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AUTO-CUT 200 XT

Manual 0-5253

TORCH INFORMATION

7-1

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

Assembled Cartridge

Cartridge Tool

Shield Cup

Art # A-04344_AB

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

Summary of Contents for Auto-Cut 200 XT

Page 1: ...VictorThermalDynamics com AUTO CUT 200 XT PLASMA CUTTING SYSTEM Operating Manual Revision AE Issue Date January 16 2014 Manual No 0 5253...

Page 2: ...ugh market leading in novation and truly dependable products that will stand the test of time We strive to enhance your productivity efficiency and cutting performance enabling you to excel in your cr...

Page 3: ...by Victor Technologies 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 a...

Page 4: ...This page intentionally blank...

Page 5: ...pplications 2 5 2 10 XTTM 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 3 3 04...

Page 6: ...Parts Rear Panel 6 8 6 09 Power Supply Replacement Parts Front 6 9 6 10 Recommended Gas Supply Hose 6 10 SECTION 7 TORCH MAINTENANCE 7 1 7 01 Consumable Removal 7 1 7 02 O Ring Lubrication 7 2 7 03 P...

Page 7: ...PENDIX 14 SUPPRESSOR PCB LAYOUT A 32 APPENDIX 15 WMS GAS BOX LAYOUT A 33 APPENDIX 16 COOLING DIAGRAM A 34 APPENDIX 17 SYSTEM SCHEMATIC PG 1 A 36 APPENDIX 18 SYSTEM SCHEMATIC PG2 A 38 APPENDIX 19 ADVAN...

Page 8: ...TABLE OF CONTENTS...

Page 9: ...used coatings on the metal and the different processes You must be very careful when cutting or welding any metals which may contain one or more of the following Antimony Chromium Mercury Arsenic Coba...

Page 10: ...Arc Current Shade No Shade No Less Than 300 8 9 300 400 9 12 400 800 10 14 These values apply where the actual arc is clearly seen Experience has shown that lighter filters may be used when the arc i...

Page 11: ...ication l arc au jet de plasma devrait consulter leur membre profes sionel de m dication et le manufacturier de mat riel de sant pour d terminer s il existe des risques de sant Il faut communiquer aux...

Page 12: ...as hydrog ne peut s chapper ou se dissiper Le gas hydrog ne accumul explosera si enflamm RAYONS D ARC DE PLASMA Les rayons provenant de l arc de plasma peuvent blesser vos yeux et br ler votre peau Le...

Page 13: ...s de la American Welding Society 550 N W LeJeune Rd Miami FL 33126 8 Norme 51 de l Association Am ricaine pour la Protection contre les Incendies NFPA LES SYSTEMES GAZ AVEC ALIMENTATION EN OXYGENE POU...

Page 14: ...s designed and manufactured to a number of standards and technical requirements Among them are Certified by CQC to the following standards GB 15579 1 2004 Arc Welding Equipment Part 1 Welding Power So...

Page 15: ...ded 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 poten...

Page 16: ...th 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...

Page 17: ...ovides 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...

Page 18: ...Ph 3 Ph 380 50 60 41 63 100 6 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...

Page 19: ...AUTO CUT 200 XT Manual 0 5253 SPECIFICATIONS 2 3 2 06 Power Supply Dimensions Art A 11460_AB 35 97 inch 914 mm 27 6 inch 701 mm 47 77 inch 1213 mm 490 lb 222 kg...

Page 20: ...4 VAC CB2 5A 120 VAC USER INPUT HEIGHT CONTROL AIR O2 PLASMA N2 H35 PLASMA Art A 11470_AB Torch Leads Port Coolant Filter Two Stage Air Filter C C M Circuit Breakers Input Power Ground Terminal on ins...

Page 21: ...8 3 bar 827 kPa 200 scfh 5664 l h For systems with optional H2 O water mist H2 O Water See Note 2 50 psi 3 5 bar 10 gph 38 lph Note 1 The air source must be adequately filtered to remove all oil or gr...

Page 22: ...ions Art A 11538 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 Le...

