FRO­NIUS TransCut 300 User manual

TransCut 300 Operating Instructions
Spare Parts List
/ Battery Charging Systems / Welding Technology / Solar Electronics
Plasma cutting unit
EN
42,0426,0039,EN 002-11042012

ud_fr_st_et_00493 01/2012
EN
Dear Reader
Thank you for choosing Fronius - and congratulations on your new, technically high-
grade Fronius product! This instruction manual will help you get to know your new
machine. Read the manual carefully and you will soon be familiar with all the many
great features of your new Fronius product. This really is the best way to get the most
out of all the advantages that your machine has to offer.
Please also take special note of the safety rules - and observe them! In this way, you
will help to ensure more safety at your product location. And of course, if you treat your
product carefully, this definitely helps to prolong its enduring quality and reliability - things
which are both essential prerequisites for getting outstanding results.
Introduction

1
EN
Safety rules
DANGER!
WARNING!
CAUTION!
„NOTE!“ indicates a risk of flawed results and possible damage to the
equipment.
NOTE!
The device is manufactured using state-of-the-art technology and according
to recognised safety standards. If used incorrectly or misused, however, it
can cause
- injury or death to the operator or a third party,
- damage to the device and other material assets belonging to the opera-
tor,
- inefficient operation of the device.
All persons involved in commissioning, operating, maintaining and servicing
the device must
- be suitably qualified,
- have sufficient knowledge of plasma cutting and
- read and follow these operating instructions carefully.
The operating instructions must always be at hand wherever the device is
being used. In addition to the operating instructions, generally applicable and
local regulations regarding accident prevention and environmental protection
must be made available and observed.
All safety and danger notices on the device
- must be kept in a legible state
- must not be damaged/marked
- must not be removed
- must not be covered, pasted or painted over.
For the location of the safety and danger notices on the device, refer to the
section headed „General remarks“ in the operating instructions for the
device.
General remarks
Important!
„DANGER!“ indicates immediate and real danger. If it is not avoided, death
or serious injury will result.
„WARNING!“ indicates a possibly dangerous situation. Death or serious
injury may result if appropriate precautions are not taken.
„CAUTION!“ indicates a situation where damage or injury could occur. If it
is not avoided, minor injury and/or damage to property may result.
„Important!“ highlights tips for correct operation and other particularly useful
information. It does not indicate a potentially damaging or dangerous situati-
on.
If you see any of the symbols depicted in the „Safety rules“, special care is
required.

2
The device is to be used exclusively for its intended purpose.
The device is designed exclusively for plasma cutting.
Utilisation for any other purpose, or in any other manner, shall be deemed to
be „not in accordance with the intended purpose“. The manufacturer shall
not be liable for any damage resulting from such improper use.
Utilisation in accordance with the „intended purpose“ also comprises
- reading all operating instructions carefully and following them thoroughly
- studying and obeying all safety and danger notices carefully
- performing all stipulated inspection and servicing work.
The device is designed for use in industry and the workshop. The manufac-
turer accepts no responsibility for any damage caused through use in living
quarters.
The manufacturer likewise accepts no liability for inadequate or incorrect
results.
Utilisation in
accordance with
„intended purpo-
se“
Before switching on the device, remove any faults that could compromise
safety.
Your personal safety is at stake!
General remarks
(continued)
Operation and/or storage of the device outside the stipulated area will be
deemed as „not in accordance with the intended purpose.“ The manufacturer
shall not be liable for any damage resulting from such improper use.
Surrounding temperature:
- during operation: -10 °C to + 40 °C (14 °F to 104 °F)
- for transport and storage: - 25 °C to + 55 °C (-13 °F to 131 °F)
Relative humidity:
- up to 50 % at 40 °C (104 °F)
- up to 90 % at 20 °C ( 68 °F)
Keep ambient air free from dust, acids, corrosive gases and substances, etc.
For use at altitudes above sea level: up to 2000 m (6500 ft)
Environmental
conditions
The operator undertakes to allow only such people to work with the device
who:
- are familiar with the fundamental instructions regarding safety and
accident prevention, and have been instructed how to use the device
- have read and understood the „Safety rules“ section and warning notices
in these operating instructions, and then signed them to confirm this
- are trained to produce the required results.
Checks must be carried out at regular intervals to ensure that operators are
working in a safety-conscious manner.
Obligations of
the operator

