Victor ULTRA-CUT 300 XT Operating Manual
  1. Manuals
  2. Brands
  3. Victor Manuals
  4. Welding System
  5. ULTRA-CUT 300 XT
  6. Operating manual

Victor ULTRA-CUT 300 XT Operating Manual

Plasma cutting system automated gas control
Hide thumbs Also See for ULTRA-CUT 300 XT:
Table of Contents

Advertisement

Quick Links

Download this manual
8 4
ULTRA-CUT 300 XT
™
PLASMA CUTTING SYSTEM
AUTOMATED GAS CONTROL
Operating
Manual
Revision: AE Issue Date: May 2, 2014
Manual No.: 0-5305
VictorThermalDynamics.com

Advertisement

Table of Contents
loading
Need help?

Need help?

Do you have a question about the ULTRA-CUT 300 XT and is the answer not in the manual?

Questions and answers

Related Manuals for Victor ULTRA-CUT 300 XT

Summary of Contents for Victor ULTRA-CUT 300 XT

  • Page 1 ULTRA-CUT 300 XT ™ PLASMA CUTTING SYSTEM AUTOMATED GAS CONTROL Operating Manual Revision: AE Issue Date: May 2, 2014 Manual No.: 0-5305 VictorThermalDynamics.com...
  • Page 2 WE APPRECIATE YOUR BUSINESS! Congratulations on your new Victor Thermal Dynamics product. We are proud to have you as our customer and will strive to provide you with the best service and reliability in the industry. This product is backed by our extensive warranty and world-wide service network. To locate your nearest distributor or service agency call 1-800-426-1888, or visit us on the web at www.VictorThermalDynamics.com.
  • Page 3 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 with Automated Gas Control, Ultra-Cut 300 XT ™ Operating Manual No. 0-5305 Published by: Victor Technologies, Inc.
  • 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 ................
  • Page 6 TABLE OF CONTENTS SECTION 4: OPERATION ................... 4-1 4.01 Power Supply Control Panel ................4-1 4.02 System Operation ................... 4-1 4.03 TSC-3000 Navigation Functions ..............4-3 4.04 TSC-3000 Initial Setup ONLY ................4-4 4.05 TSC-3000 Selecting New Process ..............4-5 4.06 TSC-3000 Selecting Recently Used Process ...........
  • Page 7 TABLE OF CONTENTS APPENDIX 2: CNC ..................A-2 CNC functions ....................... A-2 CNC Input / Output Descriptions ................... A-4 Simplified CNC Circuit....................A-6 CNC Connections......................A-8 APPENDIX 3: DMC-3000 CONTROL PCB LAYOUT ............. A-9 APPENDIX 4: DPC-3000 CONTROL PCB LAYOUT ............A-10 APPENDIX 5: DMC-3000 / DPC-3000 POWER SUPPLY PCB LAYOUT ......A-11 APPENDIX 6: TSC-3000 PCB LAYOUT ..............A-12 APPENDIX 7: CCM CPU PCB LAYOUT ..............A-14...
  • Page 8 TABLE OF CONTENTS This Page Intentionally Blank...

  • Page 9: General Information

    ULTRA-CUT 300 XT SECTION 1: GENERAL INFORMATION GASES AND FUMES Gases and fumes produced during the plasma cutting 1.01 Notes, Cautions and Warnings process can be dangerous and hazardous to your health. Throughout this manual, notes, cautions, and warnings • Keep all fumes and gases from the breathing area.

  • Page 10: Publications

    ULTRA-CUT 300 XT • To protect your eyes, always wear a welding hel- • Extra care must be taken when the workplace is moist or damp. met or shield. Also always wear safety glasses with side shields, goggles or other protective eye •...

  • Page 11: Note, Attention Et Avertissement

    ULTRA-CUT 300 XT able from American Welding Society, 550 N.W. LeJeune Rd, Miami, FL 33126 8. NFPA Standard 51, OXYGEN-FUEL GAS SYSTEMS FOR AVERTISSEMENT WELDING, CUTTING AND ALLIED PROCESSES, ob- Toute procédure pouvant provoquer des blessures tainable from the National Fire Protection Association, de l’opérateur ou des autres personnes se trouvant...
  • Page 12 ULTRA-CUT 300 XT antimoine cadmium mercure argent chrome nickel arsenic cobalt plomb INCENDIE ET EXPLOSION baryum cuivre sélénium Les incendies et les explosions peuvent résulter des béryllium manganèse vanadium scories chaudes, des étincelles ou de l’arc de plasma. • Lisez toujours les fiches de données sur la sécurité des Le procédé...

  • Page 13: Documents De Reference

    ULTRA-CUT 300 XT Nuance Minimum Nuance Suggerée disponible auprès du Superintendent of Documents, U.S. Courant Arc Protective Numéro Numéro Government Printing Office, Washington, D.C. 20402 4. Norme ANSI Z87.1, PRATIQUES SURES POUR LA PRO- Moins de 300* TECTION DES YEUX ET DU VISAGE AU TRAVAIL ET 300 - 400* DANS LES ECOLES, disponible de l’Institut Américain...

  • 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 excel- lence in our area of manufacture.
  • Page 15 ULTRA-CUT 300 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. There may be potential difficulties in ensuring electromagnetic compatibility in those locations, due to conducted as well as radiated disturbances.

  • Page 16: Statement Of Warranty

    90 Days Warranty repairs or replacement claims under this limited warranty must be submitted by an authorized Victor 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.

  • Page 17: Section 2: Specifications

    2.05 Precision Plasma Cutting Torch The torch delivers the controlled current to the work through the main arc, causing the metal to be cut. 2.06 Specifications & Electrical Requirements Ultra-Cut 300 XT™ Specifications & Design Features Max OCV (U0) 425 vdc...

  • Page 18: Power Supply Dimensions

    ULTRA-CUT 300 XT Ultra-Cut 300 XT™ Power Supply Input Power Input Current Suggested Sizes (See Note) Voltage Freq. 3-Ph 3-Ph Fuse (Amps) Wire (AWG) Wire (mm (Volts) (Hz) (kVA) (Amps) 3-Ph 3-Ph 3-Ph 50/60 50/60 NOTE * Suggested wire size based on United States NFPA 70 National Electrical Code 2011 edition published by the National Fire Prevention Association.

  • Page 19: Power Supply Rear Panel Features

    The customer will provide all gases and pressure regulators. Gases must be of high quality. Pressure regulators shall be double stage and installed within 3 meters from the Gas Console. Ultra-Cut 300 XT™ Power Supply: Gas Pressures, Flows, and Quality Requirements Quality...

