Thermal Dynamics AUTO-CUT 300 XT Manuel utilisateur

ThermalDynamics.com

480V

AUTO-CUT 300 XT™

PLASMA CUTTING SYSTEM

Operating

Manual

Revision: AE Issue Date: May 27, 2015 Manual No.: 0-5300

WE APPRECIATE YOUR BUSINESS!

Congratulations on your new Thermal Dynamics product. We are proud to have you as our customer

and will strive to provide you with the best service and reliability in the industry. This product is backed

by our extensive warranty and world-wide service network. To locate your nearest distributor or service

agency call 1-800-752-7622, or visit us on the web at www.thermal-dynamics.com.

This Operating Manual has been designed to instruct you on the correct use and operation of your

Thermal Dynamics product. Your satisfaction with this product and its safe operation is our ultimate

concern. Therefore please take the time to read the entire manual, especially the Safety Precautions.

They will help you to avoid potential hazards that may exist when working with this product.

YOU ARE IN GOOD COMPANY!

The Brand of Choice for Contractors and Fabricators Worldwide.

Thermal Dynamics is a Global Brand of manual and automation Plasma Cutting Products.

We distinguish ourselves from our competition through market-leading, dependable products that

have stood the test of time. We pride ourselves on technical innovation, competitive prices, excel-

lent delivery, superior customer service and technical support, together with excellence in sales and

marketing expertise.

Above all, we are committed to developing technologically advanced products to achieve a safer

working environment within the welding industry

Plasma Cutting Power Supply, Auto-Cut® 300 XT™

Operating Manual No. 0-5300

Published by:

Thermal Dynamics Corporation.

2800 Airport Rd.

Denton, Texas 76207

www.thermal-dynamics.com

Thermal Dynamics Corporation.

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 dam-

age caused by any error or omission in this Manual, whether such error results from negligence,

accident, or any other cause.

Publication Date: April 22, 2013

Revision Date: May 27, 2015

Record the following information for Warranty purposes:

Where Purchased: ___________________________________

Purchase Date:______________________________________

Power Supply Serial #:_______________________________

Torch Serial #:_______________________________________

WARNING

Read and understand this entire Manual and your employer’s safety practices

before installing, operating, or servicing the equipment.

While the information contained in this Manual represents the Manufacturer’s

best judgement, the Manufacturer assumes no liability for its use.

Be sure this information reaches the operator.

You can get extra copies through your supplier.

CAUTION

These INSTRUCTIONS are for experienced operators. If you are not fully familiar with

the principles of operation and safe practices for arc welding and cutting equipment,

we urge you to read our booklet, “Precautions and Safe Practices for Arc Welding,

Cutting, and Gouging,” Booklet 0-5407. Do NOT permit untrained persons to install,

operate, or maintain this equipment. Do NOT attempt to install or operate this equip-

ment until you have read and fully understand these instructions. If you do not fully

understand these instructions, contact your supplier for further information. Be sure

to read the Safety Precautions before installing or operating this equipment.

USER RESPONSIBILITY

This equipment will perform in conformity with the description thereof contained in this manual and accompanying

labels and/or inserts when installed, operated, maintained and repaired in accordance with the instructions provided. This

equipment must be checked periodically. Malfunctioning or poorly maintained equipment should not be used. Parts that

are broken, missing, worn, distorted or contaminated should be replaced immediately. Should such repair or replacement

become necessary, the manufacturer recommends that a telephone or written request for service advice be made to the

Authorized Distributor from whom it was purchased.

This equipment or any of its parts should not be altered without the prior written approval of the manufacturer. The

user of this equipment shall have the sole responsibility for any malfunction which results from improper use, faulty main-

tenance, damage, improper repair or alteration by anyone other than the manufacturer or a service facility designated by

the manufacturer.

READ AND UNDERSTAND THE INSTRUCTION MANUAL BEFORE INSTALLING OR

OPERATING.

PROTECT YOURSELF AN D OTHERS!

ASSUREZ-VOUS QUE CETTE INFORMATION EST DISTRIBUÉE À L’OPÉRATEUR.

VOUS POUVEZ OBTENIR DES COPIES SUPPLÉMENTAIRES CHEZ VOTRE FOURNISSEUR.

ATTENTION

Les INSTRUCTIONS suivantes sont destinées aux opérateurs qualiés seulement.

