Victor ULTRA-CUT 100 Operating Manual
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Victor ULTRA-CUT 100 Operating Manual

Plasma cutting system
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400V
100 200
300
400
ULTRA-CUT 100,
200, 300, 400 XT
™
PLASMA CUTTING SYSTEM
Operating
Manual
Revision: AF Issue Date: October 2, 2014
Manual No.: 0-5264
VictorThermalDynamics.com

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Summary of Contents for Victor ULTRA-CUT 100

  • Page 1 400V 100 200 ULTRA-CUT 100, 200, 300, 400 XT ™ PLASMA CUTTING SYSTEM Operating Manual Revision: AF Issue Date: October 2, 2014 Manual No.: 0-5264 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 distribu- tor or service agency call 1-800-426-1888, or visit us on the web at www.thermal-dynamics.com.
  • Page 3 West Lebanon, New Hampshire, USA 03784 (603) 298-5711 www.thermal-dynamics.com © Copyright 2013 by Victor Technologies International, Inc. All rights reserved. Reproduction of this work, in whole or in part, without written permission of the publisher is prohibited. The publisher does not assume and hereby disclaims any liability to any party for any loss or damage caused by any error or omission in this Manual, whether such error results from negligence, accident, or any other cause.

  • Page 4: 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 5 TABLE OF CONTENTS SECTION 4: OPERATION ................... 4-1 4.01 Power Supply Control Panel ................4-1 4.02 System Operation ................... 4-2 4.03 Gas Selection ....................4-4 4.04 GCM 2010 Gas Control Module Operation ............4-6 4.05 GCM 2010 First Time Operation Matching Gas Control to Lead Length ..4-10 4.06 GCM 2010 Sequence Of Operation ...............
  • Page 6 TABLE OF CONTENTS APPENDIX 7: CNC ..................A-8 CNC functions ....................... A-8 CNC Input / Output Descriptions ................. A-10 Simplified CNC Circuit ....................A-12 CNC Connections ......................A-14 APPENDIX 8: SERIAL COMMUNICATIONS ............A-15 A8.01 Cables and Switch Settings for 2 and 4 Wire ..........A-15 APPENDIX 9: CCM CPU PCB LAYOUT ..............A-18 APPENDIX 10: CCM I/O PCB LAYOUT ..............A-20 APPENDIX 11: PILOT PCB LAYOUT ..............A-22...

  • Page 7: General Information

    ULTRA-CUT 100 XT/200 XT/300 XT/400 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. • Keep all fumes and gases from the breathing area.

  • Page 8: Publications

    ULTRA-CUT 100 XT/200 XT/300 XT/400 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 9: Note, Attention Et Avertissement

    ULTRA-CUT 100 XT/200 XT/300 XT/400 XT National Standards Institute, 1430 Broadway, New 1.04 Note, Attention et York, NY 10018 Avertissement 6. ANSI Standard Z49.2, FIRE PREVENTION IN THE USE OF CUTTING AND WELDING PROCESSES, obtain- Dans ce manuel, les mots “note,” “attention,” et “aver- able from American National Standards Institute, 1430 tissement”...
  • Page 10 ULTRA-CUT 100 XT/200 XT/300 XT/400 XT FUMÉE et GAZ CHOC ELECTRIQUE La fumée et les gaz produits par le procédé de jet de Les chocs électriques peuvent blesser ou même tuer. Le plasma peuvent présenter des risques et des dangers procédé...
  • Page 11 ULTRA-CUT 100 XT/200 XT/300 XT/400 XT BRUIT RAYONS D’ARC DE PLASMA Le bruit peut provoquer une perte permanente de l’ouïe. Les rayons provenant de l’arc de plasma peuvent blesser Les procédés de soudage à l’arc de plasma peuvent vos yeux et brûler votre peau. Le procédé à l’arc de provoquer des niveaux sonores supérieurs aux limites...

  • Page 12: Documents De Reference

    ULTRA-CUT 100 XT/200 XT/300 XT/400 XT 1.06 Documents De Reference Consultez les normes suivantes ou les révisions les plus récentes ayant été faites à celles-ci pour de plus amples renseignements : 1. OSHA, NORMES DE SÉCURITÉ DU TRAVAIL ET DE PROTECTION DE LA SANTÉ, 29CFR 1910, disponible auprès du Superintendent of Documents, U.S.

  • Page 13: Declaration Of Conformity

    ULTRA-CUT 100 XT/200 XT/300 XT/400 XT 1.07 Declaration of Conformity Declaration of Conformity Victor Technologies International Inc. 16052 Swingley Ridge Road Suite 300 Chesterfield, MO 63033 U.S.A. in accordance with the following Directive(s) • 2006/95/EC The Low Voltage Directive • 2004/108/EC The Electromagnetic Compatibility (EMC) Directive...
  • Page 14 ULTRA-CUT 100 XT/200 XT/300 XT/400 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 15: Statement Of Warranty

    ULTRA-CUT 100 XT/200 XT/300 XT/400 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 not subject to misuse, repair, neglect, alteration, or accident, correct such defects by suitable repair or replacement, at Thermal’s sole option, of any components or parts of the product determined by Thermal to be defective. THIS WARRANTY IS EXCLUSIVE AND IS IN LIEU OF ANY WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. LIMITATION OF LIABILITY: Thermal shall not under any circumstances be liable for special or consequential damages, such as, but not limited to, damage or loss of purchased or replacement goods, or claims of customers of distributor (hereinafter “Purchaser”)
  • Page 16 ULTRA-CUT 100 XT/200 XT/300 XT/400 XT This Page Intentionally Blank 1-10 GENERAL INFORMATION Manual 0-5264...

  • Page 17: Section 2: Specifications

    ULTRA-CUT 100 XT/200 XT/300 XT/400 XT SECTION 2: SPECIFICATIONS 2.01 General Description Of The System A typical Ultra-Cut XT™system configuration includes: • One Power Supply • Remote Arc Starter • Gas Control Module • Torch Valve Assembly • Precision Plasma Cutting Torch •...