  • Page 20: Gas Applications

    ULTRA-CUT 300 XT Note 1: The air source must be adequately filtered to remove all oil or grease. Oil or grease contamination from compressed or bottled air can cause fires in conjunction with oxygen. For filtering, a coalescing filter able to filter to 0.01 microns should be placed as close as possible to the gas inlets on the Gas Control Module.

  • Page 21: Xt Torch Specifications

    ULTRA-CUT 300 XT 2.11 XT Torch Specifications A. Torch Dimensions Art # A-04897 End Cap 19.00" 2.25" 482.68 mm 57.15 mm Mounting Tube 2.0" 15.50" 50.8 mm 393.78 mm 6.30" 160.10 mm 2.39" 60.81 mm 3.54" 89.87 mm 2.74" 69.55 mm 1.57"...
  • Page 22 ULTRA-CUT 300 XT C. Torch Parts (Generic Parts Shown) Art # A-04741_AB Plasma Gas Shield Gas Distributor Distributor Shield Cap Electrode Cartridge Shield Cup 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 23: Section 3: Installation

    Cooling System Requirements Coolant must be added to the system on installation. The amount required varies with torch leads length. Victor Thermal Dynamics recommends the use of its coolants 7-3580 and 7-3581 (for low temperatures). Coolant Capabilities Cat. Number and Mixture...

  • Page 24: System Layout

    ULTRA-CUT 300 XT 3.02 System Layout Refer to section 3.04 for ground connections and ground cables. 175’ / 53.3 m Maximum Length 50’ / 15.25 m Maximum Length 125’ / 38.1 m Maximum Length Pilot Return Pilot Return Shield Negative...

  • Page 25: Leads And Cables All Amperage

    ULTRA-CUT 300 XT 3.04 Leads and Cables All Amperage #8 AWG Cable Pilot Return, Power Supply to Arc Starter 3/0 AWG Cable (95 mm Negative Lead, Power Supply to Arc Starter Coolant Supply Lead, Green Green Power Supply to Arc Starter...

  • Page 26: Lift The Power Supply

    ULTRA-CUT 300 XT 3.05 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 a forklift, crane, or hoist to lift the unit off the shipping pallet as shown. Keep the power supply steady and vertical.

  • Page 27: Connect Input Power And Ground Cables

    ULTRA-CUT 300 XT 3.06 Connect Input Power and Ground Cables Connect Input Power and System Ground Cables 1. Remove the input power cover to the right of the coolant filter at the rear of the power supply. To do this remove the two screws then lift up and pull away.

  • Page 28: Connect Work Cable And Pilot And Negative Leads

    ULTRA-CUT 300 XT 3.07 Connect Work Cable and Pilot and Negative Leads 1. Remove the output power cover to the left of the coolant filter at the rear of the power supply. To do this remove the two screws then lift up and pull away.
  • Page 29 ULTRA-CUT 300 XT A. Electromagnetic Interference (EMI) Pilot arc starting generates a certain amount of electromagnetic interference (EMI), commonly called RF noise. This RF noise may interfere with other electronic equipment such as CNC controllers, remote controls, height control- lers, etc. To minimize RF interference, follow these grounding procedures when installing mechanized systems: B.

  • Page 30: Connect Coolant Leads

    ULTRA-CUT 300 XT NOTE Ideally, a properly installed ground rod will have a resistance of three ohms or less. To test for a proper earth ground, refer to the following diagram. Ideally, the reading on the multimeter should be as shown.

  • Page 31: Connect Cables For Cnc, Remote Arc Starter, Gcm And He 400

    ULTRA-CUT 300 XT J55 - GCM USER INPUT J15 - CNC HEIGHT CONTROL J54 - TSC /COMM J59 - RAS CB2 - 5A 120 VAC CB3 - 5A 24 VAC J70 - HE CB4 - 5A 120 VAC F1 - 8A SB 230 VAC...

  • Page 32: Handling And Installation Of Fiber Optics

    ULTRA-CUT 300 XT J55 To GCM J55 - GCM USER INPUT J15 - CNC HEIGHT CONTROL J54 - TSC /COMM J15 To CNC Control J59 - RAS CB2 - 5A 120 VAC CB3 - 5A 24 VAC J70 - HE...
  • Page 33 ULTRA-CUT 300 XT Art # A-12015 WARNINGS Disconnect primary power at the source. Avoid the following: 1. If you need to pull the cable through a power track do not fold the fiber back on itself making a sharp bend where it exits the hose.

  • Page 34: Correct Installation

    ULTRA-CUT 300 XT 3. Once the fiber cable is installed in the CCM or gas control make sure the strain relief nut is securely tightened onto the hose so the hose can’t pull out of it like this: Hose not secured in...
  • Page 35 ULTRA-CUT 300 XT Correct routing of fiber optic cable. No sharp bends going into connectors. Art # A-09678_AB Unplugging the fiber optic connector. Do not pull on the fiber cable! Art # A-09423 For the CCM grip the fiber connector front and back squeezing the latch lever and remove from the socket.

  • Page 36: Connect Tsc-3000 Cable And Dmc-3000 Fiber Optic Cable To Ccm

    ULTRA-CUT 300 XT 3.12 Connect TSC-3000 Cable and DMC-3000 Fiber Optic Cable to CCM 1. Remove the bottom plastic plug in the CCM at the rear of the Power Supply. J55 - GCM USER INPUT J15 - CNC HEIGHT CONTROL...

  • Page 37: Set Switches On The Command - Control Module

    ULTRA-CUT 300 XT Fiber Optic Cable Plug Thin nut securing the through hole protector Art # A-11998 3.13 Set Switches on the Command - Control Module Remove the power supply upper right side. Set switches on the CCM (Command-Control Module) per the illustra- tions.
  • Page 38 ULTRA-CUT 300 XT Future Use Switches shown in OFF position Actual orientation 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).
  • Page 39 ULTRA-CUT 300 XT 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 SW12 SW13 SW-6: OK-to-Move: Contact closure, 120VAC @ 1A (Factory default setting) or DC Volts (16-18vdc@ up to 100 ma.)

  • Page 40: Height Control Connections

    ULTRA-CUT 300 XT 2 - Wire and 4 - Wire settings When used with the TSC-3000 the plug should be in the 2 wire (2W) position shown below. For other CNC controls using 4 wire communication such as the XT iCNC, place the jumper in the 4W position.