3
EN
Before using the device, all persons instructed to do so undertake to:
- follow the basic instructions regarding safety at work and accident
prevention
- read the „Safety rules“ section and warning notices in these operating
instructions, and sign them to confirm that they have understood them
and will follow them.
Before leaving the work area, ensure that no-one or nothing can come to any
harm in your absence.
Obligations of
personnel
Protecting
yourself and
others
Anyone involved with plasma cutting exposes themselves to numerous risks
e.g.:
- flying sparks, hot pieces of metal flying around
- arc radiation, which can damage eyes and/or skin
- hazardous electromagnetic fields, which risk the lives of those using
cardiac pacemakers
- risk of electrocution from mains current and cutting current
- greater noise pollution
Anyone working on the workpiece whilst cutting is taking place must wear
suitable protective clothing with the following properties:
- flame-resistant
- insulating and dry
- cover the whole body
- undamaged and in good condition
- trousers with no turn-ups
Protective clothing refers to a variety of different items. Operators should
- protect eyes and face from UV rays, heat and sparks with regulation
protective goggles with side shields.
- wear solid footwear that provides insulation even in wet conditions
- protect the hands with suitable gloves (electrically insulated and providing
protection against heat).
Insulated ear protectors should be worn to reduce the harmful effects of
noise and to prevent injury.
- harmful smoke and gases
Keep all persons, especially children, out of the working area while any
devices are in operation or cutting is in progress. If, however, there are
people in the vicinity,
- make them aware of all the dangers (risk of dazzling by arc, injury from
sparks, inhaling cutting smoke, noise, possible danger from mains or
cutting current, etc),
- provide suitable protective equipment and
- erect suitable safety screens/curtains.

4
Flying sparks may cause fires or explosions.
Never cut close to flammable materials.
Flammable materials must be at least 11 metres (35 ft) away from the arc, or
alternatively covered with a tried-and-tested cover.
A suitable, tested fire extinguisher must be available and ready for use.
Sparks and pieces of hot metal may also get into adjacent areas through
small gaps or openings. Take appropriate precautions to prevent any danger
of injury or fire.
Cutting must not be performed in areas that are subject to fire or explosion or
near sealed tanks, vessels or pipes unless these have been prepared in
accordance with the relevant national and international standards.
Danger from
flying sparks
The smoke produced during cutting contains harmful gases and vapours.
This smoke contains substances which may, under certain circumstances,
cause birth defects or cancer.
Hold your head away from any developing smoke or gases. Developing
smoke and harmful gases should
- not be breathed in
- be sucked out of the working area using appropriate methods.
Make sure the area is well ventilated. Otherwise, a protective mask with air
supply must be worn.
If there is any doubt about whether the extraction system is powerful enough,
then the measured toxic emission values should be compared with the
permissible limit values.
The following components are responsible, amongst other things, for the
smoke’s degree of toxicity:
- metallurgical composition of the workpiece
- coatings
- cleaners, degreasers, solvents etc.
The relevant material safety data sheets and manufacturer’s specifications
for the listed components should therefore be studied carefully.
Flammable vapours (e.g. solvent fumes) should be kept away from the arc’s
radiation area.
Danger from
toxic gases and
vapours
Danger from
mains current
and cutting
current
An electric shock can be fatal. Every electric shock is potentially life threate-
ning. Do not touch live parts either inside or outside the device.
Make sure that you and others are protected with an adequately insulated,
dry temporary backing or cover for the earth or ground potential. This ba-
cking or cover must extend over the entire area between the body and the
earth or ground potential.