Si vous n’avez pas une connaissance approfondie des principes de fonctionnement

et des règles de sécurité pour le soudage à l’arc et l’équipement de coupage, nous

vous suggérons de lire notre brochure « Precautions and Safe Practices forArc Wel-

ding, Cutting and Gouging, » Brochure 0-5407. Ne permettez PAS aux personnes non

qualiées d’installer, d’opérer ou de faire l’entretien de cet équipement. Ne tentez

PAS d’installer ou d’opérer cet équipement avant de lire et de bien comprendre ces

instructions. Si vous ne comprenez pas bien les instructions, communiquez avec

votre fournisseur pour plus de renseignements. Assurez-vous de lire les Règles de

Sécurité avant d’installer ou d’opérer cet équipement.

RESPONSABILITÉS DE L’UTILISATEUR

Cet équipement opérera conformément à la description contenue dans ce manuel, les étiquettes d’accompagnement et/

ou les feuillets d’information si l’équipement est installé, opéré, entretenu et réparé selon les instructions fournies. Vous devez

faire une vérication périodique de l’équipement. Ne jamais utiliser un équipement qui ne fonctionne pas bien ou n’est pas

bien entretenu. Les pièces qui sont brisées, usées, déformées ou contaminées doivent être remplacées immédiatement. Dans

le cas où une réparation ou un remplacement est nécessaire, il est recommandé par le fabricant de faire une demande de

conseil de service écrite ou par téléphone chez le DistributeurAutorisé de votre équipement.

Cet équipement ou ses pièces ne doivent pas être modiés sans permission préalable écrite par le fabricant. L’utilisateur

de l’équipement sera le seul responsable de toute défaillance résultant d’une utilisation incorrecte, un entretien fautif, des dom-

mages, une réparation incorrecte ou une modication par une personne autre que le fabricant ou un centre de service désigné

par le fabricant.

ASSUREZ-VOUS DE LIRE ET DE COMPRENDRE LE MANUEL D’UTILISATION AVANT

D’INSTALLER OU D’OPÉRER L’UNITÉ.

PROTÉGEZ-VOUS ET LES AUTRES!

This Page Intentionally Blank

TABLE OF CONTENTS

SECTION 1: SAFETY...............................................................................................................1-1

1.01 Safety Precautions - ENGLISH...................................................................1-1

1.02 Précautions de sécurité - FRENCH CANADIAN ........................................1-6

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

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

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

2.03 Plasma Cutting Torch..................................................................................2-1

2.04 System Component Layout.........................................................................2-1

2.05 Power Supply Speciﬁcations & Electrical Requirements ............................2-2

2.06 Power Supply Dimensions..........................................................................2-3

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

2.08 Gas Requirements......................................................................................2-5

2.09 Gas Applications.........................................................................................2-5

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

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

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

3.02 Cables and Leads Identiﬁcation..................................................................3-2

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

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

3.05 Connect Input Power and Ground Cables ..................................................3-5

3.06 Connect Work Cable to Power Supply........................................................3-6

3.07 Ground Connections...................................................................................3-6

3.08 Ground Connections...................................................................................3-7

3.09 Connect Gas and Coolant Supply Lines...................................................3-10

3.10 Cables for CNC, Arc Starter/Gas Control ................................................3-11

3.11 Set Switches on the Command - Control Module.....................................3-12

3.12 Height Control Connections......................................................................3-14

3.13 Connect Torch Leads to the Gas Control Module / Arc Starter.................3-15

3.14 Torch Head Installation and Connection..................................................3-17

3.15 Install ConsumableTorch Parts ................................................................3-18

3.16 Voltage Divider for iHCTorch Height Control............................................3-22

3:17 Fill Cooling System...................................................................................3-24

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

4.01 Power Supply Indicators.............................................................................4-1

4.02 Control Console Features...........................................................................4-2

4.03 System Operation.......................................................................................4-3

4.04 Gas Selection .............................................................................................4-5

4.05 Power Supply Status Codes.......................................................................4-6

4.06 Cut Quality................................................................................................4-13

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

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

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

5.03 Coolant Replacement Procedure................................................................5-2

5.04 Arc Starter Service .....................................................................................5-3

5.05 Arc Starter Spark Gap Adjustment .............................................................5-4

TABLE OF CONTENTS

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

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

6.02 Leads and Cables.......................................................................................6-1

6.03 Power Supply External Replacement Parts ...............................................6-3

6.04 Power Supply Replacement Parts - Lower Right Side................................6-4

6.05 Power Supply Replacement Parts - Upper Right Side................................6-5

6.06 Power Supply Replacement Parts - Left Side ............................................6-6

6.07 Power Supply Replacement Parts RAS - GCM 1000 XT...........................6-7

6.08 Power Supply Replacement Parts - Rear Panel.........................................6-8

6.09 Power Supply Replacement Parts - Front of GCM1000 XT........................6-9

6.10 Recommended Gas Supply Hose ............................................................6-10

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

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

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

7.03 Parts Wear..................................................................................................7-2

7.04 Torch Consumables Installation..................................................................7-3

APPENDIX 1: CNC CONTROL MODULE.............................................................................. A-1

Control PCB Connections........................................................................................ A-1

