Victor Auto-Cut 200 XT Operating Manual
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Victor Auto-Cut 200 XT Operating Manual

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

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Summary of Contents for Victor Auto-Cut 200 XT

  • Page 1 AUTO-CUT 200 XT ™ PLASMA CUTTING SYSTEM Operating Manual Revision: AE Issue Date: January 16, 2014 Manual No.: 0-5253 VictorThermalDynamics.com...
  • Page 2 We know you take pride in your work and we feel privileged to provide you with this high performance product that will help you get the job done. For more than 50 years Victor Thermal Dynamics has provided quality products you can trust, when your reputation is on the line.
  • Page 3 Manufacturer assumes no liability for its use. Plasma Cutting Power Supply, Auto-Cut 200 XT™ ® Operating Manual No. 0-5253 Published by: Victor Technologies 82 Benning Street West Lebanon, New Hampshire, USA 03784 (603) 298-5711 www.thermal-dynamics.com © Copyright 2013 by Victor Technologies All rights reserved.
  • Page 4 This page intentionally blank...

  • Page 5: Table Of Contents

    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...
  • Page 6 TABLE OF CONTENTS SECTION 5: MAINTENANCE....................5-1 5.01 General Maintenance .................5-1 5.02 Coolant Filter Cleaning Procedure ..............5-1 5.03 Coolant Replacement Procedure ..............5-2 5.04 Arc Starter Service ..................5-3 5.05 Arc Starter Spark Gap Adjustment .............5-4 SECTION 6: REPLACEMENT ASSEMBLIES & PARTS ............6-1 6.01 Replacement Power Supply ................6-1 6.02...
  • Page 7 TABLE OF CONTENTS APPENDIX 13: CAP BIAS TOP PCB LAYOUT ..............A-31 APPENDIX 14: SUPPRESSOR PCB LAYOUT ..............A-32 APPENDIX 15: WMS GAS BOX LAYOUT ................A-33 APPENDIX 16: COOLING DIAGRAM .................. A-34 APPENDIX 17: SYSTEM SCHEMATIC PG 1 ............... A-36 APPENDIX 18: SYSTEM SCHEMATIC PG2 ................
  • Page 8 TABLE OF CONTENTS...

  • Page 9: General Information

    AUTO-CUT 200 XT SECTION 1: GENERAL INFORMATION GASES AND FUMES Gases and fumes produced during the plasma cutting process can be dangerous and hazardous to your health. 1.01 Notes, Cautions and Warnings • Keep all fumes and gases from the breathing area. Keep your Throughout this manual, notes, cautions, and warnings are used to head out of the welding fume plume.

  • Page 10: Publications

    AUTO-CUT 200 XT * 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. FIRE AND EXPLOSION Fire and explosion can be caused by hot slag, sparks, or the plasma arc.

  • Page 11: Note, Attention Et Avertissement

    AUTO-CUT 200 XT 1.05 Precautions De Securite Importantes 12. CSA Standard W117.2, CODE FOR SAFETY IN WELDING AND CUTTING, obtainable from the Canadian Standards As- sociation, Standards Sales, 178 Rexdale Boulevard, Rexdale, Ontario, Canada M9W 1R3 AVERTISSEMENTS 13. NWSA booklet, WELDING SAFETY BIBLIOGRAPHY obtainable L’OPÉRATION ET LA MAINTENANCE DU MATÉRIEL...
  • Page 12 AUTO-CUT 200 XT • Pour protéger vos yeux, portez toujours un casque ou un écran • Ce produit, dans le procéder de soudage et de coupe, produit de de soudeur. Portez toujours des lunettes de sécurité munies de la fumée ou des gaz pouvant contenir des éléments reconnu dans parois latérales ou des lunettes de protection ou une autre sorte L’état de la Californie, qui peuvent causer des défauts de naissance de protection oculaire.

  • Page 13: Documents De Reference

    AUTO-CUT 200 XT 1.06 Documents De Reference 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 Consultez les normes suivantes ou les révisions les plus récentes ayant ASSOCIÉS, disponible auprès de la National Fire Protection As-...

  • Page 14: Declaration Of Conformity

    Rigorous testing is incorporated into the manufacturing process to ensure the manufactured product meets or exceeds all design specifications. Victor Technologies. has been manufacturing products for more than 30 years, and will continue to achieve excellence in our area of manufacture.
  • Page 15 AUTO-CUT 200 XT Classification: The equipment described in this manual is Class A and intended for industrial use. WARNING This Class A equipment is not intended for use in residential locations where the electrical power is provided by the public low- voltage supply system.

  • Page 16: Statement Of Warranty

    AUTO-CUT 200 XT 1.08 Statement of Warranty LIMITED WARRANTY: Victor 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...

  • Page 17: Section 2: Specifications

    AUTO-CUT 200 XT SECTION 2: SPECIFICATIONS 2.01 General Description Of The System A typical Auto-Cut 200 XT™ plasma cutting system includes: • One Power Supply • General Purpose Plasma Cutting Torch with Connecting Leads • Torch Spare Parts Kit The components are connected at installation.

  • Page 18: Power Supply Specifications & Electrical Requirements

    AUTO-CUT 200 XT 2.05 Power Supply Specifications & Electrical Requirements Auto-Cut 200 XT™Power Supply Specifications Max OCV (U0) 400 vdc Max Output Current 200 Amps Output Voltage 60 - 170 vdc Duty Cycle Rating 100% @ 200A @ 200V (40 kW) Operating range 14°F to 122°F (-10°C to + 50°C)

  • Page 19: Power Supply Dimensions

    AUTO-CUT 200 XT 2.06 Power Supply Dimensions 47.77 inch 1213 mm 35.97 inch 914 mm 490 lb / 222 kg 27.6 inch 701 mm Art # A-11460_AB Manual 0-5253 SPECIFICATIONS...

  • Page 20: Power Supply Rear Panel Features

    AUTO-CUT 200 XT 2.07 Power Supply Rear Panel Features Customer Circuit Breakers Optional Ports Plasma Gas Port USER INPUT Shield Gas Port Connector HEIGHT CONTROL Optional Water C.C.M. AIR / O / H35 J15 - CNC PLASMA PLASMA Mist Port...

  • Page 21: Gas Requirements

    The customer will provide all gases and pressure regulators. Gases must be of high quality. Pressure regulators shall be equipped with stainless-steel diaphragms and installed as close as possible to the Gas Console. Auto-Cut 200 XT™BASIC Power Supply: Gas Pressures, Flows, and Quality Requirements Quality...

