®

AUTO-CUT 300 XT
™

PLASMA CUTTING SYSTEM

Operating
Manual

Revision: AF Issue Date: January 14, 2016 Manual No.: 0-5290

ThermalDynamics.com
 ®

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
 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.

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

Operating Manual No. 0-5290

Published by:
Thermal Dynamics Corporation.
2800 Airport Rd.
Denton, Texas 76207

www.thermal-dynamics.com

© Copyright 2013, 2014, 2015, 2016 by

Thermal Dynamics Corporation.

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.

For Printing Material Specification refer to document 47x1928.

Publication Date: April 17, 2013

Revision Date: January 14, 2016

Record the following information for Warranty purposes:

Where Purchased: ___________________________________

Purchase Date:______________________________________

Power Supply Serial #:_______________________________

Torch Serial #:______________________________________

 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 qualifiés 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 for Arc Wel-
ding, Cutting and Gouging, » Brochure 0-5407. Ne permettez PAS aux personnes non
qualifiées 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 vérification 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 Distributeur Autorisé de votre équipement.
Cet équipement ou ses pièces ne doivent pas être modifiés 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 modification 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
Declaration of Conformity
We Thermal Dynamics
of 2800 Airport Road
Denton, TX 76207 U.S.A.

in accordance with the following Directive(s):

2006/95/EC The Low Voltage Directive

2004/108/EC The Electromagnetic Compatibility Directive

hereby declare that:

Equipment: Plasma Cutting Controller
Model Name/Number: Auto-Cut 300 XT
Market Release Date: April 17, 2013

is in conformity with the applicable requirements of the following harmonized standards:

CENELEC EN61010-1 Ed:3 Safety Requirements for Electrical Equipment for Measurement, Control, and
Laboratory Use Part 1: General Requirements

Classification: The equipment described in this document 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 distur-
bances.

Manufacturer’s Authorized Representative

Steve Ward V.P. Europe and General Manager
Address:Victor Technologies International Inc. (Signature)
Europa Building
Chorley N Industrial Park
Chorley, Lancashire, Steve Ward
Full Name
England PR6 7BX
V.P. Europe and General Manager
Date: April 8, 2015
(Position)
 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 distur-
bances.
 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 Consumable Torch Parts.................................................................3-18
3.16 Voltage Divider for iHC Torch 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
 TABLE OF CONTENTS

SECTION 5: MAINTENANCE...................................................................................................5-1
5.01 General Maintenance..................................................................................5-1
5.02 Coolant Filter Cleaning Procedure...............................................................5-1
5.03 Coolant Replacement Procedure.................................................................5-2
5.04 Arc Starter Service.......................................................................................5-3
5.05 Arc Starter Spark Gap Adjustment..............................................................5-4

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

6.01 Replacement Power Supply........................................................................6-1
6.02 Leads and Cables........................................................................................6-2
6.03 Power Supply External Replacement Parts ................................................6-4
6.04 Power Supply Replacement Parts - Lower Right Side................................6-5
6.05 Power Supply Replacement Parts - Upper Right Side................................6-6
6.06 Power Supply Replacement Parts - Left Side .............................................6-7
6.07 Power Supply Replacement Parts RAS - GCM 1000 XT...........................6-8
6.08 Power Supply Replacement Parts - Rear Panel..........................................6-9
6.09 Power Supply Replacement Parts - Front of GCM1000 XT......................6-10
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

 TABLE OF CONTENTS

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: INSTALL REMOTE ARC STARTER............................................................. A-73

APPENDIX 19: PUBLICATION HISTORY............................................................................ A-82

STATEMENT OF WARRANTY..................................................................INSIDE BACK COVER

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

 TABLE OF CONTENTS

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 AUTO-CUT 300 XT
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.

0-5290 SAFETY INSTRUCTIONS 1-1

AUTO-CUT 300 XT
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.

1-2 SAFETY INSTRUCTIONS 0-5290

 AUTO-CUT 300 XT
CYLINDER HANDLING -- Cylinders, if mishandled, can rupture and violently release gas. Sudden rupture
of cylinder, valve, or relief device can injure or kill. Therefore:

1. Use the proper gas for the process and use the proper pressure reducing regulator designed to operate
from the compressed gas cylinder. Do not use adaptors. Maintain hoses and fittings in good condition.
Follow manufacturer’s operating instructions for mounting regulator to a compressed gas cylinder.
2. Always secure cylinders in an upright position by chain or strap to suitable hand trucks, undercarriages,
benches, walls, post, or racks. Never secure cylinders to work tables or fixtures where they may become
part of an electrical circuit.
3. When not in use, keep cylinder valves closed. Have valve protection cap in place if regulator is not con-
nected. Secure and move cylinders by using suitable hand trucks. Avoid rough handling of cylinders.
4. Locate cylinders away from heat, sparks, and flames. Never strike an arc on a cylinder.
5. For additional information, refer to CGA Standard P-1, “Precautions for Safe Handling of Compressed
Gases in Cylinders”, which is available from Compressed Gas Association, 1235 Jefferson Davis Highway,
Arlington, VA 22202.
EQUIPMENT MAINTENANCE -- Faulty or improperly maintained equipment can cause injury or death.
Therefore:

1. Always have qualified personnel perform the installation, troubleshooting, and maintenance work. Do not
perform any electrical work unless you are qualified to perform such work.
2. Before performing any maintenance work inside a power source, disconnect the power source from the
incoming electrical power.
3. Maintain cables, grounding wire, connections, power cord, and power supply in safe working order. Do
not operate any equipment in faulty condition.
4. Do not abuse any equipment or accessories. Keep equipment away from heat sources such as furnaces,
wet conditions such as water puddles, oil or grease, corrosive atmospheres and inclement weather.
5. Keep all safety devices and cabinet covers in position and in good repair.
6. Use equipment only for its intended purpose. Do not modify it in any manner.
ADDITIONAL SAFETY INFORMATION -- For more information on safe practices for electric arc welding
and cutting equipment, ask your supplier for a copy of “Precautions and Safe Practices for Arc Welding,
Cutting and Gouging”, Form 52-529.
The following publications, which are available from the American Welding Society, 550 N.W. LeJuene Road,
Miami, FL 33126, are recommended to you:
1. ANSI/ASC Z49.1 - “Safety in Welding and Cutting”.
2. AWS C5.1 - “Recommended Practices for Plasma Arc Welding”.
3. AWS C5.2 - “Recommended Practices for Plasma Arc Cutting”.
4. AWS C5.3 - “Recommended Practices for Air Carbon Arc Gouging and Cutting”.
5. AWS C5.5 - “Recommended Practices for Gas Tungsten Arc Welding“.
6. AWS C5.6 - “Recommended Practices for Gas Metal Arc Welding”.
7. AWS SP - “Safe Practices” - Reprint, Welding Handbook.
8. ANSI/AWS F4.1, “Recommended Safe Practices for Welding and Cutting of Containers That Have Held
Hazardous Substances.”
9. CSA Standard - W117.2 = Safety in Welding, Cutting and Allied Processes.

0-5290 SAFETY INSTRUCTIONS 1-3

AUTO-CUT 300 XT
Meaning of symbols - As used throughout this manual: Means Attention! Be Alert! Your safety is involved.

Means immediate hazards which, if not avoided, will result in immediate, serious per-
DANGER sonal injury or loss of life.

CAUTION Means potential hazards which could result in personal injury or loss of life.

WARNING Means hazards which could result in minor personal injury.

Enclosure Class
The IP code indicates the enclosure class, i.e. the degree of protection against penetration by solid objects or water.
Protection is provided against touch with a finger, penetration of solid objects greater than 12mm and against
spraying water up to 60 degrees from vertical. Equipment marked IP21S may be stored, but is not intended to be
used outside during precipitation unless sheltered.

This product is solely intended for plasma cutting. Any other use may result in personal
CAUTION injury and / or equipment damage.

CAUTION
If equipment is placed on a surface that slopes more
than 15°, toppling over may occur. Personal injury and
/ or significant damage to equipment is possible.
15°
Art# A-12726

CAUTION
To avoid personal injury and/or equipment damage,
lift using method and attachment points shown here.

Art# A-12736

1-4 SAFETY INSTRUCTIONS 0-5290

 AUTO-CUT 300 XT

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0-5290 SAFETY INSTRUCTIONS 1-5

AUTO-CUT 300 XT
1.02 Précautions de sécurité - FRENCH CANADIAN
AVERTISSEMENT : Ces règles de sécurité ont pour but d’assurer votre protection. Ils récapitulent les
informations de précaution provenant des références dans la section des Informations de sécurité sup-
plémentaires. Avant de procéder à l’installation ou d’utiliser l’unité, assurez-vous de lire et de suivre les
précautions de sécurité ci-dessous, dans les manuels, les fiches d’information sur la sécurité du matériel et sur
les étiquettes, etc. Tout défaut d’observer ces précautions de sécurité peut entraîner des blessures graves ou
mortelles.
PROTÉGEZ-VOUS -- Les processus de soudage, de coupage et de gougeage produisent un niveau
de bruit élevé et exige l’emploi d’une protection auditive. L’arc, tout comme le soleil, émet des rayons
ultraviolets en plus d’autre rayons qui peuvent causer des blessures à la peau et les yeux. Le métal
incandescent peut causer des brûlures. Une formation reliée à l’usage des processus et de l’équipement est essen-
tielle pour prévenir les accidents. Par conséquent:
1. Portez des lunettes protectrices munies d’écrans latéraux lorsque vous êtes dans l’aire de travail, même
si vous devez porter un casque de soudeur, un écran facial ou des lunettes étanches.
2. Portez un écran facial muni de verres filtrants et de plaques protectrices appropriées afin de protéger vos
yeux, votre visage, votre cou et vos oreilles des étincelles et des rayons de l’arc lors d’une opération ou
lorsque vous observez une opération. Avertissez les personnes se trouvant à proximité de ne pas regarder
l’arc et de ne pas s’exposer aux rayons de l’arc électrique ou le métal incandescent.
3. Portez des gants ignifugiés à crispin, une chemise épaisse à manches longues, des pantalons sans
rebord et des chaussures montantes afin de vous protéger des rayons de l’arc, des étincelles et du métal
incandescent, en plus d’un casque de soudeur ou casquette pour protéger vos cheveux. Il est également
recommandé de porter un tablier ininflammable afin de vous protéger des étincelles et de la chaleur par
rayonnement.
4. Les étincelles et les projections de métal incandescent risquent de se loger dans les manches retroussées,
les rebords de pantalons ou les poches. Il est recommandé de garder boutonnés le col et les manches et
de porter des vêtements sans poches en avant.
5. Protégez toute personne se trouvant à proximité des étincelles et des rayons de l’arc à l’aide d’un rideau
ou d’une cloison ininflammable.
6. Portez des lunettes étanches par dessus vos lunettes de sécurité lors des opérations d’écaillage ou de
meulage du laitier. Les écailles de laitier incandescent peuvent être projetées à des distances considéra-
bles. Les personnes se trouvant à proximité doivent également porter des lunettes étanches par dessus
leur lunettes de sécurité.
INCENDIES ET EXPLOSIONS -- La chaleur provenant des flammes ou de l’arc peut provoquer un incen-
die. Le laitier incandescent ou les étincelles peuvent également provoquer un incendie ou une explosion.
Par conséquent :

1. Éloignez suffisamment tous les matériaux combustibles de l’aire de travail et recouvrez les matériaux avec
un revêtement protecteur ininflammable. Les matériaux combustibles incluent le bois, les vêtements, la
sciure, le gaz et les liquides combustibles, les solvants, les peintures et les revêtements, le papier, etc.
2. Les étincelles et les projections de métal incandescent peuvent tomber dans les fissures dans les planchers
ou dans les ouvertures des murs et déclencher un incendie couvant à l’étage inférieur Assurez-vous que
ces ouvertures sont bien protégées des étincelles et du métal incandescent.
3. N’exécutez pas de soudure, de coupe ou autre travail à chaud avant d’avoir complètement nettoyé la
surface de la pièce à traiter de façon à ce qu’il n’ait aucune substance présente qui pourrait produire des
vapeurs inflammables ou toxiques. N’exécutez pas de travail à chaud sur des contenants fermés car ces
derniers pourraient exploser.
4. Assurez-vous qu’un équipement d’extinction d’incendie est disponible et prêt à servir, tel qu’un tuyau
d’arrosage, un seau d’eau, un seau de sable ou un extincteur portatif. Assurez-vous d’être bien instruit
par rapport à l’usage de cet équipement.

1-6 SAFETY INSTRUCTIONS 0-5290

 AUTO-CUT 300 XT
5. Assurez-vous de ne pas excéder la capacité de l’équipement. Par exemple, un câble de soudage surchargé
peut surchauffer et provoquer un incendie.
6. Une fois les opérations terminées, inspectez l’aire de travail pour assurer qu’aucune étincelle ou projec-
tion de métal incandescent ne risque de provoquer un incendie ultérieurement. Employez des guetteurs
d’incendie au besoin.
7. Pour obtenir des informations supplémentaires, consultez le NFPA Standard 51B, “Fire Prevention in Use
of Cutting and Welding Processes”, disponible au National Fire Protection Association, Batterymarch
Park, Quincy, MA 02269.
CHOC ÉLECTRI QUE -- Le contact avec des pièces électriques ou les pièces de mise à la terre sous
tension peut causer des blessures graves ou mortelles. NE PAS utiliser un courant de soudage c.a. dans
un endroit humide, en espace restreint ou si un danger de chute se pose.

1. Assurez-vous que le châssis de la source d’alimentation est branché au système de mise à la terre de
l’alimentation d’entrée.
2. Branchez la pièce à traiter à une bonne mise de terre électrique.
3. Branchez le câble de masse à la pièce à traiter et assurez une bonne connexion afin d’éviter le risque de
choc électrique mortel.
4. Utilisez toujours un équipement correctement entretenu. Remplacez les câbles usés ou endommagés.
5. Veillez à garder votre environnement sec, incluant les vêtements, l’aire de travail, les câbles, le porteélec-
trode/torche et la source d’alimentation.
6. Assurez-vous que tout votre corps est bien isolé de la pièce à traiter et des pièces de la mise à la terre.
7. Si vous devez effectuer votre travail dans un espace restreint ou humide, ne tenez vous pas directement
sur le métal ou sur la terre; tenez-vous sur des planches sèches ou une plate-forme isolée et portez des
chaussures à semelles de caoutchouc.
8. Avant de mettre l’équipement sous tension, isolez vos mains avec des gants secs et sans trous.
9. Mettez l’équipement hors tension avant d’enlever vos gants.
10. Consultez ANSI/ASC Standard Z49.1 (listé à la page suivante) pour des recommandations spécifiques
concernant les procédures de mise à la terre. Ne pas confondre le câble de masse avec le câble de mise
à la terre.
CHAMPS ÉLECTRIQUES ET MAGNÉTIQUES — comportent un risque de danger. Le courant électrique
qui passe dans n’importe quel conducteur produit des champs électriques et magnétiques localisés.
Le soudage et le courant de coupage créent des champs électriques et magnétiques autour des câbles
de soudage et l’équipement. Par conséquent :
1. Un soudeur ayant un stimulateur cardiaque doit consulter son médecin avant d’entreprendre une opération
de soudage. Les champs électriques et magnétiques peuvent causer des ennuis pour certains stimulateurs
cardiaques.
2. L’exposition à des champs électriques et magnétiques peut avoir des effets néfastes inconnus pour la santé.
3. Les soudeurs doivent suivre les procédures suivantes pour minimiser l’exposition aux champs électriques
et magnétiques :
A. Acheminez l’électrode et les câbles de masse ensemble. Fixez-les à l’aide d’une bande adhésive lorsque
possible.
B. Ne jamais enrouler la torche ou le câble de masse autour de votre corps.
C. Ne jamais vous placer entre la torche et les câbles de masse. Acheminez tous les câbles sur le même
côté de votre corps.
D. Branchez le câble de masse à la pièce à traiter le plus près possible de la section à souder.
E. Veillez à garder la source d’alimentation pour le soudage et les câbles à une distance appropriée de
votre corps.

0-5290 SAFETY INSTRUCTIONS 1-7

AUTO-CUT 300 XT
LES VAPEURS ET LES GAZ -- peuvent causer un malaise ou des dommages corporels, plus particu-
lièrement dans les espaces restreints. Ne respirez pas les vapeurs et les gaz. Le gaz de protection
risque de causer l’asphyxie.
Par conséquent :
1. Assurez en permanence une ventilation adéquate dans l’aire de travail en maintenant une ventilation
naturelle ou à l’aide de moyens mécanique. N’effectuez jamais de travaux de soudage, de coupage ou de
gougeage sur des matériaux tels que l’acier galvanisé, l’acier inoxydable, le cuivre, le zinc, le plomb, le
berylliym ou le cadmium en l’absence de moyens mécaniques de ventilation efficaces. Ne respirez pas
les vapeurs de ces matériaux.
2. N’effectuez jamais de travaux à proximité d’une opération de dégraissage ou de pulvérisation. Lorsque
la chaleur ou le rayonnement de l’arc entre en contact avec les vapeurs d’hydrocarbure chloré, ceci peut
déclencher la formation de phosgène ou d’autres gaz irritants, tous extrêmement toxiques.
3. Une irritation momentanée des yeux, du nez ou de la gorge au cours d’une opération indique que la ven-
tilation n’est pas adéquate. Cessez votre travail afin de prendre les mesures nécessaires pour améliorer
la ventilation dans l’aire de travail. Ne poursuivez pas l’opération si le malaise persiste.
4. Consultez ANSI/ASC Standard Z49.1 (à la page suivante) pour des recommandations spécifiques concer-
nant la ventilation.
5. AVERTISSEMENT : Ce produitcontient des produits chimiques, notamment du plomb, reconnu par l’Éta-
tde la Californie pour causerdes malformations congénitaleset d’autresdommages touchant le système
reproductif. Se laver les mainsaprès manipulation.
MANIPULATION DES CYLINDRES -- La manipulation d’un cylindre, sans observer les précautions néces-
saires, peut produire des fissures et un échappement dangereux des gaz. Une brisure soudaine du
cylindre, de la soupape ou du dispositif de surpression peut causer des blessures graves ou mortelles.
Par conséquent :

1. Utilisez toujours le gaz prévu pour une opération et le détendeur approprié conçu pour utilisation sur
les cylindres de gaz comprimé. N’utilisez jamais d’adaptateur. Maintenez en bon état les tuyaux et les
raccords. Observez les instructions d’opération du fabricant pour assembler le détendeur sur un cylindre
de gaz comprimé.
2. Fixez les cylindres dans une position verticale, à l’aide d’une chaîne ou une sangle, sur un chariot manuel,
un châssis de roulement, un banc, un mur, une colonne ou un support convenable. Ne fixez jamais un
cylindre à un poste de travail ou toute autre dispositif faisant partie d’un circuit électrique.
3. Lorsque les cylindres ne servent pas, gardez les soupapes fermées. Si le détendeur n’est pas branché,
assurez-vous que le bouchon de protection de la soupape est bien en place. Fixez et déplacez les cylindres
à l’aide d’un chariot manuel approprié. Toujours manipuler les cylindres avec soin.
4. Placez les cylindres à une distance appropriée de toute source de chaleur, des étincelles et des flammes.
Ne jamais amorcer l’arc sur un cylindre.
5. Pour de l’information supplémentaire, consultez CGA Standard P-1, “Precautions for Safe Handling of
Compressed Gases in Cylinders”, mis à votre disposition par le Compressed Gas Association, 1235 Jef-
ferson Davis Highway, Arlington, VA 22202.
ENTRETIEN DE L’ÉQUIPEMENT -- Un équipement entretenu de façon défectueuse ou inadéquate peut
causer des blessures graves ou mortelles. Par conséquent :

1. Efforcez-vous de toujours confier les tâches d’installation, de dépannage et d’entretien à un personnel

qualifié. N’effectuez aucune réparation électrique à moins d’être qualifié à cet effet.
2. Avant de procéder à une tâche d’entretien à l’intérieur de la source d’alimentation, débranchez l’alimen-
tation électrique.
3. Maintenez les câbles, les fils de mise à la terre, les branchements, le cordon d’alimentation et la source
d’alimentation en bon état. N’utilisez jamais un équipement s’il présente une défectuosité quelconque.

1-8 SAFETY INSTRUCTIONS 0-5290

 AUTO-CUT 300 XT
4. N’utilisez pas l’équipement de façon abusive. Gardez l’équipement à l’écart de toute source de chaleur,
notamment des fours, de l’humidité, des flaques d’eau, de l’huile ou de la graisse, des atmosphères
corrosives et des intempéries.
5. Laissez en place tous les dispositifs de sécurité et tous les panneaux de la console et maintenez-les en
bon état.
6. Utilisez l’équipement conformément à son usage prévu et n’effectuez aucune modification.

INFORMATIONS SUPPLÉMENTAIRES RELATI VES À LA SÉCURITÉ -- Pour obtenir de l’information sup-

plémentaire sur les règles de sécurité à observer pour l’équipement de soudage à l’arc électrique et le
coupage, demandez un exemplaire du livret “Precautions and Safe Practices for Arc Welding, Cutting and
Gouging”, Form 52-529.
Les publications suivantes sont également recommandées et mises à votre disposition par l’American Welding
Society, 550 N.W. LeJuene Road, Miami, FL 33126 :
1. ANSI/ASC Z49.1 - “Safety in Welding and Cutting”.
2. AWS C5.1 - “Recommended Practices for Plasma Arc Welding”.
3. AWS C5.2 - “Recommended Practices for Plasma Arc Cutting”.
4. AWS C5.3 - “Recommended Practices for Air Carbon Arc Gouging and Cutting”.
5. AWS C5.5 - “Recommended Practices for Gas Tungsten Arc Welding“.
6. AWS C5.6 - “Recommended Practices for Gas Metal Arc Welding”.
7. AWS SP - “Safe Practices” - Reprint, Welding Handbook.
8. ANSI/AWS F4.1, “Recommended Safe Practices for Welding and Cutting of Containers That Have Held
Hazardous Substances.”
9. CSA Standard - W117.2 = Safety in Welding, Cutting and Allied Processes.
SIGNIFICATION DES SYMBOLES - Ce symbole, utilisé partout dans ce manuel, signifie “Attention” ! Soyez
vigilant ! Votre sécurité est en jeu.

Signifie un danger immédiat. La situation peut entraîner des blessures graves ou mortel-
DANGER les.

Signifie un danger potentiel qui peut entraîner des blessures graves ou mortel-
MISE EN GARDE les.

AVERTISSEMENT Signifie un danger qui peut entraîner des blessures corporelles mineures.

Classe de protection de l’enveloppe

L’indice de protection (codification IP) indique la classe de protection de l’enveloppe, c’est-à-dire, le degré de pro-
tection contre les corps solides étrangers ou l’eau. L’enveloppe protège contre le toucher, la pénétration d’objets
solides dont le diamètre dépasse 12 mm et contre l’eau pulvérisée à un angle de jusqu’à 60 degrés de la verticale.
Les équipements portant la marque IP21S peuvent être entreposés à l’extérieur, mais ne sont pas conçus pour
être utilisés à l’extérieur pendant une précipitation à moins d’être à l’abri.

Ce produit a été conçu pour la découpe au plasma seulement. Toute autre utilisa-
MISE EN GARDE tion pourrait causer des blessures et/ou endommager l’appareil.

0-5290 SAFETY INSTRUCTIONS 1-9

AUTO-CUT 300 XT

MISE EN GARDE
L’équipement pourrait basculer s’il est placé sur une
surface dont la pente dépasse 15°. Vous pourriez
vous blesser ou endommager l’équipement de façon
importante.

15°
Art# A-12726

MISE EN GARDE
Soulevez à l’aide de la méthode et des points d’attache
illustrés afin d’éviter de vous blesser ou d’endommager
l’équipement.
Art# A-12736

1-10 SAFETY INSTRUCTIONS 0-5290

 AUTO-CUT 300 XT
SECTION 2: SPECIFICATIONS
2.01 General Description Of The System
A typical Auto-Cut 300 XT™ plasma cutting system includes:

• One Power Supply

• General Purpose Plasma Cutting Torch with Connecting Leads
• Torch Spare Parts Kit
The components are connected at installation.

2.02 Plasma Power Supply

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

2.03 Plasma Cutting Torch

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

2.04 System Component Layout

Arc Starter /
Gas Control Module
(GCM-1000XT) G: Torch Lead Set, Shielded
K F F1 - Coolant Supply
Pilot Return A w/ Negative
Control - Coolant Return
Negative B Auto-Cut 300XT Cable - Pilot Return
Power Supply - Plasma Gas
Coolant Supply C
Ground - Shield Gas
Coolant Return D Cable
Control Cable E Positioning
Primary power Tube

CNC Cable P Torch

CNC

O Work Cable Work

Art # A-11902_AB

0-5290 SPECIFICATIONS 2-1

AUTO-CUT 300 XT
2.05 Power Supply Specifications & Electrical Requirements
Auto-Cut 300 XT™ Specifications & Design Features
Max OCV (U0) 425 vdc
Minimum Output Current 5 Amps
Max Output Current 300 Amps
Output Voltage 60 - 180 vdc
300 Amp System Duty Cycle Rating 100% @ 300A, 200V, (60kW),
Ambient Temperature 104F° (40°C)
for Duty Cycle Rating
Operating range 14°F to 122°F (-10°C to + 50°C)
Power Factor 0.93 @ 300 A DC Output
Cooling Coolant and Forced Air (Class F)

Auto-Cut 300 XT™ Power Supply

Input Power Input Current Suggested Sizes (See Note)
Voltage Freq. 3-Ph 3-Ph Fuse (Amps) Wire (AWG) Wire (mm2)
(Volts) (Hz) (kVA) (Amps) 3-Ph 3-Ph 3-Ph
380 50/60 63 97 150 #4 25
IEC 380 50/60 71 110 150 #4 25

NOTE!
* Suggested wire size based on United States NFPA 70 National Electrical Code 2011 edition
published by the National Fire Prevention Association. Listings are from table 400.5(A)(2) for
flexible cord of certain types rated for 75 deg C in ambient temperatures up to 30 deg C. Us-
ing wires of lower temperature rating or different insulation type may require larger wire size.
Derate for higher ambient.
These are suggestions only. Always refer to your local and national codes that apply to your
region for final determination of correct wire type and size.

2-2 SPECIFICATIONS 0-5290

 AUTO-CUT 300 XT
2.06 Power Supply Dimensions

55 inch
1397 mm

40.6 inch
1031.2 mm
27.5 inch 610 lb / 277 kg
698.5 mm
Art # A-11918

0-5290 SPECIFICATIONS 2-3

AUTO-CUT 300 XT
2.07 Power Supply Rear Panel Features
J56 Gas Control
J58 Arc Starter
Gas Selection Switch
Plasma Gas - In
System Earth
Water - In
Ground
Shield Gas - In
Customer
C.C.M.
Optional Port
J55 To Gas Control
J15 To CNC Control J54 TSC/Comm

Customer Optional Port Circuit Breakers

J59 To Arc Starter
Coolant Return
Coolant Supply
Fuses
AC Power Lamp

Factory installed
Ground (F)
Pilot Lead
Customer Port
Work Lead Input Power
Negative Return

Coolant Filter

Art # A-11919

2-4 SPECIFICATIONS 0-5290

 AUTO-CUT 300 XT
2.08 Gas Requirements
The customer will provide all gases and pressure regulators. Gases must be of high quality. Pressure regulators
shall be equipped with stainless-steel diaphragms and installed as close as possible to the Gas Console.
Auto-Cut 300 XT™ Power Supply: Gas Pressures, Flows, and Quality Requirements
Gas Quality Minimum Pressure Flow
99.5% Purity 120 psi
O2 (Oxygen) 200 scfh (95 lpm)
(Liquid recommended) 8.3 bar / 827 kPa
99.5% Purity
(Liquid recommended) 120 psi
N2 (Nitrogen) 300 scfh (141.6 lpm)
<1000 ppm O2, <32 ppm 8.3 bar / 827 kPa
H2O)
Compressed Clean, Dry, 120 psi
450 scfh (212.4 lpm)
or Bottled Air Free of Oil (see Note 1) 8.3 bar / 827 kPa

H35 (Argon-Hydrogen)
99.995% Purity 120 psi
H35 = 35% Hydrogen, 200 scfh (94.4 lpm)
(gas recommended) 8.3 bar / 827 kPa
65% Argon

H2O (Water) See Note 2 55 psi (3.8 bar) 10 gph (0.6 lpm)
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.
Note 2: The tap water source does not need to be deionized, but in water systems with extremely high mineral content
a water softener is recommended. Tap water with high levels of particulate matter must be filtered. Soft tap water
with an allowable water hardness of <10 ppm as CaCO3 or less, filtered at 5 microns. Resistivity must be
at least 15 k ohm per cm.
Note 3: Water Pressure Regulator No. 8-6118 is recommended to ensure proper water pressure.

2.09 Gas Applications

MATERIAL MILD STEEL STAINLESS STEEL ALUMINUM
OPERATION PLASMA SHIELD PLASMA SHIELD PLASMA SHIELD
Air Air
55A Cut Air Air Air Air
O2 O2
Air Air Air Air
Air Air
100A Cut N2 H20 N2 H20
O2 O2 H35 N2 H35 N2
Air Air Air Air
Air Air
200A Cut N2 H20 N2 H20
O2 Air H35 N2 H35 N2
300A Cut Air Air Air Air Air Air

0-5290 SPECIFICATIONS 2-5

AUTO-CUT 300 XT
2.10 XTTM-301 Torch Specifications
A. Torch Dimensions
Art # A-11538

End Cap
19"
482.7 mm 2.25"
57.15 mm

Mounting Tube

15.5" 2.0"
393.8 mm 50.8 mm
XT-301 Basic 100 Amp

6.3"
160.1 mm

2.4"
3.98" 61 mm
101.1 mm

2.7"
69.6 mm

1.6"
40. mm

1.49"
37.8 mm

B. Torch Leads Lengths

Torch Lead Assembly
Lengths
Feet Meters
10 3.05
15 4.6
25 7.6
50 15.2
75 22.8
100 30.4

2-6 SPECIFICATIONS 0-5290

 AUTO-CUT 300 XT
C. Torch Parts (Generic Parts Shown)

bu as

to s
Cartridge

tri G
Shield

bu a
r
ap

to

tri G

de
is d

r
C

D iel
Retainer

is a

tro
D sm
ld

Sh
ie

ec
p

a
Sh

Ti

Pl

El
Assemble First
Art # A-11915

D. Parts - In - Place (PIP)

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

0-5290 SPECIFICATIONS 2-7

AUTO-CUT 300 XT
E. Type Cooling
Combination of gas stream through torch and liquid cooling.

F. XTTM-301 Torch Data (with Auto-Cut 300 XT™ Power Supply)

XTTM-301 Torch Ratings
(when used with Auto-Cut 300 XT™Power Supply)
Ambient 104° F
Temperature 40° C
Duty Cycle 100% @ 300 Amps
Maximum Current 300 Amps
Voltage (Vpeak) 500V
Arc Striking Voltage 10kV
Up to 300 Amps, DC,
Current
Straight Polarity (See Note)
XTTM-301 Torch Gas Specifications
Compressed Air, Oxygen,
Plasma Gases:
Nitrogen, H35, F5
Compressed Air, Oxygen,
Shield Gases:
Nitrogen, Water
120 psi ± 10 psi
Operating Pressure
8.3 bar ± 0.7 bar
Maximum Input Pressure 135 psi / 9.3 bar
Gas flow 10 - 450 scfh / 283-12743 l/hr
Power Supply used with: Auto-Cut 300 XT

2-8 SPECIFICATIONS 0-5290

 AUTO-CUT 300 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 must be checked by qualified personnel.
Auto-Cut 300 XT™ Power Supply
Input Power Input Current Suggested Sizes (See Note)
Voltage Freq. 3-Ph 3-Ph Fuse (Amps) Wire (AWG) Wire (mm2)
(Volts) (Hz) (kVA) (Amps) 3-Ph 3-Ph 3-Ph
380 50/60 63 97 150 #4 25
IEC 380 50/60 71 110 150 #4 25

NOTE!
* Suggested wire size based on United States NFPA 70 National Electrical Code 2011 edition
published by the National Fire Prevention Association. Listings are from table 400.5(A)(2) for
flexible cord of certain types rated for 75 deg C in ambient temperatures up to 30 deg C. Us-
ing wires of lower temperature rating or different insulation type may require larger wire size.
Derate for higher ambient.
These are suggestions only. Always refer to your local and national codes that apply to your
region for final determination of correct wire type and size.

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

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

• Reduced cutting speed

• Poor cut quality
• Poor cutting precision
• Reduced consumables life.
• Oil or grease contamination from compressed or bottled air can cause fires in conjunction with oxygen.

Cooling System Requirements

Coolant must be added to the system on installation. The amount required varies with torch leads length.
Thermal Dynamics recommends the use of its coolants 7-3580 and 7-3581 (for low temperatures).
Coolant Capabilities
Cat. Number and Mixture Mixture Protects To
7-3580 ‘Extra-CoolTM’ 25 / 75 10° F / -12° C
7-3581 ‘Ultra-CoolTM’ 50 / 50 27° F / -33° C
7-3582 ‘Extreme Cool ’
TM
Concentrate* -65° F / -51° C
* For mixing with D-I CoolTM 7-3583

0-5290 INSTALLATION 3-1

AUTO-CUT 300 XT
3.02 Cables and Leads Identification
Refer to section 3.05 and 3.06 for ground connections and ground cables.
Arc Starter /
Gas Control Module
(GCM-1000XT) G: Torch Lead Set, Shielded
K F F1 - Coolant Supply
Pilot Return A w/ Negative
Control - Coolant Return
Negative B Auto-Cut 300XT Cable - Pilot Return
Power Supply - Plasma Gas
Coolant Supply C
Ground - Shield Gas
Coolant Return D Cable
Control Cable E Positioning
Primary power Tube

CNC Cable P Torch

CNC

O Work Cable Work

Art # A-11902_AB

3-2 INSTALLATION 0-5290

 AUTO-CUT 300 XT
3.03 Cables & Leads Identification
#8 AWG Cable
A Pilot Return, Power Supply
to Arc Starter

2/0 (70 mm ) Cable

Negative Lead, Power Supply
B to Arc Starter

C Green Green
Coolant Leads, Power Supply
Red to Arc Starter
D Red

Control Cable, Power Supply

E 14 to Arc Starter

F Green / Yellow #4 AWG Ground Cable

Ground Cable,
F1 Green / Yellow 1/0 (50 mm 2 ) Arc Starter
To Earth Ground

G Torch Lead Set

Control Cable,
K 37 Power Supply to
Gas Control Module

O 2/0 (70 mm2 ) Cable

Work Cable

P 37 CNC Cable (28 Wire)

Art # A-11903

0-5290 INSTALLATION 3-3

AUTO-CUT 300 XT
3.04 Position 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 the lifting eye when using straps to lift the power supply.

