ret 4 TB1 6 TB1 5 comm or Start Latched NO 4 TB1 6 TB1 5 comm used...

Page 90: ...w 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 ac tive until all torches hav...

Page 91: ...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...

Page 92: ...rt Plasma M arki ng Plasma M arki ng Corner Current Reducti on Corner Current Reducti on Cut Expanded M etal Cut Expanded M etal Spare 2 NO Spare 2 NC Spare 1b NO 1 2 3 4 5 6 7 8 9 10 11 12 TB2 1 2 3...

Page 93: ...CNC Plasma Enable 26 CNC Plasma Enable 32 Stop SW momentary 33 Stop SW Ret 34 Pilot is ON a 35 Pilot is ON b 36 Spare OUT 1 a 37 Spare OUT 1 b 132 133 137 132 133 Chassi s 136 134 135 139 138 134 135...

Page 94: ...for CNC cable Do not connect wire 1 to anything Cable Shield drain wire must be connected to ground at cutting machine Art A 11901 SW6 DC 18 19 17 15 16 23 24 22 20 21 28 29 27 25 26 33 34 32 30 31 37...

Page 95: ...BLACK OK TO MOVE 14 BLUE OK TO MOVE 16 WHITE BROWN YELLOW HOLD START 17 WHITE BROWN GREEN HOLD START 21 WHITE BLACK ORANGE PLASMA MARK 22 WHITE BLACK RED PLASMA MARK 23 WHITE BROWN ORANGE CUT EXPANDED...

Page 96: ...AUTO CUT 300 XT APPENDIX Manual 0 5300 APPENDIX 2 CCM CPU PCB Layout Test Point Test Point Art A 11675_AB...

Page 97: ...V TP3 24V TP4 3 3V TP5 ISO GND TP6 5 0V 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 LED Reference D2 Red RXD D3 R...

Page 98: ...AUTO CUT 300 XT APPENDIX Manual 0 5300 APPENDIX 3 CCM I O PCB Layout Test Point Test Point Art A 11676_AC...

Page 99: ...5VDC TP13 15VDC TP14 15VDC TP15 24VDC TP18 5V ISOLATED TP19 WORK CURRENT LED Reference D2 Green PLASMA ENABLE D3 Green E STOP_PS D4 Green GAS ON D6 Green CNC START D8 Green HOLD START D12 Green PREFLO...

Page 100: ...AUTO CUT 300 XT APPENDIX Manual 0 5300 APPENDIX 4 Pilot PCB Layout Art A 11677 Test Point Test Point...

Page 101: ...AUTO CUT 300 XT Manual 0 5300 APPENDIX A 15 Pilot PCB Test Points TP1 GND TP2 PILOT GATE TP3 5V TP4 TIP LED Reference D2 Green PILOT ENABLE D11 Green 5V...

Page 102: ...AUTO CUT 300 XT APPENDIX Manual 0 5300 APPENDIX 5 Relay and Interface PCB Layout Test Point Test Point Art A 11678_AB...

Page 103: ...TP3 5VDC TP4 12V TP5 24V TP6 15V TP7 5VDC LED Reference D2 Green 1 TORCH GAS ON D7 Green PILOT ENABLE D11 Green PILOT CURRENT DETECTED D12 Green WORKCURRENTDETECTED D22 Green CONTACTORS ON D23 Green R...

Page 104: ...AUTO CUT 300 XT APPENDIX Manual 0 5300 APPENDIX 6 Display PCB Layout Test Point Test Point Art A 11679...

Page 105: ...AUTO CUT 300 XT Manual 0 5300 APPENDIX A 19 Display PCB Test Points TP1 GND TP2 5VDC TP3 24VDC...

Page 106: ...AUTO CUT 300 XT APPENDIX Manual 0 5300 APPENDIX 7 System Bias PCB Layout Test Point Test Point Art A 11680...

Page 107: ...C TP3 DC INPUT POSITIVE TP4 Vcc1 TP5 Vcc2 TP6 GATE TP7 PRIMARY GND TP8 12V PRIMARY TP9 P_ISOL_GND TP10 DC SENSE POSITIVE LED Reference D3 Red MISSING PHASE D4 Red AC V HIGH D14 Red AC V LOW D15 Green...

Page 108: ...AUTO CUT 300 XT APPENDIX Manual 0 5300 APPENDIX 8 Main Inverter Bottom PCB Layout Test Point Test Point Art A11681_AB...

Page 109: ...tom PCB Test Points TP1 GND TP2 GATE 2A TP3 GATE 1A TP4 GATE 3A TP5 GATE 4A TP6 GATE 2B TP7 GATE 1B TP8 GATE 4B TP9 GATE 3B TP10 12VP TP11 12VDC TP12 THERMISTOR SIDE A TP13 THERMISTOR SIDE B TP14 5VDC...

Page 110: ...AUTO CUT 300 XT APPENDIX Manual 0 5300 APPENDIX 9 Main Inverter Top PCB Layout Test Point Test Point Art A11682_AB...

Page 111: ...op PCB Test Points TP1 GND TP2 GATE 2A TP3 GATE 1A TP4 GATE 3A TP5 GATE 4A TP6 GATE 2B TP7 GATE 1B TP8 GATE 4B TP9 GATE 3B TP10 12VP TP11 12VDC TP12 THERMISTOR SIDE A TP13 THERMISTOR SIDE B TP14 5VDC...