  • Page 41: Dmc-3000 Gas Manifold Control Installation

    ULTRA-CUT 300 XT 3.15 DMC-3000 Gas Manifold Control Installation The DMC-3000 Gas Control 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 any support subject to vibration or motion, the installer must fasten the module to the support securely.
  • Page 42 ULTRA-CUT 300 XT Remove 2 Screws Loosen or remove 2 screws Cover Removal 2. Carefully remove the cover from the module noting the attached wire harness that connects to J1. Remove the wire harness and then set the cover to the side.
  • Page 43 ULTRA-CUT 300 XT Art # A-09141_AB NOTE Argon must be used for the “Marking” gas. If replacing existing fittings in the base, apply thread sealant to the fitting threads, according to manufacturer’s instructions. Do not use Teflon tape as a thread sealer, as small par- ticles of the tape may break o�...

  • Page 44: Dpc-3000 Gas Pressure Control Installation

    ULTRA-CUT 300 XT 6. Install WMS Water Softener Kit in the line that feeds the inlet side of the DMC-3000. Mount the softener and bracket on the power supply where the provided 2’ hose can reach to the DMC-3000. Mounting in another location is possible with a customer provided hose.
  • Page 45 ULTRA-CUT 300 XT Mounting Dimensions DPC-3000 Top DPC-3000 Profile 6.64in 4.00 in [168.7mm] [101.6 mm] 10.90 in [276.86 mm] .30 in [7.62mm] 10.45 in [265.4 mm] 11.00 in Art # A-09143 [279.4 mm] Preparation 1. Remove the screws securing the Cover Panel to the Module.
  • Page 46 ULTRA-CUT 300 XT Art # A-09145 3. Attach all hoses and cables to the back of the DPC-3000 except the Fiber Optic cable which will be covered a little later. Avoid turning any fittings already mounted in the unit by placing a wrench on it before tighten- ing the hose fitting to it.

  • Page 47: Fiber Optic Cable Installation From Ccm To Dmc-3000

    ULTRA-CUT 300 XT Art # A-09147_AB Do Not Block Vent 3.17 Fiber Optic Cable Installation from CCM to DMC-3000. CAUTION Avoid kinking, twisting, or bunching the fiber optic cable. The cable can be damaged by being forced into tight-radius turns. Review section 3.10 for proper handling and installation of fiber optic cable.
  • Page 48 ULTRA-CUT 300 XT Art # A-09148_AB 4. Secure the thin nut on the through hole protector so both nut faces are tight against the sheet metal inside and out. Art # A-09149_AB 5. Plug the Fiber Optic Cable into the PCB as shown below. Make sure the locking tabs are engaged.

  • Page 49: Fiber Optic Cable Installation From Dmc-3000 To Dpc-3000

    ULTRA-CUT 300 XT Fiber Optic Cable to/from CCM plugs in here Art # A-11999 3.18 Fiber Optic Cable Installation From DMC-3000 to DPC-3000 1. Remove outer thin nuts from through hole protector at both ends of Fiber Optic Cable (L) that connects between the DCM-3000 and DPC-3000.
  • Page 50 ULTRA-CUT 300 XT Insert Fiber Optic cable here Art # A-09153_AB 4. Secure each of the thin nuts on the through hole protectors so both nut faces are tight against the sheet metal inside and out. 5. Plug the Fiber Optic Cable into the PCB as shown below for the DMC-3000. Make sure the locking tabs are engaged.

  • Page 51: Install Tsc-3000 Touch Screen Control

    ULTRA-CUT 300 XT Fiber Optic to/from DMC-3000 plugs in here Art # A-09155 7. Reinstall the Cover Panels making sure the wire harnesses are attached. 3.19 Install TSC-3000 Touch Screen Control Mounting Dimensions TSC-3000 Profile TSC-3000 Top 1.11 in [28.2 mm] 2.35 in...

  • Page 52: Install Remote Arc Starter

    ULTRA-CUT 300 XT Art # A-09157_AC Ground Cable to/from “Star” ground on table Communication Cable to/from CCM rear of power supply 3.20 Install Remote Arc Starter Site Location Select a clean, dry location with good ventilation and adequate working space around all components.
  • Page 53 ULTRA-CUT 300 XT 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.

  • Page 54: Input Connections

    ULTRA-CUT 300 XT Input Connections 1. Refer to the illustrations. Make the following input connections to the Arc Starter. • Coolant Supply and Return Hoses (from HE-400 Heat Exchanger). Hoses and connectors are color- coded; Red for Return, Green for Supply.

  • Page 55: Output Connections

    ULTRA-CUT 300 XT *Negative (Slave) Pilot *Negative (Master) Torch Lead Art # A-12063_AB Negative Master, Negative Slave and Pilot Cables (from Power Supply ) Art # A-12064 Control Cable from Power Supply rear panel Output Connections 1. Refer to the illustrations. Make the following output connections to the Arc Starter.
  • Page 56 ULTRA-CUT 300 XT Pilot Lead Coolant Return (Red) Coolant Supply (Green) Green Art # A-12065 Pilot Return Cable, Coolant Supply and Return Hoses (from Torch) 2. Reinstall the Arc Starter Cover. Ensure that the ground wire is not crimped between the cover and the base.
  • Page 57 ULTRA-CUT 300 XT Art # A-04758 Torch Leads 1 Nut and 1 Washer Remain in Place Ground Cable 4. Use a clamp to secure the Torch Lead Shield braid brass ring to the port on the Remote Arc Starter as shown.
  • Page 58 ULTRA-CUT 300 XT Connect Control Cable 1. Connect the Remote Arc Starter cable to the Remote Arc Starter receptacle. J55 - GCM USER INPUT J15 - CNC HEIGHT CONTROL J54 - TSC /COMM J59 - RAS CB2 - 5A 120 VAC...

  • Page 59: Connecting Torch

    ULTRA-CUT 300 XT 3.21 Connecting Torch Connect the Torch as follows: Coolant Supply, Coolant Return, and Pilot Leads Leads Cover Torch Leads End Cap Shield Gas (Right Hand Thread) Groove for O-Ring Pilot Lead O-Ring Mounting Tube To Torch Valve...

  • Page 60: Install Consumable Torch Parts

    ULTRA-CUT 300 XT 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.
  • Page 61 ULTRA-CUT 300 XT Torch Head Torch Head O-Ring 0.063 - 0.083" (1.6 - 2.1 mm) Protrusion Art # A-08300_AB Installing Assembled Cartridge Onto Torch Head 7. Slide the ohmic clip over the shield cup if using ohmic torch height sensing.

  • Page 62: 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 63: Control Cable

    ULTRA-CUT 300 XT Install the V-D Board 1. Locate the V-D Board which should be with the iCNC. 2. Inside the Power Supply, locate and remove the mounting panel’s 2 screws and panel. 3. Install the V-D board standoffs and the V-D Board from the XT iCNC then reattach the panel with the � screws, securing the V-D board in place.