  • Page 22: Xt Tm -301 Torch Specifications

    AUTO-CUT 200 XT 2.10 XT -301 Torch Specifications A. Torch Dimensions Art # A-11538 End Cap 19" 2.25" 482.7 mm 57.15 mm Mounting Tube 2.0" 15.5" 50.8 mm 393.8 mm 6.3" 160.1 mm 2.4" 61 mm 3.98" 101.1 mm 2.7"...
  • Page 23 AUTO-CUT 200 XT C. Torch Parts (Generic Parts Shown) Art # A-04741_AB Plasma Gas Shield Gas Distributor Distributor Shield Cap Electrode Shield Cup Cartridge D. Parts - In - Place (PIP) The torch is designed for use with a power supply which senses coolant return flow to confirm that torch parts are in place.
  • Page 24 AUTO-CUT 200 XT F. XT -301 Torch Data (with Auto-Cut 200 XT™ Power Supply) -301 Torch Ratings (when used with Auto-Cut 200 XT™Power Supply) Ambient 104° F Temperature 40° C Duty Cycle 100% @ 200 Amps Maximum Current 200 Amps...

  • Page 25: Section 3: Installation

    3.01 Installation Requirements Electric Supply The electrical supply network, the gas and water supply system must meet local safety standards. This conformity must be checked by qualified personnel. Auto-Cut 200 XT™Power Supply Input Power Input Current Suggested Sizes (See Note) Voltage Freq.

  • Page 26: Cables And Leads Identification

    AUTO-CUT 200 XT 3.02 Cables and Leads Identification Refer to section 3.05 and 3.06 for ground connections and ground cables. G: Torch Lead Set, Shielded - Coolant Supply w/ Negative - Coolant Return - Pilot Return Auto-Cut XT - Plasma Gas...

  • Page 27: Cables & Leads Identification

    AUTO-CUT 200 XT 3.03 Cables & Leads Identification Ground Cable, Green / Yellow 1/0 (50 mm ) Arc Starter To Earth Ground Torch Lead Set 1/0 (50 mm ) Cable Work Cable CNC Cable (14 Wire) Art # A-11688 Manual 0-5253...

  • Page 28: Position The Power Supply

    AUTO-CUT 200 XT 3.04 Position 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 the lifting eye when using straps to lift the power supply.

  • Page 29: Primary Power Connections

    AUTO-CUT 200 XT 3.05 Primary Power Connections The primary power cable and through hole cable grip must be supplied by the end user and connected to the power supply. Refer to local and national electrical codes for suggested cable and fuse sizes.

  • Page 30: Ground Connections

    AUTO-CUT 200 XT Auto-Cut XT System Cutting Machine / Gantry Torch Auto-Cut Device Power Supply Cutting Table Ground Cable 1/0 Work Cable Customer Supplied Earth Ground 1/0 Ground Cable (F1) ‘Star’ Art # A-11553 0 - 10 ft (0 - 3 m) Ideal...
  • Page 31 AUTO-CUT 200 XT 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 connec- tion to the cutting table.
  • Page 32 AUTO-CUT 200 XT To test for a proper earth ground, refer to the following diagram. Ideally, the reading on the multimeter should be 3 VAC for 115VAC line, or 1.5 VAC for 230 VAC line. CAUTION Remove all other connections from the ground rod during this test.

  • Page 33: Connect Work Cable

    AUTO-CUT 200 XT 3.07 Connect Work Cable 1. Refer to the illustration below. Pass the end of the work cable through the cord grip at the back of the power supply rear panel, then through the bottom opening in the bulkhead panel.

  • Page 34: Connect Gas Supply Lines

    AUTO-CUT 200 XT 3.08 Connect Gas Supply Lines 1. Connect the gas supply lines to the appropriate input ports shown below. The first view shows factory default for using shop air. All other gasses to use the second view, bypassing the two stage air filter.

  • Page 35: Connect Cnc Cable

    AUTO-CUT 200 XT 3.09 Connect CNC Cable 1. Connect one end of the CNC cable to the power supply receptacle marked ‘CNC’. 2. Connect the other end of the cable to the CNC device. 3. The CNC cable shield must be attached to ground.

  • Page 36: Height Control Connections

    AUTO-CUT 200 XT 3.10 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.

  • Page 37: Connect Torch Leads To The Arc Starter

    AUTO-CUT 200 XT 3.11 Connect Torch Leads to the Arc Starter 1. Remove the top cover. 2. Pass the torch leads and coolant leads through the torch leads port on the back of the module. Ensure that the leads outer jacket slides into the port.
  • Page 38 AUTO-CUT 200 XT Coolant Supply Connection (Tagged Green) Plasma Gas Connection Shield Gas Connection Coolant Return Connection (Tagged Red) Art # A-11529 Torch Leads 5. Fold the end of the leads outer webbed shielding jacket back and over the connection ring inside the module.

  • Page 39: Torch Head Installation And Connection

    AUTO-CUT 200 XT 3.12 Torch Head Installation and Connection Install the Torch as follows: 1. Install the torch mounting block on the cutting table (gantry). Fasten the block in place. 2. Leave the end cap in place on the torch leads. Remove and discard the protective end caps from the Mount- ing Tube.

  • Page 40: Install Consumable Torch Parts

    AUTO-CUT 200 XT 5. Slide the positioning tube down to the torch head. Hold the torch head stationary. Rotate the positioning tube onto the torch head. Pull the leads back as needed to ensure a proper fit through the Mounting Tube.
  • Page 41 AUTO-CUT 200 XT 1: Stack Parts 2: Press Cartridge onto Stacked Parts Electrode Plasma Gas Distributor O-Ring on Tip No Gaps Between Parts Shield Gas Cartridge Covers Distributor O-Ring on Torch Tip Shield Cap 4: Check Shield Cap Protrusion 3: Thread Shield Cup onto Cartridge...
  • Page 42 AUTO-CUT 200 XT 5. Use the removal tool to hold the cartridge assembly, while turning the shield cup onto the cartridge assem- bly. When this group is fully assembled, the shield should protrude from the front of the shield cup 0.063”...
  • Page 43 AUTO-CUT 200 XT 7. Confirm proper parts assembly as shown. Torch Head Torch Head O-Ring 0.063 - 0.083" (1.6 - 2.1 mm) Protrusion Art # A-07202 8. Slide the ohmic clip over the shield cup if using ohmic torch height sensing.