5
EN
Danger from
mains current
and cutting
current
(continued)
All cables and leads must be complete, undamaged, insulated and adequate-
ly dimensioned. Loose connections, scorched, damaged or inadequately
dimensioned cables and leads must be repaired/replaced immediately .
Do not sling cables or leads either around the body or parts of the body.
Never immerse the plasma cutting torch in liquids (e.g. for cooling purposes)
Have the mains and device supply checked regularly by a qualified electrici-
an to ensure the PE conductors are functioning properly.
The device must only be operated on a mains supply with a PE conductor
and a socket with an earth contact.
If the device is operated on a mains without a PE conductor and in a socket
without an earth contact, this will be deemed to be gross negligence. The
manufacturer shall not be liable for any damage resulting from such improper
use.
If necessary, provide an adequate earth connection for the workpiece.
Switch off unused devices.
Wear a safety harness if working at great heights.
Before working on the device, switch it off and disconnect it from the mains
supply.
Attach a clearly legible and easy-to-understand warning sign to the device to
prevent anyone from reconnecting it to the mains and switching it on again.
After opening the device:
- discharge all components that are electrically charged
- ensure that all components in the device are de-energised.
If work on live parts cannot be avoided, appoint a second person to switch off
the main switch at the right moment.
It is the operator’s responsibility to ensure that no electromagnetic interfe-
rence occurs in electrical and electronic devices
If electromagnetic interference is detected, the operator is obliged to take
action to rectify the situation.
Check for possible problems, and check and evaluate neighbouring devices’
resistance to interference according to national and international require-
ments:
- safety components
- power, signal and data transfer lines
- computer and telecommunications devices
- measuring and calibrating devices
EMC and EMF
measures

6
Supporting measures for avoidance of EMC problems:
a) Requirements for the mains connection
- if electromagnetic interference arises despite correct mains connection,
additional measures are necessary (e.g. use a suitable line filter).
- High-performance devices can affect the quality of mains voltage through
their current input. For certain types of device, therefore, there may be
special application restrictions or minimum requirements in respect of the
maximum permissible mains impedance (see Technical data). In this
event the plant operator (if appropriate after consultation with the power
supply company) must check whether the connection conditions are
appropriate.
b) Current-carrying cables and leads should be
- keep leads as short as possible
- allow them to run closely together (to avoid EMF problems)
- keep them far from other leads
c) Potential equalisation
d) Earthing the workpiece
- If necessary, establish earth connection using suitable capacitors.
e) Screening, if necessary
- screen off other devices nearby
- Screen off entire cutting installation
Electromagnetic fields may pose as yet unknown risks to health:
- effects on other persons’ health, e.g. those with pacemakers and hearing
aids
- Those with pacemakers must seek advice from their doctor before
approaching the device or any cutting that is in progress
- For safety reasons, keep distances between the cables and the
operator’s head/torso as great as possible
- Do not carry cables or hosepacks over the shoulders or wind them round
any part of the body
EMC and EMF
measures
(continued)
Specific hazar-
dous areas
When there is steam escaping from the cutting torch, this represents a
serious risk of injury (scalding of hands, body, face, eyes, etc.). The cutting
torch should therefore be held away from the body at all times.
Covers and side panels may only be opened/removed while maintenance or repair work
is being carried out.
During operation
- ensure that all covers are closed and all side panels are fitted properly.
- Keep all covers and side panels closed.