  • Page 64: Complete The Installation

    ULTRA-CUT 300 XT “Ohmic” or Shield (cup) cable. Some height controls including the iHC find the plate using an electrical or resistance measurement, thus “ohmic”, contact between the conductive end of the torch and the metal or “plate” being cut. A wire, usually a single highly flexible wire that withstands the reflective heat from the arc, is connected between the V-D board and the torch shield cup.
  • Page 65 ULTRA-CUT 300 XT 2. After the complete system has been installed, check that the coolant has been pumped through the system as follows (see NOTE): NOTE Depending on the length of the torch leads, the system may require more coolant after turning the system ON for the first time.
  • Page 66 ULTRA-CUT 300 XT This Page Intentionally Blank 3-44 INSTALLATION Manual 0-5305...

  • Page 67: Section 4: Operation

    ULTRA-CUT 300 XT SECTION 4: OPERATION 4.01 Power Supply Control Panel Gas Indicator Status Indicator AC Indicator Temp Indicator DC Indicator Art # A-11541_AB 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 68 ULTRA-CUT 300 XT 1. Connect system to primary input power. An indicator will light on the rear panel when AC power is ap- plied to the unit. Place the Plasma Enable Switch (TSC 3000; user installed Plasma Enable/E-Stop) in the “Enable”...

  • Page 69: Tsc-3000 Navigation Functions

    ULTRA-CUT 300 XT 4.03 TSC-3000 Navigation Functions PAGE HEADER Art # A-09158 SAMPLE SAMPLE SELECTION NAVIGATION MOVES CURSOR /SELECTION UP AND DOWN ON THE PAGE OR SCROLLS TEXT IN DIALOG BOX WINDOW System Status : IDLE BACK BUTTON REVERSES TO THE PREVIOUS PAGE...

  • Page 70: Tsc-3000 Initial Setup Only

    ULTRA-CUT 300 XT 4.04 TSC-3000 Initial Setup ONLY Initial steps required before First operation only. Note 400 Amp system requires a Height Controller with Elevation Height (EH) feature. HOME ENTER/CHANGE PASSWORD When power is turned on TSC 3000 goes to the Home screen.

  • Page 71: Tsc-3000 Selecting New Process

    ULTRA-CUT 300 XT 4.05 TSC-3000 Selecting New Process Select new standard process by material; thickness; amperage (1) or enter process # using pop-up number pad (2). SELECT MATERIAL, THICKNESS HOME Material – Scroll to select, Thickness – Scroll to select, Accept &...

  • Page 72: Tsc-3000 Selecting Recently Used Process

    ULTRA-CUT 300 XT 4.06 TSC-3000 Selecting Recently Used Process Home screen shows some of the most recently used processes with the last one used highlighted. Select the highlighted process by pressing the Green arrow or scroll with up/down arrows to select another recent process then press the green arrow.

  • Page 73: Tsc-3000 Creating A Custom Process

    ULTRA-CUT 300 XT 4.07 TSC-3000 Creating a Custom Process Considerable effort has been made to define the best parameters for each cutting and marking process. However for various reasons, variations in material composition, variations in cutting table performance, user preferences, etc.
  • Page 74 ULTRA-CUT 300 XT HOME CUSTOM PROCESS SETUP Customize Recent Cut. Highlight the process closest to what you want to use then press CUSTOM CUTS button. Select NEW CUT then MATERIAL & THICKNESS. TORCH CONSUMABLES LIST SELECT MATERIAL/THICKNESS Select value to change using UP/DN arrows.

  • Page 75: Back Up And Restoration Of Custom Processes

    ULTRA-CUT 300 XT 4.08 Back up and Restoration of Custom Processes. Users can create their own custom cut processes. These can be lost by accidentally deleting them on the TDC 3000 or they can be over written when updating programs. They can also be lost if the DSC 3000 should be replaced.
  • Page 76 ULTRA-CUT 300 XT Restoring Custom Processes: During file backup (see previous process) a folder and sub folders called “TD” were placed on your flash drive. You should copy this folder with its subfolders to some secure place. Making more than one copy is advised. If the need arises to restore from this backup, place the entire TD folder in the root directory (not in another folder) on a USB flash drive and plug it into the USB port on the TDC 3000.
  • Page 77 ULTRA-CUT 300 XT Renaming Custom Files You cannot rename the files while on the TSC 3000 but once you backup a file on the flash drive you can use a com- puter to rename the file on the flash drive and perform the restore to put the renamed file back on the TSC 3000.

  • Page 78: Sequence Of Operation

    ULTRA-CUT 300 XT 4.09 Sequence of Operation Ultracut with DFC 3000 using TSC 3000 The purpose of this section is to explain the steps an operator should follow when using the DFC 3000 with the TSC 3000 touch screen control panel for a specific cutting process. Also included are steps to follow for changing torch consumables.
  • Page 79 ULTRA-CUT 300 XT g) Following the firmware version indication, while CCM establishes communication with the gas control (Step e.), the coolant pump and fans come on to “prime” the system. The “gas” indicator on the front panel blinks until correct coolant flow is detected. Normally this takes only a few seconds but can last up to 4 minutes if there is a problem.
  • Page 80 ULTRA-CUT 300 XT Following a consumables change or inspection the system will initiate a purge of the gas. This serves two purposes: Remove the coolant that gets into the consumables when they have been removed. If the gas type has changed “Purge” removes the old gas from the lines and replaces it with the new gas.

  • Page 81: Gas Selection

    ULTRA-CUT 300 XT 4.10 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 82 ULTRA-CUT 300 XT 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. �. Nitrogen (N�) Shield •...