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

Art # A-11904

Set the power supply on a solid, level surface. The installer may fasten the power supply to the floor or a support-
ing fixture with hardware passing through the horizontal parts of the power supply feet.

3-4 INSTALLATION 0-5290

 AUTO-CUT 300 XT
3.05 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.
2. Carefully cut back the outer sheath on the primary input power cable to expose the individual wires. Cut
back the insulation on the individual wires. Route the cable upward through Input Power Port at the bottom
of the panel. There are 2 extra plates included at the cable entrance. Discarding one or both allows changing
the opening size for larger cable/strain relief.
3. Install stripped end of 3 phase wires into the terminal block L1, L2 and L3 and connect the individual cables
as shown.
4. Connect the power cable ground wire to the ground terminal block.
5. Route a system ground cable (F1) to the stud on the rear of the gas control/arc starter Refer to the Ground
Connections Section for full details and procedures on proper system grounding.

Stud

Factory installed
COOLANT
Ground (F)
RETURN SUPPLY

Ground Terminals

1/0 Ground (F1)

to ‘Star’ Ground Input Power
and Ground

Art # A-11916

0-5290 INSTALLATION 3-5

AUTO-CUT 300 XT
3.06 Connect Work Cable to Power Supply
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.
2. Route the end of the work cable upward through the leads strain relief at the bottom edge of the left rear
panel. Pilot and Torch are factory installed.
3. Refer to the illustration. Connect the leads as shown. Tighten securely. Do not overtighten.

+ -

Pilot

Work Cable
Art # A-11533
Torch

4. Reinstall the cover on the power supply. Secure with two screws removed earlier. Do not overtighten.

3.07 Ground Connections

Star Ground on Cutting Table

Remote Arc Starter See

(Optional RAS-1000) Manufacturer Power Supply GCM-1000 XT
CNC Gas Control Module
Torch Device
Cutting Machine / Gantry #4 AWG Ground (F)
(Factory Installed)
Cutting Table

1/0
Ground Cable
(F1)

1/0 1/0 Ground (F1)

Ground Cable 2/0 Work Cable
Customer Supplied
Earth Ground A good ground will be 1/0 Ground Cable
Rod less than 3 ohm. Ideal 1.

‘Star’ Art # A-11914_AC

0 - 10 ft (0 - 3 m) Ideal Ground
20 ft (6 m) Maximum

3-6 INSTALLATION 0-5290

 AUTO-CUT 300 XT
3.08 Ground Connections
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 automation (mechanized)
systems:

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

NOTE!
All ground wires should be as short as possible. Long wires will have increased resistance to
RF frequencies. Smaller diameter wire has increased resistance to RF frequencies, so using a
larger diameter wire is better.
2. Grounding for components mounted on the cutting table (CNC controllers, height controllers, plasma remote
controls, etc.) should follow the manufacturer’s recommendations for wire size, type, and connection point loca-
tions.
For Thermal Dynamics components it is recommended to use a minimum of 10 AWG (European 6 mm2) wire or
flat copper braid with cross section equal to or greater than 10 AWG connected to the cutting table frame. The
connection point must be to clean bare metal; rust and paint make poor connections. For all components, wires
larger than the recommended minimum can be used and may improve noise protection.
3. The cutting machine frame is then connected to the “Star” point using 1/0 AWG (European 50 mm2) or larger
wire.
4. The plasma power supply work cable (see NOTE) is connected to the cutting table at the single point “Star”
ground.

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

5. Make sure work cable and ground cables are properly connected. The work cable must have a solid connec-
tion to the cutting table. The work and ground connections must be free from rust, dirt, grease, oil and paint. If
necessary grind or sand down to bare metal. Use lock washers to keep the connections tight. Using electrical
joint compound to prevent corrosion is also recommended.
6. The plasma power supply chassis is connected to the power distribution system ground as required by electrical
codes. If the plasma supply is close to the cutting table (see NOTE) a second ground rod is not usually needed,
in fact it could be detrimental as it can set up ground loop currents that cause interference.
When the plasma power supply is far away from the ground rod and interference is experienced, it may help to
install a second earth ground rod next to the plasma power supply. The plasma power supply chassis would
then be connected to this ground rod.

NOTE!
It is recommended that the Plasma Power Supply be within 20 - 30 ft (6.1 – 9.1 m) of the
cutting table, if possible.

7. The plasma control cable should be shielded with the shield connected only at the cutting machine end. Con-
necting the shield at both ends will allow ground loop currents which may cause more interference than with no
shield at all.

0-5290 INSTALLATION 3-7

AUTO-CUT 300 XT
C. Creating An Earth Ground
1. To create a solid, low resistance, earth ground, drive a 1/2 in (12 mm) or greater diameter copper clad ground
rod at least 6 - 8 ft (1.8 - 2.4 m) into the earth so that the rod contacts moist soil over most of its length. Depend-
ing on location, a greater depth may be required to obtain a low resistance ground (see NOTE). Ground rods,
typically 10 ft (3.0 m) long, may be welded end to end for greater lengths. Locate the rod as close as possible to
the work table. Install a ground wire, 1/0 AWG (European 50 mm2) or greater, between the ground rod and the
star ground point on the cutting table.

NOTE!
Ideally, a properly installed ground rod will have a resistance of three ohms or less.

D. Low Cost Ground Rod Tester

1. A key component of reduced EMI is a good low resistance earth ground rod. There are several very expensive
instruments to measure the ground but cost from several hundred to a few thousand dollars. Below is a low
cost alternative which can be constructed by qualified personnel familiar with established electrical construction
and safety practices. Previously suggested method using an incandescent light bulb will not work with GFCI
outlets which are increasingly being used and the bulbs are becoming obsolete.
2. This method, as well as the light bulb method and some of the expensive instruments, assumes the utility ground
is perfect, Zero ohms. It connects the rod being tested in series with the utility ground and measures the resis-
tance of both in series. If the utility ground is not zero ohms, no matter how good your rod is, you won’t get a
low reading due the higher resistance of the utility ground. Fortunately this is rare. Also if your rod is right next
to another earth grounded structure you may get a false lower reading of only resistance between that structure
and your rod rather than to gnd.

NOTE!
In the United States most standard AC outlets are 120 VAC 60 Hz. Elsewhere most outlets are
220 VAC 50Hz.

3. Obtain a transformer rated for at least 25 VA with primary voltage and frequency matching your standard outlets.
The transformer should have an isolated secondary of either 220 VAC (220 -240 is OK) or 120 VAC (110-120 is
OK) and be rated for at least 100 ma. The transformer could also have dual 115VAC primaries wired in series
for 220V or in parallel for 120 VAC. An example is Triad N-68X, shown below, rated 50VA, 50/60 Hz.
Obtain a power resistor of either 1200 (1.2K) ohms, 15-25W min, if using a 120V secondary or 2200 (2.2K) ohms,
25 -30W for a 220V secondary.
4. Assemble the transformer and power resistor in a metal box. Connect a 3 wire (w/gnd) power cord with ground
wire attached to the metal box for safety. If a plastic box is used instead, connect the transformer core and the
resistor mounts to the power cord ground wire. There should be a fuse ¼ - ½ A, in series with the transformer
primary. From the transformer secondary connect one wire to the utility safety ground. This could be the cutting
table frame, the ground terminal of the 120 or 220 VAC outlet or the test box if grounded as indicated.
An excellent ground measures 1 ohm or less. Up to 3 ohms is often acceptable, higher reduces the effectiveness
of the EMI suppression.

3-8 INSTALLATION 0-5290

 AUTO-CUT 300 XT
R = 1.2K, 15W
(2.2K, 25W for 220 VAC)
Ground Rod with other
connections removed
Triad N-68X Triad N-68X

115 VAC
115 VAC
F 0.1 VAC = 1 OHM,
F

115 VAC
0.3 VAC = 3 OHM,
etc.

115 VAC
115 VAC

GND GND
220 VAC 120 VAC

Utility (building) GND

Art # A-12710

WARNING
Dangerous high voltage is present when the power supply is connected to input power. Do not con-
nect input power or operate the power supply unless the connections cover is fastened in place.

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. Adding salt
to the soil by soaking it in salt water may also reduce its resistance. When these methods are used, periodic
checking of the ground resistance is required to make sure the ground is still good.

E. Routing Of Torch Leads

1. To minimize RF interference, position torch leads as far as possible from any CNC components, drive motors,
control cables, or primary power lines. If cables have to pass over torch leads, do so at an angle. Do not run the
plasma control or other control cables in parallel with the torch leads in power tracts.
2. Keep torch leads clean. Dirt and metal particles bleed off energy, which causes difficult starting and increased
chance of RF interference.

0-5290 INSTALLATION 3-9

AUTO-CUT 300 XT
3.09 Connect Gas and Coolant Supply Lines
1. Connect the gas supply lines to the appropriate input ports as shown, upper left.

NOTE!
Coolant lines are factory installed. If attaching optional HE400 see subsection 3.14

Plasma Gas - In
Water - In
Shield Gas - In

COOLANT
RETURN SUPPLY

Art # A-11906

3-10 INSTALLATION 0-5290

 AUTO-CUT 300 XT
3.10 Cables for CNC, Arc Starter/Gas Control
1. Connect one end of each cable to the power supply. Some cables shown are options and may not apply to
your system.
2. Connect the other end of the CNC cable to the CNC device.

NOTE!
The CNC cable shield must be attached to ground at the CNC end.

J56 To Gas Control

J58 Arc Starter

J55 To Gas Control

J15 To CNC Control

J54 TSC/
Comm
COOLANT
RETURN SUPPLY
J59 To
Arc Starter

Art # A-11907

0-5290 INSTALLATION 3-11

AUTO-CUT 300 XT
3.11 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.

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.

N
O
1
2

SW8
134
Switches shown in OFF position
2

SW1
3 4
USB

SW5
2
Future Use

SW9
2
1
O

SW4
SW8 SW1 SW5 SW9 SW4 SW3
O N

2
N

SW3
2
1 2 3 4 1 2 3 4 1 2 1 2 1 2 1 2

N
O
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).
1 = ON = (Remote Analog Current Control) Also set SW11 to “A” (down) position
*SW 8-3: Auto Transfer Retry1 = OFF = Enabled Up to 3 tries (Factory default setting).
1 = ON = Disabled
SW 8-4: OFF = Disabled (Factory default setting).
ON = Remote Marking SW Enabled at TB3-1&2
SW-1-1: Auto Pilot Restart. 1 = ON = Auto Pilot Function enabled.
1 = OFF = Auto Pilot Function disabled (Factory default setting).
SW-1-2: Pilot Delay 2 = OFF, 3 = OFF, 4 = OFF: 0 Seconds (Factory default setting).
SW-1-3: Pilot Delay 2 = ON, 3 = OFF, 4 = OFF: 0.1 Seconds
SW-1-4: Pilot Delay 2 = OFF, 3 = ON, 4 = OFF: 0.2 Seconds
2 = ON, 3 = ON, 4 = OFF: 0.4 Seconds Active only when
2 = OFF, 3 = OFF, 4 = ON: 0.8 Seconds SW-1-1 is set to ON.
2 = ON, 3 = OFF, 4 = ON: 1.0 Seconds
2 = OFF, 3 = ON, 4 = ON: 1.5 Seconds
2 = ON, 3 = ON, 4 = ON: 2.0 Seconds
SW-5-1: Tip Saver Reserved for Factory use.
SW-5-2: Off Plate Reserved for Factory use.
SW-4: Postflow Time 1 = OFF, 2 = OFF: 10 Seconds (Factory default setting).
1 = ON, 2 = OFF: 20 Seconds
1 = OFF, 2 = ON: 5 Seconds
1 = ON, 2 = ON: 0 Seconds
SW-3: Gas Preflow Time 1 = Off, 2 = OFF: 3 seconds
1 = ON, 2 = OFF: 4 seconds
1 = OFF, 2 = ON: 6 seconds
1 = ON, 2 = ON: 8 seconds Art # A-11911_AB

3-12 INSTALLATION 0-5290

 AUTO-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

SW6

SW12

SW13

SW-6: OK-to-Move: Contact closure, 120VAC @ 1A (Factory default setting) or

DC Volts (16-18vdc@ up to 100 ma.)
SW-11: Set “B” position, (up) for default
SW-11: Set “A” position (down) for remote analog current control. SW-8-2 must be set to “ON”.

SW-12-1/2/3/4: Divided Arc signal All = OFF = 50:1 (Factory default setting)
Only 1 on at a time.
1 = ON = 16.6:1
2 = ON = 30:1
3 = ON = 40:1 Art # A-11912_AB
4 = ON = 25:1

SW13: Auto-Cut XT Switch positions, off

4
23
1
ON

SW13 (Note positions 3-4 are not yet used)

0-5290 INSTALLATION 3-13

AUTO-CUT 300 XT
3.12 Height Control Connections
The terminal strip has Arc Volts (-) connection to power supply negative output TORCH terminal, Arc Volts
(+) connection to power supply positive output WORK terminal. These are for a height control that requires
connection to the full non-divided arc voltage. Also available on the terminal strip are 120VAC and 24 VAC.
Note that the two 0’s are not common. The allowable current draw is 100ma @ 120VAC and 1Amp @ 24 VAC.

TB4

Art # A-11905

TB4 1 2 3 4 5 6 7

24 VAC 120 VAC Work

@ 1A @ 100 ma. Tip Volts
(Pilot)
Arc Volts
(Torch)

Art # A-11954

There are holes added in the rear panel for customer wiring. This, rather than the one in the CCM will be the
preferred place for customer added wiring (and strain relief) for connections to height controls, etc..

3-14 INSTALLATION 0-5290

 AUTO-CUT 300 XT
3.13 Connect Torch Leads to the Gas Control Module / Arc Starter
1. Remove the top cover from the Gas Control Module / Arc Starter.
2. Pass the torch leads and coolant leads through the torch leads port on the back of the module. Ensure that the
leads outer jacket slides into the port.

CAUTION
! Use protective gloves when handling the leads. Do not kink or bend the leads.

3. Inside the module, slide the leads clamp over the leads.
4. Connect the leads to the module in the sequence shown. Coolant leads and connectors are color-tagged; red
for coolant return, green for coolant supply. Shield gas and plasma gas connections are left- and right- hand
threaded and will not interchange.

Torch Leads: Coolant Supply & Return

Plasma Gas
Shield Gas

Clamp * (Clamp type may vary)

3
2

Art # A-11929

0-5290 INSTALLATION 3-15

AUTO-CUT 300 XT

Coolant Return Coolant Supply

Connection (Tagged Red) Connection (Tagged Green)

Plasma Gas
Connection
Shield Gas
Connection

Torch Leads

Art # A-04832

5. Fold the end of the leads outer jacket back over the connection ring inside the module. Slide the leads clamp
over the jacket and fasten the clamp and jacket to the connection ring. Re-install the module top cover.

5
Clamp

Art # A-11930

3-16 INSTALLATION 0-5290

 AUTO-CUT 300 XT
3.14 Torch Head Installation and Connection
Install the Torch as follows:
1. Install the torch mounting block on the cutting table (gantry). Fasten the block in place.
2. Leave the end cap in place on the torch leads. Remove and discard the protective end caps from the Mount-
ing Tube.
3. Install the O-ring in the groove at the upper end of the mounting tube. Slide the torch mounting tube onto
the leads far enough to expose the fittings on the ends of the leads.
4. Connect the Torch Head to the torch leads. Follow the sequence shown. Do not let the leads twist.

End Cap

Shown to illustrate
assembly order only;
parts must remain O-Ring
secured tightly.

Insulating Paper

Pilot Lead Plasma Lead

Torch Leads

Plasma Lead
Connector
O-Ring
Positioning Tube

Coolant Return
Check Valve
and Connector

Threaded
Positioning Tube Holes
Detail Drain Holes

Shield ('Secondary')
Gas Connector
Insulating Paper
Art # A-06258
Coolant Supply Connector

0-5290 INSTALLATION 3-17

AUTO-CUT 300 XT
5. Slide the positioning tube down to the torch head. Hold the torch head stationary. Rotate the positioning
tube onto the torch head. Pull the leads back as needed to ensure a proper fit through the Mounting Tube.
Do not let the torch leads twist.

CAUTION
! Ensure that the leads do not twist within the mounting tube. Leads must lie as shown in the
installation sketch.
6. The lower end of the Mounting Tube includes four threaded holes. Install an Allen set screw from the hard-
ware kit in any of the threaded holes to secure the Torch Head Assembly to the Mounting Tube.
7. Fasten the positioning tube into the mounting block. Slide the leads end cap down onto the torch position-
ing tube. Ensure that the end cap engages the O-ring at the top of the positioning tube.
8. Install the shield cup, and cartridge assembly (including consumables) onto the torch head.

3.15 Install Consumable Torch Parts

1. Refer to the Torch Speed Charts to select the correct parts for the application. The application will determine
which torch parts must be used. Refer to the speed charts for the proper torch parts to install for a selected
application.

CAUTION
! Do not interchange parts. Make sure both the tip and electrode in the torch correspond with
the plasma and shield gas in use for the application.

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

to s

Cartridge
tri G

Shield
bu a
r
ap

to

tri G

de
is d

r
C

D iel

Retainer
is a

tro
D sm
ld

Sh
ie

ec
p

a
Sh

Ti

Pl

El

Assemble First
Art # A-11915

3. Stack the consumable parts together.

3-18 INSTALLATION 0-5290

 AUTO-CUT 300 XT
4. Insert the stack of consumable parts into the cartridge. Ensure that the large O-ring on the torch tip fits
completely into the cartridge. If any part of the O-ring protrudes from the cartridge, the parts are not seated
properly.
1: Stack Parts 2: Press Cartridge onto Stacked Parts

Electrode

Plasma Gas
Distributor O-Ring
on Tip

Tip No Gaps
Between Parts

Shield Gas
Cartridge Covers
Distributor
O-Ring
Shield Cap on Torch Tip

3: Thread Shield Cup onto Cartridge 4: Check Shield Cap Protrusion

Shield Cup

Shield Cap

Shield Cap Protrudes Art # A-04873

0.063-0.083" (1.6 - 2.1 mm)

0-5290 INSTALLATION 3-19

AUTO-CUT 300 XT
5. Use the removal tool to hold the cartridge assembly, while turning the shield cap onto the cartridge assem-
bly. When this group is fully assembled, the shield should protrude from the front of the shield cup 0.063”
to 0.083” (1.6 - 2.1 mm). Without this protrusion the shield cup is not properly tightened onto the cartridge
assembly.

Cartridge Tool

Assembled Cartridge

Art # A-04344_AB

Shield Cup

Installing Shield Cup Onto Cartridge

6. Take the removal tool off the cartridge. Fit the cartridge assembly onto the torch head. The cartridge should
seal to the large O-ring on the torch body as shown. If the cartridge does not seal on the O-ring, the cartridge
is not fully tightened.

CAUTION

! Do not force the cartridge if it will not fully tighten. Remove the cartridge and gently clean the
threads on the torch head body with a wire brush. Apply oxygen-compatible lubricant (supplied
with the torch) to the threads.

Torch Head

Assembled Cartridge

Art # A-03893

Installing Assembled Cartridge Onto Torch Head

3-20 INSTALLATION 0-5290

 AUTO-CUT 300 XT
7. Confirm proper parts assembly as shown.

Torch Head Torch Head O-Ring

0.063 - 0.083"
(1.6 - 2.1 mm) Art # A-07202_AB
Protrusion

8. Slide the ohmic clip over the shield cup if using ohmic torch height sensing.

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

Art # A-03393_AB

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

0-5290 INSTALLATION 3-21

AUTO-CUT 300 XT
3.16 Voltage Divider for iHC Torch Height Control
For best plasma cutting performance it is necessary to maintain a constant height (standoff) above the metal while
cutting. 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 Technologies XT CNC
Controller, come with a Voltage Divider Printed Circuit Board that has to be installed inside the plasma power sup-
ply to divide the high arc voltage down to lower levels for use with control circuits.
There is a space for mounting the V-D Board located on the upper portion of an internal vertical panel near the rear
of the power supply. Predrilled holes for mounting the iHT V-D board as well as another popular height control
are provided.

CAUTION

! If using another board that doesn’t align with the existing holes, remove the panel if possible
before drilling. If not possible then every precaution must be taken to keep metal filings from
being deposited inside the power supply.
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 2 screws,
securing the V-D board in place. If using another V-D Board, follow the instructions provided mounting it
in this same location.

Space for V-D Board Ohmic clip cable port V-D Board installed

Art # A-12079
V-D Board connection

V-D Board shown with optional wire harness for iHC controller

3-22 INSTALLATION 0-5290

 AUTO-CUT 300 XT
Control Cable.
The iHC board can be supplied with a wire harness and connector (shown in previous image), to be installed in
the rear panel hole labeled “Height Control” . The connector mates with a cable from the iHC. For other height
control V-D boards a strain relief can be installed in this hole for those cables. Refer to Appendix for wiring diagram.

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

J70 - HE

CB4 - 5A 120 VAC

F1 - 8A SB 230 VAC F2 - 8A SB 230 VAC

Art # A-12080

Arc Voltage Connections.

The XT plasma supplies provide a terminal strip, TB4, on the right side ahead of the CCM module for connections
to Arc V- (Torch); Tip V (Pilot); Arc V + (Work). If the V-D board requires separate power, 24 VAC and 120 VAC is
available on the terminal strip TB4. Refer to the wiring diagram in the Appendix for more information.

TB4 1 2 3 4 5 6 7

24 VAC 120 VAC Work

@ 1A @ 100 ma. Tip Volts
(Pilot)
Arc Volts
(Torch)

Art # A-11954

“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. The XT torch includes a metal spring clip which slips into a groove in the shield cup allowing easy removal for
parts change. The Ohmic wire can be connected to this clip with a ¼” female push-on terminal.
Significant amounts of high frequency (HF) energy causing electromagnetic interference (EMI) can be conducted
along this wire due to it’s close coupling to the torch. This is the reason for mounting the V-D board away from
the CCM and close to the rear panel where the Ohmic wire does not need to pass near other sensitive electronics.
It is especially recommended that the Ohmic wire not be routed near the CCM module or along the torch leads.
Refer to Appendix for wiring diagram.

Ferrite cores.
It is recommended that the Ohmic Sensing wire be wrapped through a ferrite core with several turns, at least 3 but
more is better, to reduce the energy conducted to the V-D board and into the plasma supply. The ferrite core should
be located on the wire where it enters the plasma supply. A second ferrite core added several feet (couple of meters)
from the torch will further reduce the conducted EMI that may couple to other cable/wires and cause interference.
Refer to Appendix for wiring diagram.

0-5290 INSTALLATION 3-23

AUTO-CUT 300 XT
3:17 Fill Cooling System
1. Fill the coolant tank to the level shown, with Thermal Dynamics coolant. The coolant level is visible through
the translucent coolant tank. The amount of coolant required varies with torch leads length.
2. Replace the cap on the tank.
Coolant Capabilities
Cat. Number and Mixture Mixture Protects To
7-3580 ‘Extra-CoolTM’ 25 / 75 10° F / -12° C
7-3581 ‘Ultra-CoolTM’ 50 / 50 27° F / -33° C
7-3582 ‘Extreme CoolTM’ Concentrate* -65° F / -51° C
* For mixing with D-I CoolTM 7-3583

Coolant Tank

Fill Range

Art # A-11908

3-24 INSTALLATION 0-5290

 AUTO-CUT 300 XT
3. After the complete system has been installed, check that the coolant has been pumped through the system
as follows (see NOTE):

NOTE!
The system will most likely require more coolant after turning the system ON for the first time.

a.
Place the ON/OFF Switch to ON. The power supply will start to circulate coolant throughout the system.
b.
After about 4 minutes the system may shut down if the leads are not full of coolant.
c.
Place the ON/OFF switch to OFF. Refill Coolant Tank as needed.
d.
After 10 seconds place the ON/OFF switch to ON again.
e.
Repeat steps ‘b’ through ‘d’ until the system no longer shuts down. Depending on the length of the torch
leads this sequence may need to be done three to five times.
f. After the system stays operational allow the pump to operate for ten minutes to properly purge any air
from the coolant lines before using the system.
4. Re-fill the reservoir and re-install the filler cap.

NOTE!
Circuitry in the power supply will generate a ‘Low coolant’ message if the coolant level is too
low.

0-5290 INSTALLATION 3-25

AUTO-CUT 300 XT

This Page Intentionally Blank

3-26 INSTALLATION 0-5290

 AUTO-CUT 300 XT
SECTION 4: OPERATION
4.01 Power Supply Indicators
AC Indicator Gas Indicator A/ Status Indicator
Temp Indicator DC Indicator

A/

Art # A-11909

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.

TEMP Lamp: Normally OFF. Lamp will come ON when the internal temperature sensors detect temperatures
above normal limits. Let the unit cool before continuing operation.

GAS Lamp: Flashing during start up gas purge/pump priming, then whenever gas is flowing. Indicates ad-
equate gas pressure and coolant flow for operation.

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

A/ Status Indicator: Shows CCM code version on start up followed by the Current Control setting and
system status. Refer to Section 4.05 and Status Code Section for details.
Rear Panel AC Power Lamp
Indicates AC power is present inside the unit

0-5290 OPERATION 4-1

AUTO-CUT 300 XT
4.02 Control Console Features

Art # A-11917

Shield Gas
Plasma Gas Pressure Gauge
Pressure Gauge

Run / Set Selector

RUN

SET

Amperage PLASMA SHIELD

Selector

SHIELD GAS

CUT
OUT

A H20 MIST
H20 MIST

GCM 1000 XT
GAS CONTROL MANAGEMENT SYSTEM

Shield Plasma Gas Pressure Shield Gas Pressure Water Mist (Shield) Flow Meter
Selector Control Knob Control Knob and Control Knob
Run / Set Selector: Use SET position to adjust plasma and shield pressures and flows. Once these are set, switch
to RUN position for operation.
Plasma and Shield Gas Pressure Control Knobs: Adjust plasma and shield gas pressures. Turn knobs to set desired
levels.
Plasma and Shield Gas Pressure Gauges: Display plasma and shield gas pressures.
Shield Selector: Selects shield fluid, gas or H2O Mist (water).
Water Shield Mist (H2O) Flowmeter and Control Knob: Controls flow rate of shield water supply.

A/
Amperage Selector: Continuously adjustable to 300 Amps. Visible here:
Plasma Gas Type Selector (rear panel): Selects proper operating voltage for either Air & O2 or N2 & H35. Also
use N2/H35 setting for F5.

4-2 OPERATION 0-5290

 AUTO-CUT 300 XT
4.03 System Operation
This section contains operating information which is specific to the power supply.

WARNING
Frequently review the safety precautions in Section 1.
If the power supply cord has a plug or is not permanently connected to power, be sure the power to
the outlet is disconnected when inserting the plug into the outlet.
Disconnect primary power at the source before assembling or disassembling power supply, torch
parts, or torch and leads assemblies, or adding coolant.
It is not enough to simply move the ON/OFF switch on the unit to OFF position when cutting opera-
tions have been completed. Always open the power supply disconnect switch five minutes after the
last cut is made.

Prior to starting the system determine the process to be used. The process is determined by the type and thickness
of the metal to be cut. Select and install the required consumables, connect the required gasses to the system.
1. Connect system to primary input power. An indicator will light on the rear panel when AC power is applied
to the unit. Place the Gas Control in the RUN mode.
2. Turn ON/OFF switch to ON (up) position. System goes through the “Start up Sequence”.

• For about 10 seconds the decimal points of the 4 digit display blink from right to left.
• Next the 4 rectangular LED indicators illuminate all segments as a test.
• Then for about 6 seconds the display shows the letter “C” (code) followed by the CCM code version.
Example “C1.2.0” . During this time various input voltage tests are being performed. If a fault is found
its code is displayed and the start up sequence halts. Faults will show “E” or “L”.
• The coolant pump then starts and the Gas indicator blinks while the cutting gasses are purged for 20
seconds. Gas LED should stop blinking and gas flow (purge) stops unless gas control was left in the SET
mode or the coolant flow is not satisfied. At the same time the display shows the current control setting.
Example: “200”
• Once coolant flow is detected, usually within 5 seconds after the pump starts, the W1 and W2 input con-
tactors close and the AC indicator lights. However if correct coolant flow was not obtained the contactors
will not close and the Gas LED will continue blinking until required coolant flow has been obtained. The
Gas LED will blink for up to 4 minutes after which code E404 will be displayed indicated proper coolant
flow was not established.

POWER
I ON
OFF OFF OFF
O O O

OFF

Art # A-11910

0-5290 OPERATION 4-3

AUTO-CUT 300 XT
3. Set Gas Pressures
a. Place RUN/SET switch in SET mode.
b. Adjust plasma and shield pressure regulators to correct pressure or correct flow if using H2O Mist (refer
to cut chart manual for required pressure/flow.)
c. Return RUN/SET switch to RUN mode. Attempting to START while in the SET mode will cause fault
L303, normally indicating low gas pressure but in Auto-Cut XT units also indicates trying to START while
in SET.
4. Set cutting current.
a. Adjust the Current Control knob to the required output current on the 4 digit display.
5. Prepare to cut.
a. Protect your eyes and ears.
b. Position the Torch to the proper transfer distance above the work piece.
6. Apply START.

• Gas indicator lights; Gas pre-flow starts.

• During gas pre-flow power supply is enabled. DC lamp turns ON.
7. Pilot Arc

• At the end of pre-flow, ignition occurs (arcstarter fires) and the Pilot Arc is established.
8. Transfer

• Almost immediately, if the torch is positioned correctly, the pilot arc transfers to the work and becomes a
cutting (transferred) arc.
• Current quickly ramps up to the level set by the Current Control and the arc pierces through the metal.
• OK to Move signal becomes active and the torch is moved to perform the cut.
9. End of Cut

• START signal is removed; current ramps down and the arc goes out.
• Gases continue to flow for the selected Post-flow time then stops.
• Pump and fan will run for 4 minutes then shut off. Fan will remain on as long as power is on.
10. To make another cut repeat steps 5-9. A second cut can be started anytime after completing the first cut.
11. Shut off the system.
a. Set the ON/OFF power switch on the front panel of the unit to OFF.

WARNING
AC power is still present inside the unit.

• Fans and pump as well as all indicators turn off.

• 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.
b. Open (turn off) the main power disconnect. All power is now removed from the unit.

• Rear panel AC indicator turns OFF.

4-4 OPERATION 0-5290

 AUTO-CUT 300 XT
Operational Suggestions
1. Wait four minutes before setting the ON/OFF switch to OFF after operation. This allows the cooling fans to run
to dissipate operating heat from the power supply.
2. For maximum parts life, do not operate the pilot arc any longer than necessary.
3. Use care in handling torch leads and protect them from damage.
4. When using water as the shield note the following:
• Use clean drinking quality tap water to help prevent particulate build-up within the system water shield
plumbing.
• Particulate contamination and build-up can cause reduced consumable parts life and premature torch failure.
• A cartridge type particulate water filter may help achieve optimum cutting performance.

4.04 Gas Selection

A. Plasma Gases
1. Air Plasma
• Most often used on ferrous or carbon base materials for good quality at faster cutting speeds.
• Air plasma is normally used with air shield.
• Only clean, dry air is recommended for use as plasma gas. Any oil or moisture in the air supply will
substantially reduce torch parts life.
• Provides satisfactory results on nonferrous materials.
2. Argon/Hydrogen (H35) Plasma

• Recommended for use on 3/4 in (19 mm) and thicker stainless steel. Recommended for 1/2 inch (12 mm)
and thicker nonferrous materials. Ar/H2 is not normally used for thinner nonferrous materials because
less expensive gases can achieve similar cut quality.
• Poor cut quality on ferrous materials.
• Provides faster cutting speeds and high cut quality on thicker materials to offset the higher cost.
• A 65% argon / 35% hydrogen mixture should be used.
3. Oxygen (O2) Plasma

• Oxygen is recommended for cutting ferrous materials.

• Provides faster cutting speeds.
• Provides very smooth finishes and minimizes nitride buildup on cut surface (nitride buildup can cause
difficulties in producing high quality welds if not removed).
4. Nitrogen (N2) Plasma

• Provides better cut quality on nonferrous materials such as stainless steel and aluminum.
• Can be used in place of air plasma with air shield.
• A good clean welding grade nitrogen should be used.

B. Shield Gases
1. Compressed Air Shield

• Air shield is normally used when operating with air or oxygen plasma.
• Improves cut quality on some ferrous materials.
• Inexpensive - reduces operating costs.

0-5290 OPERATION 4-5

AUTO-CUT 300 XT
2. Nitrogen (N2) Shield

• Nitrogen shield is used with nitrogen (N2) or Ar/H2 (H35) plasma.

• Provides smooth finishes on nonferrous materials.
• May reduce smoke when used with Ar/H2 plasma.
3. Water Shield

• Normally used with nitrogen.

• Provides very smooth cut surface.
• Reduces smoke and heat input to the workpiece.
• Effective up to 1/2 inch (12.7 mm) maximum material thickness.
• Tap water provides low operating expense.