7
EN
Never touch the workpiece or tip of the cutting torch during or after cutting -
risk of burns.
Slag can sometimes fly off workpieces as they cool down. The specified
protective equipment must therefore also be worn when reworking workpi-
eces, and steps must be taken to ensure that other people are also adequa-
tely protected.
Cutting torches and other parts with a high operating temperature must be
allowed to cool down before handling.
Use only suitable load-carrying equipment supplied by the manufacturer
when transporting devices by crane.
If the device has a carrying strap or handle, this is intended solely for car-
rying the device by hand. The carrying strap is not to be used if transporting
with a crane, fork-lift or other mechanical hoist.
Power sources that are to be used in rooms/areas with increased electric risk
(e.g. near boilers) must carry the Safety sign. However, the power source
must not be located in such areas.
Specific hazar-
dous areas
(continued)
Cartridge containing cutting medium is under pressure and may burst if
damaged. Protect cartridge from direct sunlight, temperatures above 50°C,
mechanical impact, naked flames, sparks and arcs.
Never use any cutting medium unless it is in good condition and suitable for
the application in question.
A flammable gas/air mixture may develop during use.
Only use in well-ventilated areas, and never inhale an aerosol spray.
If the fluid gets into the eyes, rinse with copious amounts of water and seek
medical attention if necessary. If swallowed, call a doctor immediately and
show him/her the packaging or label.
Do not use force to open the cutting medium cartridge and do not incinerate
it, even when it is empty. Keep the cartridge in a well-ventilated place and out
of the reach of children. Leave the protective cap on the cartridge when
storing it.
Do not dispose of the cartridge with domestic rubbish, and do not allow
cutting medium to enter the waste water/sewage system. Full or part-full
cartridges should only be disposed of as special waste. Only recycle comple-
tely empty and depressurised cartridges.
The manufacturer’s instructions must be observed as well as applicable
national and international regulations. A safety data sheet may be obtained
from your service centre or downloaded from the manufacturer’s website.
Danger from
cutting medium
Special provisions apply in areas at risk of fire or explosion - observe rele-
vant national and international regulations.

8
Only operate the device when all protection devices are fully functional. If the
protection devices are not fully functional, there is a risk of
- injury or death to the operator or a third party,
- damage to the device and other material assets belonging to the operator,
- inefficient operation of the device.
Any safety devices that are not functioning properly must be repaired before
switching on the device.
Never bypass or disable protection devices.
Before switching on the device, ensure that no one is likely to be endange-
red.
- Check the device at least once a week for obvious damage and proper
functioning of safety devices.
- Only use suitable original cutting medium from the manufacturer.
- Always check the cutting medium level before you start cutting.
Safety measures
in normal mode
It is impossible to guarantee that bought-in parts are designed and manufac-
tured to meet the demands made on them, or that they satisfy safety require-
ments. Use only original replacement and wearing parts (also applies to
standard parts).
Do not carry out any modifications, alterations, etc. without the
manufacturer’s consent.
Components that are not in perfect condition must be changed immediately.
When ordering, please give the exact designation and part number as shown
in the spare parts list, as well as the serial number of the device.
Maintenance and
repair
Safety measures
at the installation
location and
during transport
A device that topples over can easily kill someone. Place the device on a
solid, level surface. The maximum permissible slope is 10°.
Special regulations apply in rooms at risk of fire or explosion. Observe
relevant national and international regulations.
Use internal directives and checks to ensure that the workplace environment
is always clean and clearly laid out.
Only set up and operate the device in accordance with the degree of protec-
tion shown on the rating plate.
When setting up the device, ensure there is a gap of 0.5 m (1.6 ft.) all round
so that cooling air can enter and exit unhindered.
When transporting the device, observe the relevant national and local guideli-
nes and accident prevention regulations. This applies especially to guidelines
regarding the risks arising during transportation.
After transporting the device, and before commissioning, you MUST carry out
a visual inspection to check whether it has been damaged in any way. Any
damage must be repaired by trained service personnel before commissio-
ning takes place.

9
EN
Devices with the CE marking satisfy the essential requirements of the low-
voltage and electromagnetic compatibility directive (e.g. relevant product
norms from the EN 60 974 series).
Safety
The operator is obliged to arrange a safety inspection of the device at least
once every 12 months.
The manufacturer recommends that the power source is calibrated during
the same 12 month period.
A safety inspection must be carried out by a qualified electrician
- after any changes are made
- after any additional parts are installed and after any conversions
- after repair, care and maintenance
- at least every twelve months.
For safety inspections, follow the appropriate national and international
standards and directives.
Further details on safety inspection and calibration can be obtained from your
service centre. They will provide you on request with any documents you may
require.
Safety inspection
Copyright of these operating instructions remains with the manufacturer.
Text and illustrations were accurate at the time of printing. We reserve the
right to make amendments. The contents of the operating instructions shall
not provide the basis for any claims whatever on the part of the purchaser.
We are grateful for any suggestions for improvement and for drawing our
attention to any errors in these instructions.
Copyright
Do not dispose of this device with normal domestic waste!
To comply with the European Directive 2002/96/EC on Waste Electrical and
Electronic Equipment and its implementation as national law, electrical
equipment that has reached the end of its life must be collected separately
and returned to an approved recycling facility Any device that you no longer
require must be returned to our agent, or find out about the approved collec-
tion and recycling facilities in your area.
Ignoring this European Directive may have potentially adverse affects on the
environment and your health!
Disposal
Class B devices comply with EMC requirements for industrial areas and
residential areas with a direct power supply from the public low-voltage grid.
Class A devices are not designed for use in residential areas with a direct
power supply from the public low-voltage grid. When Class A devices are
used in such areas, problems may arise in terms of guaranteeing electroma-
gnetic compatibility and with regard to both line-bound and radiated interfe-
rence.
EMC device
classes in accor-
dance with EN/
IEC 60974-10