  • Page 18: Specifications & Electrical Requirements

    ULTRA-CUT 100 XT/200 XT/300 XT/400 XT 2.06 Specifications & Electrical Requirements Ultra-Cut 100 XT™ Specifications & Design Features Max OCV (U0) 425 vdc Minimum Output Current 5 Amps Max Output Current 100 Amps Output Voltage 60 - 180 vdc 100 Amp System Duty Cycle Rating...
  • Page 19 ULTRA-CUT 100 XT/200 XT/300 XT/400 XT Ultra-Cut 100 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 40-45 Ultra-Cut 200 XT™ Power Supply...

  • Page 20: Power Supply Dimensions

    ULTRA-CUT 100 XT/200 XT/300 XT/400 XT 2.07 Power Supply Dimensions 47.77 inch 1213 mm 35.97 inch 100A 420 lb / 190 kg 914 mm 200A 465 lb / 211 kg 300A 560 lb / 254 kg 27.6 inch 400A 580 lb / 263 kg...

  • Page 21: Power Supply Rear Panel Features

    ULTRA-CUT 100 XT/200 XT/300 XT/400 XT 2.08 Power Supply Rear Panel Features TSC/Comm Customer Optional Circuit Breakers Ports GCM Connector CNC Connector J55 - GCM USER INPUT Coolant Return C.C.M. J15 - CNC HEIGHT CONTROL Coolant Supply J54 - TSC /COMM...

  • Page 22: Gas Requirements

    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 100 XT™ Power Supply: Gas Pressures, Flows, and Quality Requirements Quality...
  • Page 23 ULTRA-CUT 100 XT/200 XT/300 XT/400 XT Ultra-Cut 300 XT™ Power Supply: Gas Pressures, Flows, and Quality Requirements Quality Minimum Pressure Flow 99.5% Purity 120 psi (Oxygen) 200 scfh (5700 l/h) (Liquid recommended) 8.3 bar / 827 kPa 99.5% Purity (Liquid recommended)

  • Page 24: Gas Applications

    ULTRA-CUT 100 XT/200 XT/300 XT/400 XT 2.10 Gas Applications MATERIAL MILD STEEL STAINLESS STEEL ALUMINUM GAS TYPE GAS TYPE GAS TYPE OPERATION PREFLOW PLASMA SHIELD PREFLOW PLASMA SHIELD PREFLOW PLASMA SHIELD 30A Cut 50A Cut 70A Cut 100A Cut 150A Cut...

  • Page 25: Xt Torch Specifications

    ULTRA-CUT 100 XT/200 XT/300 XT/400 XT 2.11 XT Torch Specifications A. Torch Dimensions Basic 400 Amp torch dimensions Basic 100 Amp torch dimensions Manual 0-5264 SPECIFICATIONS...
  • Page 26 ULTRA-CUT 100 XT/200 XT/300 XT/400 XT B. Torch Leads Lengths Torch Lead Assembly Lengths Feet Meters 3.05 15.2 22.9 30.4 C. Torch Parts (Generic Parts Shown) Art # A-04741_AB Plasma Gas Shield Gas Distributor Distributor Shield Cap Electrode Shield Cup Cartridge D.

  • Page 27: Section 3: Installation

    ULTRA-CUT 100 XT/200 XT/300 XT/400 XT SECTION 3: INSTALLATION 3.01 Installation Requirements Electric Supply The electrical supply network, the gas and water supply system must meet local safety standards. This conformity shall be checked by qualified personnel. Ultra-Cut 100 XT™ Power Supply...

  • Page 28: System Layout 100 - 200 Amp

    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 29: System Layout 400 Amp

    ULTRA-CUT 100 XT/200 XT/300 XT/400 XT 3.04 System Layout 400 Amp Refer to section 3.08 and 3.10 for ground connections and ground cables. 175’ / 53.3 m Maximum Length 125’ / 38.1 m Maximum Length 50’ / 15.25 m Maximum Length...

  • Page 30: Leads And Cables All Amperage

    ULTRA-CUT 100 XT/200 XT/300 XT/400 XT 3.06 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 31: Lift The Power Supply

    ULTRA-CUT 100 XT/200 XT/300 XT/400 XT 3.07 Lift the Power Supply WARNING 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 32: Connect Input Power And Ground Cables

    ULTRA-CUT 100 XT/200 XT/300 XT/400 XT 3.08 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 33: Connect Work Cable And Pilot And Negative Leads

    ULTRA-CUT 100 XT/200 XT/300 XT/400 XT 3.09 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 34 ULTRA-CUT 100 XT/200 XT/300 XT/400 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.
  • Page 35 ULTRA-CUT 100 XT/200 XT/300 XT/400 XT Creating An Earth Ground 1. To create a solid, low resistance, earth ground, drive a 1/2 in (12 mm) or greater diameter copper clad ground rod at least 6 - 8 ft (1.8 - 2.4 m) into the earth so that the rod contacts moist soil over most of its length. Depend- ing on location, a greater depth may be required to obtain a low resistance ground (see NOTE).

  • Page 36: Connect Coolant Leads

    ULTRA-CUT 100 XT/200 XT/300 XT/400 XT 5. Increasing the ground rod length beyond 20 - 30 ft (6.1 – 9.1 m) does not generally increase the effectiveness of the ground rod. A larger diameter rod which has more surface area may help. Sometimes keeping the soil around the ground rod moist by continuously running a small amount of water into it will work.

  • Page 37: Connect Cables For Cnc, Remote Arc Starter, Gcm And He 400

    Art # A-11971 3.13 Handling and Installation of Fiber Optics General Information This kit is for proper handling and installation of Fiber Optic Cables used in Victor Thermal Dynamics Ultra-Cut ® automated gas boxes and Gas Control Modules. Fiber Optic cable is used in place of wire because it offers far superior immunity to electrical noise but it is more delicate and requires careful handling.
  • Page 38 ULTRA-CUT 100 XT/200 XT/300 XT/400 XT Remove fiber optic end covers and plugs. Art # A-12015 WARNING 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 39: Correct Installation

    ULTRA-CUT 100 XT/200 XT/300 XT/400 XT Hose not secured in the Strain Relief Art # A-09677_AB Correct installation: Correct way to pull the cable is to use a snake or a wire or another cable and attach it securely to the hose behind the strain relief.