  • Page 44: Voltage Divider For Ihc Torch Height Control

    Cutting tables use a Torch Height Control (THC), also called a Z axis control, most of which use feedback from the arc voltage to control the height. Several of these, including the iHC, part of the Victor Technologies XT CNC Controller, come with a Voltage Divider Printed Circuit Board that has to be installed inside the plasma power supply to divide the high arc voltage down to lower levels for use with control circuits.

  • Page 45: Control Cable

    AUTO-CUT 200 XT Control Cable. The iHC board can be supplied with a wire harness and connector (shown in previous image), to be installed in the rear panel hole labeled “Height Control” . The connector mates with a cable from the iHC. For other height control V-D boards a strain relief can be installed in this hole for those cables.

  • Page 46: 3:15 Fill Cooling System

    AUTO-CUT 200 XT 3:15 Fill Cooling System 1. Fill the coolant tank to the level shown, with Thermal Dynamics coolant. The coolant level is visible through the translucent coolant tank. The amount of coolant required varies with torch leads length.
  • Page 47 AUTO-CUT 200 XT 2. After the complete system has been installed, check that the coolant has been pumped through the system as follows (see NOTE): NOTE The system will most likely require more coolant after turning the system ON for the first time.
  • Page 48 AUTO-CUT 200 XT This Page Intentionally Blank 3-2� INSTALLATION Manual 0-5253...

  • Page 49: Section 4: Operation

    AUTO-CUT 200 XT SECTION 4: OPERATION 4.01 Power Supply Indicators AC Indicator Gas Indicator Status Indicator Temp Indicator DC Indicator Art # A-11467 AC Power Lamp Indicates unit has passed the input power tests and AC power is being supplied to the inverter modules via the input contactor when the ON/OFF switch is in ON position.

  • Page 50: Control Console Features

    AUTO-CUT 200 XT 4.02 Control Console Features Standard System PLASMA SHIELD Art # A-11468 Plasma Gas Shield Gas Pressure Gauge Pressure Gauge PLASMA SHIELD Plasma Gas Pressure Shield Gas Pressure Control Knob Control Knob Amperage / Run / Set Selector...
  • Page 51 AUTO-CUT 200 XT Optional System with Water Mist (H PLASMA SHIELD 0 MIST SHIELD GAS Art # A-11468 0 MIST Plasma Gas Shield Gas Pressure Gauge Pressure Gauge PLASMA SHIELD Plasma Gas Pressure Shield Gas Pressure Control Knob Control Knob...

  • Page 52: Operating Set-Up

    AUTO-CUT 200 XT 4.03 Operating Set-up Follow this set-up procedure each time the system is operated: WARNING Disconnect primary power at the source before assembling or disassembling power supply, torch parts, torch and leads assemblies or adding coolant. A. Coolant Level Inspection Check the coolant level in the coolant tank at the front of the unit.
  • Page 53 AUTO-CUT 200 XT H. Plasma Gas Purge Move the Power Supply ON/OFF switch to the ON position. An automatic gas purge will remove any condensation that may have accumulated in the torch and leads while the system was shut down. After the purge is complete, if the RUN/SET switch is in SET position, gases will flow.

  • Page 54: System Operation

    AUTO-CUT 200 XT 4.04 System Operation This section contains operating information which is specific to the power supply. WARNINGS Frequently review the safety precautions in Section 1. If the power supply cord has a plug or is not permanently connected to power, be sure the power to the outlet is disconnected when inserting the plug into the outlet.
  • Page 55 AUTO-CUT 200 XT 3. Set Gas Pressures a. Place RUN/SET switch in SET mode. b. Adjust plasma and shield pressure regulators to correct pressure or correct flow if using H O Mist option. (refer to manual Section 2 for required pressure/flow.) c.
  • Page 56 AUTO-CUT 200 XT 11. Shut off the system. a. Set the ON/OFF power switch on the front panel of the unit to OFF. Warning! AC power is still present inside the unit. • Fans and pump as well as all indicators turn off.

  • Page 57: Gas Selection

    AUTO-CUT 200 XT 4.05 Gas Selection A. Plasma Gases 1. Air Plasma • Most often used on ferrous or carbon base materials for good quality at faster cutting speeds. • Air plasma is normally used with air shield. • Only clean, dry air is recommended for use as plasma gas. Any oil or moisture in the air supply will substantially reduce torch parts life.

  • Page 58: Power Supply Status Codes

    AUTO-CUT 200 XT 4.06 Power Supply Status Codes NOTE See the Appendix for Advanced Troubleshooting On start-up and during operation, the power supply control circuitry performs various tests. If the circuitry detects a condition requiring operator attention, the status display on the front panel shows a 3 digit code preceded by either letter “E”...
  • Page 59 AUTO-CUT 200 XT CCM Status Code Group 2 -- Plasma Power Supply Code Message Remedy / Comments Blown wall fuse, Blown unit fuse F1 or F2 or rear panel, Bad power cable connection; Defec- Missing AC Phase tive System Bias PCB. Not used Reserved for legacy product Not used Reserved for legacy product Not used Reserved for legacy product Less than 60 VDC; Negative lead short to work or ground; Defective inverter (output...
  • Page 60 AUTO-CUT 200 XT Code Message Remedy / Comments Inverter 2A Incom- Unsupported Inverter Revision; Ribbon cable CCM J33 to Inverter Module 2 Section A dam- patible Revision aged; CCM code version incompatible with Inverter revision or model Not used Reserved for other models with additional inverter sections. Not used Reserved for other models with additional inverter sections. Not used Reserved for other models with additional inverter sections.
  • Page 61 AUTO-CUT 200 XT Code Message Remedy / Comments Inverter 2A Circuit Inverter Module 2 Section A detected a circuit fault; Damaged Inverter Module 2 Fault Not used Reserved for other models with additional inverter sections. Not used Reserved for other models with additional inverter sections. Not used Reserved for other models with additional inverter sections.
  • Page 62 AUTO-CUT 200 XT CCM Status Code Group 3 -- Gas Controller Status & Protocol Code Message Remedy / Comments Not used Reserved for other models. Reserved No information available; Contact customer service Gas Supply Pressure Autocut is in SET mode or Plasma gas pressure is too low; Defective gas pressure sensor out of range. (PS1). Gas Control Purging Normal following power up or returning from Plasma Disable.
  • Page 63 AUTO-CUT 200 XT CCM Status Code Group 6 -- CCM Code Message Remedy / Comments Analog Voltage Error Defective CCM, replace. ADC or DAC error Defective CCM, replace. Reserved No information available; Contact customer service Data Memory error Defective CCM, replace. Program memory fault Defective CCM, replace.

