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Victor Auto-Cut 200 XT User Manual

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

Table of Contents

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Victor Auto-Cut 200 XT Specifications

General IconGeneral
BrandVictor
ModelAuto-Cut 200 XT
CategoryWelding System
LanguageEnglish

Summary

General Information and Safety

Notes, Cautions, and Warnings

Explains the use of notes, cautions, and warnings in the manual for emphasis and safety.

Important Safety Precautions

Details hazards like gases, fumes, electric shock, fire, explosion, plasma arc rays, and noise.

Fire and Explosion Hazards

Discusses hazards related to fire and explosion during operation, including combustible materials.

Noise Hazards and Hearing Protection

Addresses the risk of hearing loss from plasma arc processes and necessary protective measures.

Plasma Arc Ray Protection

Explains the dangers of plasma arc rays to eyes and skin and required protective measures.

Referenced Publications

Lists relevant safety and industry standards for further information and compliance.

Declaration of Conformity

States the equipment's compliance with standards and its intended industrial use.

Statement of Warranty

Outlines the limited warranty terms, limitations, and exclusions for the product.

System Specifications

General System Description

Describes the typical components of a plasma cutting system.

Plasma Power Supply

Explains the function of the plasma power supply in the system.

Plasma Cutting Torch

Describes the role of the plasma cutting torch in delivering current.

System Component Layout

Illustrates the connection layout of system components.

Power Supply Electrical Requirements

Provides detailed electrical specifications and requirements for the power supply.

Power Supply Dimensions

Shows physical dimensions and weight of the power supply unit.

Rear Panel Features

Details the various ports and features located on the rear panel of the power supply.

Gas Requirements

Specifies the required quality, pressure, and flow for gases used with the system.

Gas Applications

Outlines recommended gas types for plasma and shield gases across different materials.

XT-301 Torch Specifications

Presents technical data and gas specifications for the XT-301 torch.

Torch Parts Identification and Cooling

Identifies torch parts, explains the part-in-place sensing, and cooling method.

Installation Procedures

Installation Requirements

Details electrical and gas supply requirements for installation.

Cables and Leads Identification

Identifies cables and leads for ground connections and ground cables.

Primary Power Connections

Guides on connecting the primary power and system ground cables to the power supply.

Ground Connections

Details grounding procedures to minimize electromagnetic interference (EMI).

Creating an Earth Ground

Step-by-step guide to creating a proper earth ground connection for the system.

Torch Leads Routing

Provides guidance on routing torch leads to minimize RF interference.

Connect Work Cable

Instructions for connecting the work cable to the power supply.

Connect Gas Supply Lines

Details how to connect gas supply lines to the appropriate ports on the power supply.

Connect CNC Cable

Instructions for connecting the CNC cable to the power supply and CNC device.

Height Control Connections

Explains connections for height control systems to the power supply terminal strip.

Connect Torch Leads to Arc Starter

Guides on connecting the torch leads to the arc starter module.

Torch Head Installation

Step-by-step instructions for installing and connecting the torch head.

Install Consumable Torch Parts

Instructions for selecting and installing consumable torch parts.

Voltage Divider for iHC Torch Height Control

Details the installation of a Voltage Divider board for iHC Torch Height Control.

Fill Cooling System

Instructions for filling the cooling system with the specified coolant.

System Operation

Power Supply Indicators

Explains the function of various indicator lamps and displays on the power supply.

Control Console Features

Overview of the standard system's control console features and their functions.

Optional Water Mist System Controls

Details control console features for systems equipped with a water mist option.

Operating Set-up Procedure

Step-by-step procedure for setting up the system before operation.

Plasma Gas Purge, Amperage, and Gas Settings

Describes plasma gas purge, amperage selection, and gas pressure/flow settings.

System Operation Steps

Detailed steps for operating the plasma cutting system from start-up to end of cut.

Gas Selection Guide

Discusses different plasma and shield gas types and their applications.

Power Supply Status Codes

Lists and explains status codes indicating system conditions or faults.

Cut Quality Factors

Discusses factors influencing cut quality and defines various quality parameters.

Maintenance and Troubleshooting

General Maintenance Schedule

Outlines a schedule for daily, monthly, and bi-annual power supply maintenance.