  • Page 40: Set Switches On The Command - Control Module

    ULTRA-CUT 100 XT/200 XT/300 XT/400 XT 3.14 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. Switch settings and connection details are provided in the Appendix. Any changes made require a restart of the power supply.
  • Page 41 ULTRA-CUT 100 XT/200 XT/300 XT/400 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 42: Height Control Connections

    ULTRA-CUT 100 XT/200 XT/300 XT/400 XT 3.15 Height Control Connections The terminal strip provides connections to negative Arc Volts (Torch or electrode), Tip Volts (Pilot) and Work. These are for a height control that requires connection to the full non-divided arc voltage. Also available on the terminal strip are 120VAC and 24 VAC.
  • Page 43 ULTRA-CUT 100 XT/200 XT/300 XT/400 XT Mounting Dimensions NOTE Height not shown is 14.125” (359 mm) Gas Box 410.97mm 16.18” 347.47mm 7.14mm 13.68” 0.28” 279.40mm 215.90mm 11.00” 8.50” Art # A-07962 NOTE The unit must be mounted so that the Flowmeters are plumb. If the Flowmeters are not plumb, incorrect flow indications may occur.

  • Page 44: Fiber Optic Cable Installation

    ULTRA-CUT 100 XT/200 XT/300 XT/400 XT 3.17 Fiber Optic Cable Installation 1. Install the through-hole protector for the fiber-optic cable in the hole in connection panel on the back of the Module. 2. Pass the fiber-optic cable connector through the hole in connection panel on the back of the Module. Pass enough of the cable into the Module to allow the cable to loop upward as shown.

  • Page 45: Gas Control Module: Control, Input, And Output Connections

    ULTRA-CUT 100 XT/200 XT/300 XT/400 XT 3. Insert the fiber-optic cable connector into the receptacle on the vertically-mounted circuit board as shown. Cable must snap into place. Circuit Board Fiber Optic Cable Art # A-04773 4. Tighten the through-hole protector for the fiber-optic cable using hand tools.
  • Page 46 ULTRA-CUT 100 XT/200 XT/300 XT/400 XT To Power Supply To Torch Valve Assembly COMM SHIELD PLASMA PREFLOW When Cutting With O2 Plasma Air MUST BE Connected POWER SUPPLY INPUTS SHIELD Gas & Water Inputs (Check Valves) Ground Stud To Torch Valve Assembly...

  • Page 47: He400Xt Cooler

    ULTRA-CUT 100 XT/200 XT/300 XT/400 XT 3.19 HE400XT COOLER Used in series with the existing cooling system of the Ultra-Cut XT™ series power supplies, the HE400XT Cooler provides necessary additional water cooling for the torch head when cutting at over 300amps. The HE400XT fan is thermally controlled to operate whenever the Ultra-Cut fan and pump is on and the coolant temperature is above a predetermined level.
  • Page 48 ULTRA-CUT 100 XT/200 XT/300 XT/400 XT CAUTION Do NOT cross the coolant lines as this will not provide cooling for the XT™ plasma torch as designed and void the warranty. Attach and tighten all #6 JIC fittings with 11/16” (18mm) wrench. Do not overtighten as it will strip the fitting threads and will cause a leak.

  • Page 49: Install Remote Arc Starter

    ULTRA-CUT 100 XT/200 XT/300 XT/400 XT 3.20 Install Remote Arc Starter Site Location Select a clean, dry location with good ventilation and adequate working space around all components. Review the safety precautions in the front of this manual to be sure that the location meets all safety requirements.
  • Page 50 ULTRA-CUT 100 XT/200 XT/300 XT/400 XT Upper screws (2 per side) Cover Ground Wire Lower screws (2 per side) Art # A-12059 Cover Removal 3. Position the Arc Starter on a flat, horizontal mounting surface. 4. Use pre-drilled holes in at least two of the feet on the bottom of the Arc Starter to secure the Arc Starter to the mounting surface.

  • Page 51: Input Connections

    ULTRA-CUT 100 XT/200 XT/300 XT/400 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 52 ULTRA-CUT 100 XT/200 XT/300 XT/400 XT NOTE * Slave and Master refer to only those set ups using two power supplies in parrallel. Slave is not used in single system operations. *Negative (Slave) Pilot *Negative (Master) Torch Lead Art # A-12063_AB...

  • Page 53: Output Connections

    ULTRA-CUT 100 XT/200 XT/300 XT/400 XT Output Connections 1. Refer to the illustrations. Make the following output connections to the Arc Starter. Pilot Lead Coolant Return (Red) Coolant Supply (Green) Green Art # A-12065 Pilot Return Cable, Coolant Supply and Return Hoses (from Torch) 2.
  • Page 54 ULTRA-CUT 100 XT/200 XT/300 XT/400 XT 3. The Arc Starter must be grounded; the grounding terminal is marked . Refer to the previous section for grounding details. Art # A-04758 Torch Leads 1 Nut and 1 Washer Remain in Place Ground Cable 4.
  • Page 55 ULTRA-CUT 100 XT/200 XT/300 XT/400 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 56: Torch Valve Installation

    ULTRA-CUT 100 XT/200 XT/300 XT/400 XT 3.21 Torch Valve Installation General Information This assembly mounts as close as possible to the torch head. It accepts preflow, plasma, and shield gases from the Gas Control Module and supplies these gases to the Torch.

  • Page 57: Connecting Torch

    ULTRA-CUT 100 XT/200 XT/300 XT/400 XT 3. Connect the gas supply lines and the control cable connector from the Gas Control Module to the Valve Kit as shown. Hold the check valves stationary while attaching the gas lines. (XTL shown)
  • Page 58 ULTRA-CUT 100 XT/200 XT/300 XT/400 XT 1. Lay out the torch leads on a clean, dry working surface. 2. Hold the Torch Leads End Cap stationary. Pull approximately 18” (0.5 m) of leads through the End Cap. 3. Remove and discard the protective end caps from the Mounting Tube.

  • Page 59: Install Consumable Torch Parts

    ULTRA-CUT 100 XT/200 XT/300 XT/400 XT 3.23 Install Consumable Torch Parts Install the consumable parts as follows to ensure proper operation. These steps will help ensure that parts are seated correctly. WARNINGS Do not install consumables into the Cartridge while the Cartridge is attached to the Torch Head.
  • Page 60 ULTRA-CUT 100 XT/200 XT/300 XT/400 XT 7. Slide the ohmic clip over the shield cup if using ohmic torch height sensing. 8. Connect the wire lead from the height finder to the ohmic clip if using ohmic torch height sensing.