4.05 Power Supply Status Codes

NOTE!
See the Appendix for Advanced Troubleshooting
On start-up and during operation, the power supply control circuitry performs various tests. If the circuitry detects
a condition requiring operator attention, the status display on the front panel shows a 3 digit code preceded by
either letter “E” (currently active fault) or letter “L” (last or latched fault) meaning a fault occurred stopping the
process but is not currently active.
Some conditions can be active indefinitely, while others are momentary. The power supply latches momentary
conditions; some momentary conditions can shut down the system. The indicator may show multiple conditions
in sequence; it is important to recognize all possible conditions that may be displayed.

NOTE!
500 codes are not used for this system

CCM Status Code

Group 1 Plasma Process
Code Message Remedy / Comments
Plasma Enable Off ; External Disable activated or CCM TB1-1&2 jumper missing; 40 circuit ribbon cable
101 Plasma Disabled
from Relay PCB to CCM disconnected or defective;
Pilot did not start within 15 seconds. Torch consumable parts worn? Ensure current control setting
102 Pilot Ignition Failure matches consumables; Plasma pressure too high; Defective Arc Starter; Defective Pilot PCB; defective
Inverter section 1A.
Pilot went out while Start active. Torch consumable parts worn? Ensure current control setting matches
103 Lost Pilot
consumables; Plasma pressure too high;
Arc was transferred to work for more than 50 ms and then went out while Start still active. Arc lost con-
104 Transfer Lost tact with work, run off edge, over hole, etc.; Standoff too high; Ensure current control setting matches
consumables; Wrong gas pressure
105 Not used Reserved for legacy product
Must transfer from Pilot to Cutting Arc in 0.085 seconds (SW8-1 OFF) or 3 sec. (SW8-1 ON). Standoff
Pilot Timeout, no
106 too high or void in work under torch; Current Control setting too low for consumables resulting in: Pilot
Transfer
current too low for consumables; Wrong gas pressure.
107 Tip Saver Fault Tip remained in contact with work in excess of 15 seconds. ( Pak200i).
Tip voltage too close to electrode voltage. Rear panel gas switch set to wrong gas; Torch consum-
Tip to Electrode volt- able parts worn out; Wrong consumables installed causing tip to electrode short; Plasma pressure too
108
age fault. low; Leak in Plasma hose to torch; Current Control set too high for consumables; Defective Pilot PCB;
Shorted torch body .
Part process not
109 Applies only to DFC 3000 Auto Gas Control. Select and load a cutting process.
configured.
110 Devise Locked DFC 3000: Process loading; wait until finished

4-6 OPERATION 0-5290

 AUTO-CUT 300 XT
CCM Status Code
Group 2 -- Plasma Power Supply
Code Message Remedy / Comments
201 Missing AC Phase Blown fuse, Bad power cable connection; Defective System Bias PCB
202 Not used Reserved for legacy product
203 Not used Reserved for legacy product
204 Not used Reserved for legacy product
Less than 60 VDC; Negative lead short to work or ground; Defective inverter (output
205 DC Output Low
shorted); CCM voltage sense (J24) disconnected or wire broken; Defective CCM.
206 Not used Reserved for legacy product
Unexpected current Current above 8A in work lead prior to pilot ignition or transfer. Negative lead short to ground
207
in work lead or arcstarter chassis; Defective HCT1 work lead current sensor; Defective Relay PCB.
Current above 6A in pilot circuit prior to ignition. Wrong or mismatched consumables causing
Unexpected current
208 tip - electrode short; Pilot lead shorted to negative in torch tube; Defective Relay PCB; Pos-
in pilot circuit
sible shorted torch.
209 Not used Reserved for legacy product
Output Current Too Work lead current detected greater than 20% above process setting. Possible erroneous
210
High signal due to defective HCT1 Work lead current sensor or Relay PCB; Defective CCM.
Work current detected more than 20% below process setting. Possible erroneous signal
Output Current Too
211 due to defective HCT1 Work lead current sensor or Relay PCB; Possible defective pilot PCB
Low
(shorted IGBT);
Plasma work current low during cutting and attributed to Inverter Module 1 Section A output
Inverter 1A Output
212 low; Inverter output disconnected; Possible defective ribbon cable; If problem persists
Current Low
replace Inverter Module 1
Plasma work current low during cutting and attributed to Inverter Module 1 Section B output
Inverter 1B Output
213 low; Inverter output disconnected; Possible defective ribbon cable; If problem persists replace
Current Low
Inverter Module 1
Plasma work current low during cutting and attributed to Inverter Module 2 Section A output
Inverter 2A Output
214 low; Inverter output disconnected; Possible defective ribbon cable; If problem persists
Current Low
replace Inverter Module 2
215 Not Used Reserved for other Systems
Plasma work current low during cutting and attributed to Inverter Module 3 Section A output
Inverter 3A Output
216 low; Inverter output disconnected; Possible defective ribbon cable; If problem persists
Current Low
replace Inverter Module 3
Plasma work current low during cutting and attributed to Inverter Module 3 Section B output
Inverter 3B Output
217 low; Inverter output disconnected; Possible defective ribbon cable; If problem persists
Current Low
replace Inverter Module 3
Inverter 1A Output Plasma work current high during cutting and attributed to Inverter Module 1 Section A output
218
Current High high; If problem persists replace Inverter Module 1
Inverter 1B Output Plasma work current high during cutting and attributed to Inverter Module 1 Section B output
219
Current High high; If problem persists replace Inverter Module 1
Inverter 2A Output Plasma work current high during cutting and attributed to Inverter Module 2 Section A output
220
Current High high; If problem persists replace Inverter Module 2
Inverter 2B Output Plasma work current high during cutting and attributed to Inverter Module 2 Section B output
221
Current High high; If problem persists replace Inverter Module 2
Inverter 3A Output Plasma work current high during cutting and attributed to Inverter Module 3 Section A output
222
Current High high; If problem persists replace Inverter Module 3
Inverter 3B Output Plasma work current high during cutting and attributed to Inverter Module 3 Section B output
223
Current High high; If problem persists replace Inverter Module 3
Inverter Module 1 Section A required for Piloting; Ribbon cable CCM 1A to Inverter Module 1
224 Inverter 1 Not Found
Section A damaged or disconnected

0-5290 OPERATION 4-7

AUTO-CUT 300 XT
Code Message Remedy / Comments
Inverter 1A Incom- Unsupported Inverter Revision; Ribbon cable CCM J31 to Inverter Module 1 Section A dam-
225
patible Revision aged; CCM code version incompatible with Inverter revision or model
Inverter 1B Incom- Unsupported Inverter Revision; Ribbon cable CCM J32 to Inverter Module 1 Section B dam-
226
patible Revision aged ; CCM code version incompatible with Inverter revision or model
Inverter 2A Incom- Unsupported Inverter Revision; Ribbon cable CCM J33 to Inverter Module 2 Section A dam-
227
patible Revision aged; CCM code version incompatible with Inverter revision or model
228 Not used Reserved for other model with another inverter section
Inverter 3A Incom- Unsupported Inverter Revision; Ribbon cable CCM J35 to Inverter Module 3 Section A dam-
229
patible Revision aged ; CCM code version incompatible with Inverter revision or model
Inverter 3B Incom- Unsupported Inverter Revision; Ribbon cable CCM J36 to Inverter Module 3 Section B dam-
230
patible Revision aged ; CCM code version incompatible with Inverter revision or model
Inverter AC Voltage rating incompatible with Power Supply voltage rating; Ribbon cable
Inverter 1A VAC
231 CCM J31 to Inverter Module 1 Section B damaged or loose; Wrong voltage Inverter Module 1
Mismatch
installed; Defective Inverter module
Inverter AC Voltage rating incompatible with Power Supply voltage rating; Ribbon cable
Inverter 1B VAC
232 CCM J32 to Inverter Module 1 Section B damaged or loose; Wrong voltage Inverter Module 1
Mismatch
installed; Defective Inverter module
Inverter AC Voltage rating incompatible with Power Supply voltage rating; Ribbon cable
Inverter 2A VAC
233 CCM J33 to Inverter Module 2 Section A damaged or loose; Wrong voltage Inverter Module 2
Mismatch
installed; Defective Inverter module
234 Not used Reserved for other model with another inverter section
Inverter AC Voltage rating incompatible with Power Supply voltage rating; Ribbon cable
Inverter 3A VAC
235 CCM J35 to Inverter Module 3 Section A damaged or loose; Wrong voltage Inverter Module 2
Mismatch
installed; Defective Inverter module
Inverter AC Voltage rating incompatible with Power Supply voltage rating; Ribbon cable
Inverter 3B VAC
236 CCM J36 to Inverter Module 3 Section B damaged or loose; Wrong voltage Inverter Module 3
Mismatch
installed; Defective Inverter module
Too Few Inverters Two or more Inverter Sections required to operate; Ribbon cable from CCM to Inverter Section
237
Found damaged or disconnected;
238 BIAS VAC Invalid Invalid AC Voltage Selection; Damaged or loose connection at J61 of System Bias Supply
System Bias PCB detected AC Voltage is higher than Power Supply rated Voltage; System
239 AC Voltage High Bias Supply J61 Voltage Selection connection damaged or disconnected; Defective System
Bias PCB; Defective CCM
System Bias PCB detected AC Voltage is lower than Power Supply rated Voltage; System
240 AC Voltage Low Bias Supply J61 Voltage Selection connection damaged or disconnected; Defective System
Bias PCB; Defective CCM
Inverter Input Voltage fault; voltage out of range or missing phase at AC Input of Inverter
Inverter 1A Input Module 1 Section A; Poor AC Power Quality; Defective W1 contactor; Loose or open connec-
241
Voltage Error tion between input terminals and W1 contactor or contactor and input of Inverter Section;
Defective Inverter module
Inverter Input Voltage fault; voltage out of range or missing phase at AC Input of Inverter
Inverter 1B Input Module 1 Section B; Poor AC Power Quality; Defective W1 contactor; Loose or open connec-
242
Voltage Error tion between input terminals and W1 contactor or contactor and input of Inverter Section;
Defective Inverter module
Inverter Input Voltage fault; voltage out of range or missing phase at AC Input of Inverter
Inverter 2A Input Module 2 Section A; Poor AC Power Quality; Defective W1 contactor; Loose or open connec-
243
Voltage Error tion between input terminals and W1 contactor or contactor and input of Inverter Section;
Defective Inverter module

4-8 OPERATION 0-5290

 AUTO-CUT 300 XT
Code Message Remedy / Comments
244 Not used Reserved for other model with another inverter section
Inverter Input Voltage fault; voltage out of range or missing phase at AC Input of Inverter
Inverter 3A Input Module 3 Section A; Poor AC Power Quality; Defective W2 contactor; Loose or open connec-
245
Voltage Error tion between input terminals and W2 contactor or contactor and input of Inverter Section;
Defective Inverter module
Inverter Input Voltage fault; voltage out of range or missing phase at AC Input of Inverter
Inverter 3B Input Module 3 Section B; Poor AC Power Quality; Defective W2 contactor; Loose or open connec-
246
Voltage Error tion between input terminals and W2 contactor or contactor and input of Inverter Section;
Defective Inverter module
Inverter 1A Circuit
247 Inverter Module 1 Section A detected a circuit fault; Damaged Inverter Module 1
Fault
Inverter 1B Circuit
248 Inverter Module 1 Section B detected a circuit fault; Damaged Inverter Module 1
Fault
Inverter 2A Circuit
249 Inverter Module 2 Section A detected a circuit fault; Damaged Inverter Module 2
Fault

250 Not used Reserved for other model with another inverter section

Inverter 3A Circuit
251 Inverter Module 3 Section A detected a circuit fault; Damaged Inverter Module 3
Fault
Inverter 3B Circuit
252 Inverter Module 3 Section B detected a circuit fault; Damaged Inverter Module 3
Fault
Inverter 1A Over Inverter circuitry is over temperature likely cause is ambient greater than 40 deg C; Reduce
253
Temp Ambient power supply cutting Duty Cycle; Reduce ambient air temperature; Add auxiliary cooler.
Inverter 1B Over Inverter circuitry is over temperature likely cause is ambient greater than 40 deg C; Reduce
254
Temp Ambient power supply cutting Duty Cycle; Reduce ambient air temperature; Add auxiliary cooler.
Inverter 2A Over Inverter circuitry is over temperature likely cause is ambient greater than 40 deg C; Reduce
255
Temp Ambient power supply cutting Duty Cycle; Reduce ambient air temperature; Add auxiliary cooler.

256 Not used Reserved for other model with another inverter section

Inverter 3A Over Inverter circuitry is over temperature likely cause is ambient greater than 40 deg C; Reduce
257
Temp Ambient power supply cutting Duty Cycle; Reduce ambient air temperature; Add auxiliary cooler.
Inverter 3B Over Inverter circuitry is over temperature likely cause is ambient greater than 40 deg C; Reduce
258
Temp Ambient power supply cutting Duty Cycle; Reduce ambient air temperature; Add auxiliary cooler.
Inverter 1A No Input Inverter section may have no input power. Contactor not closed; Defective contactor or CB4
259
Power tripped; Inverter section input not connected; Defective Inverter.
Inverter 1B No Input Inverter section may have no input power. Contactor not closed; Defective contactor or CB4
260
Power tripped; Inverter section input not connected; Defective Inverter.
Inverter 2A Over Inverter circuitry is over temperature likely cause is ambient greater than 40 deg C; Reduce
261
Temp Ambient power supply cutting Duty Cycle; Reduce ambient air temperature; Add auxiliary cooler.
Inverter 2B Over Inverter circuitry is over temperature likely cause is ambient greater than 40 deg C; Reduce
262
Temp Ambient power supply cutting Duty Cycle; Reduce ambient air temperature; Add auxiliary cooler.
Inverter 3A Over Inverter circuitry is over temperature likely cause is ambient greater than 40 deg C; Reduce
263
Temp Ambient power supply cutting Duty Cycle; Reduce ambient air temperature; Add auxiliary cooler.
Inverter 3B Over Inverter circuitry is over temperature likely cause is ambient greater than 40 deg C; Reduce
264
Temp Ambient power supply cutting Duty Cycle; Reduce ambient air temperature; Add auxiliary cooler.
Inverter 1A No Input Inverter section may have no input power. Contactor W1 not closed; Defective contactor or CB4
265
Power tripped; Inverter section input not connected; Defective Inverter.
Inverter 1B No Input Inverter section may have no input power. Contactor W1 not closed; Defective contactor or CB4
266
Power tripped; Inverter section input not connected; Defective Inverter.

0-5290 OPERATION 4-9

AUTO-CUT 300 XT
Code Message Remedy / Comments
Inverter 2A No Input Inverter section may have no input power. Contactor W1 not closed; Defective contactor or CB4
267
Power tripped; Inverter section input not connected; Defective Inverter.
Inverter 2B No Input Inverter section may have no input power. Contactor W2 not closed; Defective contactor or
268
Power CB4 tripped; Inverter section input not connected; Defective Inverter.
Inverter 3A No Input Inverter section may have no input power. Contactor W2 not closed; Defective contactor or CB4
269
Power tripped; Inverter section input not connected; Defective Inverter.
Inverter 3B No Input Inverter section may have no input power. Contactor W2 not closed; Defective contactor or CB4
270
Power tripped; Inverter section input not connected; Defective Inverter.
Inverter ID reading CCM found ID values inconsistent during reading. CCM to an Inverter section ribbon damaged
271
fault or disconnected; Improper ribbon cable routing.

CCM Status Code

Group 3 -- Gas Controller Status & Protocol
Code Message Remedy / Comments
301 Not used Reserved for other models.
302 Reserved No information available; Contact customer service
Gas Supply Pressure Autocut is in SET mode or Plasma gas pressure is too low; Defective gas pressure sensor
303
out of range. (PS1).
304 Gas Control Purging Normal following power up or returning from Plasma Disable.
305 Not used Reserved for other models.
306 Not used Reserved for other future use.
307 Not used Reserved for other models.
Gas Control Type
308 Wrong CCM, must be Auto-cut type.
Mismatch
309 Not used Reserved for other models.
310 * DPC fault Reserved for other models.
311 * DPC valve control fault Reserved for other models.
312 * DMC fault Reserved for other models.
Gas Controller not
313 * Reserved for other models.
configured.
* Applies to DFC 3000 (Auto Gas) only

4-10 OPERATION 0-5290

 AUTO-CUT 300 XT
CCM Status Code
Group 4 -- Torch Coolant System
Code Message Remedy / Comments
401 Coolant Level low Check coolant level, add as needed.
Coolant flow as measured by flow switch FS1 is less than 0.7 gpm (0.25 for Pak200i);
Low coolant flow Clogged filter; Restriction in torch lead or head; Wrong style consumables; Bad O-ring
402
on the torch check valve; broken or defective torch coolant tube/check valve; Defective
pump or bypass valve. 402 code along with 104 code is probably a low flow problem.
Coolant overheated Coolant supply temperature exceeded 75 degrees Celcius (167℉). Operating with either
403
lower side panel loose or removed; Coolant fan failed; radiator fins clogged with dirt.
Proper coolant flow of 0.7 gpm as measured by flow switch FS1 was not obtained dur-
ing up to 4 minutes of Priming. New installation can require additional Priming cycle(s)
Coolant System not to fill hoses with coolant; cycle power to restart Priming; Coolant hoses or torch hoses
404
ready. reversed; Clogged coolant filter; Restriction in torch lead or head; Wrong style consum-
ables; broken or defective torch coolant tube/check valve; Defective pump or bypass
valve.
Low Coolant Level Low coolant level during cut, does not stop cut.
405
Warning Add coolant as required.
406 Not used Reserved for other models.
Coolant overheated, high Ambient greater than 40 deg C results in coolant overheating. Reduce cutting duty cycle;
407
ambient. Reduce ambient; Add separate cooler.

NOTE!
There are no 500 codes

0-5290 OPERATION 4-11

AUTO-CUT 300 XT
CCM Status Code
Group 6 -- CCM
Code Message Remedy / Comments
601 Analog Voltage Error Defective CCM, replace.
602 ADC or DAC error Defective CCM, replace.
603 Reserved No information available; Contact customer service
604 Data Memory error Defective CCM, replace.
605 Program memory fault Defective CCM, replace.
606 +5V Logic supply low Defective CCM, replace.
Processor over tem-
607 Reduce ambient temperature; Defective CCM; replace
perature
5V supply for RS
608 485/422 communica- Defective CCM, replace.
tion low.
Firmware Update
609 Defective CCM; replace
Device Error
Firmware Update
610 Defective CCM; replace
Protocol Error
611 USB Controller Fault Defective CCM; replace
612 USB Power Fault Remove faulty USB device; Defective CCM
Unable to create Log file on USB Flash drive last firmware update attempt; Use different USB
613 USB Log Creation Fault
Flash Drive or Reformat
File VTCCMFW.USF missing from Flash Drive; Add proper files to Flash Drive for Firmware
614 No USF File
Update; Use different USB Flash Drive or Reformat
CCM Firmware file specified in VTCCMFW.USF not found ; Add proper files to Flash Drive for
615 No CCM Update File
Firmware updating
Fault occurred attempting to update DPC firmware; Add proper files to USB Flash drive for
616 DPC Update Fault
Firmware updating; Refer to CCM_LOG.TXT on Flash Drive for details
Fault occurred attempting to update DMC firmware; Add proper files to USB Flash drive for
617 DMC Update Fault
Firmware updating; Refer to CCM_LOG.TXT on Flash Drive for details
618 ADC Calibration Fault Error too large calibrating ADC; Fault persists defective CCM;
619 Flow Switch Fault Flow switch reporting coolant flow when pump off;
Non Volatile Memory
620 Non Volatile Memory Storage Corrupted and Erased; Fault persists defective CCM.
Error
A USB flash drive was detected but could not be read by CCM. Backup any files currently on
flash drive, reformat the USB flash drive to a FAT or FAT32 file system, replace only the CCM
621 USB Format Fault
update files and try again. Use different USB flash drive formatted with FAT or FAT32 file
system.
Possible EMI noise problem or code fault. Check for proper grounding and bonding of equip-
CCM Code Execution ment and routing of torch leads and cables to reduce Electromagnetic Emission Interference
622
Fault onto CCM module. If problem persists, verify CCM code version is the latest supported revi-
sion. Replace CCM module.

4-12 OPERATION 0-5290

 AUTO-CUT 300 XT
4.06 Cut Quality
Cut quality requirements differ depending on application. For instance, nitride build-up and bevel angle may be
major factors when the surface will be welded after cutting. Dross-free cutting is important when finish cut quality
is desired to avoid a secondary cleaning operation. Cut quality will vary on different materials and thicknesses.
Kerf Width
Cut Surface
Bevel Angle

Left Side Top

Cut Angle Spatter
Right Side
Cut Angle
Top Edge
Rounding

Dross
Build-Up
Cut Surface A-00007

A-00512 Drag Lines

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

Bevel Angle
4. Place the RUN/SET switch to the RUN position.
The angle between the surface of the cut edge and a plane perpendicular to the surface of the plate. A perfectly
perpendicular cut would result in a 0° bevel angle.

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

Dross Build-up and Top Spatter

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

Kerf Width
The width of material removed during the cut.
Nitride Build-up
Nitride deposits which may remain on the cut edge of the carbon steel when nitrogen is present in the plasma
gas stream. Nitride buildups may create difficulties if the steel is welded after the cutting process.

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.

0-5290 OPERATION 4-13

AUTO-CUT 300 XT
Clockwise
Left Side
Cut Angle Scrap
Right Side
Cut Angle
Counter-
Clockwise
Scrap
Workpiece

A-00512 Art # A-04182

Swirl Effect on Side Characteristics Of Cut

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

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

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

4-14 OPERATION 0-5290

 AUTO-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.
Check cooling fan; clean as needed.

Weekly
Check O-Rings in Torch and Cartridge

Monthly
Check cooling fan and radiator; clean as needed.
Check gas hoses for cracks, leaks, or abrasion.
Replace as needed.
Check all electrical connections for cracks or
abrasion. Replace as needed.
Clean water filter (if using H2O Mist)

Six Months
Replace coolant filter.
Clean coolant tank.
Vacuum out any dust buildup inside power supply.

5.02 Coolant Filter Cleaning Procedure

Periodic cleaning of the coolant filter ensures maximum coolant flow efficiency. Poor coolant flow causes inefficient
torch parts cooling with consequent faster consumable wear.
Clean the coolant filter as follows:
1. Disconnect system from main input power.
2. Unscrew and remove the filter canister by hand. Large canister located at the back of the power supply. Be
sure to keep the O-ring.
3. Inspect and replace filter as needed. Re-install the canister, tightening it by hand. Be sure the O-ring is in
place.
4. Turn the system on and check for leaks.

0-5290 MAINTENANCE 5-1

AUTO-CUT 300 XT
5.03 Coolant Replacement Procedure
Replace coolant as follows:
1. Disconnect the system from main input power.
2. Remove the lower right side panel.
3. Locate the coupling in the coolant line that comes from the bottom of the coolant tank, #1 in the following
illustration. Disconnect the coolant line at this fitting and drain the coolant into a disposable container of
sufficient size. Remember you will be draining more than the contents of the coolant reservoir.
4. Once coolant is draining, disconnect the gray hose coupling #2 in the illustration below. Allow excess coolant
to drain, then apply a maximum of 5psi to clear the lines.

CAUTION
! Applying more than 5 psi air pressure to the cooling system will result in damage. Extra cau-
tion must be used when performing this task.

Art # A11689

5. Reconnect those two fittings and then remove the filter bowl from the canister at the rear of the power sup-
ply. Pour this remaining coolant into the container and replace the filter bowl.

NOTE!
If you also need to replace the coolant still in the leads, disconnect
the leads from the power supply and manually drain them.

6. Fill the tank with fresh coolant until the right level is reached checking for leaks.
7. Turn system on, let it run for a few minutes and check coolant level, refill as needed. Refer to Section 3:16
Fill Cooling System on the procedure for this.

5-2 MAINTENANCE 0-5290

 AUTO-CUT 300 XT
5.04 Arc Starter Service
Arc Starter Service Chart
Symptom Cause Check Remedy
Flush system,
Coolant has become conductive Use conductivity meter
replace coolant.
Pilot return wire not connected Visual inspection Connect Wire.
Spark gap set too close Check with feeler gauge Set to 0.063” ±0.002”
High Frequency cap (C4)
Use capacitance meter Reconnect or replace.
possibly open
No Pilot ignition:
Spark in Arc Starter Broken or missing ferrites Visual inspection Replace.
but no ignition Remove short;
Short across in inductor (L1) Visual inspection
increase coil gaps.
Spark gap bus caps
(C1, C2, C3) Capacitance meter Replace.
broken or defective
Negative supply not
Visual inspection Reconnect.
connected correctly
Spark gap set too large Check with feeler gauge Set to 0.063” ±0.002”
Faulty transformer Resistance measurement Replace.
No Pilot ignition: Make connections;
No 120V supply Check input voltage at EMI filter
No Spark replace harness.
in Arc Starter No/ loose connection
Visual inspection Reconnect.
to spark gap
Faulty EMI filter Voltage/ Resistor measurement Replace.
Loose fitting(s) Visual inspection Tighten fittings.
No cooling or
Failure to braze joints (L1) Visual inspection Replace HF Coil.
insufficient cooling:
Leaks coolant Damaged or punctured
Visual inspection Replace coolant line(s).
coolant line(s).
Visual Inspection of color-coded Match coolant connection colors
Supply & return hose reversed
No cooling or connections to arc starter fitting colors.
insufficient cooling:
No Coolant Flow Blockage in coil or Loosen fitting slightly and check
Flush system.
supply/return hoses for coolant flow

Torch Lead Shield not

Visual inspection of lead Reconnect / tighten
connected or loose. F1 gnd
attachment to Arc Starter lead connectors.
cable not connected.
Erratic System
Make or tighten
Behavior Missing or loose Visual inspection of ground wire
connections to
(EMI Interference) ground connection to Arc Starter
good ground.
Cap C5 not connected, Visual inspection / capacitor
Replace PCB.
open or loose measurement

0-5290 MAINTENANCE 5-3

AUTO-CUT 300 XT
5.05 Arc Starter Spark Gap Adjustment
1. Shut off input power. Remove the top console cover.
2. Adjust the spark gap as shown. Re-install the top cover.

0.063" ± 0.002"
1.6 ± 0.05 mm

Art # A-11913

5-4 MAINTENANCE 0-5290

 AUTO-CUT 300 XT
SECTION 6: REPLACEMENT ASSEMBLIES & PARTS
6.01 Replacement Power Supply
Complete Unit / Component Catalog Numbers Catalog Number

Auto-Cut 300 XT™ Power Supply, 400VAC +10 -15% CE 3-8113-4

0-5290 PARTS LISTS 6-1

AUTO-CUT 300 XT
6.02 Leads and Cables
Refer to section 3.05 for ground connections and ground cables.
Arc Starter /
Gas Control Module
(GCM-1000XT) G: Torch Lead Set, Shielded
K F F1 - Coolant Supply
Pilot Return A w/ Negative
Control - Coolant Return
Negative B Auto-Cut 300XT Cable - Pilot Return
Power Supply - Plasma Gas
Coolant Supply C
Ground - Shield Gas
Coolant Return D Cable
Control Cable E Positioning
Primary power Tube

CNC Cable P Torch

CNC

O Work Cable Work

Art # A-11902_AB

Leads Catalog Numbers; Auto-Cut 300 XT Power Supply, XT-301 Torch

Leads Length
3 ft 5 ft 10 ft 15 ft 25 ft 35 ft 50 ft 60 ft 75 ft 100 ft 125 ft
Key Description
1m 1.52 m 3.05 m 4.5 m 7.6 m 10.6 m 15.2 m 18.3 m 22.8 m 30.5 m 38.1 m

A,B,C,D,E Supply Lead Set 4-3096 4-3097 4-3098 4-3099 4-3100 4-3101 4-3105 4-3102 4-3103 4-3104
Pilot Return Cable
A 9-4890 9-4891 9-4790 9-4791 9-9426 9-4792 4-3200 9-4793 9-4794 9-4796
(4 ft / 1.2 m)
B Negative Cable 9-7356 9-7357 9-7358 9-7359 9-7360 9-7361 4-3201 9-7362 9-7363 9-7364
C Coolant Hose, Supply 9-4886 9-4887 9-4780 9-4782 9-4784 9-4786 4-3202 9-4787 9-4788
D Coolant Hose, Return 9-4888 9-4889 9-4762 9-4764 9-4766 9-4768 4-3203 9-4769 9-4770
Control Cable, Power
E 9-4941 9-4916 9-4917 9-4918 9-4942 4-3204 9-4943 9-4944 9-4922
Supply to Arc Starter

F Ground Cable 9-4923 9-4924 9-4925 9-4926 9-4927 9-4928 9-4929

Ground Cable, Gas

F1 9-4931 9-4932 9-4933 9-4934 9-4935 9-4936 9-4937
to Earth
G Torch Lead Assembly 4-3044 4-3045 4-3046 4-3047 4-3048
Control Cable, Power
K Supply 9-4907 9-4908 9-4909 9-9332 9-4910 9-4911 9-4912 9-4913
to GCM 1000 XT
O Work Cable 9-7350 9-7351 9-7352 9-7353
Control Cable, CNC
P 9-7368 9-7369 9-7370 9-7371 9-7372
to Power Supply

NOTE!
Supply lead set includes Pilot Return Cable, Negative Cable, Coolant Supply & Return Hoses, and Control
Cable.

6-2 PARTS LISTS 0-5290

 AUTO-CUT 300 XT
#8 AWG Cable
A Pilot Return, Power Supply
to Arc Starter

2/0 (70 mm ) Cable

Negative Lead, Power Supply
B to Arc Starter

C Green Green
Coolant Leads, Power Supply
Red to Arc Starter
D Red

Control Cable, Power Supply

E 14 to Arc Starter

F Green / Yellow #4 AWG Ground Cable

Ground Cable,
F1 Green / Yellow 1/0 (50 mm 2 ) Arc Starter
To Earth Ground

G Torch Lead Set

Control Cable,
K 37 Power Supply to
Gas Control Module

O 2/0 (70 mm2 ) Cable

Work Cable

P 37 CNC Cable (28 Wire)

Art # A-11903

0-5290 PARTS LISTS 6-3

AUTO-CUT 300 XT
6.03 Power Supply External Replacement Parts
Item # Qty Description Catalog #

1 1 GCM 1000 XT Top Cover 9-7345

2 1 Power and Leads Cable Covers 9-7346
3 1 Lifting Eye, Cable 9-7347
4 1 Upper Side Covers (2 total) 9-7301
5 1 Lower Left Side Cover 9-7304
6 1 Lower Right Side Cover 9-7344

2
2
3

4 4

5 6

Art # A-11933

6-4 PARTS LISTS 0-5290

 AUTO-CUT 300 XT
6.04 Power Supply Replacement Parts - Lower Right Side
Item # Qty Description Ref. Des. Catalog #

1 1 Coolant Tank, Cap 8-5142

2 1 Coolant Tank 9-7306
3 1 Sensor, Coolant level 9-7307
4 1 Pump, Coolant, Assembly (with motor) 9-7309
1 Pump, Coolant, Assembly (no motor) 9-7422
5 1 Motor, Pump (motor only) 9-7424
6 1 Heat Exchanger Fan FAN1 9-7348
7 1 Radiator 9-7349
8 1 Flow, Switch (Not shown, behind cooling fan) FS1 9-7310

5 6 Art # A-011934_AB
7

0-5290 PARTS LISTS 6-5

AUTO-CUT 300 XT
6.05 Power Supply Replacement Parts - Upper Right Side
Item # Qty DescriptionRef. Des. Catalog #

1 1 Relays, Pump / Fan MC3 / MC2 9-7314

2 1 Relay, Inrush Control K1 9-7336
3 1 Relay, Inrush MC1 9-7337
4 1 Resistor, Inrush R2 9-7376
5 1 Auxilliary Transformer T1 9-7315
6 1 Display PCB 9-9252
7 1 On/Off Switch Breaker CB1 9-7316
8 1 Bias Supply 9-9253
9 1 Relay and Interface PCB 9-9251
10 1 Pilot PCB 9-9250
11 1 CCM Assembly 9-7324

7 9

6 10

1
11

Art # A-11935

6-6 PARTS LISTS 0-5290

 AUTO-CUT 300 XT
6.06 Power Supply Replacement Parts - Left Side
Item # Qty Description Ref. Des. Catalog #

1 1 Suppressor PCB 9-9254

2 1 Main Contactor (2 total) W1, W2 9-7318
3 1 Full Inverter Block (2 total) 380-415 VAC 9-7317
4 1 Partial Inverter Block 380-415 VAC 9-7319
5 1 EMI Filter PCB (3 total) 9-9264
6 1 Current Transducer, 300A HCT1 W7005324

2
3

Art # A-11958

0-5290 PARTS LISTS 6-7

AUTO-CUT 300 XT
6.07 Power Supply Replacement Parts RAS - GCM 1000 XT
Item # Qty Description Ref. Des. Catalog #

1 1 Gas Solenoid (3 required per unit) 9-6319

2 1 Water Filter Assembly 8-3460
3 1 HF Transformer 9-4959
4 1 Pressure Switch 9-6318
5 1 PCB, RAS1000 RF Cap Board 9-9423

3
1

2 5

Art # A-11937-AB

6-8 PARTS LISTS 0-5290

 AUTO-CUT 300 XT
6.08 Power Supply Replacement Parts - Rear Panel
Item # Qty Description Breaker Rating Cicuit Rating Ref. Des. Catalog #

1 1 Coolant Filter Assy. 9-7320

2 1 Coolant Filter 9-7322
3 1 Gas Selection Switch 9-3325
4 1 Fuse, 8A SB 500V (2 total) 9-7377
*5 1 Air Filter Assembly AC200-XT 9-7527
- First Stage Filter Element only 9-1021
-Second Stage Filter Element only 9-1022
* Not Shown

1
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 500 VAC F2 - 8A SB 500 VAC

Art # A-011938_AB

0-5290 PARTS LISTS 6-9

AUTO-CUT 300 XT
6.09 Power Supply Replacement Parts - Front of GCM1000 XT
Item # Qty Description Catalog #

1 1 Pressure Gauge 8-6800

2 1 Gas Regulator 9-9509
3 1 Run/Set Selector Switch 9-3426
4 1 Potentiometer with Knob 9-2685
5 1 Shield Gas Selector Switch 9-3427
6 1 Flowmeter, H2O
9-7762

Art # A-11939_AB

1 1

3
RUN

SET

PLASMA SHIELD

SHIELD GAS

CUT
OUT

A H20 MIST
H20 MIST

GCM 1000 XT
GAS CONTROL MANAGEMENT SYSTEM

5 2 2 6

6.10 Recommended Gas Supply Hose

Item # Qty Description Catalog #

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

6-10 PARTS LISTS 0-5290

 AUTO-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. Take the Removal Tool off the back of the Cartridge Assembly Use the removal tool to push the consumable
parts out of the Cartridge.

