Thermal Dynamics AUTO-CUT 30 O2 Operating Manual

Download

30O

™

AUTO-CUT

PLASMA CUTTING SYSTEM

Operating Manual

Art# A-08584

Rev: AL Issue Date: July 6, 2012 Manual No.: 0-4818 Operating Features:

208-

300

AMP

PHASE

230

400

V (CE)

460

600

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 1800-426-1888, or visit us on the web at www.thermal-

dynamics.com.

This Operating Manual has been designed to instruct you on the correct use and operation of your Thermal Dynamics product. Y our satisfaction with this product and its safe operation is our ultimate concern. Therefore please take the time to read the entire manual, especially the Safety Precautions. They will help you to avoid potential hazards that may exist when working with this product.

YOU ARE IN GOOD COMPANY!

The Brand of Choice for Contractors and Fabricators Worldwide.

Thermal Dynamics is a Global Brand of manual and automation Plasma Cutting Products for Thermadyne Industries Inc.

We distinguish ourselves from our competition through marketleading, dependable products that have stood the test of time. We pride ourselves on technical innovation, competitive prices, excellent deliver y, superior customer ser vice 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 industr y.

WARNINGS

Read and understand this entire Manual and your employer’s safety practices before installing, operating, or servicing the equipment.

While the information contained in this Manual represents the Manufacturer's best judgement, the Manufacturer assumes no liability for its use.

Plasma Cutting Power Supply, Auto-Cut® 30O Operating Manual No. 0-4818

Published by: Thermal Dynamics Corporation 82 Benning Street West Lebanon, New Hampshire, USA 03784 (603) 298-5711

www.thermal-dynamics.com

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.

Printed in the United States of America

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

Original Publication Date: December 12, 2007 Revision Date: July 6, 2012

Record the following information for Warranty purposes:

Where Purchased: ___________________________________

Purchase Date:______________________________________

Power Supply Serial #:_______________________________

Torch Serial #:_______________________________________

This page intentionally blank

TABLE OF CONTENTS

SECTION 1:

GENERAL INFORMATION ................................................................................................ 1-1

1.01 Notes, Cautions and Warnings ...................................................................... 1-1

1.02 Important Safety Precautions ....................................................................... 1-1

1.03 Publications .................................................................................................. 1-2

1.04 Note, Attention et Avertissement .................................................................. 1-3

1.05 Precautions De Securite Importantes ........................................................... 1-3

1.06 Documents De Reference ............................................................................. 1-5

1.07 Declaration of Conformity ............................................................................. 1-6

1.08 Statement of Warranty .................................................................................. 1-7

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

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

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

2.03 Remote Arc Starter ...................................................................................... 2-1

2.04 Gas Control Module ...................................................................................... 2-1

2.05 Conventional Plasma Cutting Torch ............................................................... 2-1

2.06 Specifications & Electrical Requirements ..................................................... 2-2

2.07 System Layout ............................................................................................. 2-2

2.08 Power Supply Dimensions ............................................................................ 2-3

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

2.10 Gas Specifications ....................................................................................... 2-5

2.11 Gas Applications .......................................................................................... 2-5

2.12 XTTM-301 Torch Specifications .................................................................... 2-6

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

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

3.02 System Layout ............................................................................................. 3-2

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

3.04 Lift the Power Supply .................................................................................... 3-4

3.05 Primary Power Connections .......................................................................... 3-5

3.06 Ground Connections .................................................................................... 3-10

3.07 Connect Work Cable and Pilot and Negative / Torch Leads .......................... 3-12

3.08 Connect Coolant Leads ................................................................................3-13

3.09 Connect Control Cables for CNC, Remote Arc Starter, and GCM ................. 3-14

3.10 Connect Fiber Optic Cable to CCM .............................................................3-15

3.11 Set Switches on the Command - Control Module ......................................... 3-16

3.12 Height Control Connections ......................................................................... 3-18

3.13 Install Gas Control Module .......................................................................... 3-19

3.14 Connect Fiber Optic Cable to Gas Control Module ....................................... 3-21

3.15 Connect Control, Input, and Outputs to Gas Control Module ........................3-23

3.16 Install Remote Arc Starter ........................................................................... 3-24

3.17 Install Torch Valve ........................................................................................3-33

3.18 Prepare the Torch Head ................................................................................3-34

3.19 Connect Torch .............................................................................................. 3-35

3.20 Install Consumable Torch Parts....................................................................3-37

3.21 Install Coolant..............................................................................................3-41

TABLE OF CONTENTS (continued)

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

4.01 Power Supply Control Panel .......................................................................... 4-1

4.02 Start-Up Sequence ....................................................................................... 4-2

4.03 Gas Control Module Operation ...................................................................... 4-3

4.04 Gas Control Sequence Of Operation ............................................................. 4-7

4.05 Gas Selection .............................................................................................. 4-10

4.06 Power Supply Status Codes ........................................................................ 4-12

4.07 Remote Arc Starter: Service Chart .............................................................4-16

4.08 Remote Arc Starter: Spark Gap Adjustment ............................................... 4-17

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

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

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

5.03 Internal Coolant Filter Cleaning Procedure .................................................... 5-2

5.04 Coolant Replacement Procedure ................................................................... 5-2

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

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

6.02 Auto-Cut 30O2System Layout ...................................................................... 6-2

6.03Recommended Gas Supply Hose .................................................................. 6-2

6.04 Power Supply External Replacement Parts ................................................... 6-5

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

6.06 Power Supply Replacement Parts - Right Side ............................................. 6-7

6.07 Power Supply Replacement Parts - Front Panel ............................................ 6-8

6.08 Power Supply Replacement Parts - Right Side ............................................. 6-9

6.09 Power Supply Replacement Parts - Rear Panel............................................ 6-10

6.10 Power Supply Replacement Parts - Right Side ............................................ 6-11

6.11 Power Supply Replacement Parts ................................................................ 6-12

6.12 Power Supply Replacement Parts - Right Side ............................................ 6-13

6.13 Power Supply Replacement Parts - Left Side ............................................... 6-14

6.14 Power Supply Replacement Parts - Left Side ............................................... 6-15

6.15 Power Supply Replacement Parts - Right Side ............................................ 6-16

6.16 Power Supply Replacement Parts - Right Side ............................................ 6-17

6.17 Command & Control Module Type 2 - Replacement Parts .......................... 6-18

6.18 Gas Control Module (GCM-2000) Replacement Parts .................................. 6-20

6.19 Torch Valve Assembly Replacement Parts ................................................... 6-22

6.20 Remote Arc Starter (RAS-1000) Replacement Parts ....................................6-23

6.21 Remote Arc Starter (RAS-1000) Replacement Parts ....................................6-24

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

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

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

7.03 Parts Wear.................................................................................................... 7-3

7.04 Coolant Leak Trouble-Shooting ...................................................................... 7-4

TABLE OF CONTENTS (continued)

APPENDIX 1: Remote Arc Starter Schematic .......................................................................... A-1

APPENDIX 2: Gas Control and Torch Valve Schematic ............................................................. A-2

APPENDIX 3: Gas Control Module Plumbing Diagram ............................................................... A-4

APPENDIX 4: Gas Control Module PCB Layout ....................................................................... A-5

APPENDIX 5: CCM Input / Output PCB Layout ........................................................................ A-6

APPENDIX 6: CNC - Control Module PCB Connections ............................................................ A-7

APPENDIX 7: CNC - Control Module PCB Connections ............................................................ A-9

CNC functions. ................................................................................................... A-10

CNC Input / Output Descriptions......................................................................... A-11

Simplified CNC Circuit. ....................................................................................... A-12

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

APPENDIX 8: Schematic, 230-460V Unit Cont. ....................................................................... A-16

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

APPENDIX 9: Schematic, CCC 400V Unit Cont. ...................................................................... A-20

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

APPENDIX 10: Schematic, CE 400V Unit Cont. ..................................................................... A-24

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

APPENDIX 11: Schematic, CSA 600V Unit Cont. .................................................................... A-28

APPENDIX 12: Publication History ......................................................................................... A-30

blank

AUTOCUT 30O2

SECTION 1:

GENERAL INFORMATION

1.01 Notes, Cautions and Warnings

Throughout this manual, notes, cautions, and warnings are used to highlight important information. These highlights are categorized as follows:

NOTE

An operation, procedure, or background information which requires additional emphasis or is helpful in efficient operation of the system.

CAUTION

A procedure which, if not properly followed, may cause damage to the equipment.

WARNING

A procedure which, if not properly followed, may cause injury to the operator or others in the operating area.

1.02 Important Safety Precautions

• Use an air-supplied respirator if ventilation is not adequate to remove all fumes and gases.

• The kinds of fumes and gases from the plasma arc depend on the kind of metal being used, coatings on the metal, and the different processes. You must be very careful when cutting or welding any metals which may contain one or more of the following:

Antimony Chromium Mercury Arsenic Cobalt Nickel Barium Copper Selenium Beryllium Lead Silver Cadmium Manganese Vanadium

• Always read the Material Safety Data Sheets (MSDS) that should be supplied with the material you are using. These MSDSs will give you the information regarding the kind and amount of fumes and gases that may be dangerous to your health.

• For information on how to test for fumes and gases in your workplace, refer to item 1 in Subsection 1.03, Publications in this manual.

• Use special equipment, such as water or down draft cutting tables, to capture fumes and gases.

• Do not use the plasma torch in an area where combustible or explosive gases or materials are located.

• Phosgene, a toxic gas, is generated from the vapors of chlorinated solvents and cleansers. Remove all sources of these vapors.

• This product, when used for welding or cutting, produces fumes or gases which contain chemicals known to the State of California to cause birth defects and, in some cases, cancer. (California Health & Safety Code Sec. 25249.5 et seq.)

WARNINGS

OPERATION AND MAINTENANCE OF PLASMA ARC EQUIPMENT CAN BE DANGEROUS AND HAZARDOUS TO YOUR HEALTH.

Plasma arc cutting produces intense electric and magnetic emissions that may interfere with the proper function of cardiac pacemakers, hearing aids, or other electronic health equipment. Persons who work near plasma arc cutting applications should consult their medical health professional and the manufacturer of the health equipment to determine whether a hazard exists.

To prevent possible injury, read, understand and follow all warnings, safety precautions and instructions before using the equipment. Call 1-603-298-5711 or your local distributor if you have any questions.

GASES AND FUMES

Gases and fumes produced during the plasma cutting process can be dangerous and hazardous to your health.

• Keep all fumes and gases from the breathing area. Keep your head out of the welding fume plume.

ELECTRIC SHOCK

Electric Shock can injure or kill. The plasma arc process uses and produces high voltage electrical energy. This electric energy can cause severe or fatal shock to the operator or others in the workplace.

• Never touch any parts that are electrically “live” or “hot.”

• Wear dry gloves and clothing. Insulate yourself from the work piece or other parts of the welding circuit.

• Repair or replace all worn or damaged parts.

• Extra care must be taken when the workplace is moist or damp.

• Install and maintain equipment according to NEC code, refer to item 9 in Subsection 1.03, Publications.

• Disconnect power source before performing any service or repairs.

• Read and follow all the instructions in the Operating Manual.

FIRE AND EXPLOSION

Fire and explosion can be caused by hot slag, sparks, or the plasma arc.

• Be sure there is no combustible or flammable material in the workplace. Any material that cannot be removed must be protected.

• Ventilate all flammable or explosive vapors from the workplace.

• Do not cut or weld on containers that may have held combustibles.

Manual 0-4818 Auto-Cut 300

1-1

AUTOCUT 30O2

• Provide a fire watch when working in an area where fire hazards may exist.

• Hydrogen gas may be formed and trapped under aluminum workpieces when they are cut underwater or while using a water table. DO NOT cut aluminum alloys underwater or on a water table unless the hydrogen gas can be eliminated or dissipated. Trapped hydrogen gas that is ignited will cause an explosion.

1.03 Publications

Refer to the following standards or their latest revisions for more information:

1. OSHA, SAFETY AND HEALTH STANDARDS, 29CFR 1910, obtainable from the Superintendent of Documents, U.S. Government Printing Office, Washington, D.C. 20402

NOISE

Noise can cause permanent hearing loss. Plasma arc processes can cause noise levels to exceed safe limits. You must protect your ears from loud noise to prevent permanent loss of hearing.

• To protect your hearing from loud noise, wear protective ear plugs and/or ear muffs. Protect others in the workplace.

• Noise levels should be measured to be sure the decibels (sound) do not exceed safe levels.

• For information on how to test for noise, see item 1 in Subsection 1.03, Publications, in this manual.

PLASMA ARC RAYS

Plasma Arc Rays can injure your eyes and burn your skin. The plasma arc process produces very bright ultra violet and infra red light. These arc rays will damage your eyes and burn your skin if you are not properly protected.

• To protect your eyes, always wear a welding helmet or shield. Also always wear safety glasses with side shields, goggles or other protective eye wear.

• Wear welding gloves and suitable clothing to protect your skin from the arc rays and sparks.

• Keep helmet and safety glasses in good condition. Replace lenses when cracked, chipped or dirty.

• Protect others in the work area from the arc rays. Use protective booths, screens or shields.

• Use the shade of lens as suggested in the following per ANSI/ ASC Z49.1:

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 is hidden by the workpiece.

LEAD WARNING

This product contains chemicals, including lead, or otherwise produces chemicals known to the State of California to cause cancer, birth defects and other reproductive harm. (California Health & Safety Code § 25249.5 et seq.)

Minimum Protective Suggested

Wash hands after handlingWash hands after handling

Wash hands after handling .