  • Page 61: 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 62 ULTRA-CUT 100 XT/200 XT/300 XT/400 XT J55 - GCM USER INPUT Ohmic clip cable port J15 - CNC HEIGHT CONTROL V-D Board connection J54 - TSC /COMM J59 - RAS CB2 - 5A 120 VAC CB3 - 5A 24 VAC...

  • Page 63: Complete The Installation

    ULTRA-CUT 100 XT/200 XT/300 XT/400 XT 3.25 Complete the Installation 1. Remove the cap from the coolant tank. Fill the coolant tank to the level shown, with Thermal Dynamics coolant. The coolant level is visible through the translucent coolant tank. The amount of coolant required varies with torch leads length.
  • Page 64 ULTRA-CUT 100 XT/200 XT/300 XT/400 XT NOTE Depending on the length of the torch leads, the system may require more coolant after turning the system ON for the first time. a. Place the ON/OFF Switch to ON. b. After about 4 minutes the system may shut down if the leads are not full of coolant.

  • Page 65: Section 4: Operation

    ULTRA-CUT 100 XT/200 XT/300 XT/400 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 66: System Operation

    ULTRA-CUT 100 XT/200 XT/300 XT/400 XT 4.02 System Operation This section contains operating information which is specific to the power supply. WARNING 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 67 ULTRA-CUT 100 XT/200 XT/300 XT/400 XT POWER Art # A-11542 3. Set Gas Pressure GCM 2010 a. Place Mode switch in SET PREFLOW mode. Adjust Preflow pressure as required for the cutting process. b. Set Mode Switch in SET PLASMA & SHIELD position. Adjust plasma and shield pressure regulators to correct pressure.

  • Page 68: Gas Selection

    ULTRA-CUT 100 XT/200 XT/300 XT/400 XT WARNING AC power is still present inside the unit. • Fans and pump as well as all indicators turn off. • The display may show a fault code for a moment, this is a normal part of shutting off power and does not indicate a fault.
  • Page 69 ULTRA-CUT 100 XT/200 XT/300 XT/400 XT 4. Nitrogen (N2) Plasma • Provides better cut quality on nonferrous materials such as stainless steel and aluminum. • Can be used in place of air plasma with air shield. • A good clean welding grade nitrogen should be used.

  • Page 70: Functional Overview

    ULTRA-CUT 100 XT/200 XT/300 XT/400 XT 4.04 GCM 2010 Gas Control Module Operation Functional Overview The Gas Control Module provides all Plasma and Secondary gas selection and control instrumentation. There are various controls and indicators used to set gas pressures and flows.
  • Page 71 ULTRA-CUT 100 XT/200 XT/300 XT/400 XT GCM 2010 Gas Control Module: Controls & Indicators 1. MODE Selection Switch SET PREFLOW SET PLASMA & SHIELD TEST MODE O2 - AIR O2 - O2 ENABLE H35 -N SET PREFLOW F5 - N...
  • Page 72 ULTRA-CUT 100 XT/200 XT/300 XT/400 XT 2. GAS Selection Switch Selects combinations of plasma and shield gases. O2 - AIR O2 - O2 H35 -N F5 - N AIR - AIR O2 - AIR O2 - O2 ENABLE H35 -N...
  • Page 73 ULTRA-CUT 100 XT/200 XT/300 XT/400 XT 4. Current Control Adjusts the output current of the power supply. High Precision AMPERAGE SET-UP Plasma Cutting System O2 - AIR O2 - O2 ENABLE H35 -N SET PREFLOW F5 - N SET PLASMA &...

  • Page 74: Gcm 2010 First Time Operation Matching Gas Control To Lead Length

    ULTRA-CUT 100 XT/200 XT/300 XT/400 XT 4.05 GCM 2010 First Time Operation Matching Gas Control to Lead Length For initial operation of GCM2010 with software version 2.1 or later. 1. Before applying AC power set the Power Supply ENABLE/DISABLE switch on the gas control module to DIS- ABLE.
  • Page 75 ULTRA-CUT 100 XT/200 XT/300 XT/400 XT 6. Place the MODE switch to the RUN position. 7. Set the Plasma Power Supply Enable / Disableswitch (on the Gas Control Module) to Enable. The Module performs purges of 15 seconds, 11 seconds, and another 11 seconds. This removes water from the torch parts.
  • Page 76 ULTRA-CUT 100 XT/200 XT/300 XT/400 XT Direction of Cut The plasma gas stream swirls as it leaves the torch to maintain a smooth column of gas. This swirl effect results in one side of a cut being more square than the other. Viewed along the direction of travel, the right side of the cut is more square than the left.

  • Page 77: Power Supply Status Codes

    ULTRA-CUT 100 XT/200 XT/300 XT/400 XT 4.07 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 number code preceded by either letter “E”...
  • Page 78 ULTRA-CUT 100 XT/200 XT/300 XT/400 XT CCM Status Code Code Message Remedy / Comments Group 2 -- Plasma Power Supply Blown wall fuse, Blown unit fuse F1 or F2 or rear panel, Bad power cable connection; Missing AC Phase Defective System Bias PCB.
  • Page 79 ULTRA-CUT 100 XT/200 XT/300 XT/400 XT CCM Status Code Code Message Remedy / Comments Inverter 3B Output Plasma work current high during cutting and attributed to Inverter Module 3 Section Current High B output high; If problem persists replace Inverter Module 3 Inverter Module 1 Section A required for Piloting;...
  • Page 80 ULTRA-CUT 100 XT/200 XT/300 XT/400 XT CCM Status Code Code Message Remedy / Comments 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...
  • Page 81 ULTRA-CUT 100 XT/200 XT/300 XT/400 XT CCM Status Code Code Message Remedy / Comments Inverter Module 3 Section B is over temperature; Operating with side panels re- Inverter 3B Over Temp moved, Check for restricted air flow, clogged radiator; Defective fan; If problem persists replace inverter module.
  • Page 82 ULTRA-CUT 100 XT/200 XT/300 XT/400 XT CCM Status Code Code Message Remedy / Comments Group 3 -- Gas Controller Status & Protocol Problem with fiber optic cable to GCM 2010; Dirt on fiber ends or in connec- Gas control communication tors;...
  • Page 83 ULTRA-CUT 100 XT/200 XT/300 XT/400 XT CCM Status Code Code Message Remedy / Comments Group 6 -- CCM 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 84: Remote Arc Starter Trouble Shooting

    ULTRA-CUT 100 XT/200 XT/300 XT/400 XT 4.08 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.