Cartridge Tool Cartridge Assembly

Art # A-04345_AB

0-5290 TORCH INFORMATION 7-1

AUTO-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.
O-Rings Torch Head
Inner O-Ring (Cat. No. 9-3030)
Location (Under Locking Ring)
Cat. No. 9-9041

O-Ring, Cat. No. 9-3029 Cat. No. 8-0524

O-Ring, Cat. No. 9-3028
Cat. No. 9-3026

Cat. No. 9-3025

Cartridge Assembly

Cat. No. 9-9429

Snap Ring
Art # A-04066_AE
Art # A-04071_AC

CAUTION
! Use only Thermal Dynamics No. 9-4893 O-Ring Lubricant (Christo Lube MCG-129) with this
torch part. Use of other lubricants may cause irreparable damage to the torch.

7.03 Parts Wear

Replace the Gas Distributor if it is charred or cracked.
Replace the Gas Distributor if the flange is damaged in any way.
Replace the tip and/or electrode if they are worn.

Good Tip Worn Tip Good Electrode Worn Electrode

Art # A-04861

7-2 TORCH INFORMATION 0-5290

 AUTO-CUT 300 XT
7.04 Torch Consumables Installation
1. Install the consumables as follows:

WARNINGS

Do not install consumables into the Cartridge

while the Cartridge is attached to the Torch Head.
Keep foreign materials out of the consumables and Cartridge.
Handle all parts carefully to avoid damage,
which may affect torch performance.

Art # A-03887

NOTE!
For 200-Amp consumables, when replacing the shield retainer or the shield cup,
assemble these two parts first before assembling the other consumables.
bu as

to s
Cartridge
tri G

Shield
bu a
r
ap

to

tri G

de
is d

r
C

D iel

Retainer
is a

tro
D sm
ld

Sh
ie

ec
p

a
Sh

Ti

Pl

El

Assemble First
Art # A-11915

0-5290 TORCH INFORMATION 7-3

AUTO-CUT 300 XT
1: Stack Parts 2: Press Cartridge onto Stacked Parts

Electrode

Plasma Gas
Distributor O-Ring
on Tip

Tip No Gaps
Between Parts

Shield Gas
Cartridge Covers
Distributor
O-Ring
Shield Cap on Torch Tip

3: Thread Shield Cup onto Cartridge 4: Check Shield Cap Protrusion

Shield Cup

Shield Cap

Shield Cap Protrudes Art # A-04873

0.063-0.083" (1.6 - 2.1 mm)

2. Remove the Removal Tool from the Cartridge and install the assembled Cartridge onto the Torch Head.

7-4 TORCH INFORMATION 0-5290

 AUTO-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.

Torch Head Torch Head O-Ring

0.063 - 0.083"
(1.6 - 2.1 mm) Art # A-07202_AB
Protrusion

Ohmic Clip

Art # A-03393_AB

Installing Assembled Cartridge Onto Torch Head

3. Slide the ohmic clip over the shield cup if using ohmic torch height control sensing.

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

4. Connect the wire lead from the height finder to the ohmic clip.

0-5290 TORCH INFORMATION 7-5

AUTO-CUT 300 XT
E. Coolant Leak Trouble-Shooting
Never operate the system if coolant leaks from torch. A steady drip indicates that torch parts are damaged or in-
stalled improperly. Operating the system in this condition can damage the torch head. Refer to the following chart
for guidance on coolant leakage from the torch head.

Torch leaks

Are Torch Leaking from Order Coolant

Consumable Parts No Coolant Supply or Return Check Valve
Installed? Coolant Return? Kit 9-4846

Order Coolant
Supply Tube Replacement Kit
Yes

The parts probably are worn out.

See chart for approximate life expectancy.
Are Parts New
Used
or Used? The torch may be damaged. See page
to determine if head damage has occurred.

New

Remove and Lubricate

Are Parts fully all O-rings on Torch Head,
assembled into Yes Is the Torch Damaged? No Consumables Cartridge,
the Torch? and Consumables.
Re-assemble Torch.
Still leaks?

Unsure?
Yes
Yes
Disassembly fully
and re-assemble
the Torch Properly. Replace Consumable
See Installation Manual. Replace Torch Head Yes Cartridge and Shield Cup.
Torch still leaks?

Amperage Plasma Gas Recommended Wear Depth

for Replacement
Inch mm
O2 0.04 1
50
Air 0.08 2
O2 0.04 1
100
Air 0.08 2
O2 0.08 2
200 Air 0.08 2
300 Air 0.08 2
Art # A-11955_AB
Torch
Electrodes

7-6 TORCH INFORMATION 0-5290

 AUTO-CUT 300 XT
APPENDIX 1: CNC CONTROL MODULE
Control PCB Connections
TB1
(LV) OK To Move 2 12
High +10V 11
Analog Current Control
10K Wiper / Input 10
Low (-) 9
Divided Arc Volts (+) 8
Output (-) 7
(+) 6
Start/Stop Input
(-) 5
Stop (NC) 4
(LV) OK To Move 2 3
(+) 2
CNC Plasma Enable
(-) 1

TB2
OK To Move

(+)
12
SW6
11
DC 10
9
8
Pilot On Output
(Contacts) 7
6
5 Art # A-11512_AB
(+) 4
Preflow On
(-) 3
(+) 2
Hold Start
(-) 1

TB3
Spare #2 Output 12
Normally Open Contacts 11
Spare #2 Output 10
Normally Closed Contacts 9
Spare #1 Output 8
Normally Open Contacts 7
Expanded ( -) 6
Metal (+) 5
Corner Current ( -) 4
23X5560_AB

Reduction + 3
Remote ( -) 2
Plasma Marking (+) 1

Manual 0-5290 APPENDIX A-1

AUTO-CUT 300 XT
CNC functions
CNC I/O circuits provide at least 1000V galvanic isolation from the plasma power supply.
While the CNC circuits are isolated from the power supply, many of the signal returns on J15 and TB1, TB2 & TB3
are common to each other. J15 pins 1, 4, 5, 10, 17, and TB1-1, 5, 7, 9, and TB2-1 & 3 are all common. J15 pin 12 and
TB2-10 are also connected to the others when SW6 (OK to Move select) is set for voltage.
Rear Panel CNC Connector J15:
37 Circuit (Amp CPC) Remote Standard:
These are also duplicated on TB1, TB2 & TB3 use one or the other not both.

Chassis gnd (for SC-11 cable shield) 1

Start/Stop 3 (+); 4 (-)
Ok to Move (contacts or voltage 1) 12(-); 14 (+)
Divided Arc volts (selectable ratio
50:1; 40:1; 30:1; 16.6:1, 25:1) 5 (-); 6 (+)
PreFlow ON 7 (+); 9 (-)
Corner Current Reduction 10 (+); 11 (-)
Isolated Circuit Comm (for SC-11) 8
Chassis Gnd 13
Keying plug 15
Hold Start 16(+); 17 (-)
Plasma Mark 21 (+); 22 (-)
Cut Expanded Metal 23 (+); 24 (-)
CNC Plasma Enable2 25 (+); 26 (-)
Remote Analog Current Control 3 29 (+); 30 (signal); 31 (-)
Stop (Latched) SW4 32 (+); 33 (-)(comm.)
Pilot is ON (contacts) 34; 35
Spare (contact) 36; 37

1 SW6 on CCM I/O PCB selects OK to Move for isolated contact closure or DC Volts (15-18V) at <100ma. When
set for contacts, OK to Move circuit is rated for 120 VAC / 28 VDC
2Remove factory installed jumper from TB1-1 & 2 if using CNC Plasma Enable in J15.
3-5 See below.

A-2 APPENDIX Manual 0-5290

 AUTO-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.
Users are expected to install their own CNC cable to these connections. Knockout hole is provided in rear panel of
CCM module. User shall provide strain relief / cord grip for user installed cable.
TB1
Function Connection
CNC Enable/Disable TB1-2 (+), TB1-1(-)(comm.)
OK to Move 2 TB1-3 &TB1-12 Contacts only, rated 1A @ 28 VAC/DC
Stop Latched (NC) 4 TB1-4 (+) & TB1-5 (-) (comm.) used with Start Latched
Start/Stop Ret 4 TB1-6 (+), TB1-5 (-) (comm.)
or Start Latched (NO) 4 TB1-6 (+), TB1-5 (-) (comm.) used with Stop Latched
Divided Arc Voltage TB1-8 (+), TB1-7 (-) comm.
Remote Analog Current Control TB1-9 Analog Comm. (-) or 10K CC Pot low
TB1-10 Analog in (+) or CC Pot Wiper
TB1-11 10K CC Pot Hi (+10V @ 1 ma. Supply)

TB2
Function Connection
Hold Start TB2-2 (+),TB2-1 (-) (comm. )
Preflow ON TB2-4 (+), TB2-3 (-) (comm.)
Pilot is ON (contacts) TB2-6, TB2-8 rated 1A @ 120 VAC or 28 VDC
OK to Move (contacts or DC Volts)5 TB2-12 (+), TB2-10 (-)

TB3
Function Connection
Plasma Marking TB3-2(+), TB3-1(-) (comm.)
Corner Current Reduction TB-4(+), TB3-3(-)(comm.)
Cut Expanded Metal TB3-6(+), TB3-5(-)(comm.)
Spare NO Contact TB3-7, TB3-8
Spare NC Contact TB3-9, TB3-10
Spare NO Contact TB3-11, TB3-12

Manual 0-5290 APPENDIX A-3

AUTO-CUT 300 XT
CNC Input / Output Descriptions
All inputs except the Analog Current Control are digital active low (contact or SW closure).

CNC Enable / Disable ( input)

— Requires closed connection rated for 10 ma. @ 20VDC for unit to operate.
Factory installed jumper between TB1-1&2 must be removed when connecting user supplied Enable/Disable circuit.
4 Start/Stop (input)—Switch (momentary or sustained) rating 35ma. @ 20 VDC

Start / Stop circuit configuration. Momentary Start / Stop (Latched) is only available at TB1.

MOMENTARY START / STOP

SUSTAINED START / STOP STOP
TB1-4
TB1-5
START / STOP
TB1-5
TB1-6 START
TB1-6

Divided Arc Voltage output — Arc Voltage signal is isolated from plasma supply, however (-) is common with
other isolated CNC signals. Max Divided Arc Voltage signal level depends on actual arc voltage times divide ratio
however can not exceed approximately 12 V.
3
Analog Current Control input— Analog Current Control includes analog isolation module, separate isolation
module not usually required however it’s low input is common with the other isolated CNC inputs. Scaling of
Analog Current Control input is 0V = 0A, 10V. = MAX output and is linear in between. However MIN output is 5A.
User is responsible for setting correct analog voltage to maintain at least 5A output. To use Analog Current Control
on the I/O PCB set SW 11 to down position and on the CPU PCB set SW8-2 ON (up).
Hold Start input—Normally open, close to hold start. Circuit rating 10 ma. @ 20VDC. Delays pilot ignition, gas
preflow continues. Used by some height controls to flow gas while finding height. Also used for synchronizing starts
when multiple plasma supplies are used on same cutting table. User supplies circuit to keep Hold Start inputs ac-
tive until all torches have found height. Used with CNC START. Apply START to begin gas flow. Same time apply
HOLD to delay ignition until height is found. Remove HOLD to ignite pilot, initiate arc transfer.
Preflow On input— Normally open, close to start preflow prior to normal START signal. Circuit rating 10 ma. @
20VDC. Torch Height Controls (THC) normally issue START signal to plasma supply after torch height has been
found. Then the plasma takes 1-2 seconds (or more) to perform preflow before igniting pilot. Some THCs have an
output that can start preflow early during height finding saving 1-2 seconds on each cut. PREFLOW ON should
remain active for at least 1 second after CNC START is applied. It is OK if it remains on until the end of the cut.
Need to recycle it to begin a new preflow prior to applying START for the next cut.
Pilot On output – Relay contacts rated 1A @ 120 VAC / 28 VDC. Contacts close when pilot on. Can be wired parallel
with Ok to Move contacts to start machine motion when pilot established. Used when starting over holes. Starting
over holes requires setting SW8-1 ON (up) on the CPU PCB for extended pilot time. Using extended pilot time to
start over holes or for cutting over holes will reduce parts life.

A-4 APPENDIX Manual 0-5290

 AUTO-CUT 300 XT
OK to Move output — Active when cutting arc is established, arc is transferred. Used to signal cutting table to
start X-Y motion. Relay contacts rated 1A @ 120 VAC or 28 VDC when SW6 set for contacts. When SW6 is set
for DCV, output supplies 15-18 VDC @ 100 ma. May be wired parallel with Pilot On to start cutting machine mo-
tion as soon as pilot established.Remote Selection of Plasma Marking (input)--- Plasma marking is not available
with the Auto-cut.
5
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.
5
+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.. Now an isolated (from main
plasma circuits) 10V supply is provided. Recommended value of the pot is 5K or 10K.
Ext. +10V TB1
11 +10V
10 WIPER
9
Art # A-09246

Remote Selection of Plasma Marking (input)--- Plasma marking is not available with the Auto-cut.
The following functions may not yet be available on your system. *
*Corner Current Reduction (input)--- When activated, normally from a table controller’s corner or height control
inhibit signal, signaling that the cutting speed is being reduced to navigate a corner or small radius, the cutting
current is reduced at a fixed rate to a predetermined level to provide an improved cut at the lower speed.
*Cut Expanded Metal (input)---Normally the plasma supply is optimized for pierce cutting, high pierce height
directly above the metal to be cut, short pilot time, etc. Activating this input adjusts the plasma supply to optimize
it’s parameters for cutting expanded metal, perforated metal, running edge starting, etc. Among other changes
the transfer height is reduced to same as cut height. In addition to activating the Cut Expanded Metal input CCM
switch SW1-1 should be turned on automatically restart the pilot and SW8-1 set on for longer pilot time.
*Spare contacts --- .

Manual 0-5290 APPENDIX A-5

AUTO-CUT 300 XT
Simplified CNC Circuit

Autocut 300 XT Simplified CNC OK TO MOV E SELECT

18 V D C or Con tacts

SW6A
TB1 D C VO LT S
+18VDC
OK2 (cont act) 12
C ONTA CT S
+10V (CC Pot Hi ) 11
CC Pot W iper 10
CC Pot L ow 9
Di v A rc V (+) 8
Di v A rc V (-) 7
/Start - Stop (+)
OK
6 SW6B
/Start - Stop (-) 5
Stop Mo m NC 4
OK2 (cont act) 3
/ CNC Enabl e (+) 2
/ CNC Enabl e (-) 1 B
3
+
5
4
TB2 -
+10V
OK to M OV E (+) 12
11 V OLTA GE DIV IDER
OK to M OV E (-) 10
9

5
PILOT is ON 8
GND
7
PILOT is ON 6
5

4
Prefl ow ON (+) 4
Prefl ow ON (-) 3
SW 12A

SW 12C

SW 12D
SW 12B
Hol d Start (+) 2
Hol d Start (-) 1

AL L SW OFF f o r 50: 1 ( def aul t )

SW1 2 A ( 1 ) ON = 16. 7 : 1 ( SC- 1 1 )
TB3 SW1 2 B ( 2 ) ON = 30: 1
12 SW1 2 C ( 3 ) ON = 40: 1
Spare Input 11
10
Reserved 9
Spare #1b NO 8
7 PSR

{
6
5
Reserved
4
3
/ Plasma M arki ng (-) 2
/ Plasma M arki ng (+) 1

Art # A-11931_AB

A-6 APPENDIX Manual 0-5290

 AUTO-CUT 300 XT

J54 - Rem ote HM I & CN C CO M M

(100)
(101)
1 1 - 24 V AC
(102)
2 2 - 24 V AC Re t
Harness to Relay PCB 3 3- Jumper to 24 V AC
4
(109)
(108)
5 5-H M I Pl asma Enabl e SW
6 6-H M I Pl asma Enabl e SW
(115) 7 7 - K ey Pl ug
(116)
8 8 - Tx +
(117)
9 9 - GND RS 485
Harness to CPU PCB 10 10 - GN D / 422
(118) 11 Comm
1
(142)
(119)
12 12 - Tx -
2 (120)
13 13 - Rx +
3
14 14 - Rx -
4
(133)
5
6
(134) J15-CNC
(137)
7
(139) 1
8 C hassi s
(138) 2
9 (133)
(143) 3 3- / CNC Start (+)
10 (134)
4 4- / CNC Start (-)
11 (135)
(140) 5 5- Divided A rc V (-)
12 (136)
(141) 6 6- Divided A rc V (+)
13 (137)
(136) 7 7- / Preflow ON (+)
14 (138)
(135) 8 8- COM M Ref (1K Ohm)
15 (139)
(132) 9 9- / Preflow ON (-)
16 (140)
10
17 (141)
(153) 11
18 (142)
12 12- OK to M ove (-)
J21 (143)
13
14 14- OK to M ove (+)
GND
15 15 - K ey Plug
(144)
(144) 16 16- / Hold Start (+)
1 (145)
(145) 17 17- / Hold Start (-)
2
(146) 18
3
(147) 19
4
(148) 20
5 (146)
(149) 21 21- / Plasma M ark (+)
6 (147)
(150) 22 22- / Plasma M ark (-)
7 (148)
(151) 23 23-
24- }
8 (149) Reserved
24
9 (150)
25 25- / CNC Plasma Enable (+)
10 (151)
(152) 26 26- / CNC Plasma Enable (-)
11
27
12
(154) 28
13 (132)
(155) 29 29- Remote CC Pot H igh
14 (152)
30 30- Remote CC (analog)
15 (153)
31 31- Remote CC Pot L ow
16 (154)
(156) 32 32- Stop SW (momentary) *
17 (155)
(157) 33 33- Stop SW Ret
18 (156)
(158) 34 34- Pilot is ON (a)
19 (157)
(159) 35 35- Pilot is ON (b)
20 (158)
36 36- Spare OUT #1 (a)
SPA RE #1a (159)
J22 J15-1 to chassis used for The COM M Ref at pin J15-13 connects SC-11
37 37- Spare OUT #1 (b)

SC-11 cable shield 8 is also for the SC-11 chassis to PS chassis.

* Used with Mom en tary C NC St art SW
Art # A-11931_AB

Manual 0-5290 APPENDIX A-7

AUTO-CUT 300 XT
CNC Connections
Cutting Machine CNC Cable Power Supply
J15
(1) 1
* *
( 2) 2 NC
START/STOP (3) 3 .......... Source, 16 VDC, 10 ma.
(4) 4
( 5) 5 ... Divided Arc V (-)
(6) 6 .......... Divided Arc V (+)
( 7) 7 .......... Pre Flow ON (+)
8
(9) 9 .......... Pre Flow ON (-)
(10) ..........
10 Corner Current Reduction (+)
(11) 11 ... Corner Current Reduction (-)
(12)

{
12 OK-To-Move
DC
Start Motion 13 * Relay DCV (-)
(OK-To-Move) (14)
(+) Contact or
14 (1A @ DCV (+)
SW6
15 120 VAC ( 15 - 18 VDC @
(16) 16 .......... /Hold Start(+) or 28 VDC) up to 100 ma.)
(17) 17 .......... /Hold Start(-)
18
19
20
(21) 21 .......... /Plasma Mark (+)
(22)
22 .......... /Plasma Mark (-)
(23) 23 .......... /Cut Expanded Metal (+)
(24) 24 .......... /Cut Expanded Metal (-)
(25) 25 .......... /CNC Plasma Enable (+)
(26) 26 .......... /CNC Plasma Enable (-)
27
28
(29) 29 .......... Remote CC Pot High (+10VDC)
10 K (30) ..........
30 Remote CC 0-10V Signal or Pot Wiper
(31) 31 .......... Remote CC Pot Low (-)
(32) 32 .......... Stop SW (momentary)
(33) 33 .......... Stop SW Ret
(34) 34 .......... Pilot is ON (a) Relay contact 1A @
(35) 35 .......... Pilot is ON (b) 120 VAC or 28
(36) 36 .......... Spare OUT #1 (a)
(37) 37 .......... Spare OUT #1 (b)

Shield
**

* Power Supply Gnd not used for CNC cable

Represents switch, Do not connect wire #1 to anything.
Art # A-11901
relay, open
collector transistor, etc. ** Cable Shield drain wire must be
connected to ground at cutting machine.

A-8 APPENDIX Manual 0-5290

 AUTO-CUT 300 XT
CNC Cable Color Code

TABLE 1: CABLE ITEM#4 COLOR CODE TABLE

PIN
COLOR SIGNAL DESCRIPTION
LOCATION
3 WHITE/BLUE START CNC (+)
4 WHITE/VIOLET START CNC (-)
5 WHITE/BROWN/VIOLET DIV ARC (-)
6 WHITE/BROWN DIV ARC(+)
7 YELLOW PREFLOW ON (+)
8 GREEN COMM 1K
9 WHITE/BLACK/BROWN PREFLOW ON (-)
10 WHITE/BROWN/BLUE CORNER CR (+)
11 WHITE/BLACK CORNER CR (-)
12 BLACK OK TO MOVE (-)
14 BLUE OK TO MOVE (+)
16 WHITE/BROWN/YELLOW /HOLD START (+)
17 WHITE/BROWN/GREEN /HOLD START (-)
21 WHITE/BLACK/ORANGE /PLASMA MARK (+)
22 WHITE/BLACK/RED /PLASMA MARK (-)
23 WHITE/BROWN/ORANGE /CUT EXPANDED METAL (+)
24 ORANGE /CUT EXPANDED METAL (-)
25 RED /CNC PLASMA ENABLE (+)
26 BROWN /CNC PLASMA ENABLE (-)
29 WHITE/BROWN RED REMOTE CC POT HIGH
30 WHITE REMOTE CC (ANALOG)
31 GRAY REMOTE CC POT LOW
32 VIOLET STOP SW (MOMENTARY)
33 WHITE/BLACK/YELLOW STOP SW RETURN
34 WHITE/BLACK/GRAY PILOT IS ON (A)
35 WHITE/BLACK/VIOLET PILOT IS ON (B)
36 WHITE/BLACK/BLUE SPARE OUT #1 (A)
37 WHITE/BLACK/GREEN SPARE OUT #1 (B)

PIN 1

Art # A-12757

Manual 0-5290 APPENDIX A-9

AUTO-CUT 300 XT
APPENDIX 2: CCM CPU PCB LAYOUT
= Test Point
= Test Point

Art # A-11675_AC

A-10 APPENDIX Manual 0-5290

 AUTO-CUT 300 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 /RD
TP11 CPU TEMP SENSE
TP12 +3.3VA
TP13 -15VDAC
TP14 PC2
TP15 +15VDAC
TP16 CLKO
TP18 OSC_CLOCK

LED Reference
D2 Red RXD
D3 Red TXD
D4 Red Fiber Out 2
D7 Red Fiber Out 1
D11 Green Future Use
D17 Green Future Use

Manual 0-5290 APPENDIX A-11

AUTO-CUT 300 XT
APPENDIX 3: CCM I/O PCB LAYOUT

= Test Point

Art # A-11676_AD
= Test Point

A-12 APPENDIX Manual 0-5290

 AUTO-CUT 300 XT
CCM I/O PCB J Connectors
Test Points J21 BASIC CNC

TP1 GND J22 EXTENDED CNC

TP2 /COOLANT FANS ON J23 RELAY - INTERFACE BOARD

TP3 /TORCH PUMP ON J24 ARC / TIP VOLTS

TP4 LOW COOLANT FLOW (SW) J25 TEST

TP5 COOLANT FLOW SIGNAL (PULSE) J26 GAS BOX

TP6 +15V ISOLATED J28 TO CPU

TP7 -15V ISOLATED J29 TO CPU

TP8 +18V ISOLATED

TP9 ANALOG CURRENT CONTROL 0-3.3V
TP10 GND ISOLATED
TP11 /PILOT ENABLE
TP12 +5VDC
TP13 -15VDC
TP14 +15VDC
TP15 24VDC
TP18 +5V ISOLATED
TP19 WORK CURRENT

LED Reference
D2 Green PLASMA ENABLE
D3 Green E-STOP_PS
D4 Green GAS ON
D6 Green CNC START
D8 Green HOLD START
D12 Green PREFLOW ON
D13 Green CSD
D18 Green MARK
D20 Green SPARE1
D25 Green EXP METAL
D33 Green OK TO MOVE
D37 Green PSR
D41 Green SPARE FIELD OUT 2
D43 Green SPARE FIELD OUT 1

Manual 0-5290 APPENDIX A-13

AUTO-CUT 300 XT
APPENDIX 4: PILOT PCB LAYOUT
= Test Point
= Test Point

Art # A-11677_AB

A-14 APPENDIX Manual 0-5290

 AUTO-CUT 300 XT
Pilot PCB Test Points
TP1 GND
TP2 PILOT GATE
TP3 +5V
TP4 TIP

LED Reference
D2 Green PILOT ENABLE
D11 Green +5V

Manual 0-5290 APPENDIX A-15

AUTO-CUT 300 XT
APPENDIX 5: RELAY AND INTERFACE PCB LAYOUT
= Test Point
= Test Point

Art # A-11678_AB

A-16 APPENDIX Manual 0-5290

 AUTO-CUT 300 XT
Relay and Interface PCB Test Points
TP1 GND
TP2 -15V
TP3 +5VDC
TP4 +12V
TP5 +24V
TP6 +15V
TP7 +5VDC

LED Reference
D2 Green 1 TORCH GAS ON
D7 Green PILOT ENABLE
D11 Green PILOT CURRENT DETECTED
D12 Green WORK CURRENT DETECTED
D22 Green CONTACTORS ON
D23 Green RF ON
D24 Green FANS ON
D25 Green PLASMA ENABLED
D26 Green 1 TORCH ON
D27 Green TORCH COOLANT ON

Manual 0-5290 APPENDIX A-17

AUTO-CUT 300 XT
APPENDIX 6: DISPLAY PCB LAYOUT
= Test Point

= Test Point

Art # A-11679

A-18 APPENDIX Manual 0-5290

 AUTO-CUT 300 XT
Display PCB Test Points
TP1 GND
TP2 +5VDC
TP3 +24VDC

Manual 0-5290 APPENDIX A-19

AUTO-CUT 300 XT
APPENDIX 7: SYSTEM BIAS PCB LAYOUT
= Test Point

= Test Point

Art # A-11680_AB

A-20 APPENDIX Manual 0-5290

 AUTO-CUT 300 XT
System Bias PCB Test Points
TP1 GND
TP2 24VDC
TP3 DC INPUT POSITIVE
TP4 Vcc1
TP5 Vcc2
TP6 GATE
TP7 PRIMARY GND
TP8 +12V PRIMARY
TP9 P_ISOL_GND
TP10 DC SENSE POSITIVE

LED Reference
D3 Red MISSING PHASE
D4 Red AC V HIGH
D14 Red AC V LOW
D15 Green VAC_IDA
D26 Green +12V PRIMARY
D27 Green VAC_IDB
D30 Green 24VDC
D44 Green TRANSFORMER ON

Manual 0-5290 APPENDIX A-21

AUTO-CUT 300 XT
APPENDIX 8: MAIN INVERTER BOTTOM PCB LAYOUT
= Test Point

= Test Point

Art # A-11681_AC

A-22 APPENDIX Manual 0-5290

 AUTO-CUT 300 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
TP8 GATE 4B
TP9 GATE 3B
TP10 +12VP
TP11 +12VDC
TP12 THERMISTOR SIDE A
TP13 THERMISTOR SIDE B
TP14 +5VDC
TP15 PGND

LED Reference
D3 Red CAP IMBALANCE
D4 Green READY

Manual 0-5290 APPENDIX A-23

AUTO-CUT 300 XT
APPENDIX 9: MAIN INVERTER TOP PCB LAYOUT
= Test Point

= Test Point

Art # A-11682_AC

A-24 APPENDIX Manual 0-5290

 AUTO-CUT 300 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
TP8 GATE 4B
TP9 GATE 3B
TP10 +12VP
TP11 +12VDC
TP12 THERMISTOR SIDE A
TP13 THERMISTOR SIDE B
TP14 +5VDC
TP15 PGND

LED Reference
D3 Red CAP IMBALANCE
D4 Green READY

Manual 0-5290 APPENDIX A-25

AUTO-CUT 300 XT
APPENDIX 10: CONTROL AND FAULT PCB LAYOUT
= Test Point = Test Point

Art # A-11683_AC

A-26 APPENDIX Manual 0-5290

 AUTO-CUT 300 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-
TP28 I_SNS1
TP29 GATE 2+
TP30 I_DMD1 0.5V-6.7V
TP31 GATE 2-
TP32 -12VDC
TP33 START 2
TP34 SHDN
TP35 ENABLE
TP36 READY IN
TP37 READY OUT

LED Reference
D1 Red INV FLT
D14 Red OVER TEMP
D24 Green PWM ON
D32 Red PRI OC

Manual 0-5290 APPENDIX A-27

AUTO-CUT 300 XT
APPENDIX 11: CAP BIAS BOTTOM PCB LAYOUT

Art # A-11685_AC

A-28 APPENDIX Manual 0-5290

 AUTO-CUT 300 XT
APPENDIX 12: CAP BIAS TOP PCB LAYOUT

Art # A-11686_AC

Manual 0-5290 APPENDIX A-29

AUTO-CUT 300 XT
APPENDIX 13: SUPPRESSOR PCB LAYOUT

Art # A-11684_AC

A-30 APPENDIX Manual 0-5290

 AUTO CUT 300 XT POWER SUPPLY

Manual 0-5290
Cold Plate 3 REV DESCRIPTION DATE APPROVED
--- SEE SHEET 1 ---------- -------------
Radiator

Cold Plate 2

Flow Switch
HF COIL
Cold Plate 1

Coolant
Return

APPENDIX
RETURN
PASS THRU
Level Switch
Coolant tank

Filter 1

Supply Pressure Relief

Flow
Torch Coolant
Over Flow
Return
Flow
APPENDIX 14: COOLING DIAGRAM

XT-301
Torch Coolant
Supply
Pump
HS1 Temp
Sensor

Art # A-12267
AUTO-CUT 300 XT

A-31
AUTO-CUT 300 XT
APPENDIX 15: SYSTEM SCHEMATIC PG 1

1 2 3 4 5

(1) EMI (4) INVERTER MODULE (IM) #3 (top)

1 FIL- 2
2 TER 1
J105B
IN1
PCB
OUT1
L9 1
AC INPUT IM #3 Section B
(2) (5) 2
1 2 (7)
2 1 J104B
IN2 (8) 1
(3) OUT2 (6) 2
A 1 2
GND2B J103B
2 1 (9) 1
IN3 OUT3
2
Toriod Core 019X502700

CHASSIS GND
W2A
(4)
J105A
(1) EMI
L8 1
AC INPUT IM #3 Section A
1 FIL- 2
(7) (7) 2
2
IN1
TER
PCB
OUT1
1
W2B J104A

(2) (5) (8) (8) 1

1 2 2
2 1
(9) J103A
380-415 IN2
OUT2
(9) 1
VAC (3) 1 2 W2C 2
INPUT 2
GND2B
1 (6) Toriod Core 019X502000

(Customer IN3 OUT3

supplied
power cord CHASSIS GND
must pass INVERTER MODULE (IM) #2 (middle)
B
through
ferrite core AC SUPPRESSION
assembly.) PCB
J50 019X504000 J51 (10)
LT1
L1 1 1
1
2 2
(1) 3 3
4 4
L2 1
5 (11)
6 PANEL AC INDICATOR
(2) 7
J52
(12)
8
LT2 J105A
L3 1
9
10
1
2 L6 1
AC INPUT
IM #2 Section A (lower)
11 3 (23) 2
12 4
GND J104A
Earth (3) 13 (13)
1
14 (24) 1
INTERNAL AC INDICATOR 2
AC LINE
J103A
LT1 & LT2 (25) 1
CHASSIS GND
CHASSIS GND INPUT POWER 2
NEON INDICATORS Toriod Core 019x502000

C Rear Panel & Internal

W1A INVERTER MODULE (IM) #`1 (bottom)

(20) J105B AC INPUT
(1) EMI
L5 1
MAIN PCB LEDS IM #1 Section B (upper)
1 FIL- 2
(23) (23) 2 D3, RED, CAP
2 TER 1 CONTROL PCB LEDS
PCB W1B J104B IMBALANCE
(2)
IN1 OUT1
D4, GREEN, READY D1, RED, INV FLT
(21) (24) (24) 1
1 2 2 D14, RED, OVER TEMP
CAP BIAS PCB LEDS
2 1
J103B D24, GREEN, PWM ON
IN2 (25) (25) D6, GREEN, -12V D32, RED, PRI OC
(3) OUT2 1
(22) W1C 2 D11, GREEN, +12VP
1 2
2
GND2B
1 Toriod Core 019x502700 D13, GREEN, +12V
IN3 OUT3
J105A
L4 1
AC INPUT IM #1 Section A (lower)
CHASSIS GND (23) 2
J104A