  • Page 64: Cut Quality

    AUTO-CUT 200 XT 4.07 Cut Quality Cut quality requirements differ depending on application. For instance, nitride build-up and bevel angle may be major factors when the surface will be welded after cutting. Dross-free cutting is important when finish cut quality is desired to avoid a secondary cleaning operation.
  • Page 65 Clockwise Left Side Cut Angle Scrap Right Side Cut Angle Counter- Clockwise Scrap Workpiece A-00512 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.
  • Page 66 This Page Intentionally Blank...

  • Page 67: Section 5: Maintenance

    AUTO-CUT 200 XT SECTION 5: MAINTENANCE 5.01 General Maintenance Perform the following checks periodically to ensure proper system performance. Power Supply Maintenance Schedule Daily Check coolant level; add coolant as needed. Check gas hose connections and pressures. Check cooling fan; clean as needed.

  • Page 68: Coolant Replacement Procedure

    AUTO-CUT 200 XT 5.03 Coolant Replacement Procedure Replace coolant as follows: 1. Disconnect the system from main input power. 2. Remove the lower right side panel. 3. Locate the coupling in the coolant line that comes from the bottom of the coolant tank, #1 in the following illustration.

  • Page 69: Arc Starter Service

    AUTO-CUT 200 XT 5.04 Arc Starter Service Arc Starter Service Chart Symptom Cause Check Remedy Flush system, Coolant has become conductive Use conductivity meter replace coolant. Pilot return wire not connected Visual inspection Connect Wire. Spark gap set too close Check with feeler gauge Set to 0.063” ±0.002”...

  • Page 70: Arc Starter Spark Gap Adjustment

    AUTO-CUT 200 XT 5.05 Arc Starter Spark Gap Adjustment 1. Shut off input power. Remove the top console cover. 2. Adjust the spark gap as shown. Re-install the top cover. 0.063" ± 0.002" 1.6 ± 0.05 mm Art # A-11464 5-�...

  • Page 71: Section 6: Replacement Assemblies & Parts

    AUTO-CUT 200 XT SECTION 6: REPLACEMENT ASSEMBLIES & PARTS 6.01 Replacement Power Supply Complete Unit / Component Catalog Numbers Catalog Number Auto-Cut 200 XT™ Power Supply, 400VAC +10 -15% (CCC) 3-�112-3 Manual 0-5253 PARTS LIST...

  • Page 72: Leads And Cables

    Positioning Primary power Tube Torch Ground Cable Work Cable Work Art # A-11687_AB Leads Catalog Numbers; Auto-Cut 200 XT Power Supply, XT-301 Torch Leads Length 10 ft 15 ft 25 ft 35 ft 50 ft 75 ft 100 ft 125 ft 3.05 m...

  • Page 73: Power Supply External Replacement Parts

    AUTO-CUT 200 XT 6.03 Power Supply External Replacement Parts Item # Description Catalog # Power Supply Top Panel 9-7300 Power Supply Upper Right and Left Side 9-7301 Power Supply Lower Right Side 9-7302 Power Supply Lower Left Side 9-7304 Art # A-11465_AB...

  • Page 74: Power Supply Replacement Parts - Lower Right Side

    AUTO-CUT 200 XT 6.04 Power Supply Replacement Parts - Lower Right Side Item # Description Ref. Des. Catalog # Coolant Tank, Cap 8-5124 Coolant Tank 9-7306 Sensor, Coolant level 9-7307 Pump, Coolant, Assembly 9-7309 Motor, Pump 9-8166 Heat Exchanger Fan (2 required per unit)

  • Page 75: Power Supply Replacement Parts - Upper Right Side

    AUTO-CUT 200 XT 6.05 Power Supply Replacement Parts - Upper Right Side Item # Description Ref. Des. Catalog # Pump Motor Control Relay 9-7314 Inrush Control Relay 9-7337 Inrush Relay 9-7336 Auxilliary Transformer 9-7315 Display PCB 9-9252 On/Off Switch Breaker...

  • Page 76: Power Supply Replacement Parts - Lower Left Side

    AUTO-CUT 200 XT 6.06 Power Supply Replacement Parts - Lower Left Side Item # Description Ref. Des. Catalog # AC Suppressor PCB 9-9254 Pilot PCB Assembly AC-200XT 9-9255 Half Inverter Block (Pilot PCB not included) 9-7319 Full Inverter Block 9-7317...

  • Page 77: Power Supply Replacement Parts - Upper Left Side

    AUTO-CUT 200 XT 6.07 Power Supply Replacement Parts - Upper Left Side Item # Description Ref. Des. Catalog # Gas Solenoid (2 required per unit) 9-6319 Water Filter Assembly (Optional. Requires 3rd gas solenoid) 8-3460 HF Coil Assy, Arc Starter...

  • Page 78: Power Supply Replacement Parts - Rear Panel

    AUTO-CUT 200 XT 6.08 Power Supply Replacement Parts - Rear Panel Item # Description Breaker Rating Cicuit Rating Ref. Des. Catalog # Coolant Filter Assy. 9-7320 Coolant Filter 9-7322 Gas Selection Switch 9-3325 Air Filter Assembly AC200-XT 9-7527 - First Stage Filter Element only...

  • Page 79: Power Supply Replacement Parts - Front

    AUTO-CUT 200 XT 6.09 Power Supply Replacement Parts - Front Item # Description Catalog # Pressure Gauge 8-6800 Gas Regulator 9-9509 Run/Set Selector Switch 9-3427 Potentiometer 9-2685 Flowmeter, H 9-77�2 Shield Gas Selector Switch 9-3426 Optional Controls Standard Controls with Water Mist...

  • Page 80: Recommended Gas Supply Hose

    AUTO-CUT 200 XT 6.10 Recommended Gas Supply Hose Item # Description Catalog # 3/8”Gray Synflex Hose. No fittings included. Catalog number per foot 9-3616 �-10 PARTS LIST Manual 0-5253...