  • Page 85: Section 5: Maintenance

    ULTRA-CUT 100 XT/200 XT/300 XT/400 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.

  • Page 86: Coolant Replacement Procedure

    ULTRA-CUT 100 XT/200 XT/300 XT/400 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 87: Section 6: Replacement Assemblies & Parts

    ULTRA-CUT 100 XT/200 XT/300 XT/400 XT SECTION 6: REPLACEMENT ASSEMBLIES & PARTS 6.01 Replacement Power Supply Complete Unit / Component Catalog Number Ultra-Cut 100 XT Power Supply, 400V +10 -15% 3-8116-4 ™ Ultra-Cut 200 XT Power Supply, 400V +10 -15% 3-8119-4 ™...

  • Page 88: System Layout 100 - 200 Amp

    ULTRA-CUT 100 XT/200 XT/300 XT/400 XT 6.02 System Layout 100 - 200 Amp Refer to section 3.08 and 3.10 for ground connections and ground cables. 175’ / 53.3 m Maximum Length 125’ / 38.1 m Maximum Length 100’ / 30.5 m Maximum Length...

  • Page 89: System Layout 400 Amp

    ULTRA-CUT 100 XT/200 XT/300 XT/400 XT 6.04 System Layout 400 Amp Refer to section 3.08 and 3.10 for ground connections and ground cables. 175’ / 53.3 m Maximum Length 125’ / 38.1 m Maximum Length 50’ / 15.25 m Maximum Length...

  • Page 90: Leads And Cables All Amperages

    ULTRA-CUT 100 XT/200 XT/300 XT/400 XT 6.06 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 91 ULTRA-CUT 100 XT/200 XT/300 XT/400 XT Manual 0-5264 PARTS LISTS...

  • Page 92: Power Supply External Replacement Parts

    ULTRA-CUT 100 XT/200 XT/300 XT/400 XT 6.07 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 300A/400A Panel 9-7344 Lower Right Side 100A/200A Panel...

  • Page 93: Power Supply Replacement Parts - Upper Right Side

    ULTRA-CUT 100 XT/200 XT/300 XT/400 XT 6.08 Power Supply Replacement Parts - Upper Right Side Item # Description Ref. Des. Catalog # System Bias PCB 9-9253 Pilot PCB 9-9250 CCM Assembly 9-7335 Relays, Pump / Fan MC3 / MC2 9-7314...

  • Page 94: Power Supply Replacement Parts - Lower Right Side

    ULTRA-CUT 100 XT/200 XT/300 XT/400 XT 6.09 Power Supply Replacement Parts - Lower Right Side Item # Description Ref. Des. Catalog # Coolant Tank Cap 8-5124 Coolant Tank 9-7306 Coolant level Sensor 9-7307 Pump, Coolant, Assembly 9-7309 Motor, Pump 9-8166...

  • Page 95: Power Supply Replacement Parts - Rear Panel

    ULTRA-CUT 100 XT/200 XT/300 XT/400 XT 6.10 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...

  • Page 96: Power Supply Replacement Parts - Left Side

    ULTRA-CUT 100 XT/200 XT/300 XT/400 XT 6.11 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 380-415 VAC 9-7317 (100 and 200 Amp Systems use 1)

  • Page 97: Gas Control Module (Gcm-2010) Replacement Parts

    ULTRA-CUT 100 XT/200 XT/300 XT/400 XT 6.12 Gas Control Module (GCM-2010) Replacement Parts Item # Description Catalog # 7W Solenoid for O2 use 9-9393 Gas Selection Manifold Assembly 9-9391 Check Valve, 1/4 NPT .5 PSI 9-9390 Mode Switch Assembly 9-9406 Gas Selection Switch Assembly 9-9403 LCD Interface PC Board 9-9408...

  • Page 98: Gas Control Module (Gcm-2010) Replacement Parts

    ULTRA-CUT 100 XT/200 XT/300 XT/400 XT 6.13 Gas Control Module (GCM-2010) Replacement Parts Item # Description Catalog # 1” Black Instrument Knob 9-4233 Water Flow Meter with Valve 9-7005 Toggle Switch, 2 position SPDT 9-3426 Pressure gauge, 2” diameter 8-6800 Pressure gauge, 2”...

  • Page 99: Remote Arc Starter (Ras-1000 Xt) Replacement Parts

    ULTRA-CUT 100 XT/200 XT/300 XT/400 XT 6.14 Remote Arc Starter (RAS-1000 XT) Replacement Parts Item # Description Catalog # Complete RAS 1000 XT Assembly 3-9130E Pilot Cap Assembly 9-9423 Electronic Ignition Module 9-7342 Toroidal Coil 9-7343 Art # A-12066 Manual 0-5264...

  • Page 100: He400Xt Heat Exchanger - Replacement Parts

    ULTRA-CUT 100 XT/200 XT/300 XT/400 XT 6.15 HE400XT Heat Exchanger - Replacement Parts Item # Description Catalog # Assembly, HE400XT Heat Exchanger 9-9416 9-7348 Radiator 9-7349 Capacitor 9-1059 Thermal Switch 9-1448 Art # A-12672 6-14 PARTS LISTS Manual 0-5264...

  • Page 101: Torch Maintenance

    ULTRA-CUT 100 XT/200 XT/300 XT/400 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...

  • Page 102: O-Ring Lubrication

    ULTRA-CUT 100 XT/200 XT/300 XT/400 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 103: Torch Consumables Installation

    ULTRA-CUT 100 XT/200 XT/300 XT/400 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 104 ULTRA-CUT 100 XT/200 XT/300 XT/400 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 105: Coolant Leak Trouble-Shooting

    ULTRA-CUT 100 XT/200 XT/300 XT/400 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 106 ULTRA-CUT 100 XT/200 XT/300 XT/400 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 0.08 0.04 0.08 0.08 0.06 0.08 0.08 0.06 0.08 0.08 0.06...