  • Page 83: Ccm Status Codes

    ULTRA-CUT 300 XT 4.11 CCM 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 display on the front panel shows a 3 digit number code preceded by either letter “E”...
  • Page 84 ULTRA-CUT 300 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; Missing AC Phase Defective System Bias PCB.
  • Page 85 ULTRA-CUT 300 XT Inverter 3A Output Plasma work current high during cutting and attributed to Inverter Module 3 Section Current High A output high; If problem persists replace Inverter Module 3 Inverter 3B Output Plasma work current high during cutting and attributed to Inverter Module 3 Section Current High B output high;...
  • Page 86 ULTRA-CUT 300 XT Inverter Input Voltage fault; voltage out of range or missing phase at AC Input of In- Inverter 1B Input Volt- verter Module 1 Section B; Poor AC Power Quality; Defective W1 contactor; Loose or age Error open connection between input terminals and W1 contactor or contactor and input of Inverter Section;...
  • Page 87 ULTRA-CUT 300 XT Inverter circuitry is over temperature likely cause is ambient greater than 40 deg Inverter 1A Over Temp C; Reduce power supply cutting Duty Cycle; Reduce ambient air temperature; Add Ambient auxiliary cooler. Inverter circuitry is over temperature likely cause is ambient greater than 40 deg Inverter 1B Over Temp C;...
  • Page 88 ULTRA-CUT 300 XT CCM Status Code Group 3 -- Gas Controller Status & Protocol Code Message Remedy / Comments Problem with fiber optic cable to GCM 2010 or DMC or DPC; Dirt on fiber ends Gas control communication or in connectors; blow out with clean dry air. Fiber not locked into connector;...
  • Page 89 ULTRA-CUT 300 XT CCM Status Code Group 4 -- Torch Coolant System Code Message Remedy / Comments Coolant Level low Check coolant level, add as needed. Defective or disconnected level sensor. Coolant flow as measured by flow switch FS1 is less than 0.7 gpm; Clogged filter;...

  • Page 90: Dmc-3000 Status Codes

    ULTRA-CUT 300 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.
  • Page 91 ULTRA-CUT 300 XT Status Indicators on the DMC & DPC modules flash a 2-part code. Both green and red flash the firmware version at power up. Only the red flashes for a fault. First part of the code indicates a code group, the second part a particular condition within that group. DMC and DPM may flash codes at the same time and they may be different codes.

  • Page 92: Dpc-3000 Status Codes

    ULTRA-CUT 300 XT Group 5 - Shorted Solenoid Faults Sol 1 – H35 Plasma Replace solenoid; Shorted wire harness; Defective DMC Control PCB Sol 2 – Oxygen Plasma Replace solenoid; Shorted wire harness; Defective DMC Control PCB Sol 3 – Air Plasma Replace solenoid;...
  • Page 93 ULTRA-CUT 300 XT Group 3 - Inlet Pressure Faults Plasma Gas High (>145 PSI) Reduce pressure from gas supply; defective pressure sensor (PS4). Pilot Gas High (>145 PSI) Reduce pressure from gas supply; defective pressure sensor (PS3). Shield Gas High (>145 PSI) Reduce pressure from gas supply;...
  • Page 94 ULTRA-CUT 300 XT DPC Status Code Key Code Message Cause/Remedy Group 6 - Plasma Low Proportional Valve (V4) Valve open Check for open connection; Replace valve. DPC inlet Supply pressure Raise plasma inlet pressure; check for DMC valve not open; restriction in gas supply/hoses.

  • Page 95: Remote Arc Starter Trouble Shooting

    ULTRA-CUT 300 XT 4.14 Remote Arc Starter Trouble Shooting Arc Starter Trouble Shooting Symptom Cause Check Remedy Pilot return wire not connected at torch head or broken in torch Visual inspection, continuity check Connect Wire or replace leads. lead Flush system,...
  • Page 96 ULTRA-CUT 300 XT This Page Intentionally Blank 4-30 OPERATION Manual 0-5305...

  • Page 97: Section 5: Maintenance

    ULTRA-CUT 300 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. UC-AC Maintenance schedule Monthly Check cooling fan and radiator;...

  • Page 98: Coolant Replacement Procedure

    ULTRA-CUT 300 XT 5.03 Coolant Replacement Procedure Replace coolant as follows: 1. Disconnect the system from main input power. 2. Remove the two right side panels. 3. Locate the coupling in the coolant line that comes from the bottom of the coolant tank, #1 in the following illustration.

  • Page 99: Section 6: Replacement Assemblies & Parts

    ULTRA-CUT 300 XT SECTION 6: REPLACEMENT ASSEMBLIES & PARTS 6.01 Replacement Power Supply Complete Unit / Component Catalog Number Ultra-Cut 300 XT Power Supply, 480V +10 -15% 3-8118-2 ™ Remote Arc Starter (RAS-1000 XT) 3-9130E OPTIONAL EQUIPMENT: Wheel Kit 9-7378...

  • Page 100: System Layout

    ULTRA-CUT 300 XT 6.02 System Layout Refer to section 3.05 for ground connections and ground cables. 175’ / 53.3 m Maximum Length 125’ / 38.1 m Maximum Length 50’ / 15.25 m Maximum Length Pilot Return Pilot Return Shield Negative...

  • Page 101: Leads And Cables All Amperages

    ULTRA-CUT 300 XT 6.04 Leads And Cables All Amperages #8 AWG Cable Pilot Return, Power Supply to Arc Starter 3/0 AWG Cable (95 mm Negative Lead, Power Supply to Arc Starter Coolant Supply Lead, Green Green Power Supply to Arc Starter...
  • Page 102 ULTRA-CUT 300 XT REPLACEMENT PARTS Manual 0-5305...

  • Page 103: Power Supply External Replacement Parts

    ULTRA-CUT 300 XT 6.05 Power Supply External Replacement Parts Item # Description Catalog # Power and Leads Cable Cover 9-7346 Top Panel, 9-7300 Upper Side Covers 9-7301 Lower Left Side Panel 9-7304 Lower Right Side Panel (300A/400A) 9-7344 Lifting Eye...

  • Page 104: Power Supply Replacement Parts - Upper Right Side

    ULTRA-CUT 300 XT 6.06 Power Supply Replacement Parts - Upper Right Side Item # Description Ref. Des. Catalog # System Bias PCB 9-9�53 � Pilot PCB 9-9�50 CCM Assembly 9-7335 Relays, Pump / Fan MC3 / MC2 9-7314 Relay, Inrush Control...

  • Page 105: Power Supply Replacement Parts - Lower Right Side

    ULTRA-CUT 300 XT 6.07 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...

  • Page 106: Power Supply Replacement Parts - Rear Panel

    ULTRA-CUT 300 XT 6.08 Power Supply Replacement Parts - Rear Panel Item # Description Breaker Rating Circuit Rating Ref. Des. Catalog # Coolant Filter Assy 9-7320 Coolant Filter 9-7321 Fuse, 8A SB 500 VAC 9-7377 J55 - GCM USER INPUT...

  • Page 107: Power Supply Replacement Parts - Left Side

    ULTRA-CUT 300 XT 6.09 Power Supply Replacement Parts - Left Side Item # Description Ref. Des. Catalog # AC Suppresion PCB 9-9254 Main Contactor (2 total) W1, W2 9-7318 Inverter Module, Full 480 VAC 9-7330 Inverter Module, Partial 480 VAC...