10

11
EN
General remarks
The TransCut 300 plasma cutting system
is a mobile plasma cutting device with a
fixed plasma cutting torch.
This plasma cutting torch is based on a
system with regenerative cooling which
uses a liquid cutting medium rather than
gas or compressed air.
The cutting medium (TransCut Liquid) is
transferred from the integrated tank to the
cutting torch, where it is converted into
gaseous form. The cutting medium is
poured into practical cartridges that are
easy to refill.
Basic system
principle
Fig. 1 TransCut 300 plasma cutting system
The plasma cutting system is small and compact, but at the same time so robust that it
can function reliably even under hard operating conditions. A powder-coated sheet-metal
housing with protected controls allows the unit to meet the most stringent demands. The
carrying strap facilitates easy transportation, both in-house or on-site.
Device concept
Application areas The TransCut 300 plasma cutting system is particularly well suited for mobile deploy-
ment on construction sites and in installation projects due to its integrated supply of
liquid cutting medium and its compact size. But even when used as stationary units in
workshops or industrial facilities, the machines are powerful and economical alternati-
ves.
- Air conditioning and ventilation systems
- Automotive sheet-metal work / bodywork
- Industrial plant and pipeline construction
- Metal and gantry construction / fitting shops and forges
- Maintenance / repair
- Boiler and container construction
- Assembly companies
The plasma cutting tool operates on the principle of a resonance inverter, offering a
number of advantages:
- Outstanding cutting properties
- Lightness in weight and compactness
- Excellent portability

12
Controls and connections
WARNING! Operating the equipment incorrectly can cause serious injury and
damage. You should not use the functions described until you have thoroughly
read and understood the following documents:
- These operating instructions
- all operating instructions for the system components, especially the
“Safety rules”
n° Function
(1) ‘Standby’ indicator
- flashes on and off whilst the device is in its warm-up and reheating phase
- flashes on and off whilst the cutting torch is in its cool-down phase
- lights steady when the device is ready for use
(2) Cutting current parameter
for selecting the cutting current
(3) Mode button
for selecting the operating mode for different materials
Pulse mode. Recommended for cutting ferrometallic materials
Standard mode. Recommended for cutting aluminium
(4) Fill button
For filling the hosepack and cutting torch with the cutting medium. Must be perfor-
med every time the tank is filled and when the device has not been used for a period
of time.
(5) Torch indicator
- comes on when wear parts of the cutting torch are fitted incorrectly or worn
- comes on when the cutting torch’s protective cap is fitted incorrectly
(6) Fill level indicator
- comes on when most of the cutting medium has been used up. Keep a new
cartridge of cutting medium at the ready, or fill up the tank.
- flashes on and off if the tank is empty
General remarks
Controls
(8)
(7)
(6)
(4)
(1)
(3)
(2)
Fig. 2 Controls
(5)

13
EN
Connections
Fig.3 Connections on the front and rear of the plasma cutting device
n° Function
(8) Spacer
(9) Plasma cutting torch
(10) Fill valve with protective cap
for topping up with cutting medium
(11) Mains switch
(12) Fill level inspection glass
(13) Grounding (earthing) cable
(9) (10) (11)
(13) (12)
(8)
(7) Overtemperature indicator
- comes on when the device is too hot
(8) Error indicator
- comes on if a malfunction occurs
Controls
(continued)