Page 23: ...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...

Page 24: ...100 200 Amps Maximum Current 200 Amps Voltage Vpeak 500V Arc Striking Voltage 10kV Current Up to 200 Amps DC Straight Polarity See Note XTTM 301 Torch Gas Specifications Plasma Gases Compressed Air Ox...

Page 25: ...des that apply to your region for final determination of correct wire type and size CAUTION Fuse and wire sizes are for reference only The installation must conform to national and local codes for the...

Page 26: ...ection 3 05 and 3 06 for ground connections and ground cables Primary power Ground Cable Work Art A 11687_AB Torch Work Cable P O Auto Cut XT Power Supply CNC CNC Cable Positioning Tube G Torch Lead S...

Page 27: ...T Manual 0 5253 INSTALLATION 3 3 3 03 Cables Leads Identification Torch Lead Set Art A 11688 Green Yellow 1 0 50 mm F1 Work Cable CNC Cable 14 Wire 1 0 50 mm Cable Ground Cable Arc Starter To Earth Gr...

Page 28: ...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 29: ...he individual wires Route the cable through the rear panel of the power supply 2 Insert the individual wires into the proper terminals on the contactor as shown There are factory installed wires alrea...

Page 30: ...s 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 tabl...

Page 31: ...nced 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...

Page 32: ...t power or operate the power supply unless the connections cover is fastened in place 2 Increasing the ground rod length beyond 20 30 ft 6 1 9 1 m does not generally increase the effectiveness of the...

Page 33: ...he 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 secure...

Page 34: ...or other gases Art A 11749 Torch Leads Port Work Cable Port Optional Water Mist Port Shield Gas Port Plasma Gas Port Torch Leads Ground Terminal J15 CNC CB4 5A 120 VAC F1 8A SB 230 VAC F2 8A SB 230 VA...

Page 35: ...o 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 J15 CNC CB4 5A 120 VAC F1 8A SB 230 VAC F2 8A SB 230 V...

Page 36: ...that requires connection to the full non divided arc voltage Also available on the terminal strip are 120VAC and 24 VAC Note that the two 0 s are not common The allowable current draw is 100ma 120VAC...

Page 37: ...e 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 4 Connect the leads to the module in the sequence s...

Page 38: ...ly Connection Tagged Green Coolant Return Connection Tagged Red 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...

Page 39: ...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 40: ...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 fo...

Page 41: ...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 42: ...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 43: ...Protrusion 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...

Page 44: ...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 45: ...ve 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 shie...

Page 46: ...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 47: ...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 n...

Page 48: ...AUTO CUT 200 XT INSTALLATION Manual 0 5253 This Page Intentionally Blank...

Page 49: ...ll 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 whe...

Page 50: ...r 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 pre...

Page 51: ...nce 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 Pressu...

Page 52: ...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 pro...

Page 53: ...as 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 swit...

Page 54: ...N 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 i...

Page 55: ...he 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 an...

Page 56: ...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 d...

Page 57: ...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...

Page 58: ...parts worn Ensure current control setting matches consumables Plasma pressure too high Defective Arc Starter Defective Pilot PCB defective Inverter section 1A 103 Lost Pilot Pilot went out while Star...

Page 59: ...w 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 Modu...

Page 60: ...Bias Supply 239 AC Voltage High System Bias PCB detected AC Voltage is higher than Power Supply rated Voltage System Bias Supply J61 Voltage Selection connection damaged or disconnected Defective Syst...

Page 61: ...auxiliary cooler 260 Inverter 1B Over Temp Ambient Inverter circuitry is over temperature likely cause is ambient greater than 40 deg C Reduce power supply cutting Duty Cycle Reduce ambient air tempe...

Page 62: ...s measured by flow switch FS1 is less than 0 7 gpm Clogged filter Restriction in torch lead or head Wrong style consumables broken or defective torch coolant tube check valve Defective pump or bypass...

Page 63: ...te Log file on USB Flash drive last firmware update attempt Use different USB Flash Drive or Reformat 614 No USF File File VTCCMFW USF missing from Flash Drive Add proper files to Flash Drive for Firm...