  • Page 108: Dfc-3000 Automated Gas Control System Replacement Components

    ULTRA-CUT 300 XT 6.10 DFC-3000 Automated Gas Control System Replacement Components Item # Description Catalog # Assy, DMC-3000, Demo 9-9491D Assy, DPC-3000, Demo 9-9443D Assy, TSC-3000, Remote, Demo 9-9490D Art # A-09135_AC 6-10 REPLACEMENT PARTS Manual 0-5305...

  • Page 109: Dmc-3000 Gas Control Module Replacement Parts

    ULTRA-CUT 300 XT 6.11 DMC-3000 Gas Control Module Replacement Parts Item # Description Catalog # DMC-3000 assembly 9-9491D Solenoid 9-8264 Manifold subassembly (includes 15 of item 2) 9-7546 SMPS PCB 9-8263 Control PCB 9-7291 Not shown: WMS Water Softener Kit (includes the following items)

  • Page 110: Dpc-3000 Gas Control Module Replacement Parts

    ULTRA-CUT 300 XT 6.12 DPC-3000 Gas Control Module Replacement Parts Item # Description Catalog # Assy, DPC-3000, Demo 9-9443D DPC-PCB 9-8262 SMPS PCB 9-8263 Shield Gas P Valve 9-8267 Sensor, Pressure, 1/8mnpt (six total) 9-8269 Solenoid 9-8264 Plasma Lo and Pre-Flow P Valve...

  • Page 111: Tsc-3000 Touch Screen Control Remote And Internal Replacement Parts

    ULTRA-CUT 300 XT 6.13 TSC-3000 Touch Screen Control Remote and Internal Replacement Parts Item # Description Catalog # Assy, TSC-3000, Remote, Demo 9-9490D Touch Panel Computer 9-7543 Switch, Rocker SPST 9-1042 Ribbon Cable HMI to Interface PCB 9-7547 USB Panel Mount Extension...

  • Page 112: Remote Arc Starter (Ras-1000 Xt) Replacement Parts

    ULTRA-CUT 300 XT 6.14 Remote Arc Starter (RAS-1000 XT) Replacement Parts Item # Description Catalog # Complete RAS 1000 XT Assembly 3-9130E Pilot Cap Assembly 9-7341 Electronic Ignition Module 9-7342 Toroidal Coil 9-7343 Art # A-12066 6-14 REPLACEMENT PARTS Manual 0-5305...

  • Page 113: He 400 Heat Exchanger - Replacement Parts

    ULTRA-CUT 300 XT 6.15 HE 400 Heat Exchanger - Replacement Parts Item # Description Catalog # Assembly, HE 400 Heat Exchanger 9-9416 8-6312 Radiator 8-1347 Capacitor 8-3263 Thermal Switch 9-1448 Art # A-09650 Manual 0-5305 REPLACEMENT PARTS 6-15...
  • Page 114 ULTRA-CUT 300 XT This Page Intentionally Blank 6-16 REPLACEMENT PARTS Manual 0-5305...

  • Page 115: Torch Maintenance

    ULTRA-CUT 300 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 116: O-Ring Lubrication

    ULTRA-CUT 300 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 117: Torch Consumables Installation

    ULTRA-CUT 300 XT 7.04 Torch Consumables Installation 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 118 ULTRA-CUT 300 XT CAUTION The cartridge assembly must cover the O-Ring on the torch head. Do not force the cartridge if it will not tighten fully. Remove the cartridge assembly and gently clean the threads on the torch head with a wire brush. Apply oxygen-compatible lubricant (supplied with the torch) to the threads.

  • Page 119: Coolant Leak Trouble-Shooting

    ULTRA-CUT 300 XT 7.05 Coolant Leak Trouble-Shooting Never operate the system if coolant leaks from the torch. A steady drip indicates that torch parts are damaged or installed improperly. Operating the system in this condition can damage the torch head. Refer to the following chart for guidance on coolant leakage from the torch head.
  • Page 120 ULTRA-CUT 300 XT Torch Electrodes Art # A-09653 Recommended Wear Depth for Electrode Amperage Plasma Gas Replacement Inch 0.04 0.04 0.04 0.04 0.08 0.04 0.04 0.08 0.04 0.04 0.08 0.08 0.06 0.08 0.08 0.06 0.08 0.08 0.06 0.06 0.08 0.08...

  • Page 121: Appendix 1: Cnc - Control Module Pcb Connections

    ULTRA-CUT 300 XT APPENDIX 1: CNC - Control Module 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 122: Appendix 2: Cnc

    ULTRA-CUT 300 XT APPENDIX 2: CNC 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, TB2 & TB3 are common to each other.
  • Page 123 ULTRA-CUT 300 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 124: Cnc Input / Output Descriptions

    ULTRA-CUT 300 XT CNC Input / Output Descriptions E-Stop input— Requires closed connection rated for 35ma. @ 20VDC for unit to operate. Factory installed jumper between TB1-1&2 must be removing when connecting user supplied E-Stop circuit. Start/Stop input—Switch (momentary or sustained) rating 35ma. @ 20 VDC Start / Stop circuit configurations.
  • Page 125 ULTRA-CUT 300 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 126: Simplified Cnc Circuit

    ULTRA-CUT 300 XT Simplified CNC Circuit Ult racut X T Simplified CNC OK TO MOV E SELECT 18 V D C or Con tacts SW6A D C VO LT S +18VDC OK2 (cont act) C ONTA CT S +10V (CC Pot Hi )
  • Page 127 ULTRA-CUT 300 XT J54 - Rem ote HM I & CN C CO M M (100) 1 - 24 V AC (101) 2 - 24 V AC Re t (102) 3- Jumper to 24 V AC Harness to Relay PCB...

  • Page 128: Cnc Connections

    ULTRA-CUT 300 XT CNC Connections Cutting Machine CNC Cable Power Supply START/STOP ..Source, 16 VDC, 10 ma..Divided Arc V (-) ..Divided Arc V (+) ..Pre Flow ON (+) ..Pre Flow ON (-) ..Corner Current Reduction (+)

  • Page 129: Appendix 3: Dmc-3000 Control Pcb Layout

    ULTRA-CUT 300 XT APPENDIX 3: DMC-3000 Control PCB Layout D-17 D_E1 D_E15 Art # A-09188_AB Manual 0-5305 APPENDIX...

  • Page 130: Appendix 4: Dpc-3000 Control Pcb Layout

    ULTRA-CUT 300 XT APPENDIX 4: DPC-3000 Control PCB Layout TP11 TP10 Art # A-09189_AB A-10 APPENDIX Manual 0-5305...

