Plasma Welding
P o wer Supply
U
LTIMA
Service Manual
150
February 9, 2005 Manual No. 0-2503
WARNINGS
Read and understand this entire Operating Manual and your employer’s safety practices before installing, operating, or servicing the equipment.
While the information contained in this operators manual represents our best judgement, Thermal
Dynamics Corporation assumes no liability for its use.
ULTIMA-150 Plasma Welding Power Supply
Service Manual Number 0-2503
Published by:
Thermal Dynamics Corporation
82 Benning Street
W est Lebanon, New Hampshire, USA 03784
(603) 298-5711
www.thermal-dynamics.com
Copyright 1995 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.
Printed in the United States of America
Publication Date: October 4, 2002
Record the following information for W arranty purposes:
Where Purchased:_______________________________
Purchase Date:__________________________________
Power Supply Serial #:___________________________
Torch Serial #:__________________________________
TABLE OF CONTENTS
SECTION 1: GENERAL INFORMATION .................................................................................... 1
1.01 Notes, Cautions and Warnings ...................................................................... 1
1.02 Important Safety Precautions........................................................................ 1
1.03 Publications................................................................................................... 2
1.04 Note, Attention et Avertissement................................................................... 3
1.05 Precautions De Securite Importantes ........................................................... 3
1.06 Documents De Reference............................................................................. 5
1.07 Declaration of Conformity.............................................................................. 6
1.08 Statement of Warranty .................................................................................. 7
SECTION 2: INTRODUCTION .................................................................................................... 9
2.01 Scope of Manual ........................................................................................... 9
2.02 General Service Philosophy .......................................................................... 9
2.03 Service Responsibilities ................................................................................ 9
2.04 ULTIMA-150 Power Supply Description ........................................................ 9
2.05 ULTIMA-150 Power Supply Specifications .................................................... 9
2.06 The ULTIMA-150 System ............................................................................ 10
2.07 Requirements to Complete System ............................................................ 10
2.08 Options, Accessories and Replacement Parts ............................................ 11
SECTION 3: SERVICE TROUBLESHOOTING......................................................................... 13
3.01 Introduction ................................................................................................. 13
3.02 Periodic Inspection...................................................................................... 13
3.03 Troubleshooting Information ........................................................................ 13
3.04 How to Troubleshoot the Ultima-150 Power Supply..................................... 14
3.05 Preparing to Troubleshoot ........................................................................... 14
3.06 Checking Basic Functions........................................................................... 14
3.07 AC Indicator Light Status ............................................................................ 15
3.08 Temperature Indicator Light Status ............................................................. 16
3.09 Gas Indicator Light Status........................................................................... 17
3.10 Coolant Indicator Light Status ..................................................................... 19
3.11 PILOT Indicator Light Status....................................................................... 21
3.12 DC Pilot Indicator Light Status .................................................................... 22
3.13 A/V Display Status ...................................................................................... 23
3.14 Static Test Procedures ................................................................................ 23
TABLE OF CONTENTS (continued)
SECTION 4: REPAIRS & REPLACEMENT............................................................................... 25
4.01 Introduction ................................................................................................. 25
4.02 General Anti-Static Handling Procedures.................................................... 25
4.03 Parts Replacement - General Information................................................... 25
4.04 Opening The ULTIMA-150 Plasma Welding Po wer Supply ......................... 26
4.05 PC Board Replacement Procedures ........................................................... 26
4.06 Reservoir Parts Replacement Procedures .................................................. 27
4.07 Motor Assembly Parts Replacement........................................................... 30
4.08 Coolant Filter Assembly Replacement ........................................................ 33
4.09 Hose Assembly Replacements ................................................................... 33
4.10 Internal Parts Replacement......................................................................... 34
4.11 Front Panel Parts Replacement .................................................................. 39
4.12 Rear Panel Assembly Parts Replacement .................................................. 41
SECTION 5: PARTS LISTS....................................................................................................... 43
5.01 Introduction ................................................................................................. 43
5.02 Ordering Information ................................................................................... 43
5.03 Front Panel Replacement Parts .................................................................. 44
5.04 Center Chassis Replacement Parts ............................................................ 45
5.05 Base Unit Replacement Parts ..................................................................... 46
5.06 Rear Panel Replacement Parts................................................................... 48
APPENDIX I: EYE PROTECTION CHART ............................................................................... 51
APPENDIX II: QUICK DISCONNECT LEADS ASSIGNMENT ................................................. 52
APPENDIX III: REMOTE WIRING ............................................................................................ 53
APPENDIX IV: SYSTEM SCHEMA TIC ..................................................................................... 54
APPENDIX V: HOSE DIAGRAM ............................................................................................... 56
SECTION 1:
GENERAL INFORMATION
1.01 Notes, Cautions and Warnings
Throughout this manual, notes, cautions, and warnings
are used to highlight important information. These highlights are categorized as follows:
NOTE
An operation, procedure, or backgr ound information which requires additional emphasis or is helpful in efficient operation of the system.