  • Page 107: Appendix 1: 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 108: Appendix 2: Gas Control And Torch Valve Schematic

    ULTRA-CUT 100 XT/200 XT/300 XT/400 XT APPENDIX 2: Gas Control and Torch Valve Schematic ULTRACUT GCM 2010 GAS CONTROL O2 - AIR MODE MODE O2 - O2 H35 - N2 SET PREFLOW F5 - N2 SET CUTFLOW AIR - AIR...
  • Page 109 ULTRA-CUT 100 XT/200 XT/300 XT/400 XT LCD Display Assembly 19X2220 LCD DISPLAY ENCODER w/SW 15 16 1 2 3 4 5 6 7 8 9 10 11 12 13 14 INTERFACE BOARD PS1 Plasma Outlet Pressure PS1 Plasma Outlet Pressure...

  • Page 110: Appendix 3: Gas Control Module Plumbing Diagram

    ULTRA-CUT 100 XT/200 XT/300 XT/400 XT APPENDIX 3: Gas Control Module Plumbing Diagram New Plasma Inlet SOL11 Pressure Sensor SOL5 TVA & XTL -TVA Atmosphere SOL4 PLASMA SOL19 SOL18 Pressure SOL14 Sensor SOL3 SOL2 SOL1 PLASMA SOL6 SOL15 PREFLOW SHIELD...

  • Page 111: Appendix 4: Gas Control Module Pcb Layout

    ULTRA-CUT 100 XT/200 XT/300 XT/400 XT APPENDIX 4: Gas Control Module PCB Layout TP10 TP11 TP12 TP15 TP13 Art # A-07621 TP19 TP18 TP16 TP14 Manual 0-5264 APPENDIX...

  • Page 112: Appendix 5: Gas Control Display Module Pcb Layout

    ULTRA-CUT 100 XT/200 XT/300 XT/400 XT APPENDIX 5: Gas Control Display Module PCB Layout 19X2220 REV LCD INTERFACE C 2005 Art # A-06904 APPENDIX Manual 0-5264...

  • Page 113: Appendix 6: Cnc - Control Module Pcb Connections

    ULTRA-CUT 100 XT/200 XT/300 XT/400 XT APPENDIX 6: 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...

  • Page 114: Appendix 7: Cnc

    ULTRA-CUT 100 XT/200 XT/300 XT/400 XT APPENDIX 7: 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 115 ULTRA-CUT 100 XT/200 XT/300 XT/400 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 116: Cnc Input / Output Descriptions

    ULTRA-CUT 100 XT/200 XT/300 XT/400 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 117 ULTRA-CUT 100 XT/200 XT/300 XT/400 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 118: Simplified Cnc Circuit

    ULTRA-CUT 100 XT/200 XT/300 XT/400 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...
  • Page 119 ULTRA-CUT 100 XT/200 XT/300 XT/400 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 120: Cnc Connections

    ULTRA-CUT 100 XT/200 XT/300 XT/400 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 (-) ..

  • Page 121: Appendix 8: Serial Communications

    ULTRA-CUT 100 XT/200 XT/300 XT/400 XT APPENDIX 8: SERIAL COMMUNICATIONS A8.01 Cables and Switch Settings for 2 and 4 Wire The CCM communicates with the TSC 3000 (touch screen HMI panel) using RS 4�5 (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 122 ULTRA-CUT 100 XT/200 XT/300 XT/400 XT For RS 4�5 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.
  • Page 123 ULTRA-CUT 100 XT/200 XT/300 XT/400 XT This Page Intentionally Blank Manual 0-5264 APPENDIX A-17...

  • Page 124: Appendix 9: Ccm Cpu Pcb Layout

    ULTRA-CUT 100 XT/200 XT/300 XT/400 XT Appendix 9: CCM CPU PCB Layout = Test Point Art # A-11675 A-1� APPENDIX Manual 0-5264...
  • Page 125 ULTRA-CUT 100 XT/200 XT/300 XT/400 XT CCM CPU PCB Test Points TP1 GND TP2 ISO +5.0V TP3 +24V TP4 +3.3V TP5 ISO GND TP6 +5.0V TP7 TOTAL DEMAND 3.3V=400A TP9 /WR TP10 TP11 CPU TEMP SENSE TP12 +3.3VA TP13 -15VDAC...

  • Page 126: Appendix 10: Ccm I/O Pcb Layout

    ULTRA-CUT 100 XT/200 XT/300 XT/400 XT Appendix 10: CCM I/O PCB Layout = Test Point Art # A-11676_AB A-20 APPENDIX Manual 0-5264...
  • Page 127 ULTRA-CUT 100 XT/200 XT/300 XT/400 XT CCM I/O PCB J Connectors Test Points J21 BASIC CNC J22 EXTENDED CNC TP1 GND J23 RELAY - INTERFACE BOARD TP2 /COOLANT FANS ON J24 ARC / TIP VOLTS TP3 /TORCH PUMP ON J25 TEST...

  • Page 128: Appendix 11: Pilot Pcb Layout

    ULTRA-CUT 100 XT/200 XT/300 XT/400 XT Appendix 11: Pilot PCB Layout = Test Point Art # A-11677 A-22 APPENDIX Manual 0-5264...
  • Page 129 ULTRA-CUT 100 XT/200 XT/300 XT/400 XT Pilot PCB Test Points TP1 GND TP2 PILOT GATE TP3 +5V TP4 TIP LED Reference Green PILOT ENABLE Green +5V Manual 0-5264 APPENDIX A-23...

  • Page 130: Appendix 12: Relay And Interface Pcb Layout

    ULTRA-CUT 100 XT/200 XT/300 XT/400 XT Appendix 12: Relay and Interface PCB Layout = Test Point Art # A-11678 A-24 APPENDIX Manual 0-5264...
  • Page 131 ULTRA-CUT 100 XT/200 XT/300 XT/400 XT Relay and Interface PCB Test Points TP1 GND TP2 -15V TP3 +5VDC TP4 +12V TP5 +24V TP6 +15V TP7 +5VDC LED Reference Green 1 TORCH GAS ON Green PILOT ENABLE Green PILOT CURRENT DETECTED...

  • Page 132: Appendix 13: Display Pcb Layout

    ULTRA-CUT 100 XT/200 XT/300 XT/400 XT Appendix 13: Display PCB Layout = Test Point Art # A-11679 A-26 APPENDIX Manual 0-5264...
  • Page 133 ULTRA-CUT 100 XT/200 XT/300 XT/400 XT Display PCB Test Points TP1 GND TP2 +5VDC TP3 +24VDC Manual 0-5264 APPENDIX A-27...