Coolant Filter Cleaning

Step-by-step instructions for cleaning or replacing the coolant filter.

Coolant Replacement Procedure

Detailed steps for draining, replacing, and refilling the system coolant.

Arc Starter Service Chart

Details symptoms, causes, checks, and remedies for arc starter issues.

Arc Starter Spark Gap Adjustment

Instructions for adjusting the spark gap on the arc starter.

Replacement Power Supply

Provides the catalog number for a complete replacement power supply unit.

Leads and Cables Parts

Lists catalog numbers for various leads and cables based on length.

External Power Supply Parts

Identifies external replacement parts for the power supply unit.

Lower Right Side Power Supply Parts

Lists replacement parts located on the lower right side of the power supply.

Upper Right Side Power Supply Parts

Identifies replacement parts found on the upper right side of the power supply.

Lower Left Side Power Supply Parts

Lists replacement parts located on the lower left side of the power supply.

Upper Left Side Power Supply Parts

Identifies replacement parts found on the upper left side of the power supply.

Rear Panel Power Supply Parts

Lists replacement parts located on the rear panel of the power supply.

Front Power Supply Parts

Identifies replacement parts found on the front panel of the power supply.

Recommended Gas Supply Hose

Specifies the recommended gas supply hose and its catalog number.

Consumable Torch Parts Removal

Instructions for removing consumable parts from the torch cartridge.

O-Ring Lubrication and Parts Wear

Guidance on lubricating O-rings and identifying worn torch parts.

Torch Consumables Installation

Steps for installing torch consumables correctly to ensure performance.

Coolant Leak Troubleshooting

Guides on troubleshooting coolant leaks from the torch head and parts wear.

Appendices: Technical Information

CNC Control Module PCB Connections

Diagrams and pinouts for control PCB connections on the CNC module.

CNC Functions Overview

Explains various CNC input/output functions and their requirements.

Serial Communications Setup

Details wiring and switch settings for RS 485 and RS 422 serial communications.

CCM CPU PCB Layout and Test Points

Provides a layout diagram and lists test points on the CCM CPU PCB.

CCM I/O PCB Layout and Test Points

Presents a layout diagram and lists test points on the CCM I/O PCB.

Pilot PCB Layout and Test Points

Provides a layout diagram and lists test points on the Pilot PCB.

Relay and Interface PCB Layout

Presents a layout diagram and lists test points on the Relay and Interface PCB.

Display PCB Layout and Test Points

Provides a layout diagram and lists test points on the Display PCB.

System Bias PCB Layout and Test Points

Provides a layout diagram and lists test points on the System Bias PCB.

Main Inverter PCB Layouts

Provides layout diagrams and test points for Main Inverter PCBs.

Control and Fault PCB Layout

Provides a layout diagram and lists test points on the Control and Fault PCB.

Cap Bias PCB Layouts

Provides layout diagrams for the Cap Bias Bottom and Top PCBs.

Suppressor PCB Layout

Provides a layout diagram of the Suppressor Printed Circuit Board.

WMS Gas Box Layout

Shows the layout and components of the WMS Gas Box.

Cooling System Diagram

Illustrates the system's liquid cooling circuit diagram.

System Schematic PG 1

Provides the first page of the system schematic diagram.

Advanced Troubleshooting Guide

Covers system overview, inverter details, and troubleshooting for various codes.

Power Supply Status Codes Explained

Lists and explains process-related status codes (101-110) and their causes.

Pilot Ignition and Transfer Faults

Details troubleshooting for pilot ignition failure and transfer issues.

Voltage and Current Faults

Explains faults related to voltage, current, and pilot timeout.

Inverter and System Voltage Faults

Details faults related to inverter status, voltage, and phase issues.

Cooling System Fault Codes

Explains fault codes related to coolant level, flow, overheating, and system readiness.

CANBUS Communication Errors

Explains causes and troubleshooting for CANBUS communication errors.

CCM Board Internal Faults

Lists internal faults for the CCM CPU board and general troubleshooting.

USB and File Update Faults

Explains faults related to USB port issues and program file updates.

Publication History

Provides a history of revisions and changes made to the manual.

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