  • Page 131: Appendix 5: Dmc-3000 / Dpc-3000 Power Supply Pcb Layout

    ULTRA-CUT 300 XT APPENDIX 5: DMC-3000 / DPC-3000 Power Supply PCB Layout Art # A-09597 Manual 0-5305 APPENDIX A-11...

  • Page 132: Appendix 6: Tsc-3000 Pcb Layout

    ULTRA-CUT 300 XT APPENDIX 6: TSC-3000 PCB Layout D14 D15 Art # A-09190_AB A-1� APPENDIX Manual 0-5305...
  • Page 133 ULTRA-CUT 300 XT This Page Intentionally Blank Manual 0-5305 APPENDIX A-13...

  • Page 134: Appendix 7: Ccm Cpu Pcb Layout

    ULTRA-CUT 300 XT APPENDIX 7: CCM CPU PCB Layout = Test Point Art # A-11675 A-14 APPENDIX Manual 0-5305...
  • Page 135 ULTRA-CUT 300 XT CCM CPU PCB Test Points TP1 GND TP2ISO +5.0V TP3+24V TP4+3.3V TP5 ISO GND TP6+5.0V TP7TOTAL DEMAND 3.3V=400A TP9/WR TP10 TP11 CPU TEMP SENSE TP12 +3.3VA TP13 -15VDAC TP14 TP15 +15VDAC TP16 CLKO TP18 OSC_CLOCK LED Reference D�...

  • Page 136: Appendix 8: Ccm I/O Pcb Layout

    ULTRA-CUT 300 XT APPENDIX 8: CCM I/O PCB Layout = Test Point Art # A-11676_AB A-16 APPENDIX Manual 0-5305...
  • Page 137 ULTRA-CUT 300 XT CCM I/O PCB J23 RELAY - INTERFACE BOARD J24 ARC / TIP VOLTS Test Points J25 TEST TP1 GND J26 GAS BOX TP2/COOLANT FANS ON J28 TO CPU TP3/TORCH PUMP ON J29 TO CPU TP4LOW COOLANT FLOW (SW)

  • Page 138: Appendix 9: Pilot Pcb Layout

    ULTRA-CUT 300 XT APPENDIX 9: Pilot PCB Layout = Test Point Art # A-11677 A-18 APPENDIX Manual 0-5305...
  • Page 139 ULTRA-CUT 300 XT Pilot PCB Test Points TP1 GND TP� PILOT GATE TP3+5V TP4TIP LED Reference D� Green PILOT ENABLE Green +5V Manual 0-5305 APPENDIX A-19...

  • Page 140: Appendix 10: Relay And Interface Pcb Layout

    ULTRA-CUT 300 XT APPENDIX 10: Relay and Interface PCB Layout = Test Point Art # A-11678 A-�0 APPENDIX Manual 0-5305...
  • Page 141 ULTRA-CUT 300 XT Relay and Interface PCB Test Points TP1 GND TP� -15V TP3+5VDC TP4+12V TP5+24V TP6+15V TP7+5VDC LED Reference D� Green 1 TORCH GAS ON Green PILOT ENABLE Green PILOT CURRENT DETECTED D12Green WORK CURRENT DETECTED D�� Green CONTACTORS ON D�3 Green RF ON...

  • Page 142: Appendix 11: Display Pcb Layout

    ULTRA-CUT 300 XT APPENDIX 11: Display PCB Layout = Test Point Art # A-11679 A-�� APPENDIX Manual 0-5305...
  • Page 143 ULTRA-CUT 300 XT Display PCB Test Points TP1 GND TP2+5VDC TP3+24VDC Manual 0-5305 APPENDIX A-�3...

  • Page 144: Appendix 12: System Bias Pcb Layout

    ULTRA-CUT 300 XT APPENDIX 12: System Bias PCB Layout = Test Point Art # A-11680 A-24 APPENDIX Manual 0-5305...
  • Page 145 ULTRA-CUT 300 XT System Bias PCB Test Points TP1 GND TP224VDC TP3 DC INPUT POSITIVE TP4Vcc1 TP5 Vcc� TP6GATE TP7PRIMARY GND TP8+12V PRIMARY TP9 P_ISOL_GND TP10 DC SENSE POSITIVE LED Reference MISSING PHASE AC V HIGH D14Red AC V LOW...

  • Page 146: Appendix 13: Main Inverter Bottom Pcb Layout

    ULTRA-CUT 300 XT APPENDIX 13: Main Inverter Bottom PCB Layout = Test Point A-26 APPENDIX Manual 0-5305...
  • Page 147 ULTRA-CUT 300 XT Main Inverter Bottom PCB Test Points TP1 GND TP� GATE �A TP3 GATE 1A TP4GATE 3A TP5GATE 4A TP6GATE 2B TP7GATE 1B TP8GATE 4B TP9 GATE 3B TP10 +12VP TP11 +12VDC TP1� THERMISTOR SIDE A TP13 THERMISTOR SIDE B...

  • Page 148: Appendix 14: Main Inverter Top Pcb Layout

    ULTRA-CUT 300 XT APPENDIX 14: Main Inverter Top PCB Layout = Test Point A-�8 APPENDIX Manual 0-5305...
  • Page 149 ULTRA-CUT 300 XT Main Inverter Top PCB Test Points TP1 GND TP� GATE �A TP3 GATE 1A TP4GATE 3A TP5GATE 4A TP6GATE 2B TP7GATE 1B TP8GATE 4B TP9 GATE 3B TP10 +12VP TP11 +12VDC TP1� THERMISTOR SIDE A TP13 THERMISTOR SIDE B...

  • Page 150: Appendix 15: Control And Fault Pcb Layout

    ULTRA-CUT 300 XT APPENDIX 15: Control and Fault PCB Layout = Test Point /230V Art # A11683 A-30 APPENDIX Manual 0-5305...
  • Page 151 ULTRA-CUT 300 XT Control and Fault PCB Test Points TP1 GND TP22 +12VDC TP23 +5VDC TP24 GATE 1+ TP�5 A_OUT1 TP26 B_OUT1 TP27 GATE 1- TP�8 I_SNS1 TP29 GATE 2+ TP30 I_DMD1 0.5V-6.7V TP31 GATE �- TP3� -1�VDC TP33 START �...

  • Page 152: Appendix 16: Cap Bias Bottom Pcb Layout

    ULTRA-CUT 300 XT APPENDIX 16: Cap Bias Bottom PCB Layout Art # A-11685 A-3� APPENDIX Manual 0-5305...

  • Page 153: Appendix 17: Cap Bias Top Pcb Layout

    ULTRA-CUT 300 XT APPENDIX 17: Cap Bias Top PCB Layout Art # A-11686 Manual 0-5305 APPENDIX A-33...