  • Page 134: Appendix 14: System Bias Pcb Layout

    ULTRA-CUT 100 XT/200 XT/300 XT/400 XT Appendix 14: System Bias PCB Layout = Test Point Art # A-11680 A-2� APPENDIX Manual 0-5264...
  • Page 135 ULTRA-CUT 100 XT/200 XT/300 XT/400 XT System Bias PCB Test Points TP1 GND TP2 24VDC TP3 DC INPUT POSITIVE TP4 Vcc1 TP5 Vcc2 TP6 GATE TP7 PRIMARY GND TP� +12V PRIMARY TP9 P_ISOL_GND TP10 DC SENSE POSITIVE LED Reference MISSING PHASE...

  • Page 136: Appendix 15: Main Inverter Bottom Pcb Layout

    ULTRA-CUT 100 XT/200 XT/300 XT/400 XT Appendix 15: Main Inverter Bottom PCB Layout = Test Point A-30 APPENDIX Manual 0-5264...
  • Page 137 ULTRA-CUT 100 XT/200 XT/300 XT/400 XT Main Inverter Bottom PCB Test Points TP1 GND TP2 GATE 2A TP3 GATE 1A TP4 GATE 3A TP5 GATE 4A TP6 GATE 2B TP7 GATE 1B TP� GATE 4B TP9 GATE 3B TP10 +12VP...

  • Page 138: Appendix 16: Main Inverter Top Pcb Layout

    ULTRA-CUT 100 XT/200 XT/300 XT/400 XT Appendix 16: Main Inverter Top PCB Layout = Test Point A-32 APPENDIX Manual 0-5264...
  • Page 139 ULTRA-CUT 100 XT/200 XT/300 XT/400 XT Main Inverter Top PCB Test Points TP1 GND TP2 GATE 2A TP3 GATE 1A TP4 GATE 3A TP5 GATE 4A TP6 GATE 2B TP7 GATE 1B TP� GATE 4B TP9 GATE 3B TP10 +12VP...

  • Page 140: Appendix 17: Control And Fault Pcb Layout

    ULTRA-CUT 100 XT/200 XT/300 XT/400 XT Appendix 17: Control and Fault PCB Layout = Test Point /230V Art # A11683 A-34 APPENDIX Manual 0-5264...
  • Page 141 ULTRA-CUT 100 XT/200 XT/300 XT/400 XT Control and Fault PCB Test Points TP1 GND 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...

  • Page 142: Appendix 18: Cap Bias Bottom Pcb Layout

    ULTRA-CUT 100 XT/200 XT/300 XT/400 XT Appendix 18: Cap Bias Bottom PCB Layout Art # A-11685 A-36 APPENDIX Manual 0-5264...

  • Page 143: Appendix 19: Cap Bias Top Pcb Layout

    ULTRA-CUT 100 XT/200 XT/300 XT/400 XT Appendix 19: Cap Bias Top PCB Layout Art # A-11686 Manual 0-5264 APPENDIX A-37...

  • Page 144: Appendix 20: Suppressor Pcb Layout

    ULTRA-CUT 100 XT/200 XT/300 XT/400 XT Appendix 20: Suppressor PCB Layout Art # A-11684 A-3� APPENDIX Manual 0-5264...

  • Page 145: Appendix 21: Cooling Diagram

    ULTRA-CUT 100 XT/200 XT/300 XT/400 XT Appendix 21: COOLING DIAGRAM Manual 0-5264 APPENDIX A-39...

  • Page 146: Appendix 22: System Schematic 100A, 380-415V

    ULTRA-CUT 100 XT/200 XT/300 XT/400 XT APPENDIX 22: System Schematic 100A, 380-415V PG 1 380-415 INVERTER MODULE (IM) #`1 (bottom) INPUT J105B AC INPUT IM #1 Section B (upper) MAIN PCB LEDS (Customer (20) FIL- D3, RED, CAP supplied CONTROL PCB LEDS...
  • Page 147 2/18/2013 9/30/2013 9/16/2013 Drawn Date Misc updates & corrections 6/27/2013 10/03/2012 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 042X1354...

  • Page 148: Appendix 23: System Schematic 100A, 380-415V

    ULTRA-CUT 100 XT/200 XT/300 XT/400 XT APPENDIX 23: System Schematic 100A, 380-415V PG 2 J12 = Mini-Fit Jr AMBIENT COOLANT 400 VAC -- Single 18 AWG in pins 1 & 4 480 VAC -- Single 18 AWG in pins 1 & 8...
  • Page 149 9/12/2013 PCB1 Drawn Date Misc updates & corrections 6/27/2013 10/3/2012 The information contained herein is proprietary to Victor Technologies. Size Sheet TDYN SILK More updates & corrections Not for release, reproduction or distribution without written consent. ESD SILK Drawing Number...
  • Page 150 ULTRA-CUT 100 XT/200 XT/300 XT/400 XT APPENDIX 24: System Schematic 200A, 380-415V PG 1 INVERTER 1/2 MODULE (IM) #2 (top) (20) FIL- OUT1 J105A (21) IM #2 Section A (lower) AC INPUT OUT2 J104A (22) GND2B OUT3 J103A Toriod Core...
  • Page 151 2/18/2013 9/30/2013 9/16/2013 Drawn Date Misc updates & corrections 6/27/2013 10/04/2012 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 042X1353...

  • Page 152: Appendix 24: System Schematic 200A, 380-415V

    ULTRA-CUT 100 XT/200 XT/300 XT/400 XT APPENDIX 25: System Schematic 200A, 380-415V PG 2 AMBIENT COOLANT J12 = Mini-Fit Jr 400 VAC -- Single 18 AWG in pins 1 & 4 (90) 480 VAC -- Single 18 AWG in pins 1 & 8...
  • Page 153 2/18/2013 9/30/2013 9/13/2013 Drawn Date Misc updates & corrections 6/27/2013 10/4/2012 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 042X1353...
  • Page 154 ULTRA-CUT 100 XT/200 XT/300 XT/400 XT APPENDIX 26: System Schematic 300A, 380-415V PG 1 INVERTER MODULE (IM) #3 (top) FIL- J105B IM #3 Section B OUT1 AC INPUT J104B OUT2 GND2B J103B OUT3 Toriod Core 019X502700 CHASSIS GND J105A IM #3 Section A...
  • Page 155 2/18/2013 9/30/2013 9/16/2013 Drawn Date Misc updates & corrections 6/27/2013 10/04/2012 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 042X1352...