Wash hands after handlingWash hands after handling

2. ANSI Standard Z49.1, SAFETY IN WELDING AND CUTTING, obtainable from the American Welding Society, 550 N.W. LeJeune Rd, Miami, FL 33126

3. NIOSH, SAFETY AND HEALTH IN ARC WELDING AND GAS WELDING AND CUTTING, obtainable from the Superintendent of Documents, U.S. Government Printing Office, Washington, D.C. 20402

4. ANSI Standard Z87.1, SAFE PRACTICES FOR OCCUPATION AND EDUCATIONAL EYE AND FACE PROTECTION, obtainable from American National Standards Institute, 1430 Broadway, New York, NY 10018

5. ANSI Standard Z41.1, STANDARD FOR MEN’S SAFETY-TOE FOOTWEAR, obtainable from the American National Standards Institute, 1430 Broadway, New York, NY 10018

6. ANSI Standard Z49.2, FIRE PREVENTION IN THE USE OF CUTTING AND WELDING PROCESSES, obtainable from American National Standards Institute, 1430 Broadway, New York, NY 10018

7. AWS Standard A6.0, WELDING AND CUTTING CONTAINERS WHICH HAVE HELD COMBUSTIBLES, obtainable from American Welding Society, 550 N.W. LeJeune Rd, Miami, FL 33126

8. NFPA Standard 51, OXYGEN-FUEL GAS SYSTEMS FOR WELDING, CUTTING AND ALLIED PROCESSES, obtainable from the National Fire Protection Association, Batterymarch Park, Quincy, MA 02269

9. NFPA Standard 70, NATIONAL ELECTRICAL CODE, obtainable from the National Fire Protection Association, Batterymarch Park, Quincy, MA 02269

10. NFPA Standard 51B, CUTTING AND WELDING PROCESSES, obtainable from the National Fire Protection Association, Batterymarch Park, Quincy, MA 02269

11. CGA Pamphlet P-1, SAFE HANDLING OF COMPRESSED GASES IN CYLINDERS, obtainable from the Compressed Gas Association, 1235 Jefferson Davis Highway, Suite 501, Arlington, VA 22202

12. CSA Standard W117.2, CODE FOR SAFETY IN WELDING AND CUTTING, obtainable from the Canadian Standards Association, Standards Sales, 178 Rexdale Boulevard, Rexdale, Ontario, Canada M9W 1R3

13. NWSA booklet, WELDING SAFETY BIBLIOGRAPHY obtainable from the National Welding Supply Association, 1900 Arch Street, Philadelphia, PA 19103

14. American Welding Society Standard AWSF4.1, RECOMMENDED SAFE PRACTICES FOR THE PREPARATION FOR WELDING AND CUTTING OF CONTAINERS AND PIPING

1-2

Manual 0-4818 Auto-Cut 300

THAT HAVE HELD HAZARDOUS SUBSTANCES, obtainable

from the American Welding Society, 550 N.W. LeJeune Rd, Miami, FL 33126

15. ANSI Standard Z88.2, PRACTICE FOR RESPIRATORY PROTECTION, obtainable from American National Standards Institute, 1430 Broadway, New York, NY 10018

AUTOCUT 30O2

les consignes avant d’utiliser le matériel. Composez le + 603-298-5711 ou votre distributeur local si vous avez des questions.

FUMÉE et GAZ

1.04 Note, Attention et Avertissement

Dans ce manuel, les mots “note,” “attention,” et “avertissement” sont utilisés pour mettre en relief des informations à caractère important. Ces mises en relief sont classifiées comme suit :

NOTE

Toute opération, procédure ou renseignement général sur lequel il importe d’insister davantage ou qui contribue à l’efficacité de fonctionnement du système.

ATTENTION

Toute procédure pouvant résulter l’endommagement du matériel en cas de non-respect de la procédure en question.

AVERTISSEMENT

Toute procédure pouvant provoquer des blessures de l’opérateur ou des autres personnes se trouvant dans la zone de travail en cas de non-respect de la procédure en question.

La fumée et les gaz produits par le procédé de jet de plasma peuvent présenter des risques et des dangers de santé.

• Eloignez toute fumée et gaz de votre zone de respiration. Gardez votre tête hors de la plume de fumée provenant du chalumeau.

• Utilisez un appareil respiratoire à alimentation en air si l’aération fournie ne permet pas d’éliminer la fumée et les gaz.

• Les sortes de gaz et de fumée provenant de l’arc de plasma dépendent du genre de métal utilisé, des revêtements se trouvant sur le métal et des différents procédés. Vous devez prendre soin lorsque vous coupez ou soudez tout métal pouvant contenir un ou plusieurs des éléments suivants:

antimoine cadmium mercure argent chrome nickel arsenic cobalt plomb baryum cuivre sélénium béryllium manganèse vanadium

• Lisez toujours les fiches de données sur la sécurité des matières (sigle américain “MSDS”); celles-ci devraient être fournies avec le matériel que vous utilisez. Les MSDS contiennent des renseignements quant à la quantité et la nature de la fumée et des gaz pouvant poser des dangers de santé.

• Pour des informations sur la manière de tester la fumée et les gaz de votre lieu de travail, consultez l’article 1 et les documents cités à la page 5.

1.05 Precautions De Securite Importantes

AVERTISSEMENTS

L’OPÉRATION ET LA MAINTENANCE DU MATÉRIEL DE SOUDAGE À L’ARC AU JET DE PLASMA PEUVENT PRÉSENTER DES RISQUES ET DES DANGERS DE SANTÉ.

Coupant à l’arc au jet de plasma produit de l’énergie électrique haute tension et des émissions magnétique qui peuvent interférer la fonction propre d’un “pacemaker” cardiaque, les appareils auditif, ou autre matériel de santé electronique. Ceux qui travail près d’une application à l’arc au jet de plasma devrait consulter leur membre professionel de médication et le manufacturier de matériel de santé pour déterminer s’il existe des risques de santé.

Il faut communiquer aux opérateurs et au personnel TOUS les dangers possibles. Afin d’éviter les blessures possibles, lisez, comprenez et suivez tous les avertissements, toutes les précautions de sécurité et toutes

• Utilisez un équipement spécial tel que des tables de coupe à débit d’eau ou à courant descendant pour capter la fumée et les gaz.

• N’utilisez pas le chalumeau au jet de plasma dans une zone où se trouvent des matières ou des gaz combustibles ou explosifs.

• Le phosgène, un gaz toxique, est généré par la fumée provenant des solvants et des produits de nettoyage chlorés. Eliminez toute source de telle fumée.

• Ce produit, dans le procéder de soudage et de coupe, produit de la fumée ou des gaz pouvant contenir des éléments reconnu dans L’état de la Californie, qui peuvent causer des défauts de naissance et le cancer. (La sécurité de santé en Californie et la code sécurité Sec.

25249.5 et seq.)

CHOC ELECTRIQUE

Les chocs électriques peuvent blesser ou même tuer. Le procédé au jet de plasma requiert et produit de l’énergie électrique haute tension. Cette énergie électrique peut produire des chocs graves, voire mortels, pour l’opérateur et les autres personnes sur le lieu de travail.

• Ne touchez jamais une pièce “sous tension” ou “vive”; portez des gants et des vêtements secs. Isolez-vous de la pièce de travail ou des autres parties du circuit de soudage.

Manual 0-4818 Auto-Cut 300

1-3

AUTOCUT 30O2

• Réparez ou remplacez toute pièce usée ou endommagée.

• Prenez des soins particuliers lorsque la zone de travail est humide ou moite.

• Montez et maintenez le matériel conformément au Code électrique national des Etats-Unis. (Voir la page

• Débranchez l’alimentation électrique avant tout travail d’entretien ou de réparation.

• Lisez et respectez toutes les consignes du Manuel de consignes.

INCENDIE ET EXPLOSION

Les incendies et les explosions peuvent résulter des scories chaudes, des étincelles ou de l’arc de plasma. Le procédé à l’arc de plasma produit du métal, des étincelles, des scories chaudes pouvant mettre le feu aux matières combustibles ou provoquer l’explosion de fumées inflammables.

• Soyez certain qu’aucune matière combustible ou inflammable ne se trouve sur le lieu de travail. Protégez toute telle matière qu’il est impossible de retirer de la zone de travail.

article 9.)

• Maintenez votre casque et vos lunettes de protection en bon état. Remplacez toute lentille sale ou comportant fissure ou rognure.

• Protégez les autres personnes se trouvant sur la zone de travail contre les rayons de l’arc en fournissant des cabines ou des écrans de protection.

• Utilisez la nuance de lentille qui est suggèrée dans le recommendation qui suivent ANSI/ASC Z49.1:

Nuance Minimum Nuance Suggerée

Courant Arc Protective Numéro Numéro

Moins de 300* 8 9

300 - 400* 9 12

400 - 800* 10 14

* Ces valeurs s’appliquent ou l’arc actuel est observé clairement. L’experience a démontrer que les filtres moins foncés peuvent être utilisés quand l’arc est caché par moiceau de travail.

BRUIT

• Procurez une bonne aération de toutes les fumées inflammables ou explosives.

• Ne coupez pas et ne soudez pas les conteneurs ayant pu renfermer des matières combustibles.

• Prévoyez une veille d’incendie lors de tout travail dans une zone présentant des dangers d’incendie.

• Le gas hydrogène peut se former ou s’accumuler sous les pièces de travail en aluminium lorsqu’elles sont coupées sous l’eau ou sur une table d’eau. NE PAS couper les alliages en aluminium sous l’eau ou sur une table d’eau à moins que le gas hydrogène peut s’échapper ou se dissiper. Le gas hydrogène accumulé explosera si enflammé.

RAYONS D’ARC DE PLASMA

Les rayons provenant de l’arc de plasma peuvent blesser vos yeux et brûler votre peau. Le procédé à l’arc de plasma produit une lumière infra-rouge et des rayons ultra-violets très forts. Ces rayons d’arc nuiront à vos yeux et brûleront votre peau si vous ne vous protégez pas correctement.

• Pour protéger vos yeux, portez toujours un casque ou un écran de soudeur. Portez toujours des lunettes de sécurité munies de parois latérales ou des lunettes de protection ou une autre sorte de protection oculaire.

Le bruit peut provoquer une perte permanente de l’ouïe. Les procédés de soudage à l’arc de plasma peuvent provoquer des niveaux sonores supérieurs aux limites normalement acceptables. Vous dú4ez vous protéger les oreilles contre les bruits forts afin d’éviter une perte permanente de l’ouïe.

• Pour protéger votre ouïe contre les bruits forts, portez des tampons protecteurs et/ou des protections auriculaires. Protégez également les autres personnes se trouvant sur le lieu de travail.

• Il faut mesurer les niveaux sonores afin d’assurer que les décibels (le bruit) ne dépassent pas les niveaux sûrs.

• Pour des renseignements sur la manière de tester le bruit, consultez l’article 1, page 5.

PLOMB AVERTISSEMENT

Ce produit contient des produits chimiques, comme le plomb, ou engendre des produits chimiques, reconnus par l’état de Californie comme pouvant être à l’origine de cancer, de malformations fœtales ou

• Portez des gants de soudeur et un vêtement protecteur approprié pour protéger votre peau contre les étincelles et les rayons de l’arc.

1-4

Manual 0-4818 Auto-Cut 300

d’autres problèmes de reproduction.

toute manipulation.toute manipulation.

toute manipulation. (Code de Californie de la sécurité et santé,

toute manipulation.toute manipulation.

paragraphe 25249.5 et suivants)

Il faut se laver les mains aprèsIl faut se laver les mains après

Il faut se laver les mains après

Il faut se laver les mains aprèsIl faut se laver les mains après

1.06 Documents De Reference

Consultez les normes suivantes ou les révisions les plus récentes ayant été faites à celles-ci pour de plus amples renseignements :

1. OSHA, NORMES DE SÉCURITÉ DU TRAVAIL ET DE PROTECTION DE LA SANTÉ, 29CFR 1910, disponible auprès du Superintendent of Documents, U.S. Government Printing Office, Washington, D.C. 20402

2. Norme ANSI Z49.1, LA SÉCURITÉ DES OPÉRATIONS DE COUPE ET DE SOUDAGE, disponible auprès de la Société Américaine de Soudage (American Welding Society), 550 N.W. LeJeune Rd., Miami, FL 33126

3. NIOSH, LA SÉCURITÉ ET LA SANTÉ LORS DES OPÉRATIONS DE COUPE ET DE SOUDAGE À L’ARC ET AU GAZ, disponible auprès du Superintendent of Documents, U.S. Government Printing Office, Washington, D.C. 20402

4. Norme ANSI Z87.1, PRATIQUES SURES POUR LA PROTECTION DES YEUX ET DU VISAGE AU TRAVAIL ET DANS LES ECOLES, disponible de l’Institut Américain des Normes Nationales (American National Standards Institute), 1430 Broadway, New York, NY 10018

AUTOCUT 30O2

13. Livret NWSA, BIBLIOGRAPHIE SUR LA SÉCURITÉ DU SOUDAGE, disponible auprès de l’Association Nationale de Fournitures de Soudage (National Welding Supply Association), 1900 Arch Street, Philadelphia, PA 19103

14. Norme AWSF4.1 de l’Association Américaine de Soudage, RECOMMANDATIONS DE PRATIQUES SURES POUR LA PRÉPARATION À LA COUPE ET AU SOUDAGE DE CONTENEURS

5. Norme ANSI Z41.1, NORMES POUR LES CHAUSSURES PROTECTRICES, disponible auprès de l’American National Standards Institute, 1430 Broadway, New York, NY 10018

6. Norme ANSI Z49.2, PRÉVENTION DES INCENDIES LORS DE L’EMPLOI DE PROCÉDÉS DE COUPE ET DE SOUDAGE, disponible auprès de l’American National Standards Institute, 1430 Broadway, New York, NY 10018

7. Norme A6.0 de l’Association Américaine du Soudage (AWS), LE SOUDAGE ET LA COUPE DE CONTENEURS AYANT RENFERMÉ DES PRODUITS COMBUSTIBLES, disponible auprès de la American Welding Society, 550 N.W. LeJeune Rd., Miami, FL 33126

8. Norme 51 de l’Association Américaine pour la Protection contre les Incendies (NFPA), LES SYSTEMES À GAZ AVEC ALIMENTATION EN OXYGENE POUR LE SOUDAGE, LA COUPE ET LES PROCÉDÉS ASSOCIÉS, disponible auprès de la National Fire Protection Association, Batterymarch Park, Quincy, MA 02269

9. Norme 70 de la NFPA, CODE ELECTRIQUE NATIONAL, disponible auprès de la National Fire Protection Association, Batterymarch Park, Quincy, MA 02269

10. Norme 51B de la NFPA, LES PROCÉDÉS DE COUPE ET DE SOUDAGE, disponible auprès de la National Fire Protection Association, Batterymarch Park, Quincy, MA 02269

11. Brochure GCA P-1, LA MANIPULATION SANS RISQUE DES GAZ COMPRIMÉS EN CYLINDRES, disponible auprès de l’Association des Gaz Comprimés (Compressed Gas Association), 1235 Jefferson Davis Highway, Suite 501, Arlington, VA 22202

12. Norme CSA W117.2, CODE DE SÉCURITÉ POUR LE SOUDAGE ET LA COUPE, disponible auprès de l’Association des Normes Canadiennes, Standards Sales, 178 Rexdale Boulevard, Rexdale, Ontario, Canada, M9W 1R3

Manual 0-4818 Auto-Cut 300

1-5

AUTOCUT 30O2

ET TUYAUX AYANT RENFERMÉ DES PRODUITS DANGEREUX , disponible auprès de la American Welding Society, 550 N.W. LeJeune Rd., Miami, FL 33126

15. Norme ANSI Z88.2, PRATIQUES DE PROTECTION RESPIRATOIRE, disponible auprès de l’American National Standards Institute, 1430 Broadway, New York, NY 10018

1.07 Declaration of Conformity

Manufacturer: Thermal Dynamics Corporation Address: 82 Benning Street

West Lebanon, New Hampshire 03784 USA

The equipment described in this manual conforms to all applicable aspects and regulations of the ‘Low Voltage Directive’ (European Council Directive 73/23/EEC as amended by Council Directive 93/68/EEC) and to the National legislation for the enforcement of this Directive.