  • Page 154: Appendix 18: Suppressor Pcb Layout

    ULTRA-CUT 300 XT APPENDIX 18: Suppressor PCB Layout Art # A-11684 A-34 APPENDIX Manual 0-5305...

  • Page 155: Appendix 19: Cooling Diagram

    ULTRA-CUT 300 XT Appendix 19: COOLING DIAGRAM Manual 0-5305 APPENDIX A-35...

  • Page 156: Appendix 20: Remote Arc Starter Schematic

    St Louis, Missouri 63017 USA Date Printed Date Revised 7/30/2013 7/30/2013 Drawn Date 03/13/2013 The information contained herein is proprietary to Victor Technologies. Size Sheet Not for release, reproduction or distribution without written consent. Drawing Number Title SCHEMATIC 042X1361 RAS 1000 XT Arc Starter...
  • Page 157 ULTRA-CUT 300 XT This Page Intentionally Blank Manual 0-5305 APPENDIX A-37...

  • Page 158: Appendix 21: Schematic, Dfc-3000 Auto Gas Box System

    ULTRA-CUT 300 XT APPENDIX 21: Schematic, DFC-3000 Auto Gas Box System DMC3000 - MANIFOLD CONTROLLER ASSEMBLY 19X2367 755x000 ULTRACUT POWER SUPPLY CONTROL CABLE (JMP) PLASMA ENABLE + Power Supply PCB (19X2384) LEDS 120VAC DMC PLASMA ENABLE - See list by DPC 3000 Power Supply...
  • Page 159 ULTRA-CUT 300 XT DPC3000 - PRESSURE CONTROL ASSEMBLY 19X2383 PANEL INDICATORS Power Supply PCB (19X2384) LEDS POWER LED (GRN) POWER LED (GRN) STATUS LED (RED) STATUS LED (RED) D5 = +VDC Fused (24VDC ) MANIFOLD (partial) P3 - HWID P3 - HWID...

  • Page 160: Appendix 22: System Schematic 300A, 480V

    ULTRA-CUT 300 XT APPENDIX 22: System Schematic 300A, 480V PG 1 INVERTER MODULE (IM) #3 (top) IM #3 Section B (upper) AC INPUT J105B J100 -- 30 CKT RIBBON J104B J103B 019X502700 J105A AC INPUT IM #3 Section A (lower)
  • Page 161 2/18/2013 9/30/2013 9/16/2013 Drawn Date Misc updates & corrections 6/27/2013 10/05/2012 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 042X1347...

  • Page 162: Appendix 23: System Schematic 300A, 480V

    ULTRA-CUT 300 XT APPENDIX 23: System Schematic 300A, 480V PG 2 J12 = Mini-Fit Jr AMBIENT COOLANT 400 VAC -- Single 18 AWG in pins 1 & 4 (90) 480 VAC -- Single 18 AWG in pins 1 & 8...
  • Page 163 2/18/2013 9/30/2013 9/16/2013 Drawn Date Misc updates & corrections 6/27/2013 10/5/2012 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 042X1347...

  • Page 164: Appendix 24: Advanced Troubleshooting

    ULTRA-CUT 300 XT Appendix 24: 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 165 ULTRA-CUT 300 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 166 ULTRA-CUT 300 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 167 ULTRA-CUT 300 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 168: Power Supply Status Codes

    ULTRA-CUT 300 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 169 ULTRA-CUT 300 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 170 ULTRA-CUT 300 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 �00 XT)
  • Page 171 ULTRA-CUT 300 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 172 ULTRA-CUT 300 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 173 ULTRA-CUT 300 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 174 ULTRA-CUT 300 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 175 ULTRA-CUT 300 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 176 ULTRA-CUT 300 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 177 ULTRA-CUT 300 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 178 ULTRA-CUT 300 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 179 ULTRA-CUT 300 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 180 ULTRA-CUT 300 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 181 ULTRA-CUT 300 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 182 ULTRA-CUT 300 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 183 ULTRA-CUT 300 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 184 ULTRA-CUT 300 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 185 ULTRA-CUT 300 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 186 ULTRA-CUT 300 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 187 ULTRA-CUT 300 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 188 ULTRA-CUT 300 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 189 ULTRA-CUT 300 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 190 ULTRA-CUT 300 XT Troubleshooting: 1. Check that the fiber-optic cable is fully plugged in to both sockets. Clean the cable ends with a soft cloth and blow out the sockets with air. 2. Check gas control cables. If any of the gas control cables are not connected there will be no communication as there will be no power to the control.
  • Page 191 ULTRA-CUT 300 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 �00 XT.
  • Page 192 ULTRA-CUT 300 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 193 ULTRA-CUT 300 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 194 ULTRA-CUT 300 XT �. Fans are powered by �30 VAC. The �30 VAC for the fan(s) is switched by the MC� control relay (except the AC 200 XT where the fan(s) is powered directly from the T1 transformer at J13).
  • Page 195 ULTRA-CUT 300 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 196 ULTRA-CUT 300 XT d. If jumping TP3 to TP1 does not turn the fans on then the Relay board or the 40 pin ribbon cable pin 13 is at fault. CCM I/O PCB 230 VAC from T1 To test Pump relay jump TP3 to TP1.
  • Page 197 ULTRA-CUT 300 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 198 ULTRA-CUT 300 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 199 ULTRA-CUT 300 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 200 ULTRA-CUT 300 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 201 ULTRA-CUT 300 XT CNC Cable Color Code TABLE 1: CABLE ITEM#4 COLOR CODE TABLE COLOR SIGNAL DESCRIPTION LOCATION WHITE/BLUE START CNC (+) WHITE/VIOLET START CNC (-) WHITE/BROWN/VIOLET DIV ARC (-) WHITE/BROWN DIV ARC(+) YELLOW PREFLOW ON (+) GREEN COMM 1K...

  • Page 202: Appendix 25: Publication History

    ULTRA-CUT 300 XT APPENDIX 25: PUBLICATION HISTORY Cover Date Rev Change(s) May 1, �013 First issue May 21, 2013 AB Updated with new RAS 1000 XT info per ECOB2428 July 2, 2013 Updated section 3 with information about V-D Board installation for height controller per ECOB2488 Jan.
  • Page 203 This Page Intentionally Blank...
  • Page 204 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 / FAX 800-535-0557 Canada Customer Care: 905-827-4515 / FAX 800-588-1714 International Customer Care: 940-381-1212 / FAX 940-483-8178 Printed in USA © 2012 Victor Technologies International, Inc. www.victortechnologies.com...

Table of Contents