  • Page 81: Section 7: Torch Maintenance

    AUTO-CUT 200 XT SECTION 7: TORCH MAINTENANCE 7.01 Consumable Removal 1. Use the removal tool to hold the Shield Cup & Cartridge Assembly stationary. Turn the Shield Cup to remove it from the Cartridge Assembly Cartridge Tool Assembled Cartridge Art # A-04344_AB Shield Cup 2.

  • Page 82: O-Ring Lubrication

    AUTO-CUT 200 XT 7.02 O-Ring Lubrication Lubricate all three O-Rings on the Cartridge Assembly and all three O-Rings on the Torch Head periodically with O-Ring Lubricant supplied. Remove the snap ring on the cartridge assembly and slide the locking ring downward for access to the O-Ring under the locking ring.

  • Page 83: Torch Consumables Installation

    AUTO-CUT 200 XT 7.04 Torch Consumables Installation 1. Install the consumables as follows: 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.
  • Page 84 AUTO-CUT 200 XT 1: Stack Parts 2: Press Cartridge onto Stacked Parts Electrode Plasma Gas Distributor O-Ring on Tip No Gaps Between Parts Shield Gas Cartridge Covers Distributor O-Ring on Torch Tip Shield Cap 4: Check Shield Cap Protrusion 3: Thread Shield Cup onto Cartridge...
  • Page 85 AUTO-CUT 200 XT 2, Remove the Removal Tool from the Cartridge and install the assembled Cartridge onto the Torch Head. CAUTION The cartridge assembly must cover the O-Ring on the torch head. Do not force the cartridge if it will not tighten fully. Remove the cartridge assembly and gently clean the threads on the torch head with a wire brush.
  • Page 86 AUTO-CUT 200 XT E. Coolant Leak Trouble-Shooting Never operate the system if coolant leaks from torch. A steady drip indicates that torch parts are damaged or in- stalled improperly. Operating the system in this condition can damage the torch head. Refer to the following chart for guidance on coolant leakage from the torch head.

  • Page 87: Appendix 1: Cnc Control Module

    AUTO-CUT 200 XT APPENDIX 1: CNC CONTROL MODULE CONTROL PCB CONNECTIONS (LV) OK To Move 2 High +10V Analog Current Control Wiper / Input Low (-) Divided Arc Volts Output Start/Stop Input Stop (NC) (LV) OK To Move 2 CNC Plasma Enable...

  • Page 88: Cnc Functions

    AUTO-CUT 200 XT CNC FUNCTIONS. CNC I/O circuits provide at least 1000V galvanic isolation from the plasma power supply. While the CNC circuits are isolated from the power supply, many of the signal returns on J15 and TB1 & 2 are com- mon to each other.
  • Page 89 AUTO-CUT 200 XT Internal CNC connections. TB1, TB2 & TB3 on CCM module. Connections are provided on the CCM module TB1, TB2 & TB3 terminal blocks including most of the rear panel functions plus some additional features. All these signals are isolated from the plasma power supply but signals marked (comm.) and (-) are common to each other.
  • Page 90 AUTO-CUT 200 XT CNC Input / Output Descriptions All inputs except the Analog Current Control are digital active low (contact or SW closure). CNC Enable / Disable ( input) — Requires closed connection rated for 10 ma. @ 20VDC for unit to operate.
  • Page 91 AUTO-CUT 200 XT OK to Move2 – Provides a second set of N.O. contacts that close when arc transfer is detected. Contacts are rated for maximum of 24 VAC/DC @ 1A. Simplified CNC Circuit. +10V @ 10ma. For Remote CC Pot – Previously CCM versions if one wanted to use a potentiometer for the Remote Analog Current Control (CC) input an external 10 V supply was required for Pot High..
  • Page 92 AUTO-CUT 200 XT Simplified CNC Circuit Auto-Cut XT CCM Simpli fied CNC & Gas Control OK2 (contact) +10V (CC Pot Hi) CC Pot Wiper CC Pot Low OK TO MOVE SELECT Div Arc V (+) Div Arc V (-) 18 VDC or Contacts...
  • Page 93 AUTO-CUT 200 XT PLASMA (51 PS I) (124) GAS ON (130) SW 1 RUN / SET (131) (128) (104) ENABLE AC 24V-GCM2 (B8) (123) PLAS_ENABLE SW (121) PLAS_ EN_SW_RET (124) / GAS PRESS OK (131) / BASIC ID (129) (125)
  • Page 94 AUTO-CUT 200 XT CNC Connections Cutting Machine CNC Cable Power Supply ..Source, 16 VDC, 10 ma. START/STOP ... Divided Arc V (-) ..Divided Arc V (+) ..Pre Flow ON (+) ..Pre Flow ON (-) ..Corner Current Reduction (+)

  • Page 95: Appendix 2: Serial Communications

    AUTO-CUT 200 XT APPENDIX 2: SERIAL COMMUNICATIONS A2.01 CABLES AND SWITCH SETTINGS FOR 2 AND 4 WIRE The CCM communicates with the TSC 3000 (touch screen HMI panel) using RS 485 (2 wire, half duplex). When a CNC controller is used in place of the TSC the CCM can be reconfigured for RS 422 (4 wire, half duplex) if sup- ported by the CNC.
  • Page 96 AUTO-CUT 200 XT For RS 485 it is recommended that the communication lines be terminated at each end with the line’s characteristic impedance. For RS 422 it is recommended the line be terminated at the receiver end. The CCM has a line termination switch SW14 whose default position is ON. For CCMs that are not at the end of the line (like CCM #1 &...
  • Page 97 AUTO-CUT 200 XT This Page Intentionally Blank Manual 0-5253 APPENDIX A-11...

  • Page 98: Appendix 3: Ccm Cpu Pcb Layout

    AUTO-CUT 200 XT APPENDIX 3: CCM CPU PCB LAYOUT = Test Point Art # A-11675 A-12 APPENDIX Manual 0-5253...
  • Page 99 AUTO-CUT 200 XT CCM CPU PCB Test Points ISO +5.0V +24V +3.3V ISO GND +5.0V TOTAL DEMAND 3.3V=400A TP10 TP11 CPU TEMP SENSE TP12 +3.3VA TP13 -15VDAC TP1� TP15 +15VDAC TP16 CLKO TP18 OSC_CLOCK LED Reference Fiber Out 2 Fiber Out 1...