Page 64: ...ular 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 D...

Page 65: ...should travel in a clock wise 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...

Page 66: ...This Page Intentionally Blank...

Page 67: ...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 Periodic cleaning of t...

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 caution 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 5253 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...

Page 71: ...XT Manual 0 5253 PARTS LIST 6 1 SECTION 6 REPLACEMENT ASSEMBLIES PARTS 6 01 Replacement Power Supply Complete Unit Component Catalog Numbers Catalog Number Auto Cut 200 XT Power Supply 400VAC 10 15 C...

Page 72: ...cription 10 ft 3 05 m 15 ft 4 5 m 25 ft 7 6 m 35 ft 10 6 m 50 ft 15 2 m 75 ft 22 8 m 100 ft 30 5 m 125 ft 38 1 m F1 Ground Cable Gas to Earth 9 4924 9 4925 9 4926 9 4927 9 4928 9 4929 G Torch Lead Ass...

Page 73: ...r Supply External Replacement Parts Item Qty Description Catalog 1 1 Power Supply Top Panel 9 7300 2 1 Power Supply Upper Right and Left Side 9 7301 3 1 Power Supply Lower Right Side 9 7302 4 1 Power...

Page 74: ...Ref Des Catalog 1 1 Coolant Tank Cap 8 5124 2 1 Coolant Tank 9 7306 3 1 Sensor Coolant level 9 7307 4 1 Pump Coolant Assembly 9 7309 5 1 Motor Pump 9 8166 6 1 Heat Exchanger Fan 2 required per unit FA...

Page 75: ...s Catalog 1 1 Pump Motor Control Relay MC3 9 7314 2 1 Inrush Control Relay K1 9 7337 3 1 Inrush Relay MC1 9 7336 4 1 Auxilliary Transformer 9 7315 5 1 Display PCB 9 9252 6 1 On Off Switch Breaker SW1...

Page 76: ...ent Parts Lower Left Side Item Qty Description Ref Des Catalog 1 1 AC Suppressor PCB 9 9254 2 1 Pilot PCB Assembly AC 200XT 9 9255 3 1 Half Inverter Block Pilot PCB not included 9 7319 4 1 Full Invert...

Page 77: ...acement Parts Upper Left Side Item Qty Description Ref Des Catalog 1 1 Gas Solenoid 2 required per unit 9 6319 2 1 Water Filter Assembly Optional Requires 3rd gas solenoid 8 3460 3 1 HF Coil Assy Arc...

Page 78: ...320 2 1 Coolant Filter 9 7322 3 1 Gas Selection Switch 9 3325 4 1 Air Filter Assembly AC200 XT 9 7527 First Stage Filter Element only 9 1021 Second Stage Filter Element only 9 1022 5 1 Fuse 8A SB 500V...

Page 79: ...3 1 Run Set Selector Switch 9 3427 4 1 Potentiometer 9 2685 5 1 Flowmeter H2 O 9 7762 6 1 Shield Gas Selector Switch 9 3426 PLASMA SHIELD A SHIELD GAS H20 MIST H20 MIST SET RUN PLASMA SHIELD A SHIELD...

Page 80: ...AUTO CUT 200 XT PARTS LIST Manual 0 5253 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: ...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...

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: ...New 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 Car...

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: ...ltage Rear Panel CNC Connector J15 14 Circuit Amp CPC Remote Standard Chassis gnd for SC 11 cable shield 1 1 Start Stop 3 4 1 Ok to Move contacts or voltage 2 12 14 1 Divided Arc volts selectable rati...

Page 89: ...p Ret 4 TB1 6 TB1 5 comm or Start Latched NO 4 TB1 6 TB1 5 comm used with Stop Latched Divided Arc Voltage TB1 8 TB1 7 comm Remote Analog Current Control TB1 9 Analog Comm or 10K CC Pot low TB1 10 Ana...