The equipment described in this manual conforms to all applicable aspects and regulations of the "EMC Directive" (European Council Directive 89/336/EEC) and to the National legislation for the enforcement of this Directive.

Serial numbers are unique with each individual piece of equipment and details description, parts used to manufacture a unit and date of manufacture.

National Standard and Technical Specifications

The product is designed and manufactured to a number of standards and technical requirements. Among them are:

* CSA (Canadian Standards Association) standard C22.2 number 60 for Arc welding equipment.

* UL (Underwriters Laboratory) rating 94VO flammability testing for all printed-circuit boards used.

* CENELEC EN50199 EMC Product Standard for Arc Welding Equipment.

* ISO/IEC 60974-1 (BS 638-PT10) (EN 60 974-1) (EN50192) (EN50078) applicable to plasma cutting equipment and associated

accessories.

* For environments with increased hazard of electrical shock, Power Supplies bearing the 'S' mark conform to EN50192 when

used in conjunction with hand torches with exposed cutting tips, if equipped with properly installed standoff guides.

* Extensive product design verification is conducted at the manufacturing facility as part of the routine design and manufactur-

ing process. This is to ensure the product is safe, when used according to instructions in this manual and related industry standards, and performs as specified. Rigorous testing is incorporated into the manufacturing process to ensure the manufactured product meets or exceeds all design specifications.

Thermal Dynamics has been manufacturing products for more than 30 years, and will continue to achieve excellence in our area of manufacture.

Manufacturers responsible representative: Steve Ward

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

1-6

Manual 0-4818 Auto-Cut 300

AUTOCUT 30O2

1.08 Statement of Warranty

LIMITED WARRANTY: Thermal Dynamics® Corporation (hereinafter “Thermal”) warrants that its products will be free of defects in workmanship

or material. Should any failure to conform to this warranty appear within the time period applicable to the Thermal products as stated below, Thermal shall, upon notification thereof and substantiation that the product has been stored, installed, operated, and maintained in accordance with Thermal’s specifications, instructions, recommendations and recognized standard industry practice, and not subject to misuse, repair, neglect, alteration, or accident, correct such defects by suitable repair or replacement, at Thermal’s sole option, of any components or parts of the product determined by Thermal to be defective.

THIS WARRANTY IS EXCLUSIVE AND IS IN LIEU OF ANY WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE.

LIMITATION OF LIABILITY: Thermal shall not under any circumstances be liable for special or consequential damages, such as, but not

limited to, damage or loss of purchased or replacement goods, or claims of customers of distributor (hereinafter “Purchaser”) for service interruption. The remedies of the Purchaser set forth herein are exclusive and the liability of Thermal with respect to any contract, or anything done in connection therewith such as the performance or breach thereof, or from the manufacture, sale, delivery, resale, or use of any goods covered by or furnished by Thermal whether arising out of contract, negligence, strict tort, or under any warranty, or otherwise, shall not, except as expressly provided herein, exceed the price of the goods upon which such liability is based.

THIS WARRANTY BECOMES INVALID IF REPLACEMENT PARTS OR ACCESSORIES ARE USED WHICH MAY IMPAIR THE SAFETY OR PERFORMANCE OF ANY THERMAL PRODUCT.

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

The limited warranty periods for this product shall be: A maximum of three (3) years from date of sale to an authorized distributor and a maximum of two (2) years from date of sale by such distributor to the Purchaser, and with further limitations on such two (2) year period (see chart below).

AutoCut

Parts

and UltraCut© Power Supplies and Components 2 Years 1 Year

Labor

Torch And Leads

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

Repair/Replacement Parts 90 Days 90 Days

Warranty repairs or replacement claims under this limited warranty must be submitted by an authorized Thermal Dynamics® repair facility within thirty (30) days of the repair. No transportation costs of any kind will be paid under this warranty. Transportation charges to send products to an authorized warranty repair facility shall be the responsibility of the customer. All returned goods shall be at the customer’s risk and expense. This warranty supersedes all previous Thermal warranties.

Effective August 19, 2005

Manual 0-4818 Auto-Cut 300

1-7

Australia Terms of Warranty – 2012

Effective 1st January 2012, all warranties against defects (also known as a manufacturer’s warranty) supplied with goods or services must comply with the new Australian consumer law regulations (2010).

This Warranty Statement should be read in conjunction with the Warranty Schedule contained in the operating instructions of the product. This schedule contains the warranty period applicable to the product

Any claim under this warranty must be made within the warranty period which commences on the date of purchase of the product. To make a claim under the warranty, take the product (with proof of purchase from a Cigweld Accredited Seller) to the store where you purchased the product or contact Cigweld Customer Care 1300 654 674 for advice on your nearest Service Provider.

All costs associated with lodging the warranty claim including the return of goods to Cigweld or our Nominated Accredited Distributor/Accredited Service Provider are the responsibility of the consumer.

This warranty is given. Cigweld Pty Ltd A.B.N. 56007226815 71 Gower Street, Preston Victoria, Australia, 3072 Phone: 1300 654 674 Email: enquiries@thermadyne.com.au Website: www.cigweld.com.au

This warranty is provided in addition to other rights and remedies you have under law: Our goods come with guarantees which cannot be excluded under the Australian Consumer Law. You are entitled to replacement or refund for a major failure and to compensation for other reasonably foreseeable loss or damage. You are also entitled to have the goods repaired or replaced if the goods fail to be of acceptable quality and the failure does not amount to a major failure.

Failures due to incorrect use are not covered by this warranty and consumers are reminded to only use the product in accordance with the Operating Instruction supplied with the product. Additional copies of Operating Instructions are available from Cigweld Customer Care 1300 654 674 or the Website.

SECTION 2: SPECIFICATIONS

2.01 General Description Of The System

A typical Auto-Cut® 30O2 system configuration includes:

• One Power Supply

• Remote Arc Starter

• Gas Control Module

• Torch Valve Assembly

• Conventional Plasma Cutting Torch

• Set Of Connecting Leads

The components are connected at installation.

2.02 Plasma Power Supply

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

2.03 Remote Arc Starter

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

2.04 Gas Control Module

This module allows remote setting of gas selection, pressures, and flows together with setting of cutting current.

2.05 Conventional Plasma Cutting Torch

The torch delivers the controlled current to the work through the main arc, causing the metal to be cut.

Manual No. 0-4818 Auto-Cut 300

2-1 SPECIFICATIONS

2.06 Specifications & Electrical Requirements

Auto-Cut 30O

Specifications & Design Features

Max OCV (U0) 380 vdc Minimum Output Current 10 Amps Max Output Current 300 Amps Output Voltage 60 - 230 vdc Duty Cycle Rating 100% @ 300A, 180V, (54kW), Ambient Temperature for Duty Cycle Rating

104F° (40°C)

Operating range 14°F to 122°F (-10°C to + 50°C) Power Factor 0.70 @ 300 A DC Output Cooling Forced Air (Class F)

Auto-Cut 30O2 Power Supply

Input Power Input Current Suggested Sizes (See Note)

Voltage Freq. 3-Ph 3-Ph Fuse (Amps) Wire (AWG)

(Volts) (Hz) (kVA) (Amps) 3-Ph 3-Ph

208 50/60 74 206 260 #3/0 230 50/60 72 181 230 #2/0

400 (Incl. CE) 50/60 75 109 135 #3

460 50/60 89 112 150 #2

Line Voltages with Suggested Circuit Protection and Wire Sizes

Based on National Electric Code and Canadian Electrical Code

2.07 System Layout

Refer to section 3.11 for ground connections and ground cables.

125’ / 38.1 m Maximum Length

Pilot Return

Negative Leads (2)

Coolant Supply

300-A

Primary power

CNC

Power Supply

Fiber

Optic Cable

Control

Cable

Coolant Return

Control Cable

Gas Control

Module

Plasma Gas

Shield Gas

Preflow Gas

Control

Cable

Water Shield

Remote

Arc

Starter

Torch

Valve

Assembly

50’ / 15.2 m Maximum Length

Pilot Return

Coolant Supply w/ Negative

Coolant Return

Plasma Gas Shield Gas

Positioning Tube

Shield

To rc h

Art # A-07118_AD

175’ / 53.3 m Maximum Length

Manual No. 0-4818 Auto-Cut 300

Work Cables (2)

Work

2-2 SPECIFICATIONS

2.08 Power Supply Dimensions

27 inch

680 mm

52.25 inch 1030 mm

27.5 inch 700 mm

Art # A-06939

33 inch 840 mm

37.75 inch 960 mm

535 lb / 243 kg

Manual No. 0-4818 Auto-Cut 300

2-3 SPECIFICATIONS

2.09 Power Supply Rear Panel Features

Customer Access Wiring

Gas Control

Console Connector

CNC Connector

Remote Arc Starter

Connector

Pilot (Pos) Terminal

Circuit Breaker

anel

Torch (Neg) Terminal

Work Cable Terminal

Input Power

Terminals

AC Pow

er Lamp

Ground Terminals

Terminal Cover

Support Panel

Coolant Connections

Coolant Filter

Coolant Tank

RETURN

SUPPL

Leads Bracket

Art # A-08279_AA

Manual No. 0-4818 Auto-Cut 300

2-4 SPECIFICATIONS

2.10 Gas Specifications

The customer will provide all gases and pressure regulators. Gases must be of high quality. Pressure regulators shall be double stage.

Auto-Cut 30O2 Power Supply: Gas Pressures, Flows, and Quality Requirements

Gas Quality Minimum Pressure Flow

(Oxygen)

99.5% Purity

(Liquid recommended)

120 psi

8.3 bar / 827 kPa

200 scfh (5700 l/h)

99.5% Purity

(Nitrogen)

Compressed

or Bottled Air

H35 (Argon-Hydrogen)

H35 = 35% Hydrogen,

65% Argon

O (Water) See Note 2 50 psi (3.5 bar) 10 gph (38 lph)

: The air source must be adequately filtered to remove all oil or grease. Oil or grease

Note 1

(Liquid recommended)

<1000 ppm O

, <32 ppm

Clean, Dry,

Free of Oil (see Note 1)

99.995% Purity

(gas recommended)

120 psi

8.3 bar / 827 kPa

120 psi

8.3 bar / 827 kPa

120 psi

8.3 bar / 827 kPa

300 scfh (8496 l/h)

450 scfh (12743 l/h)

200 scfh (5664 l/h)

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.

: The tap water source does not need to be deionized, but in water systems with high mineral content a water

Note 2

softener is recommended. Tap water with high levels of particulate matter must be filtered.

: Water Pressure Regulator No. 8-6118 is recommended to ensure proper water pressure.

Note 3

2.11 Gas Applications

MATERIAL

CUTTING

OUTPUT

FLOW

55 A

100 A

200 A

300 A

Manual No. 0-4818 Auto-Cut 300

MILD STEEL STAINLESS STEEL

PRE-

PLASMA SHIELD

Air Air Air Air O

Air Air Air Air Air Air Air Air Air

Air

Air Air Air Air Air Air Air Air Air

Air O

Air Air Air Air Air Air Air Air Air

Air O

Air

GAS TYPE

PRE-

FLOW

PLASMA SHIELD

Air Air Air AirAir Air

2-5 SPECIFICATIONS

ALUMINUM

GAS TYPEGAS TYPE

PRE-

FLOW

H20N2N

PLASMA SHIELD

H20

H20N2 N2H20

H20N2N

H20

2.12 XTTM-301 Torch Specifications

A. Torch Dimensions

End Cap

Art # A-08301

19.00"

482.68 mm

393.78 mm

15.50"

160.10 mm

6.30"

3.98"

101.1 mm

2.25"

57.15 mm

Mounting Tube

2.0"

50.8 mm

2.39"

60.81 mm

Manual No. 0-4818 Auto-Cut 300

2.63"

66.8 mm

1.57"

39.96 mm

1.49"

37.8 mm

2-6 SPECIFICATIONS

B. Torch Gas Leads Lengths

Gas Lead Assemblies

C. Torch Parts (Generic Parts Shown)

Length

Feet Meters

10 3.05 15 4.6 25 7.6 50 15.2

75 22.8 100 30.4 125 38.2 150 45.7 175 53.3

Art # A-04741

Shield

Retainer

Shield Retainer

Shield Cup

Shield

Shield Gas

Distributor

Shield Cap

Shield

Cap

Shield Gas

Distributor

This Art Is For Reference ONLY

Shield Gas

Distributor

Tip

Plasma Gas

Tip

Distributor

Plasma Gas

Distributor

Plasma Gas

Distributor

Electrode

Cartridge

Electrode

Cartridge

Art # A-08304_AC

Cartridge

D. Parts - In - Place (PIP)

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

E. Type of Cooling

Combination of gas stream through torch and liquid cooling.

Manual No. 0-4818 Auto-Cut 300

This Art Is For Reference ONLY

Art # A-07917_AC

2-7 SPECIFICATIONS

This Page Intentionally Blank

Manual No. 0-4818 Auto-Cut 300

2-8 SPECIFICATIONS

SECTION 3: INSTALLATION

3.01 Installation Requirements

Electric Supply

The electrical supply network, the gas and water supply system must meet local safety standards. This conformity shall be checked by qualified personnel.

Auto-Cut 30O2 Power Supply Input Wiring

Input Power Input Current Suggested Sizes (See Note)

Voltage Freq. 3-Ph 3-Ph Fuse (Amps) Wire (AWG)

(Volts) (Hz) (kVA) (Amps) 3-Ph 3-Ph

208 50/60 74 206 260 #3/0 230 50/60 72 181 230 #2/0

400 (Incl. CE) 50/60 75 109 135 #3

460 50/60 89 112 150 #2

Line Voltages with Suggested Circuit Protection and Wire Sizes

Based on National Electric Code and Canadian Electric al Code

CAUTION

Fuse and wire sizes are for reference only. The installation must conform to national and local codes for the type of wire being used and method of installation.

Gas Supply

The customer must supply all gases and pressure regulators. Gases must be of high quality. Pressure regulators must be double-stage and installed as close as possible to the gas console. Contaminated gas can cause one or more of the following problems:

• Reduced cutting speed

• Poor cut quality

• Poor cutting precision

• Reduced consumables life.

• Oil or grease contamination from compressed or bottled air can cause fires in conjunction with oxygen.