CAUTION
A procedure which, if not properly followed, may
cause damage to the equipment.
WARNING
A procedure which, if not properly followed, may
cause injury to the operator or others in the operating area.
1.02 Important Safety Precautions
WARNINGS
OPERATION AND MAINTENANCE OF
PLASMA ARC EQUIPMENT CAN BE DANGEROUS AND HAZARDOUS TO YOUR
HEAL TH.
Plasma arc cutting produces intense electric and
magnetic emissions that may interfere with the
proper function of cardiac pacemakers, hearing
aids, or other electronic health equipment. Persons who work near plasma arc cutting applications should consult their medical health professional and the manufacturer of the health
equipment to determine whether a hazard exists.
To prevent possible injury, read, understand and
follow all warnings, safety precautions and instructions before using the equipment. Call 1-603298-5711 or your local distributor if you have any
questions.
GASES AND FUMES
Gases and fumes produced during the plasma cutting
process can be dangerous and hazardous to your health.
• Keep all fumes and gases from the breathing area.
Keep your head out of the welding fume plume.
• Use an air-supplied respirator if ventilation is not
adequate to remove all fumes and gases.
• The kinds of fumes and gases from the plasma arc
depend on the kind of metal being used, coatings
on the metal, and the different pr ocesses. Y ou must
be very careful when cutting or welding any metals which may contain one or more of the following:
Antimony Chromium Mercury
Arsenic Cobalt Nickel
Barium Copper Selenium
Beryllium Lead Silver
Cadmium Manganese Vanadium
• Always read the Material Safety Data Sheets
(MSDS) that should be supplied with the material
you are using. These MSDSs will give you the information regarding the kind and amount of fumes
and gases that may be dangerous to your health.
• For information on how to test for fumes and gases
in your workplace, refer to item 1 in Subsection 1.03,
Publications in this manual.
• Use special equipment, such as water or down draft
cutting tables, to capture fumes and gases.
• Do not use the plasma torch in an area where combustible or explosive gases or materials are located.
• Phosgene, a toxic gas, is generated from the vapors
of chlorinated solvents and cleansers. Remove all
sources of these vapors.
• This product, when used for welding or cutting,
produces fumes or gases which contain chemicals
known to the State of California to cause birth defects and, in some cases, cancer . (California Health
& Safety Code Sec. 25249.5 et seq.)
ELECTRIC SHOCK
Electric Shock can injure or kill. The plasma arc process
uses and produces high voltage electrical energy. This
electric energy can cause severe or fatal shock to the operator or others in the workplace.
• Never touch any parts that are electrically “live”
or “hot.”
Date: No v ember 15, 2001 1 GENERAL INFORMATION
• Wear dry gloves and clothing. Insulate yourself
from the work piece or other parts of the welding
circuit.
• Repair or replace all worn or damaged parts.
• Extra care must be taken when the workplace is
moist or damp.