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: ...rking Plasma Marking Corner Current Reduction Corner Current Reduction Cut ExpandedMetal Cut ExpandedMetal Spare 2 NO Spare 2 NC Spare 1b NO ALL SW O FF f or 50 1 defaul t SW12A 1 ON 16 7 1 SC 11 SW12...

Page 93: ...104 136 134 135 139 138 134 135 136 137 138 139 140 141 143 142 140 141 142 143 SPARE 1 J15 1tochassisusedfor SC 11cab leshield The COMM Ref atpin8 isalsofor the S C 11 1 2 3 4 5 6 7 8 9 10 11 12 13 1...

Page 94: ...START STOP NC Source 16 VDC 10 ma Divided Arc V Pre Flow ON Pre Flow ON 10 11 10 11 Divided Arc V Corner Current Reduction Corner Current Reduction Relay DCV Contact or 1A DCV 120 VAC 15 18 VDC or 28...

Page 95: ...re with White stripe W OR W GN GN W BL W RS 422 wiring 4 wire half duplex also called RS 485 4 wire Art A 09482_AB 4W JUMPER for 4 WIRE use TX TX RX RX 2W W GN 14 Normally open NO PLASMA ENABLE close...

Page 96: ...wire RS 485 CCM 1 CCM 2 CCM last in line Data Data Art A 09483 RS 422 4 wire half duplex Tx Tx Rx Rx Tx Tx Tx Rx Rx Rx Signal GND also required but not shown 120 120 SW14 OFF SW14 ON CCM 1 CNC using R...

Page 97: ...AUTO CUT 200 XT Manual 0 5253 APPENDIX A 11 This Page Intentionally Blank...

Page 98: ...AUTO CUT 200 XT APPENDIX Manual 0 5253 APPENDIX 3 CCM CPU PCB LAYOUT Test Point Test Point Art A 11675...

Page 99: ...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 RDX D3 R...

Page 100: ...AUTO CUT 200 XT APPENDIX Manual 0 5253 APPENDIX 4 CCM I O PCB LAYOUT Test Point Test Point Art A 11676_AB 19 WORK CURRENT...

Page 101: ...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 102: ...AUTO CUT 200 XT APPENDIX Manual 0 5253 APPENDIX 5 PILOT PCB LAYOUT Art A 11677 Test Point Test Point...

Page 103: ...AUTO CUT 200 XT Manual 0 5253 APPENDIX A 17 Pilot PCB Test Points TP1 GND TP2 PILOT GATE TP3 5V TP4 TIP LED Reference D2 Green PILOT ENABLE D11 Green 5V...

Page 104: ...AUTO CUT 200 XT APPENDIX Manual 0 5253 APPENDIX 6 RELAY AND INTERFACE PCB LAYOUT Test Point Test Point Art A 11678...

Page 105: ...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 106: ...AUTO CUT 200 XT APPENDIX Manual 0 5253 APPENDIX 7 DISPLAY PCB LAYOUT Test Point Test Point Art A 11679...

Page 107: ...AUTO CUT 200 XT Manual 0 5253 APPENDIX A 21 Display PCB Test Points TP1 GND TP2 5VDC TP3 24VDC...

Page 108: ...AUTO CUT 200 XT APPENDIX Manual 0 5253 APPENDIX 8 SYSTEM BIAS PCB LAYOUT Test Point Test Point Art A 11680...

Page 109: ...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 110: ...AUTO CUT 200 XT APPENDIX Manual 0 5253 APPENDIX 9 MAIN INVERTER BOTTOM PCB LAYOUT Test Point Test Point Art A11681...

Page 111: ...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 112: ...AUTO CUT 200 XT APPENDIX Manual 0 5253 APPENDIX 10 MAIN INVERTER TOP PCB LAYOUT Test Point Test Point Art A11682...

Page 113: ...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 114: ...AUTO CUT 200 XT APPENDIX Manual 0 5253 APPENDIX 11 CONTROL AND FAULT PCB LAYOUT Test Point Test Point Art A11683 230V...

Page 115: ...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 116: ...AUTO CUT 200 XT APPENDIX Manual 0 5253 APPENDIX 12 CAP BIAS BOTTOM PCB LAYOUT Art A 11685...