NOTE

Gas supply leads must be #8 (1/2 in. ) hose or larger

Cooling System Requirements

Coolant must be added to the system on installation. The amount required varies with torch leads length.

Thermal Dynamics recommends its coolants 7-3580 and 7-3581 (for low temperatures).

Coolant Capabilities

Cat. Number and Mixture Mixture Protects To

7-3580 'Extra-Cool

7-3581 'Ultra-Cool

7-3582 'Extreme Cool

* For mixing with D-I Cool

' Concentrate* -65° F / -51° C

7-3583

25 / 75 10° F / -12° C

50 / 50 -27° F / -3° C

Manual No. 0-4818 Auto-Cut 300

3-1 INSTALLATION

3.02 System Layout

Refer to section 3.05 for ground connections and ground cables.

Primary power

CNC

Art # A-09951

50’ / 15.2 m Maximum Length

Pilot Return

Coolant Supply

Shield

w/ Negative

Coolant Return

300-A Power Supply

125’ / 38.1 m Maximum Length

Pilot Return

Negative Lead

Coolant Supply

Coolant Return

Control Cable

Remote

Arc

Starter

Shield

Fiber

Optic

Cable

Gas Control

Control

Cable

Module

Plasma Gas

Shield Gas

Preflow Gas

Control

Cable

Water

Torch

Valve

Assembly

Plasma Gas Shield Gas

Positioning Tube

Shield

Work Cables (2)

Torch

Work

175’ / 53.3 m Maximum Length

Manual No. 0-4818 Auto-Cut 300

3-2 INSTALLATION

3.03 Cables & Leads Identification

#8 AWG Cable

2/0 (70 mm ) Cable

Pilot Return, Power Supply to Arc Starter

Art # A-09952

Negative Lead, Power Supply to Arc Starter

Green

Red

Green

Red

Coolant Supply Lead, Power Supply to Arc Starter

Coolant Return Lead, Power Supply to Arc Starter

Control Cable, Power Supply

Green / Yellow # 4 AWG

Green / Yellow 1/0 (50 mm )

to Arc Starter

Ground Cable

Ground Cable, Remote Arc Starter To Earth Ground

Shielded Torch Lead Assembly, Remote Arc Starter to Torch

H, Q, R, S,T

2/0 (70 mm ) Cable

Plasma Gas Lead, Torch Valve to Torch

Shield Gas Lead, Torch Valve to Torch

Control Cable, Power Supply to Gas Control Module

Fiber Optic Cable, Power Supply to Gas Control Module

Work Cable

CNC Cable (14 Wire)

Manual No. 0-4818 Auto-Cut 300

3-3 INSTALLATION

3.04 Lift the Power Supply

WARNINGS

Do not touch live electrical parts.

Disconnect input power conductors from de-energized supply line before moving unit.

FALLING EQUIPMENT can cause serious personal injury and equipment damage.

Use all four lifting eyes when using lifting straps to lift the power supply.

Use a forklift, crane, or hoist to lift the unit off the shipping pallet as shown. Keep the power supply steady and vertical. Do not lift it any further than necessary to clear the shipping pallet.

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.

Manual No. 0-4818 Auto-Cut 300

Art # A-04796

3-4 INSTALLATION

3.05 Primary Power Connections

The primary power cable must be supplied by the end user and connected to the power supply.

Remove the connections cover on the rear of the Power Supply. Use caution when removing the panel; there is a ground wire connected to the inside of the panel. Do not disconnect this wire.

Connections Cover (Removed)

Connection Panel

Art # A-04797

Manual No. 0-4818 Auto-Cut 300

3-5 INSTALLATION

Check / Adjust Input Voltage Configuration

1. The 230/460VAC power supply includes a voltage configuration board which must be positioned to match the primary input voltage. Remove the power supply left side panel and locate the voltage configuration board on the inverter module. The input voltage configuration is shown at the top of the board.

WARNING

There is a voltage configuration board on each inverter module. Power supplies with more than one inverter module require that all voltage configuration boards must be configured identically.

2. If necessary, unplug the connector at the top right corner of the board, remove the board and re-install it with the correct input voltage shown at the top of the board.

3. Re-connect the connector. Re-install the power supply side panel.

Inverter Module

1. Unplug connector

208/230V / 460V

Input Voltage Board

(Shown in 460V Position)

2. Remove bolts.

3. Invert board.

4. Re-install board.

5. Plug in connector.

Art # A-04856_AB

Manual No. 0-4818 Auto-Cut 300

3-6 INSTALLATION

Connect Input Power and System Ground Cables

1. Carefully cut back the outer sheath on the primary input power cable to expose the individual wires. Cut back the insulation on the individual wires. Route the cable upward through the connections cover support panel on the rear panel of the power supply.

2. Insert the individual wires into the proper lug and tighten the nut onto the wires.

3. Pass the ground and input power cables through the leads bracket as shown. Connect the individual wires as shown. Connect the power cable ground wire to the ground terminal block.

CAUTION

The clear connections cover must remain in place.

4. If required, pass a system ground cable (F1) through the last opening in the connections cover support panel next to the input power cable. Connect the cable to the ground terminal block on the power supply rear panel. Refer to the Ground Connections Section for full details and procedures on proper system grounding.

Ground Terminal Block

Connections Cover

Connection Panel

to Remote Arc Starter

AC INPUT

System Ground Cable

Input power cable ground

Connections Cover Support Panel

Input power cable

System Ground Cable

Leads Bracket

to Remote Arc Starter

Art # A-07659_AB

5. Re-install the connections cover on the power supply. Snug the hardware securely by hand. Do not overtighten.

Manual No. 0-4818 Auto-Cut 300

3-7 INSTALLATION

Remote Arc

Starter (RAS-1000)

Cutting Machine / Gantry

Cutting Table

1/0

Ground Cable

(F1)

Ground Cable

Customer supplied

Earth Ground

Rod

Star Ground on Cutting Table

See

Manufacturer

1/0

To rc h

CNC

Device

Gas Control Module

Primary location

#4 AWG

Ground

(F)

1/0 Ground Cable

Power Supply

1/0 Work Cable

200Amp or less

Ultra-Cut

Auto-Cut O2

Note: The gas control module can be mounted on top of the power supply.

If it is, it should be grounded directly to the power supply with #4 AWG ground, (F). This alternate location requires grounding the power supply to the ‘Star’ ground with the 1/0 Ground Cable (F1).

0 - 10 ft (0 - 3 m) Ideal

20 ft (6 m) Maximum

Remote Arc

Starter (RAS-1000)

Cutting Machine / Gantry

Cutting Table

1/0

Ground Cable

(F1)

Ground Cable

Customer supplied

Earth Ground

Rod

Ground

Star Ground on Cutting Table

See

Manufacturer

To rc h

1/0

CNC

Device

Power Supply

1/0 Work Cable

1/0 Ground Cable

‘Star’

Auto-Cut W/RAS

200Amp or less

Gas Control Module

#4 AWG Ground (F)

(Factory Installed)

0 - 10 ft (0 - 3 m) Ideal

20 ft (6 m) Maximum

Manual No. 0-4818 Auto-Cut 300

‘Star’

Ground

Art # A-08253_AB

3-8 INSTALLATION

Auto-Cut Basic System

Without RAS

Cutting Machine / Gantry

Cutting Table

Ground Cable

Customer Supplied

Earth Ground

Rod

Torch

1/0

0 - 10 ft (0 - 3 m) Ideal

20 ft (6 m) Maximum

CNC

Device

Auto-Cut

Power Supply

1/0 Work Cable

1/0 Ground Cable

(F1)

‘Star’

Ground

GCM-1000

Gas Control Module

#4 AWG Ground (F)

(Factory Installed)

Art # A-08254_AC

Manual No. 0-4818 Auto-Cut 300

3-9 INSTALLATION

3.06 Ground Connections

A. Electromagnetic Interference (EMI)

Pilot arc starting generates a certain amount of electromagnetic interference (EMI), commonly called RF (Radio Frequency) noise. This RF noise may interfere with other electronic equipment such as CNC controllers, remote controls, height controllers, etc. To minimize RF interference, follow these grounding procedures when installing mechanized systems:

B. Grounding

1. The preferred grounding arrangement is a single point or “Star” ground. The single point, usually on the cutting table, is connected with 1/0 AWG (European 50 mm2) or larger wire to a good earth ground (measuring less than 3 ohms; an ideal ground measures 1 ohm or less. Refer to paragraph ‘C’, Creating An Earth Ground. The ground rod must be placed as close as possible to the cutting table, ideally less than 10 ft (3.0 m), but no more than 20 ft (6.1 m) from the cutting table.

NOTE

All ground wires should be as short as possible. Long wires will have increased resistance to RF frequencies. Smaller diameter wire has increased resistance to RF frequencies, so using a larger diameter wire is better.

2. Grounding for components mounted on the cutting table (CNC controllers, height controllers, plasma remote controls, etc.) should follow the manufacturer’s recommendations for wire size, type, and connection point locations.

For Thermal Dynamics components (except Remote Arc Starter and Gas Control Module) it is recommended to use a minimum of 10 AWG (European 6 mm2) wire or flat copper braid with cross section equal to or greater than 10 AWG connected to the cutting table frame. The Remote Arc Starter uses 1/0 earth ground wire and the Gas Control Module should use minimum # 4 AWG wire. The connection point must be to clean bare metal; rust and paint make poor connections. For all components, wires larger than the recommended minimum can be used and may improve noise protection.

3. The cutting machine frame is then connected to the “Star” point using 1/0 AWG (European 50 mm2) or larger wire.

4. The plasma power supply work cable (see NOTE) is connected to the cutting table at the single point “Star” ground.

NOTE

Do Not connect the work cable directly to the ground rod.

5. Make sure work cable and ground cables are properly connected. The work cable must have a solid connection to the cutting table. The work and ground connections must be free from rust, dirt, grease, oil and paint. If necessary grind or sand down to bare metal. Use lock washers to keep the connections tight. Using electrical joint compound to prevent corrosion is also recommended.

6. The plasma power supply chassis is connected to the power distribution system ground as required by electrical codes. If the power supply is close to the cutting table (see NOTE) a second ground rod is not usually needed, in fact it could be detrimental as it can set up ground loop currents that cause interference.

When the plasma power supply is far away from the ground rod and interference is experienced, it may help to install a second earth ground rod next to the plasma power supply. The plasma power supply chassis would then be connected to this ground rod.

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.

Manual No. 0-4818 Auto-Cut 300

NOTE

3-10 INSTALLATION

C. Creating An Earth Ground

1. To create a solid, low resistance, earth ground, drive a 1/2 in (12 mm) or greater diameter copper clad ground rod at least 6 - 8 ft (1.8 - 2.4 m) into the earth so that the rod contacts moist soil over most of its length. Depending on location, a greater depth may be required to obtain a low resistance ground (see NOTE). Ground rods, typically 10 ft (3.0 m) long, may be welded end to end for greater lengths. Locate the rod as close as possible to the work table. Install a ground wire, 1/0 AWG (European 50 mm2) or greater, between the ground rod and the star ground point on the cutting table.

NOTE

Ideally, a properly installed ground rod will have a resistance of one ohms or less.

To test for a proper earth ground, refer to the following diagram. Ideally, the reading on the multimeter should be

1 VAC for 115VAC line, or 0.5 VAC for 230 VAC line.

CAUTION

Remove all other connections from the ground rod during this test.

This test assumes the 115 or 230 VAC source neutral is connected to the utility earth ground.

NEUTRAL Earth Grounded

NEUTRAL PROBE

WARNING

Use extreme caution. This

test uses live voltage.

HOT

100W Incandescent light bulb*

HOT PROBE

* Can replace light bulb with a 100w resistor. Use 100 ohm for 115VAC. Use 500 ohm for 230VAC

Ground Rod with other connections removed

On 115V AC Line: 3VAC = 3 ohms 1VAC = 1 ohm

VAC

On 230V AC Line:

1.5VAC = 3 ohms

0.5VAC = 1 ohm

Art # A-07252

Ground Testing

2. Increasing the ground rod length beyond 20 - 30 ft (6.1 – 9.1 m) does not generally increase the effectiveness of the ground rod. A larger diameter rod which has more surface area may help. Sometimes keeping the soil around the ground rod moist by continuously running a small amount of water into it will work. Adding salt to the soil by soaking it in salt water may also reduce its resistance. When these methods are used, periodic checking of the ground resistance is required to make sure the ground is still good.

D. Routing Of Torch Leads

1. To minimize RF interference, position torch leads as far as possible from any CNC components, drive motors, control cables, or primary power lines. If cables have to pass over torch leads, do so at an angle. Do not run the plasma control or other control cables in parallel with the torch leads in power tracts.

2. Keep torch leads clean. Dirt and metal particles bleed off energy, which causes difficult starting and increased chance of RF interference.

Manual No. 0-4818 Auto-Cut 300

3-11 INSTALLATION

3.07 Connect Work Cable and Pilot and Negative / Torch Leads

1. Pass the ends of the work cable and pilot and negative / torch leads upward through the leads bracket at the bottom of the power supply rear panel, and through the openings in the connections cover support panel.

2. Refer to the illustration. Connect the leads as shown. Tighten securely. Do not overtighten.

CAUTION

The clear connections cover must remain in place.

NOTE

Negative Lead and Torch Lead are used interchangably during this operation

Pilot

Connections Cover

Torch

Work

PILOT WORK TORCH

Work Lead

Pilot Lead To Remote Arc Starter

Connection Panel

Torch Lead -

AC INPUT

L2 L3

To Remote Arc Starter

Connections Cover Support Panel

Art # A-07660_AB

Manual No. 0-4818 Auto-Cut 300

Lead Connection Detail

To Cutting Table

Leads Bracket

3-12 INSTALLATION

3.08 Connect Coolant Leads

1. Connect the color-coded coolant hoses to the coolant connections on the power supply rear panel. The supply line (out) is flagged green, the return line (in) is flagged red.

COOLANT

RETURN

SUPPLY

RETURN

SUPPLY

Coolant Connections

RED

GREEN

To Remote Arc Starter

Art # A-04800

Manual No. 0-4818 Auto-Cut 300

3-13 INSTALLATION

3.09 Connect Control Cables for CNC, Remote Arc Starter, and GCM

1. Connect one end of each cable to the power supply.

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

3. The CNC cable shield must be attached to ground at the CNC end of the cable. Do not ground to the Plasma Power Supply.

Customer Wiring Access Hole

To Gas Control Module

To CNC

To Remote Arc Starter

RETURN

SUPPLY

Art # A-04802

Manual No. 0-4818 Auto-Cut 300

3-14 INSTALLATION

3.10 Connect Fiber Optic Cable to CCM

1. Remove the strain relief securing nut from the strain relief on the fiber optic cable(s). Loosen the strain relief dome nut from the strain relief.