  • Page 100: Appendix 4: Ccm I/O Pcb Layout

    AUTO-CUT 200 XT APPENDIX 4: CCM I/O PCB LAYOUT = Test Point Art # A-11676_AB A-1� APPENDIX Manual 0-5253...
  • Page 101 AUTO-CUT 200 XT CCM I/O PCB J Connectors Test Points BASIC CNC EXTENDED CNC RELAY - INTERFACE BOARD /COOLANT FANS ON /TORCH PUMP ON ARC / TIP VOLTS LOW COOLANT FLOW (SW) TEST GAS BOX COOLANT FLOW SIGNAL (PULSE) +15V ISOLATED...

  • Page 102: Appendix 5: Pilot Pcb Layout

    AUTO-CUT 200 XT APPENDIX 5: PILOT PCB LAYOUT = Test Point Art # A-11677 A-1� APPENDIX Manual 0-5253...
  • Page 103 AUTO-CUT 200 XT Pilot PCB Test Points PILOT GATE TP� LED Reference Green PILOT ENABLE Green +5V Manual 0-5253 APPENDIX A-17...

  • Page 104: Appendix 6: Relay And Interface Pcb Layout

    AUTO-CUT 200 XT APPENDIX 6: RELAY AND INTERFACE PCB LAYOUT = Test Point Art # A-11678 A-1� APPENDIX Manual 0-5253...
  • Page 105 AUTO-CUT 200 XT Relay and Interface PCB Test Points -15V +5VDC +12V +24V +15V +5VDC LED Reference Green 1 TORCH GAS ON Green PILOT ENABLE Green PILOT CURRENT DETECTED Green WORK CURRENT DETECTED Green CONTACTORS ON Green RF ON Green FANS ON...

  • Page 106: Appendix 7: Display Pcb Layout

    AUTO-CUT 200 XT APPENDIX 7: DISPLAY PCB LAYOUT = Test Point Art # A-11679 A-20 APPENDIX Manual 0-5253...
  • Page 107 AUTO-CUT 200 XT Display PCB Test Points +5VDC +24VDC Manual 0-5253 APPENDIX A-21...

  • Page 108: Appendix 8: System Bias Pcb Layout

    AUTO-CUT 200 XT APPENDIX 8: SYSTEM BIAS PCB LAYOUT = Test Point Art # A-11680 A-22 APPENDIX Manual 0-5253...
  • Page 109 AUTO-CUT 200 XT System Bias PCB Test Points 24VDC DC INPUT POSITIVE TP� Vcc1 Vcc2 GATE PRIMARY GND +12V PRIMARY P_ISOL_GND TP10 DC SENSE POSITIVE LED Reference MISSING PHASE AC V HIGH AC V LOW Green VAC_IDA Green +12V PRIMARY...

  • Page 110: Appendix 9: Main Inverter Bottom Pcb Layout

    AUTO-CUT 200 XT APPENDIX 9: MAIN INVERTER BOTTOM PCB LAYOUT = Test Point A-2� APPENDIX Manual 0-5253...
  • Page 111 AUTO-CUT 200 XT Main Inverter Bottom PCB Test Points GATE 2A GATE 1A GATE 3A GATE 4A GATE 2B GATE 1B GATE 4B GATE 3B TP10 +12VP TP11 +12VDC TP12 THERMISTOR SIDE A TP13 THERMISTOR SIDE B TP14 +5VDC TP15...

  • Page 112: Appendix 10: Main Inverter Top Pcb Layout

    AUTO-CUT 200 XT APPENDIX 10: MAIN INVERTER TOP PCB LAYOUT = Test Point A-2� APPENDIX Manual 0-5253...
  • Page 113 AUTO-CUT 200 XT Main Inverter Top PCB Test Points GATE 2A GATE 1A GATE 3A GATE 4A GATE 2B GATE 1B GATE 4B GATE 3B TP10 +12VP TP11 +12VDC TP12 THERMISTOR SIDE A TP13 THERMISTOR SIDE B TP14 +5VDC TP15...

  • Page 114: Appendix 11: Control And Fault Pcb Layout

    AUTO-CUT 200 XT APPENDIX 11: CONTROL AND FAULT PCB LAYOUT = Test Point /230V Art # A11683 A-2� APPENDIX Manual 0-5253...
  • Page 115 AUTO-CUT 200 XT Control and Fault PCB Test Points TP22 +12VDC TP23 +5VDC TP24 GATE 1+ TP25 A_OUT1 TP26 B_OUT1 TP27 GATE 1- TP2� I_SNS1 TP29 GATE 2+ TP30 I_DMD1 0.5V-6.7V TP31 GATE 2- TP32 -12VDC TP33 START 2 TP34...

  • Page 116: Appendix 12: Cap Bias Bottom Pcb Layout

    AUTO-CUT 200 XT APPENDIX 12: CAP BIAS BOTTOM PCB LAYOUT Art # A-11685 A-30 APPENDIX Manual 0-5253...

  • Page 117: Appendix 13: Cap Bias Top Pcb Layout

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

  • Page 118: Appendix 14: Suppressor Pcb Layout

    AUTO-CUT 200 XT APPENDIX 14: SUPPRESSOR PCB LAYOUT Art # A-11684 A-32 APPENDIX Manual 0-5253...

  • Page 119: Appendix 15: Wms Gas Box Layout

    AUTO-CUT 200 XT APPENDIX 15: WMS GAS BOX LAYOUT Manual 0-5253 APPENDIX A-33...

  • Page 120: Appendix 16: Cooling Diagram

    AUTO-CUT 200 XT APPENDIX 16: COOLING DIAGRAM A-3� APPENDIX Manual 0-5253...
  • Page 121 AUTO-CUT 200 XT This Page Intentionally Blank Manual 0-5253 APPENDIX A-35...

  • Page 122: Appendix 17: System Schematic

    AUTO-CUT 200 XT APPENDIX 17: SYSTEM SCHEMATIC PG 1 INVERTER 1/2 MODULE (IM) #2 (top) J105A IM #2 Section A (lower) AC INPUT J104A Customer installed power cable J103A Connects directly into L1, 2 & 3 of W1 contactor and chassis gnd terminal...
  • Page 123 9/16/2013 Drawn Drawn Date Date Misc updates & corrections 6/27/2013 04/18/2012 The information contained herein is proprietary to Victor Technologies. Size Size Sheet Sheet More updates & corrections Not for release, reproduction or distribution without written consent. Drawing Number Drawing Number...