CNC functions ......................................................................................................... A-2

CNC Cable Color Code ........................................................................................... A-9

APPENDIX 2: CCM CPU PCB LAYOUT............................................................................... A-10

APPENDIX 3: CCM I/O PCB LAYOUT ................................................................................. A-12

APPENDIX 4: PILOT PCB LAYOUT..................................................................................... A-14

APPENDIX 5: RELAY AND INTERFACE PCB LAYOUT ...................................................... A-16

APPENDIX 6: DISPLAY PCB LAYOUT................................................................................. A-18

APPENDIX 7: SYSTEM BIAS PCB LAYOUT ....................................................................... A-20

APPENDIX 8: MAIN INVERTER BOTTOM PCB LAYOUT................................................... A-22

APPENDIX 9: MAIN INVERTER TOP PCB LAYOUT........................................................... A-24

APPENDIX 10: CONTROL AND FAULT PCB LAYOUT........................................................ A-26

APPENDIX 11: CAP BIAS BOTTOM PCB LAYOUT............................................................. A-28

APPENDIX 12: CAP BIAS TOP PCB LAYOUT..................................................................... A-29

APPENDIX 13: SUPPRESSOR PCB LAYOUT .................................................................... A-30

APPENDIX 14: COOLING DIAGRAM.................................................................................. A-31

APPENDIX 15: SYSTEM SCHEMATIC PG 1....................................................................... A-32

APPENDIX 16: SYSTEM SCHEMATIC PG2........................................................................ A-34

APPENDIX 17: ADVANCED TROUBLESHOOTING ............................................................ A-36

APPENDIX 18: PUBLICATION HISTORY ............................................................................ A-74

INTERNATIONAL CONTACT INFORMATION........................................................BACK COVER

AUTO-CUT 300 XT

Manual 0-5300 SAFETY INSTRUCTIONS 1-1

SECTION 1: SAFETY

1.01 Safety Precautions - ENGLISH

WARNING: These Safety Precautions are for your protection. They summarize precautionary information

from the references listed in Additional Safety Information section. Before performing any installation or

operating procedures, be sure to read and follow the safety precautions listed below as well as all other

manuals, material safety data sheets, labels, etc. Failure to observe Safety Precautions can result in injury or death.

PROTECT YOURSELF AND OTHERS -- Some welding, cutting, and gouging processes are noisy

and require ear protection. The arc, like the sun, emits ultraviolet (UV) and other radiation and can

injure skin and eyes. Hot metal can cause burns. Training in the proper use of the processes and

equipment is essential to prevent accidents. Therefore:

1. Always wear safety glasses with side shields in any work area, even if welding helmets, face shields, and

goggles are also required.

2. Use a face shield ﬁtted with the correct ﬁlter and cover plates to protect your eyes, face, neck, and ears

from sparks and rays of the arc when operating or observing operations. Warn bystanders not to watch

the arc and not to expose themselves to the rays of the electric-arc or hot metal.

3. Wear ﬂameproof gauntlet type gloves, heavy long-sleeve shirt, cufﬂess trousers, high-topped shoes, and

a welding helmet or cap for hair protection, to protect against arc rays and hot sparks or hot metal. A

ﬂameproof apron may also be desirable as protection against radiated heat and sparks.

4. Hot sparks or metal can lodge in rolled up sleeves, trouser cuffs, or pockets. Sleeves and collars should

be kept buttoned, and open pockets eliminated from the front of clothing.

5. Protect other personnel from arc rays and hot sparks with a suitable non-ﬂammable partition or curtains.

6. Use goggles over safety glasses when chipping slag or grinding. Chipped slag may be hot and can ﬂy far.

Bystanders should also wear goggles over safety glasses.