Page 112: ...AUTO CUT 300 XT APPENDIX Manual 0 5300 APPENDIX 10 Control and Fault PCB Layout Test Point Test Point Art A11683_AB...

Page 113: ...ND TP22 12VDC TP23 5VDC TP24 GATE 1 TP25 A_OUT1 TP26 B_OUT1 TP27 GATE 1 TP28 I_SNS1 TP29 GATE 2 TP30 I_DMD1 0 5V 6 7V TP31 GATE 2 TP32 12VDC TP33 START 2 TP34 SHDN TP35 ENABLE TP36 READY IN TP37 READY...

Page 114: ...AUTO CUT 300 XT APPENDIX Manual 0 5300 APPENDIX 11 Cap Bias Bottom PCB Layout Art A 11685_AB...

Page 115: ...AUTO CUT 300 XT Manual 0 5300 APPENDIX A 29 APPENDIX 12 Cap Bias Top PCB Layout Art A 11686_AB...

Page 116: ...AUTO CUT 300 XT APPENDIX Manual 0 5300 APPENDIX 13 Suppressor PCB Layout Art A 11684_AB...

Page 117: ...Torch Coolant Supply Torch Coolant Return Pump Coolant tank Filter 1 Over Flow Supply Pressure Relief XT 301 RETURN PASS THRU HF COIL Flow Switch Cold Plate 1 Cold Plate 2 Cold Plate 3 Radiator Coolan...

Page 118: ...nel Internal 019X502700 019X502000 019X502000 019X502700 019X502000 Sht 2 A1 Sht 2 E3 D3 RED CAP IMBALANCE D4 GREEN READY D6 GREEN 12V D11 GREEN 12VP D13 GREEN 12V D1 RED INV FLT D14 RED OVER TEMP D24...

Page 119: ...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...

Page 120: ...DB a VAC_IDB b 43A T1 57 58 59 56 64A 65B 66 67 69 70 64B 69 70 71 72 73 74 75 76 77 78 79 53 51 55 83 84 89 90 93 92 94 95 1 2 J74 1 2 3 4 5 6 7 8 9 10 11 12 13 14 J15 1 TORCH INTERFACE 65A 65A 230V...

Page 121: ...t 6 Divided Arc V 5 Divided Arc V 12 OK to Move 14 OK to Move 7 Preflow ON 9 Preflow ON 30 Remote CC analog 29 Remote CC Pot High 31 Remote CC Pot Low 16 Hold Start 17 Hold Start 3 CNC Start 21 Plasma...

Page 122: ...modules with a full module in the bottom location and a module in the middle position A 300A unit has full modules top and bottom with the module in the middle location The AC 200 XT has only the bott...

Page 123: ...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 D...

Page 124: ...s 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...

Page 125: ...ter 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 o...

Page 126: ...s 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 Ena...

Page 127: ...he Relay board will de energize 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...

Page 128: ...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 follow...

Page 129: ...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...

Page 130: ...rrent Anything else would indicate the Relay board is faulty Art 12307 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 J23 TO RELAY BOARD...

Page 131: ...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...

Page 132: ...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...

Page 133: ...tting 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...

Page 134: ...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...

Page 135: ...and fault detection 1 2 3 4 5 6 7 8 9 10 11 12 13 14 J62 1 2 3 4 5 6 7 8 9 10 11 12 13 14 J27 GND V 1 2 4 3 HCPL 817 U Missing Phase a Missing Phase b GND To CPU PCB J29 16 Missing Phase I O PCB SYST...

Page 136: ...VDC 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 goe...

Page 137: ...tive output and earth ground Defective or incorrectly installed user supplied equipment such as torch height controls that make con nections to power supply output Shorts are more likely to cause DC o...

Page 138: ...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...

Page 139: ...ay 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...

Page 140: ...ntinuity 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 OUT...

Page 141: ...e 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 se...

Page 142: ...nput 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 In...

Page 143: ...gnal 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...

Page 144: ...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 c...

Page 145: ...ect 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 Anythi...

Page 146: ...anels 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 m...

Page 147: ...ay be shorted c Measure for 120 VAC on the contactor coil If present but the contactor isn t pulled in it s probably a defective contactor 3 On the Relay board D22 CONTACTOR ON LED green next to relay...

Page 148: ...tion 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...

Page 149: ...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...

Page 150: ...ypass 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 The UC 400 XT had an additional external h...

Page 151: ...IP 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...

Page 152: ...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...

Page 153: ...or 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 t...

Page 154: ...er TP3 I O board to TP1 If the pump comes on now replace the CCM d If jumping TP3 to TP1 does not turn the fans on then the Relay board or the 40 pin ribbon cable pin 13 is at fault Art 12313 MC3A MC3...

Page 155: ...w 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 c...

Page 156: ...n Ajumper 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 connect...

Page 157: ...usly 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...

Page 158: ...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 613 USB Log File Creation Fault When updating the CCM DMC and DP...

Page 159: ...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...

Page 160: ...Trouble shooting and plumbing diagrams to Appendix per ECOB2552 May 30 2014 AD Updated Sect 6 Leads Catalog Numbers ECO B2664 Insert Sect 3 Ground rod tester info ECO B2676 Remove DoC ECO B2680 Add Se...

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Thermal Dynamics AUTO-CUT 300 XT, Operating Manual

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