14
Before commissioning
WARNING! Operating the equipment incorrectly can cause serious injury and
damage. You should not use the functions described until you have thoroughly
read and understood the following documents:
- These operating instructions
- All the operating instructions for the system components, especially the
safety regulations
WARNING! A machine that topples over or falls from its stand can easily kill
someone. Place machine on a solid, level surface in such a way that it re-
mains stable.
Setup regulations
Mains connection The device is designed to run at the mains voltage indicated on the rating plate. The
required mains supply fuse protection can be found in the „Technical data“ section.
If there is no network cable or mains plug on your machine, fit a network cable or plug
according to the national standards.
NOTE! Inadequately dimensioned electrical installations can lead to serious
damage. The mains lead, and its fuse protection, must be dimensioned in
accordance with the local power supply. The technical data shown on the rating
plate shall apply.
The device is designed exclusively for plasma cutting.
Utilisation for any other purpose, or in any other manner, shall be deemed to be „not in
accordance with the intended purpose“. The manufacturer shall not be liable for any
damage resulting from such improper use.
Utilisation in accordance with the „intended purpose“ also comprises
- Following all the instructions given in this manual
- Performing all stipulated inspection and servicing work.
The device must only be used in combination with the CTW 300 plasma cutting torches.
Utilisation in
accordance with
„intended purpo-
se“
General remarks
The power source is tested to IP 23S, meaning:
- protection against ingress of solid bodies with diameters greater than 12.5 mm (.49
in.)
- protection against direct sprays of water up to 60° from the vertical
You can therefore set up and operate the device outdoors in accordance with IP 23S. If it
is raining or snowing, however, the machine must not be used. Built-in electrical parts
must be protected from direct wetting.
The device is completely generator-compatible, provided the maximum apparent power
delivered by the generator is at least 8 kVA.
NOTE! The voltage supplied by the generator must never rise above or fall
below the mains voltage tolerance specified in the Technical data chapter.
Generator-
powered operati-
on

15
EN
Commissioning
WARNING! An electric shock can be fatal. If the machine is plugged into the
mains electricity supply during installation, there is a high risk of very serious
injury and damage. Only carry out work on the machine when
- the mains switch is in the „O“ position,
- the machine is unplugged from the mains.
CAUTION! Danger of scalding from escaping steam. Hold the cutting torch so
that it points away from your face and body.
General remarks
1
2
1
Fill the tank and
hosepack
2
1
2
3
1
2
4
2
1
Each time the device is started you should check that there is sufficient cutting medium
in the tank. When filling the tank, make sure that the filling valve is free of dust and other
dirt and that the cutting torch is at the same level as the machine.
NOTE! Danger of damage from leaking cutting medium. If the tank is overfilled,
any superfluous cutting medium will run off via the underside of the device. Any
materials that are sensitive to liquids must not be stored in the immediate
vicinity of the device, and it may be wise not to fill the tank to the brim.
Before starting the cutting process make sure that the device and cutting torch are filled
with cutting medium.

16
WARNING! Operating the equipment incorrectly can cause serious injury and
damage. You should not use the functions described until you have thoroughly
read and understood the following documents:
- These operating instructions
- All the operating instructions for the system components, especially the
safety regulations
Cutting
General remarks
1. Establish an earth connection to the workpiece
Important! Never attach the earth terminal to the area of the workpiece that is to be
cut off.
2. Connect to the mains and turn on the mains switch for the power source
3. Set the required operating mode depending on the material of the workpiece
Pulse mode. Recommended for cutting structural and stainless steels
Standard mode. Recommended for cutting aluminium
4. Adjust the cutting current in accordance with the material strength or the cutting
speed required
Important! Make sure during the cutting operation that the arc always passes
through the workpiece and that any „dross“ that may form is as small as possible. If
this is not the case:
- Reduce cutting speed or
- increase cutting current accordingly
Preparing for
cutting
CAUTION! Danger of injury or damage from escaping steam and hot pieces
of metal being thrown around When you press the torch trigger:
- hold the cutting torch so that it points away from your face and body
- do not point the cutting torch at people