2. Pass the cable connector through the appropriate opening. Slide the strain relief securing nut onto the cable. Make a loop of the cable; carefully press the cable connector into the appropriate receptacle on the internal control module.

3. Tighten the strain relief onto the cable(s). Do not overtighten.

Cable Receptacles

Profile Detail, Fiber Optic Cable Installation

To Gas Control Module

To Remote HMI (if installed)

To Slave Power Supply (if installed)

Art # A-06793

Manual No. 0-4818 Auto-Cut 300

3-15 INSTALLATION

3.11 Set Switches on the Command - Control Module

Remove the power supply right side. Set switches on the CCM (Command-Control Module) per the illustrations. Switch settings and connection details are provided in the Appendix.

CAUTION

Printed circuit boards in the Command - Control Module are static - sensitive. Discharge any built-up static charges in your body or surroundings before touching the printed circuit boards.

Future Use

O N

SW1

SW3 SW4

SW5

SW8

SW-1-1: Auto Pilot Restart. 1 = ON = Auto Pilot Function enabled. 1 = OFF = Auto Pilot Function disabled (Factory default setting). SW-1-2: Pilot Delay 2 = OFF, 3 = OFF, 4 = OFF: 0 Seconds (Factory default setting). SW-1-3: Pilot Delay 2 = ON, 3 = OFF, 4 = OFF: 0.1 Seconds SW-1-4: Pilot Delay 2 = OFF, 3 = ON, 4 = OFF: 0.2 Seconds 2 = ON, 3 = ON, 4 = OFF: 0.4 Seconds 2 = OFF, 3 = OFF, 4 = ON: 0.8 Seconds 2 = ON, 3 = OFF, 4 = ON: 1.0 Seconds 2 = OFF, 3 = ON, 4 = ON: 1.5 Seconds 2 = ON, 3 = ON, 4 = ON: 2.0 Seconds

SW-3: Gas Preflow Time 1 = Off, 2 = OFF: 2 seconds 1 = ON, 2 = OFF: 4 seconds 1 = OFF, 2 = ON: 6 seconds 1 = ON, 2 = ON: 8 seconds

SW-4: Postflow Time 1 = OFF, 2 = OFF: 10 Seconds (Factory default setting). 1 = ON, 2 = OFF: 20 Seconds 1 = OFF, 2 = ON: 5 Seconds 1 = ON, 2 = ON: 0 Seconds

SW-5-1: Tip Saver Reserved for Factory use. SW-5-2: Off Plate Reserved for Factory use.

SW 8-1: Pilot Time 1 = OFF = Short (85 ms.) (Factory default setting).

1 = ON = Long (3 s.)

SW 8-2: Remote Current 1 = OFF = Disabled (Factory default setting). 1 = ON = (Remote Analog Current Control)

*SW 8-3: Auto Transfer Retry1 = OFF = Enabled Up to 3 tries (Factory default setting). 1 = ON = Disabled

SW 8-4: Reserved for Factory use.

O N

Active only when SW-1-1 is set to O

* SW 8-3 is reserved for

Factory use prior to

Firmware V3.5

Art # A-06791_AB

Manual No. 0-4818 Auto-Cut 300

3-16 INSTALLATION

CAUTION

Printed circuit boards in the Command - Control Module are static - sensitive. Discharge any built-up static charges in your body or surroundings before touching the printed circuit boards.

SW11

SW6

SW12

SW13

SW-6: OK-to-Move: Contact closure, rated at 120VAC @ 1A Max. (Factory default setting) or DC Volts (16-18vdc@ up to 100 ma.)

SW-11: Analog Current Control. B = from Gas Control (Factory default setting) or A = from CNC. Position A requires that SW-8-2 be ON.

SW-12-1/2/3/4: Divided Arc signal

All = OFF = 50:1 (Factory default setting)

1 = ON = 16.6:1 2 = ON = 30:1 3 = ON = 40:1

Only 1 on at a time.

4 = Not used.

SW13-1, SW13-2: Reserved for Factory Use.

Art # A-06922_AB

Manual No. 0-4818 Auto-Cut 300

3-17 INSTALLATION

3.12 Height Control Connections

The terminal strip has Arc Volts (-) connection to power supply negative output TORCH terminal, Arc Volts (+) connection to power supply positive output WORK terminal. These are for a height control that requires connection to the full non-divided arc voltage. Also available on the terminal strip are 120VAC (120,0) and 24 VAC (24, 0). Note that the two 0’s are not common. The allowable current draw is 100ma @ 120VAC and 1Amp @ 24 VAC.

Art # A-08404

There is also a hole added in the rear panel above the J55-GCM receptacle for customer wiring. This, rather than the one in the CCM will be the preferred place for customer added wiring (and strain relief) for connections to height controls, etc..

Manual No. 0-4818 Auto-Cut 300

3-18 INSTALLATION

3.13 Install Gas Control Module

The Gas Control Module must be installed in a suitable location where it is easily accessible to the system operator. The unit must be mounted to a flat horizontal surface. If the Module is mounted to a gantry or to any other support subject to vibration or motion, the installer must fasten the module to the support securely.

The Module should be located as far away as possible from the Arc Starter due to electromagnetic interference. It is acceptable to locate the control cable in the same track as the cables from the Arc Starter.

The Module includes feet which lift the bottom panel off the mounting surface. There are ventilation holes on the bottom panel; the space between the bottom panel and the mounting surface must remain open for ventilating air to enter the module. Louvers on the back panel of the module must also remain unblocked, for the free passage of ventilating air.

Mounting Dimensions

NOTE

Height not shown is 14.125” (359 mm)

Gas Box

7.14mm

0.28”

279.40mm

11.00”

410.97mm

16.18”

347.47mm

13.68”

215.90mm

8.50”

Art # A-07962

The unit must be mounted so that the Flowmeters are plumb. If the Flowmeters are not plumb, incorrect flow indications may occur.

Manual No. 0-4818 Auto-Cut 300

NOTE

3-19 INSTALLATION

Preparation

1. Remove the screws securing the Cover Panel to the Module.

2. Remove the Cover from the Module. Remove the ground wire if needed.

Gas Control Module Cover

Remove Ground Wire

Do not remove

Cover Removal

Art # A-06882

Manual No. 0-4818 Auto-Cut 300

3-20 INSTALLATION

3.14 Connect Fiber Optic Cable to Gas Control Module

1. Install the through-hole protector for the fiber-optic cable in the hole in connection panel on the back of the Module.

2. Pass the fiber-optic cable connector through the hole in connection panel on the back of the Module. Pass enough of the cable into the Module to allow the cable to loop upward as shown.

CAUTION

Avoid kinking, twisting, or bunching the fiber optic cable. The cable can be damaged by being forced into tight-radius turns.

Circuit Board

Fiber Optic Cable

Art # A-04772

PLASMA

OUT

SHIELD

OUT

PREFLOW

OUT

AIR N

SHIELD

H S

J56

J57

POWER SUPPLY

TVA

H35

INPUTS

6 5 J

W O P

Y L P

PREFLOW

PLA

S T

R I

Manual No. 0-4818 Auto-Cut 300

3-21 INSTALLATION

3. Insert the fiber-optic cable connector into the receptacle on the vertically-mounted circuit board as shown.

Cable must snap into place.

Circuit Board

Fiber Optic Cable

4. Tighten the through-hole protector for the fiber-optic cable.

5. Reinstall the Cover Panel.

Manual No. 0-4818 Auto-Cut 300

Art # A-04773

3-22 INSTALLATION

3.15 Connect Control, Input, and Outputs to Gas Control Module

1. Make all other connections to the rear of the Module. The connections are labeled. The Module must be grounded; the grounding terminal is marked Use #4 AWG (European 21 mm2) (or thicker) wire for grounding. Keep the ground wire as short as possible.

2. Position the Module on a flat, horizontal, mounting surface.

3. Ensure that the Flowmeters are plumb.

4. Fasten the Module to the mounting surface.

5. Connect all gas / water inputs to the rear panel of the module.

CAUTION

When cutting with O

(oxygen) plasma, air must be connected to the Module.

6. Connect the appropriate control cables to terminals marked ‘TVA’ (torch valve assembly) and ‘power sup- ply’.

To Power Supply

J56

POWER

SUPPLY

Ground Stud

COMM

SHIELD PLASMA

H O

SHIELD

To Torch Valve Assembly

H O

PREFLOW

To Torch Valve Assembly

J57

When Cutting With O2 Plasma

Air MUST BE Connected

AIR

INPUTS

H35

Gas & Water Inputs (Check Valves)

TVA

Gas Control Module Rear Panel

Connection Panel

Manual No. 0-4818 Auto-Cut 300

SHIELD PLASMA

H O

SHIELD

H O

PREFLOW

J56

TVA

H35

COMM

POWER SUPPLY

Art # A-07283

When Cutting With O2 Plasma

Air MUST BE Connected

INPUTS

AIR

J57

3-23 INSTALLATION

3.16 Install Remote Arc Starter

Site Location

Select a clean, dry location with good ventilation and adequate working space around all components.

Review the safety precautions in the front of this manual to be sure that the location meets all safety requirements.

Interconnecting cables and hoses attach to the Arc Starter. There must be adequate space around the Arc Starter for these connections without crimping.

Mounting Dimensions

NOTE

Height not shown is 7.375” ( 187mm )

304.80mm

12.00”

12.70mm .50”

Arc Starter Box

6.35mm D.250”

3 PLACES

203.20mm

8.00”

50.80mm

2.00”

190.83mm

7.51”

Art # A-07961

Manual No. 0-4818 Auto-Cut 300

37.77mm

1.49”

266.70mm

10.50”

3-24 INSTALLATION

Installation

The Remote Arc Starter must be installed in a suitable location near the torch head. If the Arc Starter is mounted to a gantry or to any other support subject to motion or vibration, fasten the Arc Starter to the support securely.

1. Loosen, but do not remove, the lower screws securing the cover to the Arc Starter. Remove the upper screws securing the Cover Panel to the Arc Starter.

NOTE

A wire grounds the cover to the Arc Starter base as shown below. This wire must remain in place.

2. Remove the Cover Panel from the Arc Starter.

Upper screws (2 per side)

Cover

Ground Wire

Lower screws (2 per side)

Art # A-09625

Cover Removal

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

Manual No. 0-4818 Auto-Cut 300

3-25 INSTALLATION

4. Use pre-drilled holes in at least two of the feet on the bottom of the Arc Starter to secure the Arc Starter to the mounting surface.

Minimum 2

Art # A-09626

Input Connections

1. Refer to the illustrations. Make the following input connections to the Arc Starter.

• Coolant Supply and Return Hoses (from power supply). Hoses and connectors are color-coded; Red

for Return, Green for Supply.

Art # A-09627

Return

Supply

Coolant Supply and Return Hoses (from power supply)

Manual No. 0-4818 Auto-Cut 300

3-26 INSTALLATION

Coolant Return (Red)

Art # A-09628

Red

Coolant Supply (Green)

Green

Copper plate

Art # A-09629

Negative Cable from power supply.

Negative Cable (from Power Supply rear panel)

Manual No. 0-4818 Auto-Cut 300

3-27 INSTALLATION

Art # A-09630

Pilot Return Cable from Power supply

PILOT Return Cable (from Power Supply rear panel)

NOTE:

The pilot return cable has a strain relief connector that must be installed in the rear panel of the remote arc starter box.

Control Cable from Power Supply rear panel

Manual No. 0-4818 Auto-Cut 300

Art # A-09631

3-28 INSTALLATION

Output Connections

1. Refer to the illustrations. Make the following output connections to the Arc Starter.

NOTE:

For newer leads with only black wire, it must be connected to the pilot return. There are no inner shield wires.

Pilot Lead

Art # A-09632

Pilot Lead Connection Detail

Pilot Return Cable and Inner Shield Lead (from Torch Leads)

Manual No. 0-4818 Auto-Cut 300

3-29 INSTALLATION

Art # A-09633

Some items are removed for clarity.

Coolant Return Fitting (Tagged with Red)

Coolant Supply Fitting (Tagged with Green)

Coolant Supply (Green) to Torch

Coolant Return (Red) from Torch

Coolant Supply and Return Hoses (from Torch)

Reinstall the Arc Starter Cover. Ensure that the ground wire is not crimped between the cover and the base.

Upper screws (2 per side)

Cover

Ground Wire

Lower screws (2 per side)

Art # A-09625

The Arc Starter must be grounded; the grounding terminal is marked . Refer to the previous section for

grounding details.

Manual No. 0-4818 Auto-Cut 300

3-30 INSTALLATION

Art # A-04758

Torch Leads

1 Nut and 1 Washer Remain in Place

Ground Cable

• Use a clamp to secure the Torch Lead Shield brass ring to the port on the Remote Arc Starter as shown.

Art # A-04759

Torch Leads Shield

Shield Clamp

Coolant and Pilot Leads to Torch Valve Assembly

Connect Control Cable

1. Connect the Remote Arc Starter cable to the Remote Arc Starter receptacle.

Manual No. 0-4818 Auto-Cut 300

3-31 INSTALLATION

COOLANT

RETURN

SUPPLY

RETURN

Power Supply Rear Panel

SUPPLY

Remote Arc Starter

Remote Arc Starter Input Connection Panel

Art # A-04801

Manual No. 0-4818 Auto-Cut 300

3-32 INSTALLATION

3.17 Install Torch Valve

General Information

This assembly mounts as close as possible to the torch head. It accepts preflow, plasma, and shield gases from the Gas Control Module and supplies these gases to the Torch.

Mounting

113.03 mm

4.450”

6.63 mm

.261” Dia.

36.83 mm

1.450”

Art # A-08433

1. Mount the Valve Kit as close as possible to the Torch. The valve kit can be mounted in any convenient position, provided the outlet side (with two fittings) is closer to the torch than the inlet side (with three fittings and a control cable connector).

2. Connect the Valve Kit outlets to the torch leads as shown.

Do not remove brass plugs

Outlet Side

Manual No. 0-4818 Auto-Cut 300

Right-hand Thread:

To Torch Shield Gas fitting

Art # A-04761

To Torch Plasma Gas fitting

Left-hand Thread:

3-33 INSTALLATION

3. Connect the gas supply lines and the control cable connector from the Gas Control Module to the Valve Kit as shown. Hold the check valves stationary while attaching the gas lines.

Torch Valve, Inlet Side

Control Cable Connector

Water Shield Inlet

Shield Gas Inlet

Art # A-06926

Preflow Gas Inlet

Plasma Gas Inlet

CAUTION

Hold all fittings stationary while attaching hoses or leaks can be created. Side pressure can break the check valves or weaken their connection to the torch valve assembly. All fittings must be checked for leaks after assembly.