  • Page 156: Appendix 26: System Schematic 300A, 380-415V

    ULTRA-CUT 100 XT/200 XT/300 XT/400 XT APPENDIX 27: System Schematic 300A, 380-415V PG 2 AMBIENT J12 = Mini-Fit Jr COOLANT 400 VAC -- Single 18 AWG in pins 1 & 4 (90) 480 VAC -- Single 18 AWG in pins 1 & 8...
  • Page 157 2/18/2013 9/30/2013 9/16/2013 Drawn Date Misc updates & corrections 6/27/2013 10/4/2012 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 042X1352...
  • Page 158 ULTRA-CUT 100 XT/200 XT/300 XT/400 XT APPENDIX 28: System Schematic 400A, 380-415V PG 1 INVERTER MODULE (IM) #3 (top) FIL- J105B IM #3 Section B OUT1 AC INPUT J104B OUT2 GND2B J103B OUT3 Toriod Core 019X502700 CHASSIS GND J105A IM #3 Section A...
  • Page 159 2/18/2013 9/30/2013 9/16/2013 Drawn Date Misc updates & corrections 6/27/2013 10/03/2012 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 042X1341...

  • Page 160: Appendix 28: System Schematic 400A, 380-415V

    ULTRA-CUT 100 XT/200 XT/300 XT/400 XT APPENDIX 29: System Schematic 400A, 380-415V PG 2 AMBIENT J12 = Mini-Fit Jr COOLANT 400 VAC -- Single 18 AWG in pins 1 & 4 480 VAC -- Single 18 AWG in pins 1 & 8...
  • Page 161 2/18/2013 9/30/2013 9/16/2013 Drawn Date Misc updates & corrections 6/27/2013 10/3/2012 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 042X1341...

  • Page 162: Appendix 30: Advanced Troubleshooting

    Appendix 30: 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 163 ULTRA-CUT 100 XT/200 XT/300 XT/400 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 164 ULTRA-CUT 100 XT/200 XT/300 XT/400 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 165 ULTRA-CUT 100 XT/200 XT/300 XT/400 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 166 ULTRA-CUT 100 XT/200 XT/300 XT/400 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 167 ULTRA-CUT 100 XT/200 XT/300 XT/400 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 168 ULTRA-CUT 100 XT/200 XT/300 XT/400 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 169 ULTRA-CUT 100 XT/200 XT/300 XT/400 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 170 ULTRA-CUT 100 XT/200 XT/300 XT/400 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 20� fault but we have to rule it out.
  • Page 171 ULTRA-CUT 100 XT/200 XT/300 XT/400 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 172 ULTRA-CUT 100 XT/200 XT/300 XT/400 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).
  • Page 173 ULTRA-CUT 100 XT/200 XT/300 XT/400 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 174 ULTRA-CUT 100 XT/200 XT/300 XT/400 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 175 ULTRA-CUT 100 XT/200 XT/300 XT/400 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 176 ULTRA-CUT 100 XT/200 XT/300 XT/400 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 177 ULTRA-CUT 100 XT/200 XT/300 XT/400 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 178 ULTRA-CUT 100 XT/200 XT/300 XT/400 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 179 ULTRA-CUT 100 XT/200 XT/300 XT/400 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 180 ULTRA-CUT 100 XT/200 XT/300 XT/400 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 181 ULTRA-CUT 100 XT/200 XT/300 XT/400 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 182 ULTRA-CUT 100 XT/200 XT/300 XT/400 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, 20�-230V, 3�0- 415V or 4�0V isn’t identified then both ID signals are high resulting in an invalid signal.
  • Page 183 ULTRA-CUT 100 XT/200 XT/300 XT/400 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 184 ULTRA-CUT 100 XT/200 XT/300 XT/400 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 185 ULTRA-CUT 100 XT/200 XT/300 XT/400 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 186 ULTRA-CUT 100 XT/200 XT/300 XT/400 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 187 ULTRA-CUT 100 XT/200 XT/300 XT/400 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 J�-1 and J�-9. If present the relay board is OK.
  • Page 188 ULTRA-CUT 100 XT/200 XT/300 XT/400 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 189 ULTRA-CUT 100 XT/200 XT/300 XT/400 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.
  • Page 190 ULTRA-CUT 100 XT/200 XT/300 XT/400 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 191 ULTRA-CUT 100 XT/200 XT/300 XT/400 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 192 ULTRA-CUT 100 XT/200 XT/300 XT/400 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 193 ULTRA-CUT 100 XT/200 XT/300 XT/400 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 194 ULTRA-CUT 100 XT/200 XT/300 XT/400 XT CCM I/O PCB 230 VAC from T1 To test Pump relay jump TP3 to TP1. MC3A (66) (65B) Relay PCB MC3B CHASSIS GND Torch Coolant Pump J4-13 (67) 24 VAC (64B) (162) Coolant pump Control...
  • Page 195 ULTRA-CUT 100 XT/200 XT/300 XT/400 XT • 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 196 ULTRA-CUT 100 XT/200 XT/300 XT/400 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 � & 9, gives the signal “Basic ID” telling the CCM not to expect any CANBUS.
  • Page 197 ULTRA-CUT 100 XT/200 XT/300 XT/400 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 198 ULTRA-CUT 100 XT/200 XT/300 XT/400 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 199 ULTRA-CUT 100 XT/200 XT/300 XT/400 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 (+)

  • Page 200: Appendix 31: Publication History

    ULTRA-CUT 100 XT/200 XT/300 XT/400 XT APPENDIX 31: PUBLICATION HISTORY Cover Date Rev Change(s) April 18, 2013 AA First issue May 21, 2013 AB Updated with new RAS 1000 XT information per ECOB2428 July 2, 2013 Updated section 3 with information about V-D Board installation for height controller per ECOB2488 Jan.
  • Page 201 This Page Intentionally Blank...
  • Page 202 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...

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