(24) 1
(1) EMI
2
1 FIL- 2
D 2 TER 1 J103A
IN1
PCB
OUT1
(25) 1
(2) 2
1
2
2
1
Toriod Core WORK (+)
019x502000
IN2
OUT2
(3) 1 2
2
GND2B
1 System Bias LEDs & Test Points Component Locations (not including PCB components)
IN3 OUT3 TEST POINTS LEDS C4 Capacitor, fan starting, 8uf 440VAC (Sht 2, D2)
TP1 SECONDARY GND D3, RED, MISSING PHASE
TP2 24VDC D4, RED, AC V HIGH CB1 Circuit Breaker /ON/OFF SW, 15A 480V
CHASSIS GND TP3 DC INPUT POSITIVE D14, RED, AC V LOW (Sht 1, E1)
TP4 VCC1 D26, GREEN, +12V PRI CB2-4 Circuit Breaker, 5A, 250V (Sht 2, B3)
TP5 VCC2 D30, GREEN, 24VDC
(1-20) TP6 GATE D44, GREEN, T1 ON F1, 2 Fuse, 8A, 500V, S.B. (Sht 1,E1)
(2-21) TP7 PRIMARY GND FAN1 Fan, Heat Exchanger , 230 VAC (Sht 2, D2)
TP8 +12V PRIMARY FL1 Flow meter, pulse output (Sht 2, B2)
(3-22) TP9 P ISOL GND
CB1 FS1 Flow SW, 0.5 GPM (3.8 lpm), N.O. (Sht 2, A2)
ON / OFF (FRONT PANEL)
To J27 on CCM I/O PCB HCT1 Current Sensor, Hall Effect 200A, Work Lead
16 A (Sht 1, C8)
(Sht 2, E3)
K1 Relay, 24VAC, Inrush Control, (Sht2, B9)
(27A&B)

J62
(26)

(28)

E 24 VDC (29) L1 Inductor, (Sht 1, B7)

F2 SYSTEM BIAS +24VDC 1 L3-9 Toriod Core Common Mode Ind (Sht1 B8, A-D3)
F1 8A, 500V, SB SUPPLY PCB 24 VDC (30)
8A, 500V, SB
019X501900 +V
2
MISSING PHASE a (31) LS1 Level Switch, Coolant Tank (Sht 2, A3)
3
MISSING PHASE b (32) LT1, LT2 Indicator, Neon, 250V, AC Volts Present
AC INPUT 4
(86A) AC V HIGH a (33) (Sht 1, B2 & C2)
1 5
2 AC V HIGH b (34) M1 Motor, Pump, ½ hp 230VAC, 50/60 Hz, 1Ph
6
3
4 7
AC V LOW a (35) (Sht 2, C2)
(27A) 5 24 VDC_RET (36) MC1 Relay, 120VAC, Inrush, coil (Sht2, B9)
8
6
7 9
24 VDC_RET (37) contact (Sht2, A1)
(85A) 8
10
AC V LOW b (38) MC2 Relay, 120 VAC, Fan Control, coil
9 GND VAC_IDA a (39)
(86B)
10 11 (Coil at Sht 2, A7)(Contacts at Sht 2, D1)
11
12
/ VAC_IDA b (40) MC3 Relay, 120 VAC, Pump Motor Control, coil
12 VAC_IDB a (41)
(27B) 13 13 (Coil at Sht 2, A7)(Contacts at Sht 2, C1)
14
K1A K1B 14
/ VAC_IDB b (42) R2 Inrush, 4.7 Ohm, 30W (Sht2, A1)
15
R3,4 Ext RC, 100 ohm 55W (Sht1, A7)
208-230V-ID

16
230V 400V 480V ERR
17
(85B) /VAC_IDAb 0 1 0 1 SA1-4 Snubber, Contactor & Relay coils
480V-ID
400V-ID

18
/VAC_IDBb 0 0 1 1
(Sht 2, A8 & A9)
COM

J60 Measure relative to TP1 (24VDC_RET) T1 Aux Transformer (Sht 2, B2)

J63 "0" = 10-12V "1" = 24V
F J61 TB4 Terminal Block (Sht 1, C9)
10
11
12
1
2
3
4
5
6
7
8
9

4
3
2
1

VOLTAGE SELECTION TS1 Temperature Sensor, NTC, Coolant Return

Wire #48 from J61-1 to: (Sht 2, A5)
TO AUX TRANSFORMER J61-2 for 208-230 VAC TS2 Temperature Sensor, NTC, Ambient (Sht 2, A5)
(43A) (48) J61-3 for 400 VAC W1 Contactor , Input (Coil Sht 2, A8), (Contacts C2)
(44A) J61-4 for 480 VAC
TO J12 W2 Contactor , Input (Coil Sht 2, A8), (Contacts A2)
Art # A-11956_AC T1 PRIMARY
(Sht 2, A1)
1 2 3 4 5

A-32 APPENDIX Manual 0-5290

 AUTO-CUT 300 XT

6 7 8 9 10

TO CCM
CPU PCB J36
(Sht 2, C3)

J100 -- 30 CKT RIBBON

(49F)
ELECTRODE (-) 5
4
3 A
2
(51F) PILOT BOARD TEST POINTS
WORK (+) 1 LED'S TP1 GND (49)
D2 PILOT ENABLE TP2 PILOT GATE
J102B D11 +5V TP3 +5V
OUTPUT J43

1
TO CCM ELECTRODE
CPU PCB
J35
J58A PILOT PCB
(Sht 2, C3) J44 (49) L3 TORCH
R3 & R4 EARTH GROUND 1
J100 -- 30 CKT RIBBON
(49E) 1

(51E)
5
ELECTRODE (-) 4
3 J58C J41CHASSIS GND
2 PILOT GCM1000XT
WORK (+) 1 (50) 5 2
(52)
1
J102A 4 1
OUTPUT 3
TIP
2
1

(51F) J40 019X501600

INVERTER J45

10
J42

1
2
3
4
5
6
7
8
9

1
2
3
4
5
6
7
8
TO I/O BOARD
B
CHASSIS GND
10 ckt Ribbon

TO J3 on RELAY PCB (53)

(Sht 2, A5)
TIP VOLTS SHIELD

To J24 on I-O PCB WORK

(-)
(Sht 2, D3)

Electrode
TO CCM ARC VOLTS (55)
CPU PCB
J33 L1 (51)
(Sht 2, C3) (+)
HCT1
(51C)

J100 -- 30 CKT RIBBON J102A

Hall Effect Sensor
Tip
5
(49C) WORK
ELECTRODE (-) (51) (51)
4
3
1 Work (+)
2
WORK (+)
1

4
1

OUTPUT

J16 C
1

TO CCM J46-M TB4

2
1

CPU PCB
COMMON

(49)
+15 VDC

SIG (+)
-15 VDC

J32 7 ARC VOLTS (TORCH)

J46-F (52)
(Sht 2, C3) TIP VOLTS (PILOT)
2
1

J100 -- 30 CKT RIBBON (51) 5 WORK

J102B
(51B)

(56) o (60)
5
(49B) AC 120V- TB4-4 4
ELECTRODE (-)
4 (57) b AC 120V- Ret- TB4-3
(61) 3
120 VAC @ 100 ma.
3
TO J1 on RELAY PCB
2 (58) g AC 24V-TB4-2
(62) 2
WORK (+) 1 (Sht 2, B9)
OUTPUT (59) w AC 24V- Ret -TB4-1
(63) 1
24 VAC @ 1A
TO CCM (J10 Sht 2, B8)
CPU PCB
J31
(Sht 2, C3) RIBBON CABLE 30 ckt.
J100 -- 30 CKT RIBBON
RIBBON CABLE 40 ckt CCM (J23) - RELAY PCB (J4)
CCM (J31-36) - INVERTER (J100) 32 COMMON
J102A 1 COMMON
(49A) 2 /1TORCH START * 33 -15 VDC
5 1 READY + 34 COMMON
ELECTRODE (-) 4 2 READY - 3 NA D
3 (50) 4 /1TORCH GAS SOL ON * 35 24 VDC
2 3 INVERTER_FLT + 36 COMMON
WORK (+) 1 4 INVERTER_FLT - 5 /MAIN TORCH IDLE *
6 /1TORCH PRESS OK * 37 24 VDC
5 OVERTEMP_FLT + 38 COMMON
OUTPUT
6 OVERTEMP_FLT - 7 FLOW SENSOR (pulses)
8 LOW COOLANT FLOW 39 24 VDC
7 PWR_PRESENT + 40 COMMON
8 PWR_PRESENT - 9 COOLANT LEVEL OK
9 OUT_COM (+3 to 5VDC) 10 COMMON
11 NA RIBBON CABLE 16 ckt
10 VAC_SELA CCM ( J37) - DISPLAY
11 VAC_SELB 12 /PLASMA ENABLE-HMI
13 /COOLANT PUMP ON PCB (J17)
12 IS_IDA
13 IS_IDB 14 COMMON
15 /PILOT ENABLE 1,3,5,7 24 VDC
14 IS_IDC
16 /RAS ON 2,4,6,8 COMMON
15 ENABLE +
17 /CONTACTORS ON 9,10 NC
16 ENABLE -
18 COMMON 11-16 SERIAL DATA
17 START2 +
18 START2 - 19 /COOLANT FANS ON
19 SPARE 20 /1TORCH CONTACTOR ON *
21 /PLASMA ENABLE RELAY RIBBON CABLE 10 ckt
20 SYNC_IN + RELAY PCB (J3) – PILOT PCB (J42)
E

21 SYNC_IN - 22 COMMON
22 NC 23 PILOT CURRENT SIG-
23 NC 24 NC 1,2 24 VDC
24 47 OHM to COMM 25 PILOT CURRENT SIG+ 3,4,7,10 COMMON
25 DEMAND + 26 COMMON 5 PILOT ENABLE +
26 DEMAND - 27 WORK CURRENT SIG- 6 PILOT ENABLE –
27 47 OHM to COMM 28 WORK CURRENT SIG+ 8 PILOT CURRENT SIG –
28 CURRENT + 29 NC 9 PILOT CURRENT SIG +
29 CURRENT - 30 AMBIENT TEMP
30 47 OHM to COMM 31 COOLANT TEMP
* Used with 1 Torch Option

Art # A-11956_AC
Rev Revision By Date Rev Revision By Date
00 Initial Design DAT 10/03/2012
01 Add F2 DAT 11/21/2012 F
Date Printed Date Revised
02 Add T1 Inrush Ckt DAT 2/18/2013 9/30/2013 9/16/2013
Drawn Date
03 Misc updates & corrections DAT 6/27/2013 DAT 10/04/2012
Size Sheet
04 More updates & corrections DAT 9/12/2013 C 1 of 2
Title Drawing Number
SCHEMATIC
Auto-Cut XT 300A CE 380-415 VAC 042X1351
6 7 8 9 10

Manual 0-5290 APPENDIX A-33

AUTO-CUT 300 XT
APPENDIX 16: SYSTEM SCHEMATIC PG2
1 2 3 4 5

TO HCT1 (Work)
J12 = Mini-Fit Jr AMBIENT COOLANT
400 VAC -- Single 18 AWG in pins 1 & 4 1
TS2
480 VAC -- Single 18 AWG in pins 1 & 8
LS1 (90) TS1
2
230 VAC -- 18 AWG wires in pins 1,5,2,6 (89)
3

From Sys Bias J63 COOLANT LEVEL 4

(Sht 1, F2)
A J71
FS1

(59)
(58)
(57)
(56)
COOLANT J74 (84) (92) (93)
(43A) (44A) 1 (83)

COMMON
2 (94)

+15 VDC
MC1A

-15 VDC
SIG (+)
0.7 GPM (95)

Gas Selection
From Gas Sel SW
R2

2
1

8
7
6
5
4
3
2
1

4
3
2
1

6
5
4
3
2
1
J5 J7 J1 J2
4.7 30W (87)
in GCM 1000 XT
via J55-27 & 28
COOLANT FLOW SW LEVEL SENSORS WORK CURRENT SENSOR TEMP SENSOR

GAS_SEL_RET
(166) 1
2
+5VDC
RELAY & INTERFACE PCB
(Sht2, D9) (167) 3 SIGNAL (pulse) D2, GREEN, 1TORCH GAS ON Test Points
J12
1
5
2
6
3
7
4
8

GAS_SEL 4 GAS SELECT INPUT D7, GREEN, PILOT ENABLED TP1, GND
T1 (Sht2, D9)
J6 D11, GREEN, PILOT CURRENT TP2, -15V
D12, GREEN, WORK CURRENT TP3, +5VDC
460V (79) D22, GREEN, CONTACTORS ON TP4, +12V
24V RET BLUE
6
12
11 D23, GREEN, RF ON TP5, +24V
10 D24, GREEN, FANS ON TP6, +15V
1 2 3 4 RED (77) (78) 120VAC_2 D25, GREEN, PLASMA ENABLED
5 9 TP7, +5VDC
B
5 6 7 8
24V YELLOW CB2 5 A (76) 8 D26, GREEN, 1TORCH ON
4 7
24VAC D27, GREEN, COOLANT ON
(74) (75) 6
BLUE
400V 120V_2 RET 3
CB3 5 A (73)
5
4
RED
2 3
(71) (72) 2
YELLOW 120VAC_1
120V_2 1
CB4 5 A
1

14
13
12
11
10
9
8
7
6
5
4
3
2
1
220V J9 BIAS TRANSFORMER 019X501700
J15
120V-1 RET J14 1 TORCH INTERFACE

To J100 of IM #1B
120V_1 To J100 of IM #1A
(Sht 1, C,D6)
0V J31 - 30 CKT RIBBON J32 - 30 CKT RIBBON
CCM
CPU
To J100 of IM #2A N/C PCB
(Sht 1, B,C6)
J33 - 30 CKT RIBBON J34 - 30 CKT RIBBON

J13 To J100 of IM #3B

4
3
2
1

To J100 of IM #3A
C
(Sht 1, A,B6)
MC3A J35 - 30 CKT RIBBON J36 - 30 CKT RIBBON
(64A)

(65A)
(64B)

(65B)

J16 M1
(66) 1
2
3 J28 30 CKT RECEPTACLE - BOTTOM ENTRY
19X501100

MC3BCHASSIS GND Torch Coolant Pump Harness from Pilot PCB J45
J13 to CB5 (67) (Sht 1, B8) CCM I-O PCB
and to MC2 J28 30 CKT PIN HEADER
I / O PCB LEDS
& MC3, also ----------------------------------------------
(69)
230 VAC

J14, J16 230 VAC _ SW _ RET

D2 CNC PLASMA ENABLE
all 18 AWG (A9)
ARC VOLTS

D3 E-STOP_PS
TIP VOLTS

R BK (53) D4 GAS ON (Auto-cut, PAK)

MC2A FAN1 D6 CNC START
WORK

J72 C4
D8 HOLD START
(65A) (69) 1
BN D12 PREFLOW ON
(70) 2 BL 1 D13 CSD (corner current reduction)
3 2
D18 MARK
MC2B R
3
4 D20 SPARE
(51) 5
(64A) J73 6 D25 EXP METAL
D
(69) 1 (55) 7 D33 OK_CNC
8 D37 PSR
(70) 2
3
J24 D41 SPARE OUT 2
D43 SPARE OUT 1
(70) 230 VAC _ SW 230 VAC_SW
(A9) goes to J70 I / O PCB TEST POINTS
for HE 400 -------------------------------------
CHASSIS GND TP1 PCB COMMON
TP2 COOLANT FANS ON
TP3 PUMP ON
TP4 LOW FLOW (SW)
Harness from System Bias PCB TP5 FLOW SIGNAL (pulse, Ultracut only)
(Sht 1 F2) TP6 +15VDC_ISO (ref to TP10)
24 VDC (29) TP7 -15VDC_ISO (ref to TP10)
24 VDC (30)
1 TP8 +16-18 VDC_ISO (ref to TP10)
2 TP9 ANALOG CURRENT SIGNAL
MISSING PHASE a (31) 3 (remote & Autocut only)
MISSING PHASE b (32) 4 TP10 ISOLATED VOLTAGE COMMON
AC V HIGH a (33) 5 TP11 1 TORCH CONTACTOR ON
E
AC V HIGH b (34) 6 TP12 +5 VDC
AC V LOW a (35) 7 TP13 -15 VDC
24 VDC_RET (36) 8
TP14 +15 VDC
24 VDC_RET (37) 9
TP15 +24 VDC
AC V LOW b (38) TP18 +5 VDC_ISO (ref to TP10)
10
VAC_IDA a (39) 11
/ VAC_IDA b (40) 12 I / O PCB DIP SW
VAC_IDB a (41) 13 ---------------------------------------------
/ VAC_IDB b (42) 14 SW6 OK TO MOVE
(CONTACTS, VOLTS)
J27 SW11 ANALOG CC SOURCE
. 230V 400V 480V ERR SW12 DIVIDED ARC VOLTAGE
J62-12 (/VAC_IDAb) 0 1 0 1 (50:1, 16.7:1, 30:1, 40:1, 25:1)
J62-14 (/VAC_IDBb) 0 0 1 1
19X501200

Measure relative to TP1 (24VDC_RET)

"0" = 10-12V "1" = 24V

Art # A-11957_AC

1 2 3 4

A-34 APPENDIX Manual 0-5290

 AUTO-CUT 300 XT

6 7 8 9 10

TO PILOT PCB J70 - HE

MC2 Fan Control 230 VAC _ SW
(70) 230 VAC to HE 400 (70) 1

10 CKT RIBBON
(D2) 2
230 VAC _ SW _ RET
(69) 230 VAC Ret (69) 3
4

(161)
SA3 (D2)

(160)
SA1 (96) SA2 5
6
7
ARC_SUPPRESSOR
MC3 Pump Motor Control W1 W2

/ PILOT ENABLE RET

J59 - RAS A

(162)

(163)
PILOT A SIG Vin+
SA4

PILOT A SIG Vin-

/ PILOT ENABLE
CHASSIS GND 1
2
ARC_SUPPRESSOR (96) (97) 3 3 - Key Plug
ARC_SUPPRESSOR ARC_SUPPRESSOR 4
(98) 5
(99) 120 VAC to RAS (99) 6
7
(97) 120 VAC Ret (98) 8
9
MC1 10
11
10

16
15
14
13
12
11
10
9
8
7
6
5

4
3

2
1

9
8
7
6
5
4
3
2
1
J3 J8 (60) (107) 12
13
14
CONTROL OUTPUTS
PILOT PCB
24 VDC (100) 120VAC
18
GND (101)
17
(102) J54 - Remote HMI & CNC COMM
16
(103)
15 AC 24V GCM1 (100)
(104)
24 VAC 120 VAC_1 14
(62)
AC 24V GCM2
(62) (101) 1 1 - 24 VAC
13 AC 24V-TB4-2
(102) 2 2 - 24 VAC Ret
12 (106) 3 3- Jumper to 24 VAC
11 AC 120V - GCM (60) (109) 4
10
(108)
AC 120V- TB4-4
(108)
5 5-HMI Plasma Enable SW
9
(109)
6 6-HMI Plasma Enable SW
120 VAC_2 8
(110) (115) 7 7 - Key Plug
7
(111) AC 24V Ret- GCM1
(116)
8 8 - Tx+ B
6
(63)
AC 24V - RET - GCM2
(63) (117)
9 9 - GND RS 485
HMI/GCM
5 AC 24V- Ret -TB4-1 Harness 10 10 - GND / 422
4 (118) 11
Comm
3
(113)
AC 120V- Ret- GCM K1
(119)
12 12 - Tx-
2
(61) (62) 1
(120)
13 13 - Rx+
J4 -- 40 CKT RIBBON CABLE 1 AC 120V- Ret- TB4-3 2 14 14 - Rx-
J10 4 (107)
1
3 (61)
USB Cable to Front Panel 2
(63) 5
3
4
J38 J39
INRUSH CONTROL Display PCB
J47
1
2
3
4
5
6
7
8
9

1
2
3
4
USB (116) J17
GND 1
PORT (117)
RS 232 D-SUB GND
Rx-
2
3
(120) Harness
1 1 (115)
SERIAL PROG
NORMAL PROGRAM

Tx+ 4

4 WIRE
2 2 (119)
Rx+ 5
PORT 3 3 Tx- 6
(118)
4 4
1
5
6
5
6
J30 019X501800
2 16 CKT RIBBON
3 PROG 7 7
J37 J55 - GCM
2 WIRE

USB IC 8 8
4
9 9 (121)
5 1 1- PLAS_ENABLE SW * C
10 10 (122)
6 2 2- PLAS_ EN_SW_RET
11 11 (123)
3 3- GAS PRESS OK RET
J18 12 12 (124)
(125)
4 4- / GAS PRESS OK
J19 J20 (126)
5
6
5- POT HIGH (GCM 1000)
6- POT WIPER (GCM 1000)
(127)
J29 30 CKT RECEPTACLE - BOTTOM ENTRY (128)
7 7- POT LOW (GCM 1000)
8 8- BASIC ID RET
(129)
9 9- / BASIC ID **
(130)
10 10-
(131)
11 11-
GAS ON 12 GCM 1000 XT
J29 30 CKT PIN HEADER 13 Jumper
J23- 40 ckt ribbon cable (130) (112)
1 14 14-
(131) (114)
CPU PCB LEDs 2
(112) (103)
15 15- 24 VAC - RET
3 AC 24V-GCM1 16
---------------------------- ENABLE 4
(114) (110)
17 * Plasma Enable SW
D2 RXD (red) 5
(121)
AC 24V Ret - GCM1 18 in GCM 2010.
PLAS_ENABLE SW 6 19
D3 TXD (red) PLAS_ EN_SW_RET 7
(122)
20
Jumpered in
D4 CAN BUS (slave) (124) GCM 1000 XT
/ GAS PRESS OK 8 21
(129) AC 24V-GCM2
D7 CAN BUS (MAIN) / BASIC ID 9
(128)
22 and DMC 3000.
TB1 10 (111) 23
D11 5 VDC POWER 11 AC 24V Ret-GCM2 24 ** Jumper in
OK2 (contact) 12 (123) GCM1000XT
D17 STATUS CODE +10V (CC Pot Hi) 11 12 25
D18 INITIALIZING / 13 (166) 26
CC Pot Wiper 10 (125)
14 27 27- GAS SEL SW RET
PROGRAMMING (red) CC Pot Low 9 (126)
15 J69 28 28- GAS SEL SW
Div Arc V (+) 8 (127)
16 29
Div Arc V (-) 7 (166) D
CPU PCB TEST POINTS /Start - Stop (+) 6 J26 GAS_SEL_RET
2 (167) 30
1 31
-------------------------------------------- /Start - Stop (-) 5 (167) 32
Stop Mom NC 4 GND GAS_SEL
TP1 GND (PCB common) OK2 (contact) 3 (142) (106) 33 J15-1 to chassis used for
1 AC 120V - GCM 34 SC-11 cable shield
TP2 +5V_ISO (REF TP5) / CNC Enable (+) 2
2 35
TP3 +24 VDC / CNC Enable (-) 1 (113)
3 36 J15-13 connects SC-11
AC 120V- Ret- GCM
TP4 +3.3V 4
(133)
37 chassis to PS chassis.
5
TP5 GND_ISO OK 6
(134) J15-CNC The COMM Ref at pin 8
(137)
TP6 +5.0 V 7
(139)
CHASSIS GND
1
is also for the SC-11
TP7 TOTAL DEMAND 8
TB2 (138) 2
9 (133)
(3.3V = 400A) OK to MOVE (+) 12 10
(143)
(134)
3 3- / CNC Start (+)
4 4- / CNC Start (-)
TP9 /WR 11 11
(140)
(135)
5 5- Divided Arc V (-)
OK to MOVE (-) 10 12 (136)
TP10 /RD 9 13
(141)
(137)
6 6- Divided Arc V (+)
(136) 7 7- / Preflow ON (+)
TP11 CPU TEMP SENSE PILOT is ON 8 +10V 14
(135)
(138)
8 8- COMM Ref (1K Ohm)
TP12 +3.3VA 7 15 (139)
(132) 9 9- / Preflow ON (-)
PILOT is ON 6 16 (140)
TP13 -15VDAC 5 17 (141)
10 10- / Corner Current Reduction (+)
(153) 11 11- / Corner Current Reduction (-)
TP14 PC2 Preflow ON (+) 4 18 (142)
12 12- OK to Move (-)
Preflow ON (-) 3
TP15 +15VDAC Hold Start (+) 2 J21 (143)
13
14 14- OK to Move (+)
TP16 CLKO Hold Start (-) 1 GND GND
15 15 - Key Plug
TP18 OSC_CLOCK (144)
(144)
16 16- / Hold Start (+)
1 (145)
(145) 17 17- / Hold Start (-)
2
(146) 18
CPU PCB DIP SW 3
(147) 19
E
4
--------------------------------------------- TB3 5
(148)
(146)
20
(149) 21 21- / Plasma Mark (+)
SW1 AUTO PILOT RESTART Spare #2 NO 12 6
(150)
(147)
22 22- / Plasma Mark (-)
11 7 (148)
SW3 PREFLOW TIME 10 8
(151)
(149)
23 23- / Cut Expanded Metal (+)
SW4 POSTFLOW TIME Spare #2 NC 24 24- / Cut Expanded Metal (-)
9 9 (150)
25 25- / CNC Plasma Enable (+)
SW5 FUNCTION Spare #1b NO 8 10
(152)
(151)
26 26- / CNC Plasma Enable (-)
7 11
SW8 SYSTEM CONTROL / Cut Expanded Metal (-) 6 12
27
(154) 28
(pilot time, etc.) / Cut Expanded Metal (+) 5 13
(155)
(132)
29 29- Remote CC Pot High
SW9 RESERVED (future) / Corner Current Reduction (-) 4 14 (152)
30 30- Remote CC (analog)
/ Corner Current Reduction (+) 3 PSR 15 (153)
SW10 ADDRESS (default = 0) / Plasma Marking (-) 2 16 (154)
31 31- Remote CC Pot Low
(156) 32 32- Stop SW (momentary) *
SW13 UNIT TYPE (AC / UC) / Plasma Marking (+) 1 17
(157)
(155)
33 33- Stop SW Ret
18 (156)
SW14 LINE TERMINATION 19
(158)
(157)
34 34- Pilot is ON (a)
(159) 35 35- Pilot is ON (b)
(serial comm.) 20 (158)
36 36- Spare OUT #1 (a)
SPARE #1a (159)
J22 37 37- Spare OUT #1 (b)

* Used with Momentary CNC Start SW

Art # A-11957_AC
Rev Revision By Date Rev Revision By Date
00 Initial Design DAT 10/03/2012
01 Add F2 DAT 11/21/2012 F
Date Printed Date Revised
02 Add T1 Inrush Ckt DAT 2/18/2013 9/30/2013 9/12/2013
PCB1 Drawn Date
03 Misc updates & corrections DAT 6/27/2013 DAT 10/4/2012
TDYN SILK Size Sheet
ESD SILK
04 More updates & corrections DAT 9/12/2013 C 2 of 2
Title Drawing Number
SCHEMATIC
114Xabcd
Auto-Cut XT 300A CE 380-415 VAC 042X1351
5 6 7 8 9 10

Manual 0-5290 APPENDIX A-35

AUTO-CUT 300 XT
APPENDIX 17: 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. The IMs are mounted one over
the other numbered from bottom to top. The sections are
also designated from bottom to top with section A being on
the bottom of each module. An IM with one section is con-
sidered to be a ½ or “partial” module with the upper or “B”
section missing. ½ modules are used with the 200A & 300A
power supplies and will always be in the middle position.
IMs with 2 sections are considered to be “full” modules.
Each inverter section can supply up to 67A but does not do
so in all configurations:
A 400A unit uses 6 sections. 400A / 6 = 66.67A per section.
A 300A unit uses 5 sections. 300A / 5 = 60A per section.
A 200A unit uses 3 sections. 200/3 = 66.67A per section.
A 100A unit uses 2 sections. 100/2=50A per section.

Unit configurations. Art # 12299

With the exception of the AC 200 XT all other units have the
same chassis with room for up to 3 IMs. The unused areas
have blank panels filling the empty locations which are
required for proper air flow. A 100A system uses 1 full IM;
200A uses 1 and ½ modules with a full module in the bottom
location and a ½ module in the middle position. A 300A
unit has full modules top and bottom with the ½ module
in the middle location. The AC 200 XT has only the bottom
and middle locations for IMs. An internal Arc Starter and
Gas Control are located in the place of the 3rd or upper IM.

Inverter module cooling.

The power semiconductors of the inverter modules are liq-
uid cooled allowing us to get more power in a smaller area
and at lower cost. Each IM has a liquid cooled heatsink or
“cold plate” shared by the 2 inverter sections. The magnetic
components, transformers and inductors, are air cooled and
mounted on the back side of the IMs where they are exposed
to high volumes of air flow from the cooling fans whose air
also cools liquid coolant in the radiator or heat exchanger.
It is important that lower right side panel be in place or the
air flow will not be proper for cooling the magnetics.

Inverter control.
The inverter sections are operated as separate inverters
whose outputs are connected in parallel. They are controlled
independently from the Command and Control Module
(CCM) which is the “brains” of the system. Each inverter
section has a separate ribbon cable connected to it coming
from the CCM which has 6 connectors, J31 – J36 correspond- Art # 12300
ing to the inverter sections 1A through 3B. The ribbon cables
are labeled on the inverter ends as INV with the number and

A-36 APPENDIX Manual 0-5290

 AUTO-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.
Other boards in the system include the System Bias Supply, the Relay & Interface PCB, Display PCB, Pilot PCB
and AC Suppression PCB. The CCM has 2 boards, the I/O (input/output) and the CPU (central processing unit)
board. The CE units will also have one or more EMI Filter boards on the input power.
System Bias supply PCB is powered from the 3 phase AC input and works from about 150V to over 600V covering
all the normal voltage ranges. It can operate from 2 phases (single phase) so it still provides bias power and can
report a fault if a phase is missing. The supply’s output is 24 VDC which powers the Relay board, the Display, the
Pilot board and the 2 boards in the CCM. System Bias also contains circuits to detect missing phase and determine
if the AC voltage is within the correct range, not too high or too low. It also signals to the CCM what voltage the
unit is configured for. The System Bias supply PCB includes a relay, K1, which only applies voltage to Auxiliary
transformer, T1, primary when the input voltage is in the correct range.
The Relay and Interface PCB Accepts and distributed the output of the Aux Transformer. It has relay to control
the pump, fans, input contactors, the Arc Starter and the Inrush relays. A circuit on the Relay board accepts input
from the Work current sensor, HCT1, and Pilot current sensor (on the Pilot PCB) and sends the Enable signal to
the Pilot boards IGBT switches via the J3 to J42 ribbon cable. Other inputs on the Relay board include those from
the Negative Temperature Coefficient (NTC) ambient and coolant temperature sensors. Coolant tank level switch
and coolant flow switch, which determines if the flow is above the required minimum rate, also send signals to the
Relay Board. Ultra-Cut units include a flow sensor whose output to the Relay Board is a series of pulses whose
frequency indicates the flow rate and can detect the presence of gas bubbles in the coolant. All these signals pass
to the CCM via a 40 conductor ribbon cable going to the CCM I/O board.
The Display Board Has LEDs for AC, TEMP, GAS & DC. It also has a 4 digit 7 segment display for status and fault
information. AC LED indicates the input contactors to the inverters have been commanded to close, but does not
mean they are closed. TEMP means one or more inverters or the coolant has exceeded the allowed temperature.
GAS means gas is flowing and coolant flow is OK. DC means the inverters output voltage is above 60 VDC.
The first digit of the 7 segment display shows the letter, “C”; “E”; “L” or is blank. During the initial power up se-
quence the letter “C” followed by the other 3 digits, indicates the CCM code revision. Status or Fault codes which
may occur during the power up sequence or any time thereafter are preceded by letters “E” for an active fault or
“L” for a “latched” or “last” fault that stopped the process but is no longer active. When there is no Fault or active
Status code, the output current setting is displayed with the first digit blank. If the system is an Ultra-Cut XT using
the Auto Gas Control, DFC 3000, the display will show “0” until a process has been loaded. If there is a fault or
other status showing the display will alternate between the current setting and the fault.
The Pilot PCB contains a pair of parallel IGBT transistors working as an electronic switch to connect and disconnect
the torch tip from the 1st inverter section.
When the pilot electronic switch is closed and the pilot is ignited by the Arc Starter, current from the 1st section
flows between electrode and tip. Then as transfer begins, a small current from the 2nd inverter flows from elec-
trode to work. When transfer is detected the pilot switch is opened and current from the 1st section is free to flow
to the work through the diode which is also on the Pilot board. The Pilot PCB also contains a pilot current sensor
to detect and measure the level of pilot current. Additional resistor/capacitor (RC) circuits on the pilot PCB assist
and stabilize the pilot and transferred arcs.

2nd INVERTER SECTION

ELECTRODE

(INV 1 B)

PILOT SW (IGBT)
1st INVERTER SECTION (+)
(INV 1 A)
TIP

Art # 12301 WORK (+)

Manual 0-5290 APPENDIX A-37

AUTO-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.

Differences between various models.