3.18 Prepare the Torch Head

1. Remove and discard the jumper on the torch head, as shown.

Jumper

Art # A-07323

Manual No. 0-4818 Auto-Cut 300

Discard

3-34 INSTALLATION

3.19 Connect Torch

Connect the Torch as follows:

Coolant Supply, Coolant Return, and Pilot Leads

Leads Cover

Torch Leads End Cap

Pilot Lead

Insulating Paper

Coolant Return

Check Valve

and Connector

Groove for O-Ring

O-Ring

Plasma Lead

Connector

Positioning Tube

Plasma Lead

Plasma Gas

(Left Hand Thread)

O-Ring

Shield Gas

(Right Hand Thread)

To Torch Valve

Manual No. 0-4818 Auto-Cut 300

Shield ('Secondary') Gas Connector

Insulating Paper

Coolant Supply Connector

3-35 INSTALLATION

Art # A-07324

1. Lay out the torch leads on a clean, dry working surface.

2. Hold the Torch Leads End Cap stationary. Pull approximately 18" (0.5 m) of leads through the End Cap.

3. Remove and discard the protective end caps from the Mounting Tube.

4. Install the O-ring in the groove at the upper end of the Mounting Tube.

5. Install the Mounting Tube as follows:

a. Position the Mounting Tube at the end of the leads assemblies as shown.

b. Slide the Mounting Tube upward onto the leads assemblies.

c. Press the upper end of the Mounting Tube into the lower end of the Torch Leads End Cap. Ensure that

the O-Ring on the Tube engages the mating groove inside the Torch Leads End Cap.

d. Ensure that the Mounting Tube is free to rotate within the Torch Leads End Cap.

6. Connect the gas and coolant leads to the Torch Head.

a. Coolant supply and return connections to the Torch Head are of different lengths.

b. Plasma and secondary gas connections to the Torch Head are threaded differently; the plasma gas

connection is left-hand thread, the shield gas connection is right-hand thread.

c. Hold the Torch Head leads connectors stationary; turn the leads fittings with a wrench to secure the

leads to the Torch Head. Do not overtighten.

CAUTION

The gas and coolant leads include compression fittings. Do not use sealant on these connections.

Slowly apply pressure to the gas lines. Check for leaks at all connections before continuing. If there are no leaks, shut off the gas supplies and continue with installation.

7. Connect the pilot lead to the Torch Head. Press the two ends of the connector firmly together. Thread the plastic lead cover/connector onto the mating Torch Head connector.

8. Press the Torch Head Assembly upward to connect to the Mounting Tube. Pull the leads back as needed to ensure a proper fit through the Mounting Tube and Torch Leads End Cap. Hold the Torch Head Assembly stationary; rotate the Mounting Tube to thread it onto the Torch Head.

CAUTION

Ensure that the leads do not twist within the mounting tube. Leads must lie as shown in the installation sketch.

9. The lower end of the Mounting Tube includes four threaded holes. Install an Allen set screw in any of the threaded holes to secure the Torch Head Assembly to the Mounting Tube.

10.Install the appropriate consumable parts as shown on the following pages. The torch manual includes diagrams showing the correct parts to install, depending on the metal to be cut and the gases in use.

Manual No. 0-4818 Auto-Cut 300

3-36 INSTALLATION

3.20 Install Consumable Torch Parts

Install the consumable parts as follows to ensure proper operation. These steps will help ensure that parts are seated correctly.

WARNINGS

Do not install consumables into the Cartridge while the Cartridge is attached to the Torch Head. Keep foreign materials out of the consumables and Cartridge. Handle all parts carefully to avoid damage, which may affect torch performance.

Art # A-03887

1. Check the appropriate cut chart for the right combination of parts for the cutting application.

2. For 200 Amp parts only, thread the Shield Retainer onto the Shield Cup.

3. Stack the consumable parts together.

Art # A-08303

Shield

Retainer

Shield Cup

1 - Assemble “A” 200 A only.

Shield Cap

2 - Assemble “B”.

Shield Gas

Distributor

Tip

Plasma Gas

Distributor

Electrode

3 - Assemble “B” to “C”. 4 - Assemble “A” to “B-C” assembly.

Cartridge

4. Insert the stack of consumable parts into the cartridge. Ensure that the large O-ring on the torch tip fits completely into the cartridge. If any part of the O-ring protrudes from the cartridge, the parts are not seated properly.

5. Use the cartridge tool to hold the cartridge assembly, while turning the shield cup (and shield retainer for 200 Amp parts) onto the cartridge assembly. For 300 Amp parts turn the shield retainer onto the shield cup now. When this group is fully assembled, the shield should protrude from the front of the shield cup or shield retainer. Without this protrusion the shield cup is not properly tightened onto the cartridge assembly.

6. Take the cartridge tool off the cartridge. Fit the cartridge assembly onto the torch head. The Speed Lok ring should clidk into place and the cartridge assembly should touch the large O-ring on the torch body.

Manual No. 0-4818 Auto-Cut 300

3-37 INSTALLATION

Torch Head

Torch Head O-Ring

0.063 - 0.083" (1.6 - 2.1 mm)

Protrusion

Art # A-08300_AB

CAUTION

Do not force the cartridge if it will not fully tighten. Remove the cartridge and gently clean parts and apply oxygen-compatible lubricant (supplied with the torch) to o-rings as needed.

Manual No. 0-4818 Auto-Cut 300

3-38 INSTALLATION

55 - 100 Amp Parts Assembly

Electrode

Plasma Gas Distributor

Tip

Shield Gas Distributor

Shield Cap

3: Thread Shield Cup onto Cartridge

1: Stack Parts

O-Ring

on Tip

2: Press Cartridge onto Stacked Parts

No Gaps

Between Parts

Cartridge Covers O-Ring on Torch Tip

4: Check Shield Cap Protrusion

Shield Cup

Shield Cap Protrudes

0.063-0.083" (1.6 - 2.1 mm)

Installing Assembled Cartridge Onto Torch Head

Shield Cap

Art # A-04873

Manual No. 0-4818 Auto-Cut 300

3-39 INSTALLATION

300 Amp Parts Assembly

aine

Shield Ret

Shield

Cap

Shield G

Distributor

Tip

Plasma Gas

Distributor

Art # A-08302

Cartridge

Shield C

Electrode

1 - Assemble “B”

2 - Assemble “C” if not already done

3 - Assemble “B” to “C”

4 - Assemble “A” to “B - C”

CAUTION

In “C” there is an insulating sleeve that must be in place on the Cartrudge before the Shield Cup is attached.

7. Place the ohmic clip over the shield cup if using ohmic torch height sensing.

Ohmic Clip

Art # A-03393_AB

8. Connect the wire lead from the height finder to the ohmic clip if using ohmic torch height sensing.

Ohmic height sensing is not recommended with water shield. Water on the plate interferes electrically with the ohmic sensing circuit.

Manual No. 0-4818 Auto-Cut 300

NOTE

3-40 INSTALLATION

3.21 Install Coolant

1. Remove the cap from the coolant tank. Fill the coolant tank to the level shown, with Thermal Dynamics coolant. The coolant level is visible through the translucent coolant tank. The amount of coolant required varies with torch leads length.

Coolant Capabilities

Cat. Number and Mixture Mixture Protects To

7-3580 'Extra-Cool

7-3581 'Ultra-Cool

7-3582 'Extreme Cool

* For mixing with D-I Cool

' Concentrate* -65° F / -51° C

7-3583

25 / 75 10° F / -12° C

50 / 50 27° F / -3° C

Manual No. 0-4818 Auto-Cut 300

3-41 INSTALLATION

COOLANT

RETURN

SUPPLY

RETURN

SUPPLY

Fill Range

Coolant Tank

Art # A-04803

2. After the complete system has been installed, check that the coolant has been pumped through the system as follows (see NOTE):

Depending on the length of the torch leads, the system may require more coolant after turning the system ON for the first time.

a. Place the ON/OFF Switch to ON.

b. After about 30 seconds the system may shut down if the leads are not full of coolant.

c. Place the ON/OFF switch to OFF.

d. After 10 seconds place the ON/OFF switch to ON again.

e. Repeat steps ‘b’ through ‘d’ until the system no longer shuts down. Depending on the length of the torch

leads this sequence may need to be done three to five times.

f. After the system stays operational allow the pump to operate for ten minutes to properly purge any air

from the coolant lines before using the system.

Manual No. 0-4818 Auto-Cut 300

NOTE

3-42 INSTALLATION

3. Re-fill the reservoir and re-install the filler cap.

4. Purge coolant from the torch before firing the torch. Ensure there are no leaks before use. If leaks are evident, consult the coolant leak trouble-shooting guide in the maintenance section of this manual.

Manual No. 0-4818 Auto-Cut 300

3-43 INSTALLATION

Intentionally Blank

Manual No. 0-4818 Auto-Cut 300

3-44 INSTALLATION

SECTION 4: OPERATION

4.01 Power Supply Control Panel

AC Indicator

Temp Indicator

Art # A-04862

AC Power Indicator

Indicates AC power is being supplied to the inverters when the ON/OFF switch is in ON position. When switch is first set to ON, the indicator stays off until the inrush cycle is complete and the correct voltage is confirmed.

TEMP Indicator: Normally OFF. Indicator turns ON when the internal temperature sensors detect

temperatures above normal limits. Let the unit cool before continuing operation.

Gas Indicator

DC Indicator

Status Indicator

GAS Indicator: The indicator blinks when the gas control is not ready. Causes for not being ready are when

purging, Mode switch is not set to Run, gas pressure is not correct or there are communiation errors. When gas flow is called for (preflow, cutting, postflow ) the indicator is on steady. It is off at all other times.

DC Indicator: Indicates the power supply is generating output DC voltage.

Status Indicator: Shows system status. The number of flashes indicates the status. Refer to the

Status Code Section for details. On power supply start-up, the indicator flashes to show the revision level of the operating software installed in the system.

Manual No. 0-4818 Auto-Cut 300

4-1 OPERATION

4.02 Start-Up Sequence

1. Connect system to primary input power.

2. Turn ON/OFF switch to ON (up) position. AC Indicator

turns ON after about 5 seconds.

POWER

OFF

Art # A-04812

3. Check the AC indicator. If indicator is ON, system is ready to operate (pending fault checks by internal circuitry). If indicator does not light after a few seconds check that each inverter is correctly configured for the input voltage and all 3 phases are present. Check Status Indicator for any codes that can help determine problem.

OFF

Manual No. 0-4818 Auto-Cut 300

4-2 OPERATION

4.03 Gas Control Module Operation

Functional Overview

The Gas Control Module provides all Plasma and Secondary gas selection and control instrumentation. There are various controls and indicators used to set gas pressures and flows.

MODE

RUN

TEST

RUN

SET PREFLOW

SET PLASMA

& SHIELD

TEST

PREFLOW

SET PREFLOW

SET PLASMA

& SHIELD

GAS

PLASMA

O2 - AIR

H35 - N

AIR - AIR

GAS

O2 - AIR

H35 - N

STAT U S

AIR - AIR

- H2O

Thermal Dynamics

- H2O

Plasma Cutting System

AMPS

Automated

SHIELD

H20

MIST

ENABLESTATU S

DISABLE

PLASMA POWER SUPPLY

ENABLE

DISABLE

PLASMA

POWER SUPPLY

AMPS

GCM 2000

Manual No. 0-4818 Auto-Cut 300

PRESSURE

GAS

FLOW

Art # A-06889

4-3 OPERATION

PRESSURE

GAS

FLOW

Gas Control Module: Controls & Indicators

1. MODE Selection Switch

MODE

RUN

SET PREFLOW

SET PLASMA

& SHIELD

TEST

MODE

RUN

SET PREFLOW

SET PLASMA

& SHIELD

TEST

PREFLOW

GCM 2000

GAS

O2 - AIR

H35 - N

AIR - AIR

2 - H2O

PLASMA

Thermal Dynamics

Automated

Plasma Cutting System

SHIELD

PRESSURE

GAS

FLOW

AMPS

ENABLESTATUS

DISABLE

PLASMA POWER SUPPLY

H20 MIST

Art # A-06890

• Normally in the RUN position during torch operation.

• In the SET PREFLOW position, Preflow or Piloting gas (Air or N2) flows to the torch allowing the operator to adjust pressure. Gas automatically shuts off after 2 minutes if left in the SET PREFLOW position.

• In the SET PLASMA & SHIELD position, selected cutting gases, Plasma & Shield, flow to the torch to allow operator to set the pressure (regulator & gauge) and flow (knob at top of flowmeter). Gases automatically shut off after 2 minutes if left in the SET PLASMA & SHIELD position. GCM 2000 gas control revision AC or later includes inlet pressure sensors. In SET PLASMA & SHIELD if either gas pressure is outside the range of 100135 PSI the Status LED will blink a code fo 3 blinks followed by a space then repeating the 3 blinks. User must determine which gas has to be adjusted.

• TEST mode will also cause selected PLASMA & SHIELD gasses to flow to the torch.

Manual No. 0-4818 Auto-Cut 300

4-4 OPERATION

2. GAS Selection Switch

Selects combinations of plasma and shield gases. Each time the switch is changed it initiates a purge of the new gas.

O2 - AIR

GAS

RUN

SET PREFLOW

SET PLASMA

& SHIELD

TEST

MODE

PREFLOW

GCM

2000

H35 - N

AIR - AIR

2 - H2O

H35 - N

Thermal Dynamics

Automated

Plasma Cutting System

SHIELD

PRESSURE

GAS

Art # A-06891_AB

STATUS

ENABLE

AMPS

DISABLE

PLASMA

POWER SUPPLY

MIST

FLOW

O2 - AIR

AIR - AIR

N2 - H2O

GAS

PLASMA

Manual No. 0-4818 Auto-Cut 300

4-5 OPERATION

3. Amperage Control

Adjusts the output amperage of the power supply.

MODE

RUN

SET PREFLOW

SET PLASMA

& SHIELD

TEST

PREFLOW

AMPS

Thermal Dynamics

Automated

Plasma Cutting System

SHIELD

AMPS

ENABLESTATUS

DISABLE

PLASMA POWER SUPPLY

H20 MIST

GAS

O2 - AIR

H35 - N

AIR - AIR

- H2O

PLASMA

Art # A-06892

GCM 2000

GAS

PRESSURE

FLOW

4. Plasma Power Supply Enable / Disable Switch

The DISABLE position removes input power from the Power Supply inverters, disables the coolant pump and fan, the pilot contactor & HF and removes AC power from the gsa control solenoids shutting off all gas flow. When the switch is returned to the ENABLE position an automatic gas purge is started and then the system is returned to normal operation under control of the CNC device.