FIRES AND EXPLOSIONS -- Heat from ﬂames and arcs can start ﬁres. Hot slag or sparks can also cause

ﬁres and explosions. Therefore:

1. Remove all combustible materials well away from the work area or cover the materials with a protective

non-ﬂammable covering. Combustible materials include wood, cloth, sawdust, liquid and gas fuels, sol-

vents, paints and coatings, paper, etc.

2. Hot sparks or hot metal can fall through cracks or crevices in ﬂoors or wall openings and cause a hid-

den smoldering ﬁre or ﬁres on the ﬂoor below. Make certain that such openings are protected from hot

sparks and metal.“

3. Do not weld, cut or perform other hot work until the work piece has been completely cleaned so that there

are no substances on the work piece which might produce ﬂammable or toxic vapors. Do not do hot work

on closed containers. They may explode.

4. Have ﬁre extinguishing equipment handy for instant use, such as a garden hose, water pail, sand bucket,

or portable ﬁre extinguisher. Be sure you are trained in its use.

5. Do not use equipment beyond its ratings. For example, overloaded welding cable can overheat and create

a ﬁre hazard.

6. After completing operations, inspect the work area to make certain there are no hot sparks or hot metal

which could cause a later ﬁre. Use ﬁre watchers when necessary.

7. For additional information, refer to NFPA Standard 51B, “Fire Prevention in Use of Cutting and Welding

Processes”, available from the National Fire Protection Association, Battery march Park, Quincy, MA 02269.

AUTO-CUT 300 XT

1-2 SAFETY INSTRUCTIONS Manual 0-5300

ELECTRICAL SHOCK -- Contact with live electrical parts and ground can cause severe injury or death.

DO NOT use AC welding current in damp areas, if movement is conﬁned, or if there is danger of falling.

1. Be sure the power source frame (chassis) is connected to the ground system of the input power.

2. Connect the work piece to a good electrical ground.

3. Connect the work cable to the work piece. A poor or missing connection can expose you or others to a

fatal shock.

4. Use well-maintained equipment. Replace worn or damaged cables.

5. Keep everything dry, including clothing, work area, cables, torch/electrode holder, and power source.

6. Make sure that all parts of your body are insulated from work and from ground.

7. Do not stand directly on metal or the earth while working in tight quarters or a damp area; stand on dry

boards or an insulating platform and wear rubber-soled shoes.

8. Put on dry, hole-free gloves before turning on the power.

9. Turn off the power before removing your gloves.

10. Refer to ANSI/ASC Standard Z49.1 (listed on next page) for speciﬁc grounding recommendations. Do not

mistake the work lead for a ground cable.

ELECTRIC AND MAGNETIC FIELDS — May be dangerous. Electric current ﬂowing through any conduc-

tor causes localized Electric and Magnetic Fields (EMF ). Welding and cutting current creates EMF

around welding cables and welding machines. Therefore:

1. Welders having pacemakers should consult their physician before welding. EMF may interfere with some

pacemakers.

2. Exposure to EMF may have other health effects which are unknown.

3. Welders should use the following procedures to minimize exposure to EMF:

A. Route the electrode and work cables together. Secure them with tape when possible.

B. Never coil the torch or work cable around your body.

C. Do not place your body between the torch and work cables. Route cables on the same side of your

body.

D. Connect the work cable to the work piece as close as possible to the area being welded.

E. Keep welding power source and cables as far away from your body as possible.

FUMES AND GASES -- Fumes and gases, can cause discomfort or harm, particularly in conﬁned

spaces. Do not breathe fumes and gases. Shielding gases can cause asphyxiation.

Therefore:

1. Always provide adequate ventilation in the work area by natural or mechanical means. Do not weld, cut,

or gouge on materials such as galvanized steel, stainless steel, copper, zinc, lead, beryllium, or cadmium

unless positive mechanical ventilation is provided. Do not breathe fumes from these materials.

2. Do not operate near degreasing and spraying operations. The heat or arc rays can react with chlorinated

hydrocarbon vapors to form phosgene, a highly toxic gas, and other irritant gases.

3. If you develop momentary eye, nose, or throat irritation while operating, this is an indication that ventila-

tion is not adequate. Stop work and take necessary steps to improve ventilation in the work area. Do not

continue to operate if physical discomfort persists.

4. Refer to ANSI/ASC Standard Z49.1 (see listing below) for speciﬁc ventilation recommendations.

5. WARNING: This product contains chemicals, including lead, known to the State of California to cause birth

defects and other reproductive harm. Wash hands after handling.

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