Auto-Cut 200 or 300 XT units use the basic gas control/arc start circuits consisting of single gas inlets, one for Plasma,
one for Gas Shield and one for water inlet, optional for AC 200 XT, for H2O Mist shield. There is a pressure regula-
tor and gauge for each gas inlet and water flow meter/control when the H2O Mist option is used. All 3 are turned
on/off with control solenoids. Changing gas types requires connecting different gasses to the rear panel and setting
the gas switch on the rear panel to match the plasma gas type. There is no separate pilot (Preflow) gas at this time.
The Auto-Cut Arc starter is the conventional spark gap type with water cooled coil that we’ve used for several years.
This arc starter injects the HF onto the torch electrode via the negative lead with the return via the tip and pilot lead.
The Ultra-Cut XT units use the remote arc starter, RAS 1000 XT. In place of the spark gap the RAS 1000 XT uses a
solid state ignition module to create the HF pulses which are injected onto the tip and return via the electrode, the
opposite direction of that used in the Auto-Cut, Auto-Cut XT and the older RAS 1000 used with the Ultra-Cut units.
The AC 200 XT had the gas control and arc starter built into the main enclosure in the area that is used for the top
inverter module in other units of this family. The AC 300 XT has a separate gas control/Arc Starter that sits on top
of the main enclosure very similar to the GCM 1000 of our earlier Auto-Cut models. It is in fact called a GCM 1000
XT. Both Auto-Cut XT models have an analog current control (Potentiometer). On the front panel of the main unit
for the AC 200 XT and in the upper box, the GCM 1000 XT, for the AC 300 XT version. In either case the amperage
setting is displayed on the front panel digital display.
Both Auto-Cut models have the gas mode switch on the rear, for the AC 300 XT next to the gas inlets of the GCM
1000 XT. On the AC 200 XT it’s near the connectors, fuses & circuit breakers. The switch should be set according
to the type of gas, AIR/O2 or N2, H35 or other non-oxidizing gas, being used for the plasma.
In the AC 200 XT the Pilot board is mounted on the upper section of the second inverter module (IM#2) the ½ mod-
ule, in the place of the second or “B” section if it was a full module. The AC 300 XT and all Ultra-Cut XT models
have the Pilot board on the opposite side from the inverters, the “circuit breaker” side, in the upper rear behind the
CCM module. Refer to the Replacement Parts section of the manual for illustrations showing the locations.
Ultra-Cut XT units, 100, 200, 300 & 400A units all can use either the GCM 2010 “manual” Gas control or the DFC
3000 Auto Gas Control. These gas controls remain unchanged from earlier Ultra-Cut units.
Ultra-Cut XT units use the same flow switch, FS1, as the Auto-Cut XT units to detect and prevent operation when
coolant flow is below the minimum of 0.75 GPM (2.8 l/m). However, the Ultra-Cut XTs include a coolant flow
sensor, FL1, which also measures the flow and can detect if there are gas bubbles in the coolant which can reduce
consumable part life. Detecting bubbles or low flow from FL1 will NOT prevent cutting but will show a code as a
warning that something is not right. The code is E406.
Ultra-Cut XTs have standard consumables for cutting currents lower than those used for Auto-Cut XT, 15A vs. 55A
as well as marking at lower currents. To improve operation at these lower currents an additional output inductor,
L1, is added in series with the 1st inverter section (IM#1A).

A-38 APPENDIX Manual 0-5290

 AUTO-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. They have their own set of status codes which
should be covered in another section. This guide assumes you have first considered the Status Code Tables in the
Operation Section of the unit manual. Individual codes will point to different inverter sections while this guide
groups similar codes together. For example code E (or L) 249 indicates an inverter fault in Inverter 2A. This guide
covers codes 247-252 in one section as they are all the same, varying only by which inverter and section they refer to.
The codes are separated into 6 groups.

Group 1 Plasma Process -- Relating to pilot, transfer, torch voltages, etc.

Group 2 Plasma Power Supply -- Primarily the Inverter Sections
Group 3 Interface to Gas controls -- Mainly the DFC 3000
Group 4 Cooling System -- The liquid cooling system for the torch and inverters
Group 5 CCM -- Communications port to the gas controls

For the XT units we are using a 3 digit code with group 1 codes in the 100’s, group 2 in the 200s etc. These cor-
respond to the older codes used in previous units, where 1-1 is now 101. For the most part the codes have the
same meaning. Where an older code no longer applies to the XT system we don’t use it over again and have left it
reserved to avoid confusion. For example the code 204 (2-4) which meant the inverter module wasn’t ready. We
now detect that error in a different way that has a somewhat different meaning so we have reserved the 204 Code.
While most of the codes indicate a fault has occurred, a few of them, such as 304 (formerly 3-4), simply refer to
the current status. 304 indicates either “priming” where the pump is filling the system with coolant or more often
“purging” where the gas is flowing to dry the consumables after replacing them or purging the gas lines when a
different gas type has been selected.

Troubleshooting (General)
In many cases where the cause may be listed as a cable or wire disconnected but also includes loose or broken.
All Ribbon cables have an extra receptacle near one end for measuring signals on the cable.
A number of the measurements will require probing of some small connectors or measuring signal on ribbon cables.
For probing the small connectors, standard meter probes are usually too big. We suggest making a couple probes
using steel wire. Copper buss wire isn’t stiff enough. A paper clip is a little too big. One idea is take a socket from
an Amp mate-n-loc or similar connector into which your meter probe will fit and crimp a small piece of steel wire,
(0.020 to 0.025” dia.; (0.5-0.6 mm) works best), into where wire would normally be crimped. The wire should be
soldered and crimped. The steel wire may be found in hobby stores that cater to model building.

Art # 12302 Art # 12303

Insulate all but the end of the wire and slide these onto your meter probe. If your meter has alligator clip adaptors
you could hold the wire in these as well, be sure they don’t short together.

Problems that do not set Status or Fault codes:

1. At power on GAS LED blinks continuously, no code set. Real problem is no or low coolant flow but it takes
4 minutes before code is set and people don’t wait that long.

Manual 0-5290 APPENDIX A-39

AUTO-CUT 300 XT
Power Supply Status Codes
Group 1, Process Codes
101 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 & Auto-Cut 300XT. The Auto-Cut 200XT which
uses a 14 pin CNC does not have the Plasma Enable in the cable. These may be used to connect to the cutting
table E-Stop switch. In either case the jumper would be removed from TB1-1 & 2. 101 is not a latched code, it
clears as soon as the condition is fixed.
Causes for 101 code other than one of the Enable switches being off (see detailed descriptions below):

• Gas Control Cable from J55 to gas control not connected.

• Ribbon cable from Relay board to I/O board not connected.
• CNC cable not connected (if using a Plasma Enable switch or output from the cutting table or robot).
• Defective Relay PCB
• Defective CCM I/O PCB
Special case: Display alternates between E101 and ----. This happens when there is both a missing phase and
Plasma enable is off. It is probably a bug in the code, it should be showing E101 & E201 (missing phase code).
We will likely fix this in a later code release but be aware of it for now.

External or CNC Plasma Enable D2, CNC PLASMA ENABLE LED, is not on.

• LED D2 on the CCM will be on if this input is satisfied either with the jumper on TB1- 1 & 2 or an external
or CNC switch. If the jumper is in place and the LED is not on, the CCM is most likely defective.
• If the jumper at CCM TB1-1 & 2 has been removed to use an external switch, install a jumper as a test. If
D2 illuminates the problem is with the switch or it’s wiring.
• If Plasma Enable is wired through the CNC cable remove the cable and jumper J15 pins 25 & 26. If D2
still not on there may be a problem in the wiring inside the power supply.
Plasma Enable from Gas Control or TSC 3000
If the External or CNC Plasma Enable is satisfied, D2 is on, a relay K7 on the CCM I/O PCB energizes supply-
ing +15V to another relay K1 on the I/O board. An active low signal, /Plasma Enable-HMI, comes from TSC
3000 Plasma Enable switch via the Relay PCB or if TSC 3000 is not installed the signal originates on the Relay
PCB. This signal applies ground to the K1 relay energizing it and lighting the LED, D3 on the I/O board. K1’s
contacts go back to the Relay board and the Gas control connector J55 to allow turning on relays and solenoids
on those devices. The AC 200 XT does not use the separate Gas Control or the TSC 3000.
When the circuit between J54-1 & 3 is closed (jumper,
Simplified schematic, all connectors are not shown. XT Power Supply etc.) K7 is energized and requires a Plasma Enable SW
Refer to unit schematics for details. or equivlant to enable the plasma.
With J54-1 & 3 open K7 is denergized and it's NC
CCM I/O PCB contacts complete the Plasma Enable-HMI circuit.

K6
1 +15VDC TSC 3000
2 J54 J61 J54 J25 iCNC J54 J30 iCNC
RELAY PCB -1 -1 -1 XT 2 & -1 XT 211
4 24 VAC
D2 XT 242
GREEN 3 24 VAC
-3 -3 -3 -3
5

PLASMA ENABLE - CNC

K1 Plasma
2
GND Enable
K7
1 3 To 1 SW
4 Relay 2 -6 -6 -6 -22 -6 -25
D3
GREEN PCB 4 -5 -5 -5 -15 -5 -20
5
PS_ENABLE
3
8 6 To Gas 5
7 Control GCM 2010 GCM 1000 XT
HMI PLASMA
ENABLE BYPASS (or jumper in (AC 300 XT
PLASMA ENABLE other gas controls)
/PLASMA ENABLE - HMI DMC 3000)

J55 J56 Plasma Enable SW J56

J26-6 -1 -1 -1
J26-7 -2 -2 -2

Jumper in
AC 200 XT Art # 12304

A-40 APPENDIX Manual 0-5290

 AUTO-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.
The GND obtained by either path passes through the GCM 2010 Plasma Enable switch or through a jumper
(J56-1 to J56-2) present in the other gas controls (GCM 1000 XT or DMC 3000) and is connected to the coil of K1
on the I/O PCB. If the CNC Plasma Enable is also active (D2 is on) +15V will be connected to K1’s coil through
the relay K7 on the I/O PCB. This energizes K1 and turns on D3, Plasma Enable LED. The contacts of K1 go
back to the Relay board and to the Gas control to enable power to connect to relays and solenoids in those items.
Troubleshooting:
1. If both D2 and D3 are on and you still have 101 fault replace the CCM. Otherwise go to step 2 except if
it’s an AC 200 XT skip to step 4.
2. If D3 is not on and there is a TSC 3000 in use remove its cable from J54. K7 on the Relay board will de-
energize and satisfy the Plasma Enable to K1. If D3 is now on problem was in the TSC 3000 or its cable.
Otherwise reconnect the cable.
3. For an Ultra-Cut with DFC 3000 or GCM 2010 or an Auto-Cut 300 with a GCM 1000 XT remove the cable
from J55 the gas control connector and jumper pins 1 & 2. If D3 is on now problem is in the Gas Control
or its cable. If D3 still not on replace the Gas Control cable.
4. If neither of the above steps works, on the CCM I/O board, jumper J26-7 to GND (TP1 on I/O). If D2 is
on and D3 still does not light then replace the CCM.
5. If D3 does light in the above step find the 40 pin ribbon cable plugged in to the top of the CCM. Confirm
that it is plugged in to both the CCM and the Relay board and the connector tabs are locked in place.
Now using the spare receptacle measure voltage between GND (TP1 on I/O) and the ribbon cable pin 12.
It should be zero V. If not, if it’s something like 10-15VDC, the ribbon cable is open or the Relay board
is defective.
GCM 2010 PLASMA ENABLE / E-STOP SIMPLIFIED CIRCUIT
XT PLASMA SUPPLY
RELAY BOARD
AC24V GCM1 15
GCM 2010 GAS CONTROL

AC24V Ret - GCM1 7

J10 GAS
CONTROL
CABLE GCM 2010 CONTROL BOARD

F20 1A
CCM I/O BOARD (103) 16 16
(56) 12

3
(112) 14 14
(58) 15

K1 K?
(110) 17 13
(57) 13
1
PLASMA ENABLE D13 4

(114) (59) GREEN 5

4 15 15 16

J56 2
J26 J55 J5
E-STOP

Art # 12306

Manual 0-5290 APPENDIX A-41

AUTO-CUT 300 XT
102 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.
Possible Causes for 102 code:

• No HF to the torch due to broken pilot wire connection in the torch leads.
• No HF to the torch due to defective Arc Starter.
• Arc Starter not receiving power.
• Pilot board not enabled.
• Pilot board defective.
• Relay board defective.
• Work lead current sensor defective.
• CCM defective.
Troubleshooting:
1. Determine if the problem is a lack of HF (Arc Starter) or if it’s due to the pilot circuit.
Auto-cut XT Arc Starter (inside main chassis for AC200 XT; in the GCM1000XT for AC300XT) has open spark
gap. If the spark gap is firing it is receiving power. A few early Ultra-Cut XT units were shipped with the
RAS1000 Arc Starter. Troubleshoot them the same as the GCM1000XT below. Most Ultra-Cut XT units now
use the RAS1000XT Arc Starter which doesn’t use a spark gap and is covered in the next section.

Arc starter with Spark Gap (Auto-Cut)

No spark at spark gap
1. Check that spark gap is set for 0.062” +/- 0.002”. If gap is too high there may not be enough voltage from
T1 to fire the gap.
2. Check for power to the high frequency (HF) transformer (T2 in AC 200 XT; T1 in GCM1000XT) during the 15
seconds following prefow (ignition phase). Arc starter power comes through the rear panel circuit breaker
CB4, make sure it isn’t tripped.
a. For the GCM1000XT (AC300XT) 120 VAC from J59-7 & 9 on the power supply rear panel connects to
J58-7 & 9 on the GCM 1000XT. See diagram below. From J58 on the GCM1000XT it goes directly to the
line filter and passes through the filter to primary of T1. During the ignition phase, check for 120 VAC
on the T1 side of the line filter.
b. For AC200XT the HF transformer T2 has insulated Faston (also known as push on , stab-on, spade, etc.)
on its primary wires. Disconnect these and measure for 120 VAC on the harness side during ignition
phase.
3. If 120 VAC not present go to step 4.
a. If 120 VAC is present and still no spark, T1 (T2 in AC200XT) may be bad. Remove power and measure
resistance of T1 (T2 in AC200XT) primary and secondary. The primary should measure about 3-7 ohms.
The secondary about 25-35 K ohms. If either measurement not correct replace T1 (T2 in AC200XT).
b. If T1 (T2 in AC200XT) measures OK, check for shorted capacitors C1-C3 (very unlikely).
4. No 120 VAC to T1 (T2 in AC200XT) primary during the ignition phase (15 seconds following Preflow) check
for 120 VAC into the line filter (GCM1000XT only). If it’s there replace the filter. If 120 VAC isn’t present at
the line filter or if this is an AC 200XT go to step 5 in section Either Arc Starter below.

A-42 APPENDIX Manual 0-5290

 AUTO-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.
a. During the ignition phase, measure for 120 VAC at the input terminals marked 120 VAC on the Ignition
module, a gray rectangular box with screw terminals on one side.

WARNING
Do not let the meter probes (or your hands) come in contact with the other terminals marked
Hb and Ho or the other end of the wires connected to them. These can have 10,000 volt
pulses which can cause physical harm and will damage your meter.

2. If 120 VAC is not present go to step 3.

a. If 120 VAC is present and still no spark, the Ignition Module may be bad.
3. 120 VAC to the remote Arc Starter comes from J59-7 & 9 on the power supply rear panel and connects to
J58-7 & 9 on the RAS1000XT. Remove the cable from J59 and during the ignition phase measure for 120
VAC between pins 7 & 9.
a. If 120 VAC is present problem is in the cable to the RAS 1000 XT or the J58 connector and internal har-
ness in the Arc Starter.
b. If 120 VAC is present proceed to the next step.
4. 120 VAC to J59 comes from the relay board J8-3 with return on pin 11. On the Relay board, RF ON LED,
D23, should be on during the igniting phase. If it is not skip to the next step.
a. If D23 is on and there is not 120 VAC at J8-3 & 11 then the Relay board is bad.

Either Arc Starter

5. /RAS ON signal not on. CCM sends active low signal “ /RAS ON” over the 40 pin ribbon cable on pin
16 to the Relay & Interface board. On the relay board RAS Control relay (K2) closes (RF ON LED, D23 on)
sending 120 VAC to J8-3 with return on J8-11. From here it either goes to the HF transformer T2 (AC200XT)
or to J59 as described above.
a. Measure the signal “/RAS ON” on pin 16 of the 40 pin ribbon cable relative to TP1 on either the CCM
I/O board or the Relay board. If it is low (less than 1V) skip to step 6. Otherwise continue this step.

NOTE!
If the CCM thinks there is already a pilot it would not enable the HF. Pilot board
has a current sensor that sends a differential analog pilot current level signal to the
Relay board which in turn passes that signal to the CCM. On the Relay board D11
LED “Pilot Current Detected” or just “PILOT” lights if it sees a signal from the pilot
board.

Manual 0-5290 APPENDIX A-43

AUTO-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.
7. Faulty detection circuit. There isn’t any pilot current but a fault in the circuits measuring pilot current is
indicating there is current.
a. Measure between pins 8 (-) and 9 (+) on the Pilot ribbon cable from Relay board J3 to Pilot board J42. If
there is no pilot current it should be zero. Anything else indicates the Pilot board current sensor is faulty
causing the Relay board D11 to be on. Replace the Pilot board assembly.
b. If the Pilot current signal on the pilot ribbon cable was zero, measure between pins 23 (-) and 25 (+) on
the 40 pin ribbon cable between the Relay board and the CCM. This would also normally be zero if there
is no pilot current. Anything else would indicate the Relay board is faulty.
Relay & Interface Board
CCM I/O Board 120 VAC_RET
J23 J4 120 VAC_1 From J9-7
From I/O PCB From J9-1 J8 J59 - RAS
TO RELAY BOARD (Rear Panel)

120 VAC RET

1 1 16
2 2 15
1
3 3 120 VAC 14
2
4 4 13
5 24VDC_SW 3
5 12
6 4
6 11
7 5
7 10
8 8
D21
K2 9 (99) 6
7
9 9 8
10 10
1
7 (98) 8
9
11 11 6
12 3 10
12 5
13 13 D23 120 VAC to RAS
4
11
14 4 12
14 GREEN 3
15 13
15 2
/ RAS ON 16 16
5
1
14
17 17
18 18 RF ON RAS CONTROL
19 19
20 20
21 21
T2
22 (99) 6.5K 1W
22
23 23
24 24 (98)
25 25
26 AC200XT only 6.5K 1W
26
27 27
28 28 120 / 6000 VAC
29 29
30 30
31 31
32 32
TP1 33 33
34 34
GND 35 TP1
35
36 36
37 37
GND
38 38
39 39
40 40
Art # 12307

8. If “ /RAS ON” signal is low on pin 16 of the 40 pin ribbon cable, relative to TP1 on the CCM I/O board,
during the ignition time then we need to determine if the Relay board is defective. If /RAS ON signal is
not low the CCM or the 40 pin ribbon cable may be defective.
a. If the Relay board RF ON LED, D23, is not on while the /RAS ON signal is low, then the Relay board is
defective.
b. Is D23 is on, measure for 120 VAC on J8-3 to J8-11. If not present the Relay board is defective.
c. If 120 VAC is present at J8 during the ignition time go back and perform steps 2-4.

A-44 APPENDIX Manual 0-5290

 AUTO-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. The second LED, D2, also
green, is on when the pilot is enabled, that is the pilot IGBT switch is turned on. The pilot is enabled near
the end of preflow time and remains on until the transfer is established or for 15 seconds after which a 102
code is displayed. If D2 performs as expected you know the CCM, Relay board and work current sensor
are not causing the problem.
2. If D11 on the Pilot board is not on check if the 10 pin ribbon cable is connected between the Pilot board (J42)
and the Relay board (J3). Measure for 24 VDC on the Pilot ribbon cable test connector pin 2 (+) and pin 10
(-). If 24V is present and neither D11 nor D2 lights then the Pilot board may be defective. Pilot board end
of the ribbon cable could also be the cause.
What should happen on the Relay board is LEDs D12, work Current Detected & D11, Pilot Current Detected
should both be off. When you apply START after 2 seconds (Preflow time) D7, Pilot Enable, should come on.
Also D23, RF ON, should come on indicating the Arc Starter is being enabled. Normally D23 would only
be on for a moment until pilot current is detected. Then D11 would be on (and D23 off) until arc transfer or
pilot timeout (15 sec.) Since a pilot has not been detected D11 should not come on.
3. If the work current sensor is defective it could be telling the relay board (and thus the CCM) that there is
already a transferred arc so no need for pilot. D12, a green LED on the Relay board, is on if work current is
detected. If D12 is not on skip to step 5, otherwise disconnect J1, the work sensor connector. If D12 is still
on the Relay board is defective.
4. If D12 goes out when J1 is disconnected, plug it back in and measure voltage from TP1 (common) to J1-1,
should be positive 12-15VDC. Now measure J1-2, should be negative 12-15VDC. Now measure J1-3, should
be 0 +/- 0.05V. If any of these are wrong disconnect J1 and measure again (on the relay board, not the har-
ness). If still wrong the relay board is defective. Otherwise it’s the work sensor.
5. Pilot Enable signal comes from the CCM on pin 15 of the 40 pin ribbon cable between the Relay board (J4)
and the CCM (J23). It should be low, less than 2V relative to TP1 on either the CCM I/O board or the Relay
board. You can also measure this on TP11 of the I/O board. If the signal does not go low when the pilot
should be enabled at the end of preflow time then the CCM is probably defective. You can also jumper
TP11 on the CCM I/O board to TP1, also on the I/O, to see if that will light D7, the Pilot Enable LED, on the
Relay board. If it does, that further confirms the CCM is bad. If jumping TP11 to TP1 does not light D7 on
the Relay board, the problem is likely the Relay board or possibly the ribbon cable.

103 Lost Pilot

Code 103 occurs when Pilot has ignited as sensed by the pilot current sensor on the Pilot board , but went out
on its own while CNC Start is still active before the pilot timeout (85 ms. or 3 sec.).
Possible causes:
• Preflow gas pressure too high, for manual gas controls check cut charts for proper setting. For DFC 3000
check that the process is correct for the consumables.
• Cutting current set too low for the torch parts being used. Pilot current level is automatically set based on
the cutting current. A low cutting current results in a lower pilot current that may not be able to sustain
a pilot for higher current torch parts.
• Remote Analog Current Control switches set wrong can also result in lower than normal pilot current
setting. See section on these switch settings under next section for code 104.
• Broken torch pilot wire.
• Defective Inverter module puts out less current than it’s set for.

Manual 0-5290 APPENDIX A-45

AUTO-CUT 300 XT
104 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.
• Torch standoff too high for cutting process being used.
• Plasma gas flow too low due to a leak somewhere between the plasma regulator or the DPC 3000 and the
torch. Check for leaks.
• Remote analog current control switches set wrong.
o If remote analog current control is being used, SW8-2 (CCM CPU PCB) is on and SW11 (CCM I/O
PCB) is set to “A” (down) position, but no analog voltage connected to TB1-10 or J15-30 (CNC cable)
then cut demand will be zero, pilot will be weak, depending on torch height it may still transfer but
will immediately go out.
o If remote analog current control is not being used but either SW11 is set to the down position or SW8-2
is on also results in zero cut demand.
o If system is Auto-Cut XT, current control is an analog voltage from the GCM 1000 XT or the AC 200
XT front panel pot. The current control setting will be shown on the front panel 4 digit display. SW8-
2 should be off and SW11 set to up position. With pot at max, check for 3.3V on CCM I/O PCB TP9
(TP1 common). While turning the pot toward minimum TP9 voltage should vary linearly to zero V.

GCM 1000 XT J56 J55 Auto-Cut XT Power Supply

(AC 300 XT) 1 1
2 2 CCM
R1 3 3 J26 +10.0V

10K 4
5
4
5
(125)
16
TP9
(126)
Divide 1 SW11
6 6 (127) 15
7 7 14 0-3.3VDC
8 8 13 by 3. 2
3
9 9 12
10 10 11 TP1 GND
11 11 AC 200 XT 10
12 12 9
13 13 R1 8
GND
From Remote
14
15
14
15
10K 7
6 analog Current
16 16 5 Control GND
4
3
2
1
Art # 12309

105 Not Used. This is one of the reserved codes from the earlier product.

106 Pilot Timeout, no Transfer

Pilot time is limited to either 0.085 seconds (85 ms.) with CCM SW8-1 off (default for pierce starting) or 3 seconds
with SW8-1 on (used for cutting over holes, expanded metal, etc.). Arc must transfer before pilot time ends.
Code 106 is set if no arc transfer (current in work lead) was sensed before pilot timed out. If the unit does not
detect pilot current the arc starter will operate up to 15 seconds then set the 102 code. If you are getting 106 there
is pilot current somewhere. If it’s not visible perhaps it’s inside the consumables or following some other part.
Causes for 106 code:
No Pilot Visible:

• Pilot inside the consumables

Visible Pilot:

• First the obvious, make sure the work lead is connected both to the work and the power supply. Also
make sure the work itself is making good electrical contact with cutting table. If rusty or painted metal,
you may need to clean a spot and attach the work lead directly to the metal.
• Torch too far from work.

A-46 APPENDIX Manual 0-5290

 AUTO-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.
• Preflow pressure/flow too low.
• Remote Analog Current Control switches set wrong can also result in lower than normal pilot current
setting. See section on these switch settings under section for code 104.
• Defective work lead current sensor circuit. If transfer is not sensed cut current remains at the lower start-
ing level and pilot timer (85 ms. or 3 sec) will time out.
107 Not Used. This is one of the reserved codes from the earlier product.

108 Tip to Electrode Voltage Fault

The Pilot voltage, measured between tip and electrode varies with different current and gas type, flow rate and
consumable design.
Once the arc is transferred the pilot switch opens leaving the tip basically floating. The voltage then is deter-
mined by how much of a cold gas barrier surrounds the arc. Too much current or too little gas and the arc
starts to contact the tip reducing the voltage difference between tip and electrode and leading to a double arc
that destroys the consumables.
The CCM measures both electrode and tip voltage and calculates the difference. If the difference between tip
and electrode is found to be less than a minimum voltage we stop cutting and set a fault for the 108 code. The
normal tip to electrode voltage is different for different processes so the min value for each process is embedded
in the cut charts when using the DFC 3000 or in the CCM code if using the GCM 2010 or for Auto-Cut XT gas
controls (GCM 1000XT or the built in one in the AC 200 XT).
New for the Auto-Cut XT units is a switch on the rear of the power supply that needs to be set according to the
plasma gas. If using an oxidizing gas (O2 or Air) set it as indicated for those gasses (left if AC 200 XT or up for
AC300XT) or if using a non-oxidizing gas (N2, H35 or other inert gas) set it to the right or down as indicated for
those gas types.. This switch adjusts the range of voltage for the gas type to better protect the torch. A wrong
setting could result in false setting of the 108 code.
During piloting and ramping (the time from transfer until the current reaches full cut current), we lower the
allowed tip to electrode voltage to about 80% of that allowed during cutting because the current is lower and
the gas flow is lower during that time.
Causes for 108 code:

• Gas Flow/pressure too low for consumable parts being used.

o If gas source pressure is not well regulated it is possible pressure may be OK at times and drop too
low at other times such as during a cut.
o A leak of the preflow/plasma gas after the pressure/flow control (GCM 2010, DPC, GCM 1000 XT)
can reduce the pressure/flow to the torch because some if it is bypassing the torch, while seeming to
have enough pressure/flow at the gas control.
• Cut current set too high for consumable parts being used.
• With DFC 3000 a faulty component would be expected to set a fault code in either the DPC or DMC.
However, if a wrong process is selected which doesn’t match the consumable type or if using a custom
process where pressure has been set too low or current too high that could cause 108 without setting any
faults in the DFC 3000.
• A broken pilot wire in the torch lead making intermittent contact can allow piloting or sometimes the
torch can transfer using only HF (high frequency). This intermittent connection will upset the tip voltage
measurement and can result in the 108 code. Symptom is - it may cut for a short time then fault. Check
for an open/broken torch lead pilot wire.
• Physically shorted torch body between anode (tip) and cathode (electrode).
The fault resulting in a 108 code is measured while cutting. It is more likely a shorted torch body, depending
on the resistance of the short, it will set code 208 (Unwanted Current) as that is measured prior to starting cut
However, it must be considered as a last resort.

Manual 0-5290 APPENDIX A-47

AUTO-CUT 300 XT
109 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. The solution is to load a process. The code will continue to be displayed until the CNC Start is applied at
which time the code will clear.

110 Not Used. This is one of the reserved codes from the earlier product.

Group 2 – Plasma Power Supply codes

General:

LEDS
Several LEDs are used as indicators on the different inverter module boards. RED LEDs indicate faults. Green
LEDs should be on for the most part. Green LEDs are: On the main board, D4-READY; On the Cap Bias Board,
D6, -12V, D11 +12VP (primary referenced), D13, +12V; On the Control board D24, PWM will only be on when
the inverter is enabled and its brightness varies with the duty cycle of the PWM.
Signals:
General description of some Inverter Signals passed to the CCM that can generate fault codes in Group 2.
“Ready” also called AC IN FLT (D4, READY LED, green, on Main Inverter board)
On the inverter main board we measure the input voltage. The 3 phases are rectified and lightly filtered to
achieve an average voltage. Due to the light filtering a missing phase will also lower the average voltage so it
will be detected. Voltage in the correct range turns on the READY LED D4 (on the far left of the main boards,
in the upper part of the “B” section or lower part of the “A” section). Voltage outside the correct range or miss-
ing phase will turn D4 off.
An AC Input Fault by itself (no other faults occurring at the same time) will set codes in the 241-246 group
depending on which inverter sees the problem.
INV FLT (D1, INV FLT LED, red, on the Inverter Control and Fault board)
Several things can cause Inv Flt (Inverter Fault). Inverter fault is indicated by an LED, D1 on the Inverter Con-
trol and Fault board. Inverter Fault, when it occurs, is latched on. The latch is reset next time the inverter is
enabled unless it is still active in which case it is immediately latched again. Inverter Fault will set the codes
247-252 unless it’s in conjunction with another fault in which case that fault code may be set.
Things that can set the inverter fault:
• The local (to the inverter) + 12V & -12V bias supplies out of tolerance. There are LEDs on the Cap/Bias
board that light indicating these bias supplies are present but don’t verify they are in tolerance. It’s not
likely this would happen. More likely that fault related to the +/-12V the supply would be missing and
it’s LED not on.
• Capacitor imbalance. In a cap imbalance condition D3, red Led on the main board (lower left corner of
bottom or “A” section and upper left corner of the upper or “B” section), will latch on.
• Primary over current. This is an over current condition in main switching transformer’s primary. This will
latch on but is cleared when the inverter is enabled unless it is still active in which case it is immediately
latched again.
• Inverter over temperature sets the Fault signal and LED but has its own fault signal to the CCM. See OT
Flt below.
OT FLT (D14, OT FLT, Inverter Control and Fault board)
• Inverter over temperature lights LED D14 on the Inverter Control and Fault board and will latch the fault
signal and it’s LED but also has its own separate fault so that will be reported as a code in the range of
253-258 or 259-264.

A-48 APPENDIX Manual 0-5290

 AUTO-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.
IS_ID (A, B, or C)

VAC_SEL (A or B)

201 Missing AC Phase

The System Bias Supply board contains circuits to detect if one of the 3 AC input phases is missing. Along with
that it can also detect if the AC voltage is too low or too high. Three phase voltage is supplied from the input
terminals through the ON/OFF Switch / circuit breaker CB1 to the System Bias board. The System Bias can
operate on any 2 of the 3 phases to supply control power and fault detection.
I/O PCB
SYSTEM BIAS PCB
J62 J27
1 1 U?
+V
2 Missing Phase a 2 1 4 Missing Phase
3 3
CB1 F1 J60-9,18 4
Missing Phase b
4 To CPU PCB
5 5 2 3 J29-16
3 phase AC J60-5,14 6 6
7 7 HCPL-817
F2 J60-1,10 8 8 GND
9 9
10 10
ON / OFF 11 11
12 12
GND 13 13
14 14

Art # 12310

Normally when the phase is not missing the transistor is on which turns on the opto-isolator making the signal
“Missing Phase” low.
Causes for 201, missing phase code. Codes are displayed two different ways, with an “L” meaning “Latched”
or “Last”, before the number meaning it was a problem but isn’t right now or with an “E” meaning the problem
exists now.

L201 :
Most likely cause is an intermittent problem with the incoming power or possibly a loose connection on the
power cord at the back or the Ultra-Cut or Auto-Cut plasma supply.

E201:

• Phase missing from the wall fuse box, blown fuse.

• F1 or F2, 8A 500V slow blow fuses blown.
• CB1 one phase open.
• System Bias board defective.
• I/O board defective.
Troubleshooting:
1. System Bias board has a red LED, D3, that lights if it detects a missing phase. If D3 is on, check J60 for all 3
phases.
a. If all 3 phases are not present at J60 check for incoming power, then the F1 & F2 fuses. Finally the CB1.
b. If all 3 phases present and about equal voltage then change the System Bias board.
2. If D3, Missing Phase LED, is not on check for voltage at J27-3 & 4 on the CCM. Normal voltage, with no
missing phase, at J27 (or J62 on the System Bias board) pin 3 and pin 4, relative to I/O PCB ground. (TP1)
should be between 10-14VDC with pin 3 being a couple volts higher than pin 4. If this is normal, problem
may be in the CCM.
3. If the voltage at J27-3 & 4 is higher than 10-14VDC and up to 20-24VDC, make the same measurement at
J62 pin 4. If still high there and you have confirmed all 3 phases are present at J60 then the System Bias is
defective.
4. If the voltage at J62-4 is not high the wires between J27 and J62 may be broken.

Manual 0-5290 APPENDIX A-49

AUTO-CUT 300 XT
202-204 Not used. Reserved codes from the earlier product.