5. PREFLOW Control Knob and Pressure Gauge

Used to set preflow gas pressure. MODE switch must be in SET PREFLOW position.

6. PLASMA and SHIELD Control Knobs, Pressure Gauges, and Flow Meters

Used to set plasma and shield gas pressures and flows. MODE switch must be in SET PLASMA & SHIELD position.

7. H2O Mist Control Knob and Flow Meter

Used to set water flow rate. MODE switch must be in SET PLASMA & SHIELD position. GAS selection switch must be in N2-H2O position.

Water mist is not used in all applications. Ohmic height sensing is not recommended with water mist shield. Water on the plate interferes electrically with the ohmic sensing system.

8. Shield Pressure / Flow Selector Switch

At lower flow rates the shield gas pressure is first set per the cut charts then the flow is set using the flow meter with the Gas switch set in the “Flow” position. Some torch parts require higher flow rates that exceed the capacity of the flow meter. In those cases, set the Gas switch to the Pressure position and use the regulator and gauge to set the pressure per the cut charts.

Manual No. 0-4818 Auto-Cut 300

NOTE

4-6 OPERATION

4.04 Gas Control Sequence Of Operation

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

STATUS LED Codes

LED Description

Gas control is ready to operate or is in cutting

Steady

Continuous

Blinking

2 Blinks

3 Blinks 4 Blinks CANBus error, Unacknowledged message 5 Blinks CANBus error, Bus off 6 Blinks CANBus error, communication timed out.

Parts Change and Purge.

sequence (preflow, pilot, cut or postflow) Gas control is not ready. May be purging, mode

switch not in Run position or Gas Selection or Mode switch in between positions Power Supply Enable/Disable switch in Disable position. Gas supply pressure out of range. Must be between 100 - 135 PSI

1. On the GCM set the Plasma Power Supply switch to .

2. Set Mode switch to RUN.

3. Inspect and change the torch parts if necessary.

4. Set the Gas Selection switch to the desired gas process.

5. Apply AC power and set the Plasma Power Supply switch (on the Gas Control Module) to . The Module performs purges of coolant and gas from lines if new gas was selected.

6. Status LED blinks on/off during purge then on steady if Mode SW is in RUN position and inlet gas pressure is OK.

Gas Supply Pressure.

For best results the gas supply pressure should be a minimum of 120 PSI and a maximum of 135 PSI. The following process is for GCM 2000 systems with revision AC or after. These systems will have input pressure sensors.

1. Following the parts change and purge, if the inlet pressure is OK, (Status LED is on steady) proceed to the next subsection of “Pressure and Flow Setting”.

2. If following the parts change and purge, the inlet pressure is not within the proper range of 100 to 135 PSI the Status LED will repeatedly blink 3 times. Adjust the supply pressure as needed and set the Enable / Disable switch to Disable then back to Enable to start another purge. Setting the Mode switch to “Set Plasma & Shield” then back to “Run” will reset the pressure error code without purging the lines. Proceed to next step to set pressures and flows.

Manual No. 0-4818 Auto-Cut 300

4-7 OPERATION

Pressure and Flow Setting

1. Set the Preflow (Piloting) gas pressure.

a. Set the Mode switch to “SET PREFLOW”. Refer to the torch section of the manual (cut charts section 8)

for proper settings.

b. Use the Preflow regulator knob to set preflow gas pressure. If the Mode switch is left in the “SET

PREFLOW” position for 2 minutes, the flow will be shut off.

2. Set the Plasma gas pressures and flows.

a. Set the Mode switch to “SET PLASMA & SHIELD”. Refer to the torch section of the manual (cut charts

section 8) for proper settings.

b. Use the Plasma regulator knob and pressure gauge to set plasma pressures. Next, set the flow using the

flow meter and knob above it.

3. Shield gas pressures and flows (except for N2/H2O process).

a. Set the Mode switch to “SET PLASMA & SHIELD”. Refer to the torch section of the manual (cut charts

section 8) for proper settings.

b. Some cut chart processes will specify both a pressure and a flow setting and other just a pressure

setting. If both are required, set the Shield Gas switch to “Flow”. If only the pressure is specified, set the Shield Gas switch to “Pressure”.

c. Set the Shield Pressure using the Shield regulator knob and pressure gauge. If required, set the Shield

flow using the Shield Flow meter and knob above it.

4. N2/H2O process set H2O MIST

a. Set the Mode switch to “SET PLASMA & SHIELD”. Refer to the torch section of the manual (cut charts

section 8) for H2O Mist settings.

b. Use the H2O Mist control knob and flow meter to set water flow rate.

5. Place the MODE switch to the “RUN” position.

6. Cutting Current

a. Adjust current control digital thumbwheel switch for the desired cutting current.

System is ready to cut.

NOTE

When switching gases between operations, allow enough purge time to clear the prior gas from the torch leads.

If during the set process either preflow or Plasma / Shield stops due to the 2 minute timeout, switching to RUN and back to the SET position will give another 2 minutes of gas flow.

CAUTION

While nothing prevents the operator from switching gases during piloting or cutting it is not recommended to do so. If the operator switches gases during piloting or cutting, the arc stops, then the system purges the new gas. Switching gases during piloting or cutting may damage torch parts or the piece being cut.

Manual No. 0-4818 Auto-Cut 300

4-8 OPERATION

Cut Quality

Cut quality requirements differ depending on application. For instance, nitride buildup and bevel angle may be major factors when the surface will be welded after cutting. Dross-free cutting is important when finish cut quality is desired to avoid a secondary cleaning operation. Cut quality will vary on different materials and thicknesses.

Kerf Width

Cut Surface

Left Side

Cut Angle

Right Side

Cut Angle

A-00512

Top

Spatter

Build-Up

Dross

Cut Surface

Drag Lines

Bevel Angle

Top Edge Rounding

A-00007

Cut Surface

The condition (smooth or rough) of the face of the cut.

Bevel Angle

The angle between the surface of the cut edge and a plane perpendicular to the surface of the plate. A perfectly perpendicular cut would result in a 0° bevel angle.

Top-Edge Rounding

Rounding on the top edge of a cut due to wearing from the initial contact of the plasma arc on the workpiece.

Dross Buildup and Top Spatter

Dross is molten material which is not blown out of the cut area and resolidifies on the plate. Top spatter is dross which accumulates on the top surface of the workpiece. Excessive dross may require secondary cleanup operations after cutting.

Kerf Width

The width of material removed during the cut.

Nitride Buildup

Nitride deposits which may remain on the cut edge of the carbon steel when nitrogen is present in the plasma gas stream. Nitride buildups may create difficulties if the steel is welded after the cutting process.

Manual No. 0-4818 Auto-Cut 300

4-9 OPERATION

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

Right Side

Cut Angle

A-00512

Clockwise

Scrap

Counter-

Clockwise

Scrap

Workpiece

Art # A-04182

Swirl Effect on Side Characteristics Of Cut

To make a square - edged cut along an inside diameter of a circle, the torch should move counterclockwise around the circle. To keep the square edge along an outside diameter cut, the torch should travel in a clockwise direction.

Underwater Cutting

Cutting on a water table either underwater or with the water touching the plate or with a water muffler system is not recommended. If a water table is used the water level must be a minimum of 4 inches from the bottom of the plate. Failure to follow this recommendation could result in poor cut quality and short consumable parts life.

Ohmic Height Sensing

Ohmic Height Sensing is not recommended with water shield (‘water mist secondary’). Water on the plate interferes electrically with the ohmic height sensing system.

4.05 Gas Selection

A. Plasma Gases

1. Air Plasma

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

• Air plasma is normally used with air shield.

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

Manual No. 0-4818 Auto-Cut 300

4-10 OPERATION

3. Oxygen (O

) 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.

Manual No. 0-4818 Auto-Cut 300

4-11 OPERATION

4.06 Power Supply Status Codes

On start-up and during operation, the power supply control circuitry performs various tests. If the circuitry detects a condition requiring operator attention, the status indicator on the control panel flashes a 2-part code to indicate a code group and then a particular condition within the group. After 4 seconds, the sequence repeats.

Example: Indicator flashes 4 times; the condition is in group 4. After a 1.2 second delay, the indicator blinks 3 times; the condition code is 4-3, indicating that the coolant is overheating. After a 4-second delay, the indicator repeats the sequence until the condition is corrected.

Some conditions can be active indefinitely, while others are momentary. The power supply latches momentary conditions; some momentary conditions can shut down the system. The indicator may show multiple conditions in sequence; it is important to recognize all possible conditions that may be displayed.

NOTE

These codes are for systems with Firmware versions 2.4 or later. If your system’s Firmware is a prior version, contact your distributor for updates.

Manual No. 0-4818 Auto-Cut 300

4-12 OPERATION

Status Code Key

Status

Message Cause/Remedy

Code

1-1 System not Enabled or Missing

AC Input Phase

Plasma Enable Off ; External E-Stop Activated or CCM TB1-1&2 jumper missing; Missing AC Phase; No power to GCM 2000 or 2010 Gas Control, check GCM control cable connected, reset CP4 or CP5 circuit breaker in power supply, blown fuse F19 in GCM.

1-2 Pilot Ignition Failure

Pilot did not start within 15 seconds. Preflow pressure too high; Defective Arc Starter

1-3 Lost Pilot Pilot went out without shutoff signal; Preflow pressure

too high; cut current set too low for consumables.

1-4 Loss of Transfer Arc transfer (>50 ms.) then arc lost with START still on.

Standoff too high; Current set too low. 1-5 Of the Plate Function not currently enabled. 1-6 Pilot Timed out w/o Transfer Must transfer from Pilot to Cutting Arc in 85 ms. (SW8-1

OFF) or 3 sec. (SW8-1 ON). Standoff too high or void in

work under torch; cut current too low for consumables;

Preflow pressure too low. 1-7 Tip Saver Function not currently enabled. 1-8 Possible Shorted Torch Detected tip voltage too close to electrode voltage.

Plasma flow/pressure too low; Plasma leak; cut current

too high; shorted torch body; consumable parts worn out.

2-1 Missing Phase Blown fuse, Broken or loose connection on power cable 2-2 Wrong input voltage

Inverter(s) not configured correctly for input voltage;

Poor power quality (brownouts, dropouts);

Input power capacity / wiring too small causing voltage

drop; broken or loose power cable connections. 2-3 Inverter or Pilot Regulator Over

Temperature

Failed fan; Ambient above 40 deg C. (104 F); Blocked

airflow 2-4 Power Supply not Ready PCB7, PCB4, poor connection, Defective inverter 2-5 DC Output Low Output less than 60 VDC; Defective inverter, shorted

output; Shorted pilot regulator (chopper); CCM voltage

sense (J6) wire open or disconnected. 2-6 Primary over current or

imbalance fault

Over current or imbalance detected in inverter primary

circuit, remove power to reset; defective inverter; voltage

surge. 2-7 Unexpected current Current >20A in work or pilot leads before pilot ignition;

Possible shorted torch; Defective current sensor. 2-8 Unexpected current in pilot

circuit

Current > 5A in pilot circuit; wrong or mismatched

consumables; Pilot lead shorted to negative in torch tube;

Possible shorted torch 2-9 Unexpected current in work

lead

Current > 5A in work lead; Short to chassis in RAS;

Negative lead short to gnd.

Manual No. 0-4818 Auto-Cut 300

4-13 OPERATION

Status Code Key (cond)

Status

Code

3-1 Gas Con tro l Co mmunica tion

fault, Cannot establish Communication with gas control.

3-2 Gas Con tro l Co mmunica tion

reply fault, connection was established but CCM did receive a reply to a process reques t.

3-3 Gas Pressure Low

3-4 Gas Control not ready Purging; not in RUN mode; Gas Control faulty, replace PCB.

3-5 Gas Control Proto col Fault Applicat ion error o r firmware co mpatibility fault

Message Cause/Remedy

If GCM 1000: Control cable not connected or Basic ID signal open.

GCM 2010 & 2000: Dirt on fiber ends or in connectors, blow out with clean dry air; fiber not locked into connector; sharp bends in fiber; fiber defective; Gas Control PCB defective, replace. CCM defective, replace.

Gas Control did not reply to signal from CCM in allowed time. Dirt on fiber ends or in connectors, blow out with clean dry air; fiber not locked into connector; s harp ben ds in fiber; fiber defective. If problem pers is ts Gas Contro l PCB likely defective, replace board.

If GCM 1000, Plasma < 15 PSI; faulty or disconnected pressure SW. If GCM2010_AG, GCM2000_AC or later or Gas Control has been updated with 19X2219_AG or later PCB: Plasma or Shield input out of range 105-135

3-6 Invalid Current Control level

from GCM

3-7 Gas Control returns wrong

GCM sent output current level outside the range of the power supply, Check firmware co m

at ib ilit

Check firmware co mpatibility

command sequence

3-8 CCM and Gas Co n t rol ty pe

Ins tall correct CCM or Gas Control for s ys tem

(Autocut-Ultracut) mismatch

3-9 Gas Con tro l Co mmunica tion

Reply not compatible with request; Check firmware compatibility

reply fa ult

3-10 Warning. -- Gas Control System will function but control may not be optimized for best

4-1 Coolant Level low fault Check coolant level, add as needed. 4-2

Low coolant flow after power on purge.

Suction leak introducing air into coolant, suspect rear panel filter seal;

clogged filter; defective pump. Not cu t ting: < 0.7 g al/min fo r 15 sec; Cutting: flow between 0.35 to

0.7 ga l/min for 3 s ec. or

4-3

Coolant overheated

deg. C, 158 deg F)

4-4

Coolant S ys tem not ready

(>70

Coolant fan failed; radiator fins clogged with dirt; Ambient temperature >

40 deg C.

. If new installation recycle power to restart pump, may take a few times to

fill hoses; During power on purge / priming, flow did not reach 0.35

Damaged torch coolant tube; Suction leak introducing air into coolant,

suspect rear panel filter seal; clogged filter; defective pump. gal/min for at least 5 seconds

4-5 Low Coolant Level - Warning

Manual No. 0-4818 Auto-Cut 300

While cutting detected low coolant level, does not stop cut.

Add coolant as required.

4-14 OPERATION

Status Code Key (cond)

Status

Code

5-1 CANBUS Failure to

Acknowledge fault.

CANBUS Off d ue to

5-2 Dirt on fiber ends or in connectors, blow out with clean dry air; fiber not

exces s ive d ata erro rs ;

5-3 Dirt on fiber ends or in connectors, blow out with clean dry air; fiber not

CANBUS data error warning

Errors increas ing, will s oon fault.