Page 117: ...AUTO CUT 200 XT Manual 0 5253 APPENDIX A 31 APPENDIX 13 CAP BIAS TOP PCB LAYOUT Art A 11686...

Page 118: ...AUTO CUT 200 XT APPENDIX Manual 0 5253 APPENDIX 14 SUPPRESSOR PCB LAYOUT Art A 11684...

Page 119: ...Scale Supercedes Superceded By Reference OF App 1 3 8 8 2013 AJR 1 1 UNLESS OTHERWISE SPECIFIED Information proprietary to Victor Technologies Not for release reproduction or distribution N A 41X223 D...

Page 120: ...r Level Switch Torch Coolant Supply Torch Coolant Return Pump Coolant tank Filter 1 Over Flow Supply Pressure Relief XT 301 HF COIL Flow Switch Cold Plate 1 Cold Plate 2 Radiator Coolant Return Flow R...

Page 121: ...AUTO CUT 200 XT Manual 0 5253 APPENDIX A 35 This Page Intentionally Blank...

Page 122: ...WORK ELECTRODE 019x502000 019x502700 019x502000 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 CONTROL PCB LED...

Page 123: ...C 51C 51A Sht 2 D3 Sht 2 A6 Sht 2 A5 ELECTRODE WORK 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 C...

Page 124: ...TORCH INTERFACE 65 64C 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 1 2 3 4 J71 Sht 1 C8 Sht 1 B6 Sht 1 B6 Sht 1 A6 Sht 1 E4 Sht...

Page 125: ...6 7 8 9 10 11 12 13 14 J15 CNC SOL1 PLASMA SW 1 RUN SET PS1 PLASMA 51 PSI SOL2 SHIELD AC 24V Ret GCM2 D9 AC 24V Ret GCM2 B8 111 111 AC 24V GCM2 B8 AC 24V GCM2 D9 104 130 131 123 124 R1 10K 130 127 12...

Page 126: ...IM 200Auses 1 and 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 X...

Page 127: ...y 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...

Page 128: ...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 129: ...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 130: ...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 131: ...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 132: ...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 133: ...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 134: ...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 135: ...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 136: ...I O PCB TP9 TP1 common While turning the pot toward minimum TP9 voltage should vary linearly to zero V Art 12309 2 1 3 SW11 TP9 TP1 GND 0 3 3VDC GND Divide by 3 From Remote analog Current Control CCM...

Page 137: ...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 rang...

Page 138: ...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 S...

Page 139: ...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...

Page 140: ...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 IM...

Page 141: ...put 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 C...

Page 142: ...onents 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...

Page 143: ...uld 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...

Page 144: ...ld most likely be a bad con nection 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 sec...

Page 145: ...tion 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 ribb...

Page 146: ...ly 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...

Page 147: ...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...

Page 148: ...s 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_IN...

Page 149: ...ection 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 injur...

Page 150: ...hen 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_...

Page 151: ...30 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...

Page 152: ...tween 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...

Page 153: ...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 so...

Page 154: ...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 t...

Page 155: ...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 co...

Page 156: ...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...

Page 157: ...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 tor...

Page 158: ...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 press...

Page 159: ...w and in ad dition 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...

Page 160: ...cation 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 T...

Page 161: ...ooting 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...

Page 162: ...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 wit...

Page 163: ...AUTO CUT 200 XT Manual 0 5253 APPENDIX A 77 This Page Intentionally Blank...

Page 164: ...ygen from shield gases on pg 2 8 and updated several parts lists and art in Section 6 Updated footers and corrected system schematic art in Appendix per ECOB2454 July 2 2013 AD Updated section 3 with...

Page 165: ......

Page 166: ...esia Customer Care Ph 6221 8990 6095 Fax 6221 8990 6096 Rawang Malaysia Customer Care Ph 603 6092 2988 Fax 603 6092 1085 Melbourne Australia Australia Customer Care Ph 1300 654 674 tollfree Ph 61 3 94...

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