205 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 sec-
tions of IM#1 are enabled and CCM measures the power supply output voltage between negative (Torch) to
positive (Work) at the output terminals. If this is less than a set value during preflow or if at any time during
piloting or cutting it drops to below that value for a short time, the inverters are shut off and code 205 is set.
205 will almost always be indicated as an “L”, not an “E” fault because as soon as it’s detected the inverters
are shut off and so no longer have the fault of low output voltage. Currently the low voltage value is -60VDC.
Causes of 205 code can include shorts outside the plasma power supply, shorts inside the plasma power supply
and measurement errors.
a. Short external to the plasma power supply:

• The negative lead goes from the rear of the power supply to the remote arc starter or to the GCM 1000
XT in the case of the AC 3000 XT.
o Cable pinched in or exiting the power track
o Short inside the Arc Starter such as a wire coming loose and grounding to the chassis.
o Short inside the torch mounting tube.
• Trouble shoot for external negative lead shorts by removing the lead from the rear of the power supply
and try to start. It won’t start but if you get the same 205 code the problem is inside the unit.
b. Short inside the supply:

• All the inverters outputs except that of IM1A are in parallel. If any inverter’s output is shorted it will
appear as a short across the power supply output.
Troubleshoot by removing all (or one at a time) of the inverter output connectors except those on IM1A.
Then apply Start to the unit. If it starts now one of the other inverters had shorted output. To find
the defective one reconnect one at a time until the fault reappears.
206 Not used. Reserved codes from the earlier product.

207 Unexpected Current in the Work Lead.

HCT1, a Hall Effect current sensor on the positive (work buss bar) measures the work lead current. Inverter
section 1A is enabled during preflow time but there should be no current in the work lead before the pilot is
ignited and before the arc is transferred to the work. If current greater than 8A is detected before or during
preflow something is wrong.
1. 207 code before START applied:

• Defective work current sensor, HCT1.

• Defective Relay PCB
• Defective CCM
Defective Sensor

• The work current sensor, HCT1, receives power, +15VDC and -15VDC from the Relay PCB. Both must
be present for the sensor to work properly. Measure between Relay PCB TP1 (or J1-4) to J1-1 for +15VDC
and to J1-2 for -15VDC.
• If either + or – 15VDC not present remove the J1 connector and repeat the measurement at J1-1 & 2 on the
Relay board. If the voltage is now present the sensor is defective or shorted (the harness may be shorted).
If voltages still not present, the Relay board is defective.

A-50 APPENDIX Manual 0-5290

 AUTO-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. If greater than +/- 0.04VDC with no work lead current, the sensor is defective. If the
signal voltage is within the limits and D12 is on, then the Relay board is defective.
• If D12 is not on and the 207 code is still active, either the Relay board or the CCM is defective.
CCM or ribbon cable

• The work current signal leaving the relay board is on the 40 pin ribbon cable (Relay J4 to CCM J23) pins
27 (-) & 28 (+). If the voltage here exceeds 0.1VDC with no work current the Relay board is likely defec-
tive. Another possibility is in the 40 pin ribbon cable either pin 27 or 28 is shorted to an adjacent pin.
Otherwise the CCM is defective.
2. 207 code after START applied (during preflow):

• Short between power supply negative output and Work circuit.

• Short between power supply negative output and earth ground.
• Defective or incorrectly installed user supplied equipment such as torch height controls that make con-
nections to power supply output.
Shorts are more likely to cause DC output voltage low (code 205). However, if the short has enough resistance
it is possible to show code 207. To test, remove negative output cable and reapply Start. If 207 code does not
appear problem is a short somewhere outside the power supply.

User Installed Equipment

For user installed equipment to cause 207 code it would have to be connected on the output (to the rear) of the
current sensors. To test, disconnect user equipment and apply CNC START. If code 207 is gone user equipment
was defective or connected incorrectly.

208 Unexpected current in Pilot Circuit

The Pilot board includes a current sensor to measure the pilot current. There should not be any pilot current
until the inverters and the pilot board are enabled and the arc starter has fired to ignite the pilot. Pilot current
or the signal indicating pilot current should not be present until the arc starter has fired.
Unwanted current signal due to defective sensor or defective circuit boards will most likely be present as soon
as the power up sequence completes and will be indicated as an active fault, E208. An actual short allowing
real current to flow in the pilot circuit will not occur until the inverter and pilot board are enabled near the end
of preflow. This will result in the inverters immediately being shut off and displaying a “last” or “latched”
fault, L208. An LED, D2, on the Pilot board lights when the Pilot Board is enabled.
1. 208 code before START applied:

• Defective Pilot board (current sensor circuit).

• Defective Relay PCB
• Defective CCM
Pilot PCB
Pilot current signal is on the 10 pin ribbon cable (Pilot J42, Relay PCB J3) between pins 8 (-) and 9 (+). With no
current, the signal should be zero +/- 0.05 V. Also the Relay board has an LED, D11, “Pilot Current Detected”,
which will light if the pilot current signal exceeds 0.15V. If the signal is not zero V.Pilot PCB is likely the cause.
To be sure, disconnect the Pilot board ribbon cable from the Relay board at J3. If D11 goes out, the Pilot board
was the cause. Double check by measuring pin 8 & 9 again. If it’s zero V. now, the Pilot board is defective. If
D11 is still on or pin 8 & 9 voltage still high check the Relay board.

Manual 0-5290 APPENDIX A-51

AUTO-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. If voltage is zero then the CCM is defective.
2. 208 code comes on during preflow:
IM#1 and the Pilot board are enabled near the end of preflow. To have unwanted current there must be a path
(short) for current to flow between the inverter negative output (negative cable/torch electrode) and the Pilot
return/tip before the arc starter is enabled for pilot ignition.
Possible causes are:

• Short between electrode and tip due to mismatch of consumables, damaged consumables or foreign mat-
ter between tip and electrode. An electrode at the end of its life may lose material that can short between
electrode and tip.
• Defective or incorrectly installed user supplied equipment such as torch height controls that make con-
nections to power supply output.
• Short between power supply negative output cable and pilot cable.
• Shorted torch body.
Troubleshooting:
1. Remove and insulate (may have voltage on it) the pilot cable from the rear of the unit. Attempt to pilot. If
no 208 code shows, it confirms problem is outside the power supply.
2. Remove and check consumable for damage, cleanliness and missing (gas dist, etc.) or wrong components.
3. Disconnect user supplied equipment and see if fault still exists.
4. Inspect Arc Starter for broken/disconnected wires or burnt components.
5. Inspect inside the torch mounting tube for shorts.
6. If all else fails disconnect the pilot wire from the back of the torch head. Insulate it well or keep it away from
any metal, it may have HF (high frequency) on it when you try to start. Try to start, if the 208 is gone now
the torch head is shorted.

209 Not used. Reserved codes from the earlier product.

210–211 Output current, measured by the work lead current sensor, is too high (210) or too low (211).
These are warnings and do not shut down the process but may explain poor cut quality or poor parts life.
Individual inverter sections have their own current sensors and the work lead has a current sensor whose
signal should equal the sum of the individual inverter sections. Each section is set to output a certain current
based on its ”demand” signal. If the current differs from the total “demand”, sum of the individual demands,
the individual sections are checked to determine if their output is correct compared with their demand signals.
If the individual sections are correct but the work current sensor signal differs from the total demand by more
than 16% code 210 (too high) or 211 (too low) is displayed.
If an individual inverter section was found to be in error causing the total current to be wrong, a different code
would be displayed in the range of 212 to 223 depending on which section was at fault.
Possible causes for work current signal too high:

• HCT1 Work Current Sensor

• Relay PCB
• CCM

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 AUTO-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.
o Inverter + output shorted to chassis.
Troubleshooting:
1. For current too low due to a short disconnect work lead from back of unit. Check for continuity to chassis,
there should be none. Inspect for incorrectly connected user equipment.
2. If no shorts were found or if fault was current signal too high see section on code 207 for detailed description
of the power and signal paths for the work lead current sensor.
3. In the section on code 207 for Relay PCB it describes measuring the work current sensor signal when there
is no current. The signal should be zero and we assume it is or else you should have gotten the 207 code. If
the zero current signal is correct but there is an error while cutting, measure the signal on the 40pin ribbon
cable (Relay board J4 to CCM J23) pins 27 (-) & 28 (+). The signal voltage should equal the cutting current
* 0.0266. For example for 100A (100*0.0266) =2.66V.

• If this signal is correct the fault is the CCM

• If it’s not correct the error may be in the Relay board or sensor. Follow the instructions for code 207 to
measure the voltage to and signal from the current sensor at J1 on the Relay board. The signal voltage
should equal the cutting current * 0.0133. For example for 100A (100*0.0133) =1.33V. For 400A would be
400*0.013 3= 5.33V.
• If power and signal are correct Relay board is faulty. If not correct the HCT1 work current sensor is bad.
212-223 Incorrect output from an inverter section.
Work current high or low due to wrong output from one inverter section. Individual code indicates which section.
Causes may be:

• The named inverter section output connector, J102 A or B, is not plugged in or is damaged.
• Ribbon cable with bad connection, perhaps not fully locked in place at either the inverter or the CCM.
• Defective inverter section.
Troubleshooting:
1. If it reports the current of an individual inverter section is too high, the problem is the inverter.
2. If the report is current too low (which included no current) check the connections.
3. The ribbon cable for the first inverter section (IM#1A) must connect to that section only but if there are 2
additional sections, unit is 200A or greater, swap the ribbon cable going into those sections.
a. If it now reports a different section as bad, the one whose cable was moved, then the original section was
bad.
b. If it still reports the original section the ribbon cable or the CCM is bad (unlikely).
c. Swap both ends of the ribbon cable with one next to it. If still reports the original section then the problem
is with the CCM if not then it’s the ribbon cable.
4. If it’s the first inverter section or it’s a 100A unit so there’s no other inverter to swap cables with, replace the
inverter.
Additional hint: Inverter control PCBs have a green LED, D24, PWM ON, that lights when that section is enabled
and has a demand signal. The LED brightness is relative to the output so may be very dim if output is low. If
that LED doesn’t light may indicate a defective inverter (control board).

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AUTO-CUT 300 XT
224 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.
Causes & troubleshooting:

• As this is just a continuity test it is very unlikely to be a bad inverter. Most likely a poor connection or
defective ribbon cable.
o Check ribbon cable connections at both ends of INV1A to CCM J31 (1A) cable. Make sure it is plugged
into J31, the top connector, on the CCM.
o Plug a different inverter cable into J31, doesn’t matter which one for this test as long as it’s plugged
into an inverter on the other end. If still gives 224, “Inverter 1 not found” fault, it’s a bad CCM. Oth-
erwise it’s the ribbon cable.
225-230 Inverter Revision and CCM incompatible.
If sometime in the future we should make a change to the inverter making it incompatible with older CCM we
have included a hardware key that would change to indicate this. During the power up sequence, before power
is connected to the inverters, the CCM does a continuity test to determine what is the hardware key configura-
tion. The key uses 3 lines of the CCM to inverter ribbon cable which are named IS_ID_A, IS_ID_B, IS_ID_C (on
pins 12, 13 & 14) and checks for continuity to a 4th line OUTCOM (pin 9). The test consists of applying voltage
to OUTCOM and looking for that voltage coming back on the 3 ID pins. The present configuration has all 3
lines connected to OUTCOM so all 3 should be high.
To get the 225-230 code now when we don’t have any incompatible revisions would most likely be a bad con-
nection in the ribbon cable between the CCM and the inverter or a defective CCM (unlikely).

• On the inverter section swap the ribbon cable with that of a different inverter section. If fault remains
unchanged, still calls out the original inverter section, the problem is with either ribbon cable or CCM.
• On the inverter end put the ribbon cables back in their original positions. Now swap suspect ribbon
cable with another one on the CCM. If the fault now moves to a different section it’s the ribbon cable. If
it remains with the original section the problem is the CCM.
231-236 Inverter VAC Mismatch.
Different inverter modules are manufactured for 480VAC, 380-415VAC & 208-230VAC operation voltages.
There is a key, called inverter ID, read through the inverter’s ribbon cable, to identify which voltage range
the inverter is designed for. The unit itself is wired differently for the different input voltages and part of that
includes a jumper at J61 on the System Bias board that indicates to the System Bias board what voltage the unit
is wired to accept.
At power on, the System Bias board measures the incoming voltage, determines what input voltage range it
fall into and sends that range information to the CCM. Before Appling power to the inverters by turning on
the input contactors, the CCM checks that each connected inverter is of the correct voltage matching that of the
System Bias board. The inverter ID’s are read from the lowest section to the highest so in all cases if it truly
is a wrong voltage inverter it should call out the A section whose code is read first. A VAC mismatch of a B
section is likely another problem.
Possible causes:

• Wrong voltage inverter (very unlikely but easy to check).

• System Bias board wrong J61 jumper (unlikely but easy to check)
• Defective inverter.
• Ribbon Cable
• CCM
• System Bias board defective.

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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.
a. For the jumper Wire #48 should be connected from J61-1 to:
i. J61-2 for 208-230 VAC
ii. J61-3 for 400 VAC
iii. J61-4 for 480 VAC
Check for proper connection and continuity.
b. System Bias may be defective reporting the wrong voltage ID. On the output of the System Bias board
at J62 measure relative to TP1 or ( J62-8, 24VDC_RET) to J62-12 for signal /VAC_IDAb and J62-14 for
signal /VAC_IDBb. The 2 signals should read according to this table. “0” = 10-12V; “1” = 24V.

signal 230V 400V 480V ERR

/VAC_IDAb 0 1 0 1
/VAC_IDBb 0 0 1 1

2. Defective inverter, ribbon cable or CCM.

a. On the inverter section swap the ribbon cable of the inverter section whose fault was indicated with that
of a different inverter section. If fault remains unchanged, still calls out the original inverter section, the
problem is with either ribbon cable or CCM. If fault changes to the different section, the one the ribbon
cable was swapped with, then it’s the inverter that’s defective.
b. If the fault remained unchanged in Step A, on the inverter end, put the ribbon cables back in their original
positions. Now swap suspect ribbon cable with another one on the CCM. If the fault now moves to a
different section it’s the ribbon cable. If it remains with the original section the problem is the CCM.

237 Too Few Inverters Found

There must be a minimum of 2 inverter sections present to operate. We know the ribbon cable for inverter sec-
tion 1A is connected or else we would have code 224. During the power up sequence, before power is connected
to the inverters, the CCM does a continuity test through the ribbon cable to see if an inverter is connected. If it
doesn’t see continuity with at least one other inverter it assumes none are connected.
Possible causes:

• Ribbon cable disconnected or defective.

• Inverter defective
• CCM defective.
Troubleshooting:
1. Check that all cables are connected, latches locked down, at both the inverter and CCM ends.
2. If this fault occurs it’s most likely on a 100A unit which only has one section (1B) in addition to the 1A sec-
tion. If there were 2 or more additional sections it’s extremely unlikely all ribbon cables or CCM connectors
would be defective.
a. Swap the ribbon cables of the inverter section 1A and 1B. If fault remains unchanged, still 237, problem
is with either ribbon cable or the CCM. If fault changes from 237 to 224 indicating inverter 1A missing,
then it’s the inverter that’s defective.
b. If the fault remained unchanged in step a., on the inverter end put the ribbon cables back in their original
positions. Now swap suspect ribbon cables on the CCM. If the fault now changes it’s the ribbon cable.
If it remains the same it is the CCM.
c. If there are 2 or more ribbon cables in addition to the one on section 1A then CCM is seeing none of them
connected which indicates the CCM is faulty.
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238 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.
Possible causes:

• Unit is connected to voltage below the 208-230V range or above the 480V range. (unlikely unless there
is a problem with the incoming voltage.)
• Defective System Bias board
• Bad connection between System Bias output J62 and CCM input J27 on the I/O board.
• Defective CCM
Troubleshooting:
1. Measure all 3 phases of the input voltage and confirm they are within the tolerance specified in the unit
manual.
2. Refer to section 231-236 Inverter VAC Mismatch and perform troubleshooting in step 1.b. If the 2 signals
don’t match the incoming voltage, if both are high, then the System Bias is defective.
3. If step 2 was OK make the same measurement at J27 on the CCM I/O PCB. If OK here the CCM is defective.
Otherwise inspect the connections at J62 and J27.

239 AC Voltage High

Voltage OK -- At power up the System Bias board measures the input voltage and determined if it is within the
range of voltage set by the J16 jumper. See section 231-236 Inverter VAC Mismatch Troubleshooting step 1.a
for details of the jumper. Normally when the input voltage is OK the System Bias board turns on a relay K1
on the left die of the board to apply power to the T1 Auxiliary transformer. D44, a green “Transformer ON”
LED, will light when K1 is energized. T1 provides power to the gas controls and the TSC 3000 as well as the
pumps and fans.
Voltage High -- If the AC voltage is determined to be too high it lights D4, ACV HIGH, a red LED on the System
Bias board, and sets the signal “AC V HIGH b” on J62-6 to a “high” about 24VDC (normal for a “low” here is
10-14VDC). To prevent the possibility of excessive voltage applied to several items (gas controls, pumps, fans
etc.) K1 is opened removing power from T1 and D44 goes off. If it’s more than a momentary glitch the gas
controls and the TSC 3000 (if used) will reset. Communication with the cutting table may be interrupted. With
the DFC 3000 Auto Gas Control and perhaps the cutting table control, the process will have to be reloaded.
D4 is on and the signal “AC V HIGH b” is high only while the voltage is actually high. The signal “AC V HIGH
b” does not latch on.
If the fault is E239 that means it is currently active, that is, currently detected as being too high. If it’s L239 that
means the voltage too high previously but it is not too high now. Applying START will clear the fault unless
it becomes active again.
The voltage that triggers an AC Voltage High fault is above 550V for 480VAC line; above 470V for a 380, 400 or
415V nominal line; above 270V for a 208 or 230VAC line.
Possible causes:

• Incoming voltage is or was too high.

• Bad connection at J62 or J27
• Bad connection at J61 jumper
• System Bias board defective
• CCM defective.

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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).
Usually, if the plasma is at fault the problem will be present all the time.
2. It is unlikely that an open connection on the J61 jumper would result in a 239 fault, more likely to be a Volt-
age Mismatch fault. However, if it’s intermittent at exactly the right time, perhaps not fully plugged in, it
could possibly show up as 239. Check J61.
3. If the incoming voltage is OK and the problem persists it may be the System Bias board, the CCM or the
connection between J62 and J27.
a. If the incoming voltage is OK and D4 is on or signal “AC V HIGH b” on J62-6 is “high” (about 24VDC,
relative to TP1 or J62-8 ) the System Bias board is defective.
b. If D4 is not on and the signal “AC V HIGH b” on J62-6 is “low” (about 10-14VDC, relative to TP1 or
J62-8) then System Bias is OK and problem is in the CCM.
c. If J62-6 is near zero volts there may be bad connection between J62-6 and J27-6 or J62-7 and J27-6.

240 AC Voltage Low

Refer to the first paragraph for code 239 for explanation of what should happen when the input voltage is correct.
Voltage Low -- If the System Bias board determines AC voltage is too low it lights a red LED, D14, ACV LOW,
and sets the signal “AC V LOW b” on J62-10 to a “high”, about 24VDC (normal for a “low” here is 10-14VDC).
Power is not removed from T1 as low voltage won’t damage anything, However, if it’s too low for too long,
some things like contactors, AC solenoids, the gas controls or TSC 3000 may stop working. A low voltage, if it’s
low enough, may also light D3, the red Missing Phase LED. This does not indicate the phase is actually missing.
The voltage that triggers an AC Voltage Low fault is 380V for a 480VAC nominal line; 300V for a 380, 400 or
415VAC nominal line; 175V for a 208 or 230 VAC line.
Possible cause:

• Incoming voltage is now, or was previously, too low.

o Power distribution wires or power cord too small for the load.
o Loose or high resistance connection somewhere in the power distribution or power cord connection.
• Bad connection at J62 on the System Bias board or J27 on the CCM.
• Bad connection at J61 jumper on the System Bias board.
• System Bias board defective.
• CCM defective.
Troubleshooting:
1. If the fault is L240, applying START will clear the fault unless it becomes active again. An occasional problem
may be due to incoming voltage dips or sags (voltage drops lasting from ½ cycle to as much as a minute).
Usually, if the plasma is at fault, the problem will be present all the time. After ruling out everything else
we may have to attach a monitor to the power input to determine if this is the problem.
2. Voltage can be OK when not cutting or cutting at lower currents but at higher current too much voltage may
be lost due to undersize power cord or distribution wires.
a. Measure the voltage while cutting at higher current to determine if the drop is excessive.
b. Verify all power connections are clean and secure.
c. Verify correct wires size for the current draw per the recommendations in our manual as well as the local
electrical codes.
3. It is unlikely that an open connection on the J61 jumper would result in a 240 fault, it is more likely to cause
a Voltage Mismatch fault. However, if it’s intermittent at exactly the right time, perhaps not fully plugged
in, it possibly could show up as 240. Check the jumper at J61.

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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”
(about 24VDC, relative to TP1 or J62-8 ) the System Bias board is defective.
b. If D14 is not on and signal “AC V HIGH b” on J62-10 is “low” (about 10-14VDC, relative to TP1 or J62-8)
then System Bias is OK and problem is in the CCM.
c. If J62-10 is near zero volts there may be a bad connection between J62-10 and J27-10 or J62-7 and J27-7.

241-246 Inverter Section Input Voltage Error.

The System Bias board checks for input voltage high, low or missing a phase from the power coming in from the
power cord. It is unlikely but not impossible that a problem with the incoming power could result in 241-246
codes. The 241-246 codes more likely point to problems with the power into or within a single inverter section
or in the case of missing phase it may be the contactor that supplies up to 3 inverter sections.
Once the input contactors close, applying voltage to the inverters, they test for input too high or too low and
for missing phase. When the input voltage is in the correct range, a green LED, D4, named READY, lights on
the left side of the main inverter board. If D4 is not on, either the input voltage is out of range or the inverter
is defective.
You can still get the 241-246 code with a missing phase with the READY LED on. The LED will be going on
and off rapidly but appears to the eye to be on. In this case you can measure the signal on the ribbon cable.
The signal previously called READY is now called AC_INPUT_FLT. It is a differential signal on pins 1(+) &
2(-) of the inverters 30 pin ribbon cable. If the AC input is correct you should read 5-6V between the pins. If
AC_INPUT_FLT is true voltage on pins 1 & 2 will be less than 2V.
Some of the other faults such as Inverter Fault and Over Temperature also set the AC_INPUT_FLT (not Ready).
However, they will latch on associated LEDs or set different fault codes. In the event of an Input Voltage Fault
the CCM does not remove power from the inverter.
Things that can cause Input Voltage Fault codes:
1. Intermittently having the power drop out on one or more phases for at least 1 ms. a longer term loss would
more likely trigger a different fault. If it’s the incoming power it would be likely not always be the same
inverter.
2. Phase missing or intermittent to a specific inverter the fault would always call out that inverter.
3. Intermittent connections on the fault signal internal to the inverter.

247-252 Inverter Fault

Once the input contactors close applying voltage to the inverters several tests are performed. The Inverter Fault
signal latches on so even if the cause has gone away you can see that there was a fault as indicated by red LED
D1, INV FLT on the inverter Control & Fault PCB. It is reset by applying start signal or cycling power. If the
fault is still present it will come back on.
Things that cause an inverter fault:

• One or more of the local bias supplies (+/-12VDC) failed or out of spec. Green LEDs on Cap Bias board
labeled +12V (D13) & -12V (D6) indicate the supplies are present but not necessarily that they are in toler-
ance.
• Input capacitor voltage imbalance indicated by D3 CAP IMBALANCE LED (red) on left side of main
inverter board. Applies to units with series connected capacitors (380-480V units).
• Too much current in the main transformer (switching transformer) primary, D32, PRI OC LED (red), on
inverter control board.
INV_FLT is a differential signal on pins 3(+) & 4(-) of the inverters 30 pin ribbon cable. If there is not a fault you
should read 5-6V between the two pins. If INV_FLT is true voltage on pins 3 & 4 will be less than 2V.

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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.
Inverters semiconductors (transistors and diodes) are liquid cooled. Anything that increases the coolant tem-
perature too high can cause overheating of the inverters. The inverters magnetics (transformer & inductors)
are air cooled by the same fan(s) that cool(s) the liquid.
Possible causes:

• Cooling fan(s) not operating.

• Disrupted air flow.
• Defective inverter module.
• Inverter Ribbon cable bad connection.
• Defective CCM.
Originally 100 and 200A units had 2 smaller fans while 300 & 400A used a single larger fan along with a larger
radiator. More recently, the single larger fan may be used in the 100 & 200A as well.
Troubleshooting:
1. Confirm that air is exhausting from both the top (top fan)and bottom (bottom fan of units with 2 fans) of the
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. Refer to section for code 403 for troubleshooting
defective fans.

WARNING
! Fan blades can be moving and accidental contact with a mirror or other
inspection devise can cause personal injury or damage to the machine.

2. Leaving the side panels and cover off, especially the left lower side or the top cover will reduce the air flow.
Also if the radiator fins become clogged with dust it will reduce air flow. Clean the radiator periodically by
blowing air into it to clear dirt from the fins.

259-264 Inverter Over Temperature due to high Ambient.

The CCM measures the ambient temperature where the cooling air enters the louvers on the left side of the
front panel. If an inverter goes over temperature and we have determined that the ambient exceeds 40 deg C
we will get one or more of the high ambient codes, 252-264. The sensor, TS2, is a NTC (Negative Temperature
Coefficient) resistor whose resistance varies with temperature. It is mounted on the inside of the front panel
next to the louvers on the left. To access it requires removing one or more of the inverter modules. If the ambi-
ent is high but no inverter is too hot there is no fault.
Possible causes:

• Ambient is too high.

• Cooling fan(s) not operating.
• Disrupted air flow.
• TS2, Ambient temperature sensor, shorted (very unlikely) or otherwise defective.
• Defective Relay board.
• Defective CCM.
• Defective Relay board.

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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. Be careful
not to get the mirror or your hands into the blades. 100 & 200A units have 2 smaller fans, 300 & 400A have
one larger one.
3. It is unlikely these high ambient temperature codes would be set before some other temperature related
code but just in case we’ll note that leaving the side panels and cover off, especially the left lower side or
the top cover will reduce the air flow. Also the radiator fins clogged with dust will reduce air.
4. To test TS2 remove J2 from the Relay board and measure the resistance between pins 4 & 6 of the J2 harness
connector. The resistance varies from about 33K ohms at 0 degrees C to about 12K ohms at 20C to 5.3K
ohms at 40C.
5. If TS2 is within the correct range the problem may be with the Relay board or the CCM.
a. The output from the relay board going to the CCM is on pin 30 of the 40 pin ribbon cable (J4 of Relay
board to J23 of the CCM I/O board). It is an analog voltage that should range between 0.44V at 0 deg
C to 1.6V at 40C. If it is confirmed that the room ambient is not above 40C and Ambient temperature
signal at pin 30 is higher than 1.6V then the Relay board is defective.
b. If Ambient temperature signal at pin 30 is OK, less than 1.6V, and the room ambient is not above 40C
then the CCM is bad.

265-270 Inverter No Input Power

There are several digital signals on the ribbon cables between the inverter sections and the CCM that involve
some level of voltage. These include AC_INPUT_FLT\, INVERTER _FLT\, OVERTEMP_FLT\ and POWER_
PRESENT. Normally all of these should be high. Before power is applied to the inverter modules the CCM
has already performed a continuity check to see if that section is in place and it’s ribbon cable connected (code
224 & 237). As soon as power is applied to the inverter modules the CCM checks these 4 signals and, having
already confirmed there is an inverter whose ribbon cable is connected. If it finds none of the signals have volt-
age, it assumes there is no power into the section or something is wrong with that inverter section’s bias power.
Possible causes:

• The 3 input phases, J103-105 to that inverter section not connected.

• The circuit breaker CB2 providing the 120 VAC to the contactor (and Remote Arc Starter) has tripped.
• The contactor powering that section (and others) defective.
• Relay board defective.
• Inverter defective.
• CCM defective.
Troubleshooting:
1. Check that the input power cables are connected to the inverters.
2. Check if the contactor for that section (W1 for 1A, 1B, 2A; W2 for 2B, 3A, 3B) is energized.
a. There is a rectangular section in the middle of each contactor top that can be used to attach auxiliary con-
tacts. This can also be an indicator of contactor operation as it pulls in when the contactor is energized.
b. Check for CB2 on the rear panel being tripped. The white button marked “5” indicating it’s 5 amps, will
pop out if tripped. Reset it and if it pops out again something (contactor coil?) may be shorted.
c. Measure for 120 VAC on the contactor coil. If present, but the contactor isn’t pulled in, it’s probably a
defective contactor.

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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.
b. If D22 is on but 120 VAC is not present at J8-1 and J8-9 (make sure meter is set for ACV) then the relay
board is defective.
c. D22 is not on, go to the 40 pin ribbon cable test connector and measure voltage on pin 17 (relative to
TP1 on either the Relay board or the CCM I/O Board). It should be low, less than 1 volt. If it is the relay
board is likely bad. If it’s high, about 24VDC then the CCM may be bad, not telling the contactor to turn
on.
4. The inverter section may be defective with a bad bias supply. Swap the inverter end of the ribbon cable
with one next to it.
a. If it now reports a different code, that of the inverter that was swapped with, then the original section
is bad.
b. If it still reports the same section even though the ribbon cable was swapped then the CCM is bad.

271 Inverter ID Reading Fault.

Refer to section for codes 225-230 for a description of the ID signals. If this code appears it means one of these
ID signals has gone false some time after power up.
Possible causes:

• An intermittent ribbon cable or one not fully latched in place.

• EMI interference.
Troubleshooting:
1. First recycle power to see if the fault is still there. It may now show up as one of the 225-230 codes which
will indicate which inverter.
2. Determine when the code shows up. If it is EMI it may not happen every time but if, when it happens, it is
always at the beginning of piloting, it may be EMI interference. Check the system ground cables and if an
AC200XT check the torch shield connection to the unit rear panel.
3. If it happens intermittently during cutting or idling it might be an intermittent ribbon cable. This code does
not say which inverter section so you have to check each ribbon cable for proper connection on each end. It’s
highly unlikely for a ribbon cable to be intermittent but if you have more than 2 sections try disconnecting
one section at a time and cut at lower current. See if you find one that causes the problem and if so replace
that ribbon cable.

Group 3 codes relate to the GAS Controls Status and Communication Protocol
Also refer to GCM 2010 Status Codes at the end of this Group 3 codes section.

301 Gas Control Communication Fault

No signal detected over the fiber-optic link from the gas control. In the case where there are additional devices
other than Gas Control connected to the CANBUS this code would indicate the Gas Control is having commu-
nication problems while the other CANBUS devices are OK. We don’t currently have any other devices on the
CANBUS so it is more likely that code 501 will be what is set. In any case troubleshooting is the same as for 501.
Possible cause:
• Most likely cause is dirty or defective fiber-optic cable or connector.
• Cable to GCM 2010, DMC or DPC not connected or broken.
• Defective control board or power supply in the Gas Control
• Defective CCM

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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. This may show up as a 301 or 501 code. Also if the cable is broken
or defective such that the gas control is not enabled it may have power but in the case of the DMC or DPC
its fault light will blink error 101 while the CCM will only detect that there is no communication and it will
show 301 or possibly 501.

302 Gas Control communications reply fault

Communication has been established but Gas Control did not reply to a request from the CCM in the time al-
lowed. Likely cause is Fiber-optic problems (see code 501) or if problem persists defective Gas Control main PCB.

303 Gas Pressure fault

Gas pressure faults only show up when you try to start the torch, not during purging or setting flows .
With the Auto-Cut 200 XT and the Auto-Cut 300 XT (GCM 1000 XT), the gas pressure sensor is only on the
plasma gas and is in series with Run/Set switch. A 303 code here indicates either plasma gas missing or very
low pressure, less than 50 PSI, or RUN/SET switch is in SET position.
Starting with GCM2010 revision AG we measure inlet pressure of both plasma and shield gas at the inlet of
the gas selection manifold. If pressure is either too low or too high it sets 303 code. Earlier revision should not
display 303 code. GCM2010 will display which gas is the problem and its actual pressure. The pressure at the
point where it is measured should be in the range of 100-135 PSI. Exception is for shield gas if the Gas switch
is set to Pressure then the min pressure can be 85 PSI.
In the GCM 2010 Gas Control, on the main PCB, measure between test points TP1 (ground) and TP18 (shield)
and TP19 (plasma) to measure the output of the pressure sensors. Voltage should be between 2.6V to 3.5V for
100-135 PSI. With shield switch set to pressure low limit is 2.1V. Whichever gas is outside those limits will
be the one causing the fault. Remember the pressure may drop during operation, set the code, then recover
displaying L303 when you are measuring it.

• To test for faulty pressure sensor or inadequate gas supply with too much restriction. On the GCM 2010
place the Mode switch to SET Plasma & Shield, turn the mechanical pressure regulators to max pressure
and compare mechanical gauges with the pressure display. If the pressure display doesn’t approximately
match the gauge the sensor is likely defective. If the gauge and the pressure display both show low pres-
sure the supply to the gas control has too much restriction. Perhaps the hose is too long or too small.
304 Gas Control not ready
This is the normal code when the gas control is conducting a purge at start up or when the process is loaded
or changed or when the plasma system has been disabled and is returned to “Enable”. If it is a GCM 2010 the
Mode switch may not be set to the RUN mode.
Code 304 combined with 204 & 402 when the Plasma Enable on the GCM 2010 gas control is set to disable can
indicate a fault in the CCM I/O PCB. When switching back to Enabled the pump will not restart so continues
to display 4-2 indicating no coolant flowing.
Normally the code during a disable should be 101. Circuits on the I/O PCB detect the Plasma Enable is disabled
and send signal to the microcontroller in the CCM. If a fault in the CCM prevents that signal from getting sent
to the microcontroller it doesn’t know the system is disabled so it sets these other 3 codes.

305 Gas Control Protocol Error

Application error or firmware incompatibility fault. Consult factory for latest firmware update. Possible elec-
tromagnetic interference from the Arc Starter; inspect grounding, bonding, and isolation.

306 Not Used. This is one of the reserved codes from the earlier product.

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307 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.

308 Mismatch between the CCM and gas control type.

The Auto-Cut XT CCM is designed to work with the GCM 1000 (AC 300 XT) or the built in gas control of the AC
200 XT. Attempting to use a GCM 2010 or DFC 3000 Auto Gas Control on an Auto-Cut will result in a 308 code.
Similarly attempting to use a CCM from an Auto-Cut XT in an Ultra-Cut XT supply will also result in a 308 code.