  • Page 124: Appendix 18: System Schematic Pg2

    AUTO-CUT 200 XT APPENDIX 18: SYSTEM SCHEMATIC PG2 J12 = Mini-Fit Jr AMBIENT COOLANT 400 VAC -- Single 18 AWG in pins 1 & 4 480 VAC -- Single 18 AWG in pins 1 & 8 (90) 230 VAC -- 18 AWG wires in pins 1,5,2,6...
  • Page 125 1/16/2013 9/30/2013 9/12/2013 Drawn Date Misc updates & corrections 6/27/2013 04/18/2012 The information contained herein is proprietary to Victor Technologies. Size Sheet More updates & corrections Not for release, reproduction or distribution without written consent. Drawing Number Title SCHEMATIC 042X1343...

  • Page 126: Appendix 19: Advanced Troubleshooting

    AUTO-CUT 200 XT APPENDIX 19: ADVANCED TROUBLESHOOTING System Overview The Auto-Cut 200 & 300 XT & Ultra-Cut 100, 200, 300 & 400 XT power supplies include one, two or three inverter mod- ules (IM). Each IM may have either 1 or 2 inverter sections designated A or B sections.
  • Page 127 AUTO-CUT 200 XT section (INV 1A, INV 1B, etc.). A 100A unit will only have ribbon cables in J31 & J32; a 200A will have J31-J33 filled with the others empty. 300A will have J34 missing with the others filled.
  • Page 128 AUTO-CUT 200 XT The AC Suppression PCB has capacitors and other transient suppression components to protect the system from transients on the AC lines. It also provides power for the neon AC present indicators which illuminate when AC power is connected even with ON-OFF switch, CB1, off.
  • Page 129 AUTO-CUT 200 XT Status codes. The codes for the power supply are displayed on the Display PCB 4 digit numerical display. Some codes refer to the Gas Controls but more detailed Gas Control codes will be found on the individual gas controls. The gas con- trols used with the XT family of plasma supplies have not changed.
  • Page 130 AUTO-CUT 200 XT Power Supply Status Codes Group 1, Process Codes Plasma Enable Is Disabled Code 101 is activated by either an open circuit between TB1-1 & 2 on CCM I/O PCB or Plasma Enable switched off on the GCM 2010 or on the TSC 3000. TB1-1 & 2 comes from the factory with a jumper installed. An in- staller may remove the jumper and connect a separate Plasma Enable switch or use the Plasma Enable wires included in the 37 pin CNC cable used with the Ultra-Cut XT &...
  • Page 131 AUTO-CUT 200 XT If a TSC 3000 is not connected or unit is an Auto-Cut, K7 on the Relay PCB is de-energized and GND is con- nected through its normally closed contacts. If the TSC is connected, 24 VAC through a jumper in the TSC 3000 energizes K7, opening its NC contacts and now GND connects through the TDC 3000 Plasma Enable switch.
  • Page 132 AUTO-CUT 200 XT Pilot Ignition Failure Code 102 is activated when there is no pilot current after 15 seconds of firing the Arc Starter. Pilot ignition requires the Pilot board to be enabled, pilot switch (IGBT) turned on and high voltage pulses (HF) from the arc Starter (either the Remote Arc Starter RAS 1000 XT or GCM 1000 XT or the arc starter built in to the AC 200 XT) applied between the tip and the electrode of the torch.
  • Page 133 AUTO-CUT 200 XT Arc starter without Spark Gap (Ultra-Cut) 1. Check for power to the RAS 1000XT’s Ignition Module during the 15 seconds following preflow (ignition phase). Arc starter power comes through the rear panel circuit breaker CB4, make sure it isn’t tripped.
  • Page 134 AUTO-CUT 200 XT Reasons why RAS Control relay would not close: 6. Pilot current flowing. There actually is pilot current flowing somewhere. Unlikely as it would normally set the 208 fault but we have to rule it out. a. Disconnect J41 on the Pilot board, if HF still doesn’t fire and the Relay board Pilot LED, D11, is still on, it’s due to a fault in the detection circuits.
  • Page 135 AUTO-CUT 200 XT Troubleshooting Pilot Board problems. 1. The Pilot board is behind the CCM in the AC 300 XT and all Ultra-Cut XTs or on the upper section of the second inverter module in an AC 200 XT and has two LEDs. The first one, D11, a green LED, indicates the board has bias power and should be on all the time when the unit is turned on.
  • Page 136 AUTO-CUT 200 XT Transfer Lost Arc transferred to metal for at least 50 ms. then went out. Causes for 104 code: • Cut demand set much lower than recommended for torch parts, i.e. 100A consumables in torch but cut current set for 30 or 50A (or zero). Current may be too low to keep arc on.
  • Page 137 AUTO-CUT 200 XT • Cut current set too low for torch parts being used. Pilot current is set based on cut current. If cut current is too low pilot current will be lower and may not transfer at the height used for higher current consum- ables.
  • Page 138 AUTO-CUT 200 XT Part Process not Configured. This represents a status, not a fault. This is used with the DFC 3000 only. It means the operator hasn’t loaded the cutting process from either the TSC 3000 or from the program embedded in the cutting table CNC control- ler.
  • Page 139 AUTO-CUT 200 XT PWR Present • When power is first applied to the inverter (contactor closed) CCM checks for presence of the +12V bias on the Inverter Control and Fault board. If not present will set codes in the range of 265-270.
  • Page 140 AUTO-CUT 200 XT 202-204 Not used. Reserved codes from the earlier product. DC Output Low DC output (voltage) low means one or more inverter sections are enabled but the output voltage is below a preset voltage. Shortly after receiving the Start signal from the CNC, but before the end of preflow, both sections of IM#1 are enabled and CCM measures the power supply output voltage between negative (Torch) to positive (Work) at the output terminals.
  • Page 141 AUTO-CUT 200 XT Relay PCB • Relay board LED D12, Work Current Detected, will light if the current sensor signal exceeds 0.05V. If D12 is on, measure the sensor output signal at J1-3 with signal common on J1-1. This signal should be 0V +/- 0.04VDC.
  • Page 142 AUTO-CUT 200 XT Relay Board or CCM If D11 on the Relay PCB is still on after the previous tests, measure the output to the CCM on the 40 pin ribbon cable (Relay J4 to CCM J23) between pins 23 (-) and 25 (+). It should be less than 0.1V. If not, the Relay board is bad.
  • Page 143 AUTO-CUT 200 XT Possible cause for work current to low. • All the above plus a short to chassis caused by: o User installed equipment connect behind the current sensor that makes a connection to work or earth allowing current flow to bypass work sensor.