5-4 CCM Message not sent Dirt on fiber ends or in connectors, blow out with clean dry air; fiber not

6-1 CCM Analog Voltage Error Replace CCM

6-2 CCM A DC o r DA C erro r Rep la ce CCM

6-3

Coolant Flow too High err or

flow > 2.7 gal/min

6-4 CCM Da ta Memo ry e rror Rep la ce CCM

Message Cause/Remedy

If GCM 1000, Basic ID signal missing; Other gas controls, Fiber disconnected or broken, Transceiver (what fiber plugs into) fault, replace Gas contro l PCB or CCM

locked into connector; shar

bends in fiber; fiber d efective;

locked into conn ector; s harp bends in fiber; fiber defective;

locked into conn ector; s harp ben ds in fiber; fiber defective; CANBUS hardware e rror (CCM or Gas Con trol PCB)

Torch coolant tube broken or missing;

CCM fault, replace CCM

Manual No. 0-4818 Auto-Cut 300

4-15 OPERATION

4.07 Remote Arc Starter: Service Chart

Arc Starter Service Chart

Symptom Cause Check Remedy

Coolant has become conductive Use conductivity meter

Pilot return wire not connected Vis ual inspection Connect Wire. Spark gap set too close Check with feeler gauge Set to 0.063" ±0.002"

No Pilot ignition:

Spark in Arc Starter

but no ignition

No Pilot ignition:

No Spark

in Arc Starter

No cooling or

insufficient coolin

Leaks coolant

No cooling or

insufficient coolin

No Coolant Flow

Erratic System

Behavior

(EMI Interference)

High Frequency cap (C4) poss ibly open Broken or m issing ferrites Visual inspection Replace.

Short across in inductor (L1) Visual ins pection

Spark (C1, C2, C3) broken or defective Nega tive s upp ly not connected correctly Spark gap set too large Check with feeler gauge Set to 0.063" ±0.002" Faulty transformer Resistance measurement Replace.

No 120V supply Check input voltage at EMI filter

No/ loose connection to spark gap Faulty EMI filter Voltage/ Resistor measurement Replace. Loose fitting(s) Visual inspection Tighten fittings. Failure to braze joints (L1) Visual inspection Replace HF Coil.

Damaged or punctured coolant line(s).

Supply & return hose reversed

Blockage in coil or supply/return hoses

shield connector missin

Mis sing or loose ground connection

Cap C5 not connected, open or loose

ap bus caps

hield Drain / Torch lead inner

or loose.

Use capacitance meter Reconnect or replace.

Capacitance meter Replace.

Visual inspection Reconnect.

Visual inspection Replace coolant line(s).

Visual Inspection of color-coded connections

Loosen fitting slightly and check for coolant flow

Visual inspection of lead attachment to Arc Starter

Visual inspection of ground wire to Arc Starter

Visual inspection / capacitor measurement

Flush system, replace coolant.

Remove short; increase coil gaps.

Make connections; replace harness.

Match coolant connection colors to arc starter fitting colors.

Flush system.

Reconnect / tighten lead connectors.

Make or tighten connections to good ground.

Replace PCB.

Manual No. 0-4818 Auto-Cut 300

4-16 OPERATION

4.08 Remote Arc Starter: Spark Gap Adjustment

0.063" ± 0.002"

1.6 ± 0.05 mm

Art # A-04857

Manual No. 0-4818 Auto-Cut 300

4-17 OPERATION

Intentionally Blank

SECTION 5: MAINTENANCE

5.01 General Maintenance Checks

Perform the following checks periodically to ensure proper system performance.

Power Supply Maintenance Schedule

Daily

Check coolant level; add coolant as needed. Check gas hose connections and pressures.

Monthly

Check cooling fan and radiator; clean as needed. Check gas hoses for cracks, leaks, or abrasion. Replace as needed. Check all electrical connections for cracks or abrasion. Replace as needed.

Six Months

Clean or replace external coolant filter. Clean coolant tank. Vacuum out any dust buildup inside power supply. Check internal coolant filter

5.02 External Coolant Filter Cleaning Procedure

Periodic cleaning of the coolant filter ensures maximum coolant flow efficiency. Poor coolant flow causes inefficient torch parts cooling with consequent faster consumable wear.

Clean the coolant filter as follows:

1. Disconnect the system from main input power.

Filter Screen

Filter Holder

Art # A-04811

2. Unscrew and remove the filter bowl by hand. Be sure to keep the O-ring.

3. Remove and clean the filter. Re-install the bowl, tightening it by hand. Be sure the O-ring is in place.

4. Turn the system on and check for leaks.

Manual No. 0-4818 Auto-Cut 300

5-1 MAINTENANCE

5.03 Internal Coolant Filter Cleaning Procedure

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

5.04 Coolant Replacement Procedure

Replace coolant as follows:

1. Disconnect the system from main input power. At the bottom of the coolant tank, disconnect the coolant line fitting and collect coolant in a disposable container.

2. Connect the system to main input power and turn it on to allow the pump to empty the tank. The pump will run approximately for 20 seconds before the flow switch causes an interlock. This procedure may be repeated a few times until the tank is completely empty.

3. Connect the coolant line fitting and fill the tank with fresh coolant until the right level is reached.

COOLANT

RETURN

SUPPLY

RETURN

SUPPLY

Fill Range

Coolant Tank

Art # A-04803

4. Turn system on, let it run for a few minutes and check coolant level, refill if necessary.

Manual No. 0-4818 Auto-Cut 300

5-2 MAINTENANCE

SECTION 6: REPLACEMENT ASSEMBLIES & PARTS

6.01 Replacement Power Supply

Complete Unit / Component Catalog Number

Auto-Cut® 30O

Power Supply, 208/230V 3-9115-1

Auto-Cut® 30O2 Power Supply, 460V 3-9115-2

Auto-Cut® 30O Auto-Cut® 30O

Auto-Cut® 30O

Power Supply, 400V 3-9115-3

Power Supply, 400V, (CE) 3-9115-4

Power Supply, 600V, (CSA) 3-9115-5

Gas Control Module (GCM-2000) with Torch Valve Assembly 3-9133

Gas Control Module (GCM-2000) Only 9-9435

Torch Valve Assembly Only 9-9436

Remote Arc Starter (RAS-1000) 3-9130

OPTIONAL EQUIPMENT:

Wheel Kit 9-9379

Manual No. 0-4818 Auto-Cut 300

6-1 Parts List

6.02 Auto-Cut 30O2System Layout

Refer to section 3.05 for ground connections and ground cables.

Primary power

CNC

Art # A-09951

125’ / 38.1 m Maximum Length

Pilot Return

Negative Lead

300-A Power Supply

Fiber

Optic

Cable

Control

Cable

175’ / 53.3 m Maximum Length

Coolant Supply

Coolant Return

Control Cable

Gas Control

Module

Plasma Gas

Shield Gas

Preflow Gas

Control

Cable

Water

Shield

Remote

Arc

Starter

Torch

Valve

Assembly

Work Cables (2)

50’ / 15.2 m Maximum Length

Pilot Return

Coolant Supply w/ Negative

Coolant Return

Plasma Gas Shield Gas

Positioning Tube

Shield

Work

Torch

6.03Recommended Gas Supply Hose

Item # Qty Description Catalog #

1 3/8”Gray Synflex Hose. No fittings included. Catalog number per foot 9-3616

Manual No. 0-4818 Auto-Cut 300

6-2 Parts List

Length

1 m

10'

3.1 m 15'

4.5 m 20'

6.1 m 25'

7.6 m 30'

9.1 m 35'

10.6 m 50'

15.2 m 75'

22.9 m

100'

30.5 m

125'

38.1 m

150'

45.7 m

175'

53.3 m

A,B,C,

D,E*

Catalog Numbe rs for Auto-Cut 30O

BFF1**G

Cables and Leads

H,Q,R,

S,T

I,J K L O P

Fiber

Supply

Lead

Set

Nega tive

Lead

4-3027 9-4892

Ground

Wire

9-4923

(3' / 1 m )

Ground

Wire,

RAS

9-4931

(3' / 1 m)

Torch

Lead Set

Gas

Lead

Set

4-3026

Torch

Lead

Set

Control

Cable

9-4907

(3' / 1 m)

Optic

Control

Cable

9-4898

(3' / 1 m)

Work

Cable

(X 2)

Control

Cable

4-3028 9-4897 4-3062 4-3035 9-9300

4-3029 9-4798 9-4924 9-4932 4-3063 4-3036 9-4908 9-4899 9-9301

4-3064

4-3030 9-4799 9-4925 9-4933 4-3065 4-3037 9-4909 9-4900 9-9302 9-8312

4-3066

4-3050 9-9427 4-3078 4-3051 9-9332 9-9335 9-9303

4-3031 9-4800 9-4926 9-4934 4-3079 4-3038 9-4910 9-4901 9-9304 9-8313

4-3032 9-4801 9-4927 9-4935 4-3039 9-4911 9-4902 9-9305 9-8315

4-3033 9-4802 9-4928 9-4936 4-3040 9-4912 9-4903 9-9306 9-8316

4-3034 9-4804 9-4929 9-4937 4-3041 9-4913 9-4904 9-9307 9-8317

9-4930 9-4938 4-3042 9-4914 9-4905

4-3043 9-4906

*NOTE: When purchasing a supply leads set, you must also order one extra negative lead from column B

**NOTE: If GCM is placed on power supply, 2 (F1) cables are required. Refer to grounding information in section 3.

Manual No. 0-4818 Auto-Cut 300

6-3 Parts List

#8 AWG Cable

Pilot Return, Power Supply to Arc Starter

Art # A-09952

2/0 (70 mm ) Cable

Negative Lead, Power Supply to Arc Starter

Green

Red

Green

Red

Coolant Supply Lead, Power Supply to Arc Starter

Coolant Return Lead, Power Supply to Arc Starter

Control Cable, Power Supply

Green / Yellow # 4 AWG

Green / Yellow 1/0 (50 mm )

to Arc Starter

Ground Cable

Ground Cable, Remote Arc Starter To Earth Ground

Shielded Torch Lead Assembly, Remote Arc Starter to Torch

Plasma Gas Lead, Torch Valve to Torch

H, Q, R, S,T

2/0 (70 mm ) Cable

Shield Gas Lead, Torch Valve to Torch

Control Cable, Power Supply to Gas Control Module

Fiber Optic Cable, Power Supply to Gas Control Module

Work Cable

CNC Cable (14 Wire)

Manual No. 0-4818 Auto-Cut 300

6-4 Parts List

6.04 Power Supply External Replacement Parts

Item # Qty Description Catalog #

1 1 Power Supply Front Panel N/A

2 1 Power Supply Rear Panel N/A

3 1 Power Supply Top Panel 9-0445G/9-0455B

4 1 Power Supply Right Side 9-0500G/9-0500B

5 1 Power Supply Left Side 9-0501G/9-0501B

6 1 Louver Panel N/A

7 1 Power Supply Connections Cover N/A

8 1 Lifting Eye 9-9373

Manual No. 0-4818 Auto-Cut 300

Art # A-08281_AB

6-5 Parts List

6.05 Power Supply Replacement Parts - Right Side

Item # Qty Description Ref. Des. Catalog #

1 1 Heat Exchanger Fan FAN1, FAN2 9-9338

2 1 Radiator 9-9339

Art # A-08283

Manual No. 0-4818 Auto-Cut 300

6-6 Parts List

6.06 Power Supply Replacement Parts - Right Side

Item # Qty Description Ref. Des. Catalog #

1 1 Output Filter PC PCB8 9-9341

2 1 Sensor HCT2 9-9368

3 1 Magnetic Contactor, pilot MC2 9-9343

4 1 Resistor R6 9-9340

5 1 Resistor R9

6 1 Capacitor C2

Art # A-04777_AB

Manual No. 0-4818 Auto-Cut 300

6-7 Parts List

6.07 Power Supply Replacement Parts - Front Panel

Item # Qty Description Ref. Des. Catalog #

7 1 Main Power Switch (‘Circuit Protector’) CP1 9-9344

for 230/460 VAC units

Art # A-04779_AB

Manual No. 0-4818 Auto-Cut 300

6-8 Parts List

6.08 Power Supply Replacement Parts - Right Side

Item # Qty Description Ref. Des. Catalog #

1 Chopper Module 9-9389

1 Sensor HCT1 9-9342

Chopper Module

HCT1

Art # A-07064_AB

Manual No. 0-4818 Auto-Cut 300

6-9 Parts List

6.09 Power Supply Replacement Parts - Rear Panel

Item # Qty Description Breaker Rating Cicuit Rating Ref. Des. Catalog #

12 1 Circuit Breaker (RAS) 125V, 2.5 A 120VAC @ 1A CP2 9-9348

13 1 Circuit Breaker (’TDC’) 125V, 3.15A 24VAC @ 2A CP3 9-9349

14 1 Circuit Breaker (AGC) 125V, 10A 24VAC @ 5A CP4 9-9350

15 1 Circuit Breaker (AGC) 125V, 2.5A 120VAC @ 1A CP5 9-9348

16 1 Circuit Breaker (AGC) 125V, 2.5A 15VDC @ 1A CP6 9-9348

17 1 Circuit Breaker (Pump) 250V, 10A 200VAC @ 3A CP7 9-9351

18 1 Circuit Breaker (Fan) 125V, 3.15A 24VDC @ 1A CP8 9-9349

1 Coolant Tank 9-5948

1 Tank Cap 8-5142

1 Filter, Coolant 8-4276

CIRCUIT

Tank Cap

COOLANT

RETURN

SUPPLY

J55

G C

J15

C N C

J59

R A S

BREAKERS

125V 2.5A

125V3.15A

125V2.5A

125V 3.15A

RAS

CCM

GCM

125V 10A

GCM

PUMP

250V 10A

FAN

CP2

CP3

CP4

CP5

CP6

CP7

CP8

Coolant Tank

Manual No. 0-4818 Auto-Cut 300

Filter

Art # A-06017_AC

Art # A-04932_AB

6-10 Parts List

6.10 Power Supply Replacement Parts - Right Side

Item # Qty Description Ref. Des. Catalog #

1 1 Resistor R7 9-9363 2 1 Rectifier (Diode) D1 9-9345 3 1 Transformer T1 9-9355

for 230/460 VAC units 4 1 Diode D2 9-9486 5 1 Terminal Strip TB3 N/A

Art # A-04785_AC

Manual No. 0-4818 Auto-Cut 300

6-11 Parts List

6.11 Power Supply Replacement Parts

Item # Qty Description Catalog #

3 Inverter Module 208/230V 9-9360D 3 Inverter Module 400V CE and 400V Non CE 9-9482D 3 Inverter Module 600V 9-9485D

Art # A-08284

Manual No. 0-4818 Auto-Cut 300

6-12 Parts List

Thermal Dynamics AUTO-CUT 30 O2 Operating Manual

Specifications and Main Features

Frequently Asked Questions

User Manual