309 Gas Control Communication reply fault.

Relay doesn’t match what was requested. Possible firmware incompatibility. Consult factory for latest firm-
ware update.
Possible electromagnetic interference from the Arc Starter; inspect grounding; bonding; and isolation.

310-313 DFC 3000 Auto Gas Faults.

These different codes displayed on the power simply indicate one of the Auto Gas modules (DPC for codes
310 or 311; DMC for 312 and 313 could be either) is reporting a fault. You need to refer to the specific modules
blinking red LED status indicator and the Status code tables for more information.

GCM 2010 Status Codes

GCM 2000 has an LED on the front panel which blinks various codes.
GCM 2010 has LCD display which displays many of the Status messages. However, there are a few relating to
communications that aren’t clear.
When there is a communication error it will be displayed but once it has recovered the display will show what
the error was by displaying:

^E4 – Low level CAN bus error where the CCM did not acknowledge receiving a message from the Gas Control.
^E5 – Low level CAN bus error where the bus is off.
^E6 – CAN bus communication (the fiber-optic) has timed out.
Group 4 codes relate to the Liquid Cooling System
Cooling system description. System includes a reservoir, a pump, one or more heat exchangers, flow switch,
level switch and flow sensor on some models. Also included are a filter and various fittings and hoses. New
coolant is installed into the reservoir or “tank” from an opening in the unit’s front panel where there is a visual
level indicator. Coolant flows to the pump inlet from the bottom of the tank, is pumped through a pressure
relief or “bypass” valve which limits MAX pressure to 150 PSI bypassing excess flow back into the reservoir.
The coolant temperature sensor, TS1, a linear NTC sensor, is mounted on the bypass valve.
From the bypass valve, in most systems, coolant is plumbed to the rear panel coolant supply fitting where it
goes to the torch via the RAS 1000 XT, the remote arc starter.
Exceptions are the Ultra-Cut 400 XT which has an additional external heat exchanger and the Auto-Cut 200 XT
which has an internal arc starter.
For the Ultra-Cut 400 XT the HE 400 XT external heat exchanger is placed between the plasma power supply
and the RAS 1000 XT with the supply coolant passing through the radiator for extra cooling.
In the Auto-Cut 200 XT coolant goes to the water cooled HF (high frequency) coil and then to the torch supply
lead attached to the internal torch connection bulkhead.
For the coolant return in most systems the return from the Torch goes to the RAS 1000 XT and on to the return
fitting on the rear of the power supply. In the Ultra-Cut 400 XT the return from the RAS1000XT first passes
through the HE 400 XT then to the rear panel of the power supply. For the Auto-Cut 200 XT the coolant returns
from the torch to the torch bulkhead inside the unit.
Coolant returning from the torch is routed through the rear panel filter then through the radiator (internal heat
exchanger) and through the flow switch. Ultra-Cut models also have a flow sensor in series with the flow switch

Manual 0-5290 APPENDIX A-63

AUTO-CUT 300 XT
that can detect bubbles in the coolant. Upon leaving the radiator, coolant goes into the bottom inverter “cold
plate” or liquid cooled heat sink. It flows through the inverters in series and returns to the tank.

401 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
during a cut but will instead show the 405 fault as a warning. As soon as the cut stops it will not allow another
to start until the issue is corrected.
Possible causes:

• Coolant is low
• Level switch defective, disconnected or installed upside down.
• Relay board defective or J7 disconnected.
• CCM defective.
Troubleshooting:
1. Confirm visually that the level switch float is below the coolant, if not add more coolant to the tank.
2. Check J7 on the Relay board.
a. If properly connected remove J7 and check continuity between pins 2 and 4 (pins 2 & 3 of J71 on the
switch itself).
b. If no continuity at J71 on the switch, if it is still open, replace the switch.
3. If there was continuity at J7 plug it back in and measure voltage on pin 9 of the 40 pin ribbon cable (Relay
board J4 to CCM J23). Common is TP1 on either the Relay or the I/O board.
a. Pin 9 should be high, about +10 to +15V. If it’s not the relay board is bad or the ribbon cable is shorted.
b. To test the ribbon cable remove both ends, J4 on the Relay board and J23 on the I/O board and measure
from pin 9 of the ribbon cable to both pin 8 and pin 10 of the cable. Both should be open. If not replace
the ribbon cable. Otherwise it’s the Relay board.
4. If pin 9 of the 40 pin ribbon cable was high in step 3.a the CCM is defective.

402 Low coolant Flow

The flow switch FS1 is positioned in series with the radiator where it measures the flow returning from the
torch. The flow switch serves two purposes, one to insure there is adequate flow for cooling needs and two,
it insures the torch consumables are in place so the negative output of the power supply is not exposed. This
function is called “Parts in Place” or PIP. The output cannot be enabled if parts are not in place. The normally
open flow switch requires 0.7 GPM (2.65 liter/min.) +/- about 10% to close.
When the system is turned on and enabled and fails to achieve proper coolant flow after 4 minutes code 404
will be set. Getting code 402 means it initially had enough flow but something has caused the flow to be re-
duced. Listed here are things that might happen during cutting to cause reduced flow. For other causes like
component failures refer to code 404.
Possible causes for low flow:

• Coolant filter clogged.

• Flow bypass valve incorrect adjustment or defective. Call the factory for instructions.
• Defective pump.
• Coolant supply or return hose twisted or pinched reducing flow.
If coolant flow is not low but code is being set, possible causes:

• Flow switch disconnected or defective.

• Relay PCB.
• CCM.

A-64 APPENDIX Manual 0-5290

 AUTO-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. It also means you should be able to measure the flow to determine if it is really low or the sensor has
a problem.
2. First recycle power. If flow is still low or a component is defective the code should change to 404. Go to
that section for further troubleshooting.
3. If after recycling power there is no code, continue cutting to see if it occurs again. Take note of when it oc-
curs, for example if it’s with the torch at one end of the table, perhaps the leads get pinched there? In any
case go to code 404 section for more information.

403 Coolant overheated.

TS1 is a linear negative temperature coefficient (NTC) resistor sensor attached to the brass fitting at the exit of
the bypass valve. Here we determine the coolant being supplied to the torch is below the required temperature
which is currently 75 deg C (167F). The radiator is on the lower right side of the unit. The fan(s) are behind it
and blow out through the radiator. 100A & 200A units may either have 2 smaller fans or one larger one. The
300 & 400A units have one larger one.
Fans operate during cutting and for 4 minutes after last cut then shut off. Exception is AC 200 XT where the
fans are on whenever power is on. The external heat exchanger, HE400, fan is thermostatically controlled so it
only comes on when coolant is over 60 deg C. It will shut off when the other fans shut off.
Possible reasons for coolant overheated:
Coolant fan(s) failed or defective fan control relay MC2.

• Radiator fins clogged with dirt.

• Duty cycle exceeded (ambient temperature above 40 deg C and operating at high duty cycle).
• Operating with an object placed in close proximity to the air outlet (right side of the unit) or the front
panel inlet openings.
• Operating for extended time with right lower side panel removed.
• Defective Relay board.
• Defective CCM.
Troubleshooting:
1. Check for air blowing out of the unit. Remember, except for the AC 200 XT, the fans only run when CNC
START is applied and for 4 minutes after cutting, you may have to apply start again to restart the 4 minute
time. Fans may be forced on by jumping TP2 on the CCM I/O board to TP1 (ground).
a. If using the external HE400XT heat exchanger, optional for 300A, standard for 400A, check for air blow-
ing out of it. Note that the HE400XT fan, controlled by a thermal switch in the HE400XT, only runs if
the coolant is over 60 deg C and the internal fans are operating. With the 100 & 200A if it has 2 fans
make sure both fans are operating by checking for air both top and bottom of the opening. The fans are
difficult to see, perhaps you can use an inspection mirror. Be careful not to get the mirror or your hands
into the blades.

Manual 0-5290 APPENDIX A-65

AUTO-CUT 300 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).

CCM I/O PCB 230 VAC from T1 To J70-3

To test fan relay jump TP2 to TP1. J13

4
3
2
1
TP2 TP1 R BK
MC2A J72 C4 FAN1
(65A) (69) 1
BN
(70) 2 BL
3
Relay PCB J8 MC2B R
J4-19 1 (64A)
24 VAC J73
2
3 (69) 1
4
(70) 2
5 (161) 3
+24 K4 6
1 7 MC2
2 8 SA3 Fan Control (70)
D24 9
To J70-2
4 10
11
3 12
5 13
CHASSIS GND
14
15 ARC_SUPPRESSOR
Fan Bias Control
16
(160)
Art # 12311

3. Check for 230 VAC at either of the fan connectors, J72 & J73. It may also be measured at the rear panel con-
nector J70 for the HE400XT fan.
a. If the fans are not getting 230 VAC, measure for 24 VAC on the coil of MC2. If present and the relay
contacts aren’t closed the relay is defective. Note, the coil is rectified so you won’t measure continuity
of even a good coil.
b. If 24 VAC is not on the MC2 coil check for D24 on the relay board being ON. If it’s on, the Relay board
should be providing the 24 VAC so if it’s not the Relay board must be defective.
c. If D24 is not on, measure on the CCM I/O board between TP2 and the common at TP1. It should be low,
near zero volts. If not the CCM is probably defective. Jumper TP2 (I/O board) to TP1. If the fans now
come on replace the CCM.
d. If jumping TP2 to TP1 does not turn the fans on then the Relay board or the 40 pin ribbon cable pin 19
is at fault.

404 Coolant System Not Ready

When power is applied to the system with External Plasma Enable satisfied and Plasma Power Supply Enabled
(switch on 2010 or TSC 3000), assuming there is enough coolant in the tank, after some initial tests taking about
15-20 seconds (see manual section 4 for details of the Start-Up Sequence) the pump will start. Coolant will be
pumped through the system. Flow is measured by the FS1 flow switch placed in the torch coolant return path
just before the radiator (see plumbing diagram). If the flow doesn’t reach at least 0.75 GPM (2.8 lpm) within
4 minutes it will set the 404 fault. The reason for the 4 minutes is a new dry system especially one with long
torch leads will take some time before the leads, hoses, radiator and cold plates are full of coolant. More coolant
may have to be added. On a system that has been run before it normally takes only a few seconds to establish
proper flow. In any case the pump will run for 4 minutes before setting the 404 fault.
First determine if the pump motor is running and if so is there any coolant flowing. With the right lower side
panel removed touch the pump and feel for vibration to indicate if the motor is running. Observe the clear
coolant hoses to see if they are full of coolant. There are two hose fittings on the back of the tank. The upper
one is the coolant return. Remove the tank filler cover. You should see a fairly strong stream of coolant from
that fitting. The lower fitting is from the pump bypass valve. If the pump is operating some coolant may be
exiting that fitting as well. If these fittings are below the coolant level you may have to drain out some of the
coolant to see this. If a strong stream is exiting the bypass (lower) fitting but nothing from the upper fitting,
you probably have some kind of blockage.

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 AUTO-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.
• Coolant supply & return leads are reversed, check valve in torch coolant return prevents reverse flow.
• Torch parts removed or are wrong style so torch check valve shuts off flow.
• Torch coolant tube damaged or the tube extension (if required) missing.
• No power to pump motor.
• Pump/motor failure.
• Bypass valve defective or adjusted incorrectly.
Damaged Coolant Tube
Coolant tube includes a check valve at its upper end. When cartridge with consumables is not installed the
spring loaded coolant tube is fully extended closing the check valve preventing coolant from leaking out.
When consumables are in place they push the tube inward, opening the check valve, allowing coolant to flow.
The coolant tube has fingers on the end to contact the inside of the electrode and allow coolant to flow through
the openings between the fingers.
The fingers can be bent over or broken if reasonable care is not taken when the cartridge is not in place. If the
fingers are bent or broken it shortens the tube so the consumables may not push the tube in enough to open
the check valve resulting in no coolant flow. The coolant tube assembly may be replaced separately from the
torch head.
Some consumables use an extension on the coolant tube. A missing extension will not allow the check valve
to open.
Internal Check Valve
Fingers
Coolant Tube Extension

Art # 12312

No Power to the Pump Motor

The pump motor is powered by 230 VAC controlled by the MC3 control relay. During the 4 minutes after turning
on power, before the 404 fault code is displayed, measure for 230 VAC at the motor connector J16 pin 1 to pin 3.
a. If the pump motor is not getting 230 VAC, measure for 24 VAC on the coil of MC3. If present and the relay
contacts aren’t closed the relay is defective. Note, the coil is rectified so you won’t measure continuity of
even a good coil.
b. If 24 VAC is not on the MC3 coil check for D27 on the relay board being ON. If it’s on the Relay board should
be providing the 24 VAC so if it’s not the Relay board may be defective. Measure for 24 VAC at J9-6 to J9-12
on the Relay board. If 24 VAC is present and D27 is on, the Relay board or the wire harness is defective.
c. If D27 is not on, measure on the CCM I/O board between TP3 and the common at TP1. It should be low,
near zero volts. If not the CCM is probably defective. Jumper TP3 (I/O board) to TP1. If the pump comes
on now replace the CCM.

Manual 0-5290 APPENDIX A-67

AUTO-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. J13

4
3
2
1
TP3 TP1
MC3A J16
(66) M1
1
(65B) 2
3

Relay PCB J8
1
MC3B CHASSIS GND Torch Coolant Pump
J4-13 24 VAC
2 (64B) (67)
3
4
5 (162)
+24 K5 6
1 7 MC3
2 8 SA4 Coolant pump Control
D27 9
4 10
11
3 12
5 13
14
15 ARC_SUPPRESSOR
Coolant Pump Control
16
(163) Art # 12313

Coolant flows but flow is less than the required minimum:

Test and adjust the pump/bypass valve:
This test measures the “dead head” or blocked flow pressure at the rear panel coolant supply fitting. Perform
this test only after the coolant system is fully primed, that is after the coolant is circulated throughout the system
and is mostly free of bubbles. It requires a pressure gauge with #6 JIC fitting.
The gauge needs to be able to read at least 173 PSI. Remove the coolant supply hose and connect the pressure
gauge in its place. For the Auto-Cut 200 XT connect the gauge in place of the torch coolant supply hose on the
torch connection bulkhead. This is a #5 JIC fitting.

NOTE!
Do not put the gauge in-line and attempt to pinch off the hose to block the flow. It
is very difficult to totally block the flow and failure to do so will result in incorrect
setting of the bypass.

Turn the on the unit. You will have 4 minutes to perform the test/adjustment before the system times out with
a coolant flow fault. If that happens recycling the power gives you another 4 minutes.
1. The pressure on the gauge should be close to 173 (170-175) PSI. If it is the pump and the bypass are OK.
2. If the pressure is less than 173 PSI adjust the bypass screw clockwise to raise the pressure. If you can
change the pressure with the bypass screw but cannot reach 173 PSI it is likely the pump is worn out or
damaged. If the pressure does not change using the bypass screw it is likely the bypass is defective.
3. If the pressure is above 173 reduce the pressure by adjusting the bypass valve screw counter clockwise.
Coolant flow test:
In addition to the pressure test or in place of it if you don’t have a gauge, determine if the flow returning from
the torch (the flow that passes through the FS1), is greater than the required minimum. With the unit switched
off remove the return hose from the back of the power supply. Place it in a container of a known volume. Turn
the unit on and let the pump run exactly 30 seconds. It should pump at least 3/8 gal. (1.4 l). Use a larger con-
tainer in case the flow is greater and it overflows.
If the flow is lower than 0.75 GPM:

• Look for restrictions such as sharp bends or something pinching the coolant hoses or torch leads.
• Other possibilities are the bypass valve has been adjusted wrong (someone may have turned the adjust-
ment screw) see pressure test/adjustment above
• The pump is worn out (may be the case with an older unit).

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 AUTO-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. This could be disconnected at either end, J74 or J5 on the relay board.
Defective FS1– The flow switch, normally open, closes when flow through it exceeds 0.75 GPM, could be open.
Easiest place to measure the switch is at the J5 harness connector that plugs into the Pilot board. Assuming you
have previously determined flow is sufficient, disconnect J5 from the Pilot board, start the unit so the coolant
is flowing and measure continuity between the 2 pins of J5.

• If there is no continuity either the switch is open or the harness between J5 and J74 at FS1 is open.
• If there is continuity between the J5 pins with sufficient coolant flow then either relay board or the CCM
is faulty.
• Relay board
• CCM
405 Low Coolant Level Warning
If the coolant level becomes low while cutting it is not necessary to immediately stop the cut as there is still
enough coolant to continue so we display E405 as a warning. Once the cut stops if the coolant is still low the
display changes to E401 and prevents starting another cut. Refer to the section for code 401 for troubleshooting.

406 Coolant Flow Low Warning

Ultra-Cut XT units, in addition to a coolant flow switch, include a turbine flow sensor FL1, referred to in the
plumbing diagram as a “bubble sensor”, with a pulse output that accurately measures coolant flow and in ad-
dition can detect the presence of gas bubbles in the coolant. Gas bubbles from leaking seals in the torch or hose
fittings have been proven to reduce consumable life. This code is a warning, it does not prevent cutting but if
it persists the cause should be investigated.

407 Coolant Overheated due to High Ambient

As described in the section for codes 259-264 the CCM measures the ambient temperature using sensor TS2 and,
like with the inverters, if the coolant is over temperature we first check the ambient and if it is above 40 deg C
we attribute the cause of the coolant over temperature to high ambient and of course the solution is to lower
the ambient or reduce the duty cycle.
The other possibility is the ambient measuring circuit is defective and the coolant is overheated. In that case
you would have to go to the section for code 403 to find the cause of the coolant overheating and go to section
for codes 259-264 to determine what is wrong with the TS2 circuit.

The 5 Group relates to CANBUS (Fiber optic) communication errors

501 CANBUS Failure to Acknowledge fault.
The CCM communicates with the gas controls (except GCM 1000 XT) over a fiber-optic cable using the CANBUS
protocol. The CCM is looking for a signal from the gas control (GCM 2010 or DMC) over the fiber-optic link.
No signal has been detected. Communication with the DPC which is relayed through the DMC sets a different
code, 301, if there is a problem with it.
Possible causes:

• Gas control is GCM 1000 XT (Auto-Cut 300XT) which has no fiber-optic, with Basic ID problem.
• CANBUS / Fiber-optic problem to either the GCM 2010 or the DMC (part of DFC 3000).
• Control Cable to DMC or GCM 2010 defective.
• Gas control (DMC or GCM 2010) main PCB blown fuse or defective.
• DMC power supply PCB blown fuse or defective.
• CCM defective.
Manual 0-5290 APPENDIX A-69
AUTO-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. If somewhere this circuit is open, in the Gas Control cable, connector pins, connection from the
rear panel GCM connector, J55, to the CCM (J26) CCM will expect to see a CANBUS connection and report
this error because there is no CANBUS connected.
2. DFC 3000. If the gas control does not have power it will not communicate. Check for power to the gas
control boards.
a. When using Auto Gas (DFC3000) with DMC & DPC if there is no power to the DMC main board, the
green power light on the DMC front panel will not be lighted. The main board receives several voltages
from its separate power supply board. For communication it needs +5VDC. There is a green LED, D17
(first on the left of the row of LEDs.) that lights when the main board has +5V power.
b. The DMC power supply board has several blue LEDs that light when it has power. If none of these are
on check for the control cable being connected or the circuit breaker, CB2, on the plasma supply rear
panel may be tripped in which case there is probably a short somewhere.
c. The DMC power supply which supplies several voltages could be missing one or more and still have
some blue LEDs lighted. Check for voltages.
3. GCM 2010.
4. CANBUS / Fiber-optic communication errors can be difficult to troubleshoot, especially when they are
intermittent. See “Test the Fiber” below. Things to look for are:
a. The connectors not locked in place at either end of the fiber.
b. The fiber is damaged or bent sharply. This should not be the case if the fiber is inside the protective hose
and the hose properly secured in the strain relief but that is not always the case.
c. Dirt on the ends of the fiber or in the receiver/transmitter where the fiber plugs in. Blow out gently with
clean dry air such as is used to clean a camera lens.
d. Excessive electrical interference. While the fiber is immune to EMI it can bother circuits at either end.
Check that all the grounding connections are connected per the manual and are clean and tight. Check
the resistance of the ground rod (with all wires disconnected from it). It may have increased due to dryer
weather conditions. See the instructions in the Plasma Installation manual.
e. Defective receiver/transmitter or other circuits on either CCM or Gas Control main board. Otherwise
replace either (or both) Gas Control main board or CCM.

Transmitter / Receiver Tests. The transmitter/receiver pair on the PCB and the fiber cable looks like this:

Art # 12314

Test the fiber:

Note that the fiber goes from black on one end to blue on the other. Shine a bright light into one end and you
should be able to see light from the other end. This tells you the light is getting through but doesn’t prove it
is strong enough.
The CCM is the communication master. It transmits then expects a reply from the Gas Control Module (GCM).
The GCM does not transmit on its own, only in response to a request from the CCM.

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 AUTO-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.
A few seconds after power is turned on and when the pump has started up the CCM will try to transmit continu-
ously for a while. You can unplug the fiber from the CCM and should see the transmitter red LED on the CCM
PCB blinking. It may stop after a while so recycle power before deciding it isn’t working. If no light, check one
of the other transmitter/receiver pairs. If none of them blink the problem is in the CCM.
If at least one transmitter blinks plug the fiber back into that one then at the Gas Control end of the fiber (un-
plugged) you should see the red light coming out of the blue end.
The Gas Control transmitter does not transmit except in response to a request from the CCM so you will not see
any light from the GCM transmitter with the cable unplugged. However, if you turn the connector 90 deg and
insert the blue end into the receiver (black housing), leaving transmitter open, then the GCM should receive the
requests from the CCM and should blink it’s transmitter (gray housing) in response. If not, problem is likely
on the GCM board assuming it has power.
It is still possible even though you see the red light coming out the GCM end of the fiber that dirt in the transmit-
ter or receiver or on the fiber ends or the fiber is damaged so the light even though visible is not strong enough
for the GCM board. If all else fails replace the fiber cable and both CCM and GCM PCB.
502 CANBUS off due to excessive errors.
See 501 code for troubleshooting CANBUS faults.

503 CANBUS Data Error Warning.

This is a warning, does not shut the system down but is an indication that it probably will shut down soon (502
code). Troubleshooting is same as for 501.

504 Reserved for future use.

Should not get this but if it happens may be due to EMI. Contact customer service.

Group 6 codes relate to the CCM and program updates. One exception is 619 which is a
coolant flow switch FS1 fault.
601-611 Various CCM CPU board internal faults.
For most of these faults try recycling the power but if the problem returns only thing to do is replace the CCM.
Exceptions are:
1. 603 This is one of the reserved codes from the earlier product. Not used so it should never appear, if it does
contact customer service.
2. 607 Processor over temperature could occur if the ambient in the area of the CCM is too high. Try opening
the upper right side panel, perhaps blow some air to cool it off. If that doesn’t help or the ambient was not
too hot to begin with, replace the CCM.
3. 611 Code has various causes most of which require replacing the CCM. However, one possible cause is
the programming jumper on the CPU board (under the Static suppression PCB) has been left in the PROG
position. This is a factory setting used during initial programming and should never be found in the field.
It is NOT used for application code updates However, if someone did move it 611 will be the result.

612 USB port power fault.

USB port supplies +5V to power some USB devices such as the flash drive (thumb drive, memory stick), used for
program updates. A flash drive is the only device currently being used with this USB port. This fault detected
no or low voltage to the port. This could be a shorted flash drive or some other device that draws too much
current exceeding the limits of the USB power supply.
Try another flash drive or if you know this one is OK (it works with a computer), then replace the CCM.

Manual 0-5290 APPENDIX A-71

AUTO-CUT 300 XT
613 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. This may be a problem with the flash drive having too many other files on it or a problem
with its format that may not be compatible with the CCM.
1. Try putting the update files on a different, preferably empty, flash drive.
2. Or save all the flash drive files in another place on your computer, then delete all the files on the flash drive.
Now copy onto the flash drive only the files required for program updates.
3. If the above doesn’t work, making sure you still have copies of the files, format your flash drive which erases
everything on it. Now load only the files required for program update.

614 No USF File

The file VTCCMFW.USF is required on the flash drive along with the program files when performing a program
update. If it’s either missing or corrupted the display will show b614. The “b” indicates the fault is generated
by the Bootloader program rather than the normal application program code. Note that each new revision of
the program files is supplied with a new VTCCMFW.USF. Even though the name is the same it requires the
new version of this file that is supplied with the application code.
1. Install the correct VTCCMFW.USF on the flash drive.
2. If you already have the correct version of VTCCMFW.USF perhaps the flash drive is the problem. Follow
the instructions for code 613.

615-617 No Update File for CCM, DPC or DMC found

Program files for the CCM, DMC & DPC may be updated through the plasma supply’s USB port. The GCM2010
is updated by other means. For a unit with GCM 2010 the CCM may still be updated using the USB. Program
update files are in the format Cx_x_0.S (CCM); Mx_x_0.S (DMC) and Px_x_0.S (DPC).
If the Bootloader finds there are 3 devices, CCM, DMC & DPC on the CANBUS but the flash drive doesn’t have
all 3 update files it will go ahead and update those it has but will show a code indicating that one or more are
missing (615 for CCM; 616 for DMC; 617 for DPC).
Try another flash drive or if you know this one is OK (it works with a computer), then replace the CCM.

This completes the Advanced Troubleshooting information.

A-72 APPENDIX Manual 0-5290

 AUTO-CUT 300 XT
APPENDIX 18: INSTALL REMOTE ARC STARTER
Scope
These instructions cover the RAS-1000 XT Remote Arc Starter installation with the Auto-Cut 300 XT system. Instal-
lation and service of this equipment is restricted to properly trained personnel; unqualified personnel are strictly
cautioned against attempting repairs or adjustments not covered in this manual, at the risk of voiding the Warranty.
Read these instructions thoroughly. A complete understanding of the characteristics and capabilities of this equip-
ment will assure the dependable operation for which it was designed.

General Description
The Remote Arc Starter is for use with Thermal Dynamics Auto-Cut 300 XT systems. Do not use this device with
any other equipment.
The Remote Arc Starter generates a high - frequency pulse to start a pilot arc for a Thermal Dynamics Plasma
Cutting Torch. The Remote Arc Starter includes a liquid cooled coil. The power supply circulates coolant through
the Remote Arc Starter and through the torch. A wire harness connected to the plasma power supply controls the
operation of the Remote Arc Starter.

Site Location
Select a clean, dry location with good ventilation and adequate working space around all components.
Review the safety precautions in the front of this manual to be sure that the location meets all safety requirements.
Interconnecting cables and hoses attach to the Arc Starter. There must be adequate space around the Arc Starter for
these connections without excessive kinking or bending.

Specifications
The following system layout shows the cables and leads needed to set up the RAS with the Auto-Cut 300 XT system.

Remote
Arc Starter Gas Hose G: Torch Lead Set
Adapter - Plasma R - Coolant Supply
I*
F Ground Wire - Coolant Return
Gas Console - Pilot Return
Q
K Control Cable (GCM-1000 XT
Plasma and
Shield Hoses S J*
(2) Gas Hose
A Adapter - Shield
Pilot Return Auto-Cut 300 XT
Negative B Power Supply
I* Plasma Lead to Torch 4’
Coolant Supply C J* Shield Lead to Torch 4’
Coolant Return D
Positioning
Control Cable E Tube
Torch
F1 Ground Wire

Work Cable O Work

Art # A-12869
CNC
CNC Cable P
Controller

Manual 0-5290 APPENDIX A-73

AUTO-CUT 300 XT
Mounting Dimensions

NOTE!
Height not shown is 7.375” ( 187mm ) .

38.10mm 190.50mm
1.50in 7.50in

50.80mm
2.00in

203.20mm
8.00in

50.80mm
2.00in

Art # A-12058
38.10mm
1.50in

A-74 APPENDIX Manual 0-5290

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

NOTE!
A ground wire connects the cover to the Arc Starter base. This wire must remain in place.

2. Remove the Cover Panel from the Arc Starter.

Upper screws (2 per side)

Cover

Ground Wire

Lower screws
(2 per side)

Art # A-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.
Minimum 2

Art # A-12060

Manual 0-5290 APPENDIX A-75

AUTO-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.
Art # A-12061

Supply

Return
Coolant Supply and Return Hoses
(from power supply)

Art # A-12062

Red

Coolant Return (Red)

Green

Coolant Supply (Green)

A-76 APPENDIX Manual 0-5290

 AUTO-CUT 300 XT
2. Refer to illustration. Connect the Pilot wire and Negative cables using a star washer on each.

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

Negative Master, Negative Slave and Pilot Cables (from Power Supply )

Art # A-12064

Control Cable from Power Supply rear panel

Manual 0-5290 APPENDIX A-77

AUTO-CUT 300 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
Red

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.
Upper screws (2 per side)

Cover

Ground Wire

Lower screws
(2 per side)

Art # A-12059

A-78 APPENDIX Manual 0-5290

 AUTO-CUT 300 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. Use a clamp to secure the Torch Lead Shield braid brass ring to the port on the Remote Arc Starter as shown.
Art # A-04759

Torch Leads Shield

Shield Clamp

Coolant and Pilot Leads

to Torch Valve Assembly

Manual 0-5290 APPENDIX A-79

AUTO-CUT 300 XT
Connect Control Cable
1. Connect the Remote Arc Starter cable to the Remote Arc Starter receptacle.

COOLANT
RETURN SUPPLY

J59 To
Arc Starter

Art # A-12870

A-80 APPENDIX Manual 0-5290

 AUTO-CUT 300 XT

This Page Intentionally Blank

Manual 0-5290 APPENDIX A-81

AUTO-CUT 300 XT
APPENDIX 19: PUBLICATION HISTORY
Cover Date Rev Change(s)
April 17, 2013 AA First Release
July 2, 2013 AB Updated section 3 with information about V-D Board installation for height controller
per ECOB2488
Jan. 16, 2014 AC Updated many items, text and art throughout the manual. Added Advanced Trouble
shooting and plumbing diagrams to Appendix per ECOB2552.
Oct. 30, 2014 AD Updated Sect. 6 Leads Category Numbers. ECO-B2664
Insert Sect. 3 ‘Ground rod tester’. ECO-B2676
Update DoC. ECO-B2680
Add Sect. 6 ‘Current transducer’. ECO-B2681

May 27, 2015 AE Returned to Thermal Dynamics trade dress. New Read Me pages and DOC. Added
new safety section. New safety icons throughout. Updated Gas Requirement chart.
Updated art for upper left side showing toroid. Added note to grounding art Sec. 3
and weekly maint. check Sec. 5. Updated spark gap specs Sec. 5. Updated pump and
motor spare parts list in Sec. 6. Added Remote Arc Starter to Appendix. ECOB2713
Jan. 14, 2016 AF Changed the order of TOC and DOC, added Water Spec Section 2.08 pg. 2-5, corrected
spelling mistakes Section 4, corrected part number for items line G “Torch Leads As
sembly” Sec 6.02 pg. 6-2, corrected coolant tank cap catalog number from 9-7305
to 8-5142 pg. 6-4, updated art A-04066 pg. 7-2 (o-ring p/n changed from 9-3027 to
8-0524), corrected CNC Enable/ Disable text pg. A-4, updated Advanced Trouble
shooting text pg. A-63, added Warranty Statement inside rear page. VCR-01537

A-82 APPENDIX Manual 0-5290

 STATEMENT OF WARRANTY
LIMITED WARRANTY: Thermal Dynamics® Corporation (hereinafter “Thermal”) warrants that its products will be free of defects
in workmanship or material. Should any failure to conform to this warranty appear within the time period applicable to the Thermal
products as stated below, Thermal shall, upon notification thereof and substantiation that the product has been stored, installed,
operated, and maintained in accordance with Thermal’s specifications, instructions, recommendations and recognized standard
industry practice, and not subject to misuse, repair, neglect, alteration, or accident, correct such defects by suitable repair or
replacement, at Thermal’s sole option, of any components or parts of the product determined by Thermal to be defective.

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

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

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

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

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

Auto-Cut XT™ and Ultra-Cut XT™ Power Supplies and Components 2 Years 1 Year

Torch And Leads

XTTM300 / XTTM-301 Torch (Excluding Consumable Parts) 1 Year 1 Year

Repair/Replacement Parts 90 Days 90 Days

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

Effective October 23, 2012

THE AMERICAS
Denton, TX USA
U.S. Customer Care
Ph: 1-800-279-2628 (tollfree)
Fax: 1-800-535-0557 (tollfree)
International Customer Care
Ph: 1-940-381-1212
Fax: 1-940-483-8178

Oakville, Ontario, Canada

Canada Customer Care
Ph: 1-905-827-4515
Fax: 1-800-588-1714 (tollfree)

EUROPE
Chorley, United Kingdom
Customer Care
Ph: +44 1257-261755
Fax: +44 1257-224800

Milan, Italy
Customer Care
Ph: +39 0236546801
Fax: +39 0236546840

ASIA/PACIFIC
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Customer Care
Ph: 6221-8990-6095
Fax: 6221-8990-6096

Rawang, Malaysia
Customer Care
Ph: +603 6092-2988
Fax: +603 6092-1085

Melbourne, Australia
Australia Customer Care
Ph: 1300-654-674 (tollfree)
Ph: 61-3-9474-7400
Fax: 61-3-9474-7391
International
Ph: 61-3-9474-7508
Fax: 61-3-9474-7488

Shanghai, China
Sales Office
Ph: +86 21-64072626
Fax: +86 21-64483032
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Sales Office
Ph: +65 6832-8066
Fax: +65 6763-5812

U.S. Customer Care: 866-279-2628 / fax 800-535-0557 • Canada Customer Care: 905-827-4515 / fax 800-588-1714
International Customer Care: 940-381-1212 / fax 940-483-8178

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