  • Page 144 AUTO-CUT 200 XT Inverter 1 not found. There must be an inverter connected in the 1st section, 1A, to be able to pilot. During the power up sequence, before power is connected to the inverters, the CCM does a continuity test to see if its section 1A ribbon cable (J31 on CCM) is connected.
  • Page 145 AUTO-CUT 200 XT Troubleshooting: 1. If System Bias board has either the wrong jumper or is defective it will call out the first inverter section, code 231, because all the inverters won’t match the incorrect signal and 1A is checked first.
  • Page 146 AUTO-CUT 200 XT System Bias voltage identification is invalid. At power up the System Bias board measures the input voltage and sends signals to the CCM indicating which range of voltage it has detected. See section 231-236 for details. If one of the 3 voltage ranges, 208-230V, 380- 415V or 480V isn’t identified then both ID signals are high resulting in an invalid signal.
  • Page 147 AUTO-CUT 200 XT Troubleshooting: 1. If the fault is L239 applying START will clear the fault unless it becomes active again. An occasional prob- lem may be due to incoming voltage swells (voltage increases lasting from ½ cycle to as much as a minute).
  • Page 148 AUTO-CUT 200 XT 4. If the incoming voltage is OK and the problem persists it may be System Bias, CCM or connection between J62 and J27. a. If the incoming voltage is OK and D14, ACV LOW, is on or the signal “AC V LOW b” on J62-10 is “high”...
  • Page 149 AUTO-CUT 200 XT 253-258 Inverter Over Temperature. Each inverter section (IS) contains one or more temperature sensors. If any of these detect an over temperature condition it activates the signal “OVERTEMP_FLT going to the CCM over the inverter sections ribbon cable.
  • Page 150 AUTO-CUT 200 XT Troubleshooting: 1. If room temperature exceeds 40 deg C, cool the room, or operate the unit at reduced duty cycle or lower current. 2. Confirm that air is exhausting from opening in the right side panel. As the fan(s) are behind the radiator it’s hard to see them to confirm they are turning but perhaps you can use an inspection mirror.
  • Page 151 AUTO-CUT 200 XT 3. On the Relay board D22, CONTACTOR ON LED (green) next to relay K1 lights if K1 is being told to energize. a. If it’s on check for 120 VAC between J8-1 and J8-9. If present the relay board is OK.
  • Page 152 Gas pressure faults only show up when you try to start the torch, not during purging or setting flows . With the Auto-Cut 200 XT and the Auto-Cut 300 XT (GCM 1000 XT), the gas pressure sensor is only on the plasma gas and is in series with Run/Set switch.
  • Page 153 AUTO-CUT 200 XT Gas Control returns wrong command sequence. Firmware incompatibility. Consult factory for latest firmware update. Possible electromagnetic interference from the Arc Starter; inspect grounding; bonding; and isolation. Mismatch between the CCM and gas control type. The Auto-Cut XT CCM is designed to work with the GCM 1000 (AC 300 XT) or the built in gas control of the AC 200 XT.
  • Page 154 AUTO-CUT 200 XT Coolant Level Low The coolant reservoir (tank) has a normally open (tank dry) float type level switch, LS1. When the coolant level in the tank is below about ½ full this fault will signal the need to add coolant. It will not stop the process dur- ing a cut but will instead show the 405 fault as a warning.
  • Page 155 AUTO-CUT 200 XT Troubleshooting: 1. First note whether the fault is an “E” meaning it’s currently low or an “L” meaning it was low but isn’t now. Flow that remains low could indicate a failed component or a blockage such as clogged filter or pinched hose.
  • Page 156 AUTO-CUT 200 XT 2. Fans are powered by 230 VAC. The 230 VAC for the fan(s) is switched by the MC2 control relay (except the AC 200 XT where the fan(s) is powered directly from the T1 transformer at J13).
  • Page 157 AUTO-CUT 200 XT Reasons for 404 faults (Coolant not flowing): • In new installation, coolant has not circulated all the way through the leads. Add more coolant if neces- sary and recycle the power to restart the pump and 4 minute timer.
  • Page 158 The gauge needs to be able to read at least 173 PSI. Remove the coolant supply hose and connect the pressure gauge in its place. For the Auto-Cut 200 XT connect the gauge in place of the torch coolant supply hose on the torch connection bulkhead.
  • Page 159 AUTO-CUT 200 XT Coolant flow is correct but system doesn’t detect it due to defective components: • Defective or disconnected FS1 flow switch. • Relay board. • CCM. Flow Switch FS1 disconnected – FS1 comes with wire about 1 ft. long and a connector that connects to a 3 wire harness.
  • Page 160 AUTO-CUT 200 XT Troubleshooting: 1. GCM 1000XT (also called a Basic Gas Control) does not use CANBUS (fiber-optic) communication. A jumper in the gas control connector J56 pins 8 & 9, gives the signal “Basic ID” telling the CCM not to expect any CANBUS.
  • Page 161 AUTO-CUT 200 XT The black end of the fiber cable is inserted into the transmitter which is the gray housing on the PCB. The other end of the transmitting fiber is blue and goes into the receiver with the black housing.
  • Page 162 AUTO-CUT 200 XT USB Log File Creation Fault When updating the CCM, DMC and DPC programs from a flash drive, a log file called CCM_LOG.TXT is cre- ated on the flash which reports on the results of the update including any problems. If that log file can’t be created you get 613.
  • Page 163 AUTO-CUT 200 XT This Page Intentionally Blank Manual 0-5253 APPENDIX A-77...

  • Page 164: Appendix 20: Publication History

    AUTO-CUT 200 XT APPENDIX 20: PUBLICATION HISTORY Cover Date Change(s) Jan. 3, 2013 First issue. Feb. �, 2013 dded information to CCM Status Code 201 section 4 per ECOB23�5 May �, 2013 Removed Oxygen from shield gases on pg. 2�� and updated several parts lists and art in Section 6.
  • Page 166 I N N O V A T I O N T O S H A P E T H E W O R L D ™ U.S. Customer Care: 800-426-1888 / 800-535-0557 Canada Customer Care: 905-827-4515 / 800-588-1714 • International Customer Care: 940-381-1212 / 940-483-8178 © 2012 Victor Technologies International, Inc. victortechnologies.com Printed in U.S.A.

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