• Install and maintain equipment according to NEC
code, refer to item 9 in Subsection 1.03, Publications.
• Disconnect power source before performing any
service or repairs.
• Read and follow all the instructions in the Operating Manual.
FIRE AND EXPLOSION
Fire and explosion can be caused by hot slag, sparks, or
the plasma arc.
• Be sure there is no combustible or flammable material in the workplace. Any material that cannot
be removed must be protected.
• Ventilate all flammable or explosive vapors from
the workplace.
• Do not cut or weld on containers that may have
held combustibles.
• Provide a fire watch when working in an area where
fire hazards may exist.
• Hydrogen gas may be formed and trapped under
aluminum workpieces when they are cut underwater or while using a water table. DO NOT cut
aluminum alloys underwater or on a water table
unless the hydrogen gas can be eliminated or dissipated. T rapped hydrogen gas that is ignited will
cause an explosion.
NOISE
Noise can cause permanent hearing loss. Plasma arc processes can cause noise levels to exceed safe limits. You
must protect your ears from loud noise to prevent permanent loss of hearing.
• T o protect your hearing from loud noise, wear pr otective ear plugs and/or ear muffs. Protect others
in the workplace.
• Noise levels should be measured to be sure the decibels (sound) do not exceed safe levels.
• For information on how to test for noise, see item 1
in Subsection 1.03, Publications, in this manual.
PLASMA ARC RA YS
Plasma Arc Rays can injure your eyes and burn your skin.
The plasma arc process produces very bright ultra violet
and infra red light. These arc rays will damage your
eyes and burn your skin if you are not properly pr otected.
• To protect your eyes, always wear a welding helmet or shield. Also always wear safety glasses with
side shields, goggles or other protective eye wear.
• Wear welding gloves and suitable clothing to protect your skin from the arc rays and sparks.
• Keep helmet and safety glasses in good condition.
Replace lenses when cracked, chipped or dirty.
• Protect others in the work area from the arc rays.
Use protective booths, screens or shields.
• Use the shade of lens as suggested in the following
per ANSI/ASC Z49.1:
Minimum Protective Suggested
Arc Current Shade No. Shade No.
Less Than 300* 8 9
300 - 400* 9 12
400 - 800* 10 14
* These values apply where the actual arc is clearly
seen. Experience has shown that lighter filters
may be used when the arc is hidden by the workpiece.
1.03 Publications
Refer to the following standards or their latest revisions
for more information:
1. OSHA, SAFETY AND HEAL TH STANDARDS, 29CFR
1910, obtainable from the Superintendent of Documents, U.S. Government Printing Office, Washington,
D.C. 20402
2. ANSI Standard Z49.1, SAFETY IN WELDING AND
CUTTING, obtainable from the American Welding Society, 550 N.W. LeJeune Rd, Miami, FL 33126
3. NIOSH, SAFETY AND HEALTH IN ARC WELDING
AND GAS WELDING AND CUTTING, obtainable
from the Superintendent of Documents, U.S. Government Printing Office, Washington, D.C. 20402
4. ANSI Standard Z87.1, SAFE PRACTICES FOR OCCUP ATION AND EDUCA TIONAL EYE AND FACE PROTECTION, obtainable from American National Standards Institute, 1430 Broadway, New York, NY 10018
5. ANSI Standard Z41.1, STANDARD FOR MEN’S
SAFETY -TOE FOOTWEAR, obtainable from the American National Standards Institute, 1430 Broadway, New
York, NY 10018
GENERAL INFORMATION 2 Date: Nov ember 15, 2001
6. ANSI Standard Z49.2, FIRE PREVENTION IN THE USE
OF CUTTING AND WELDING PROCESSES, obtainable from American National Standards Institute, 1430
Broadway, New York, NY 10018
7. AWS Standar d A6.0, WELDING AND CUTTING CONTAINERS WHICH HAVE HELD COMBUSTIBLES, obtainable from American Welding Society, 550 N.W.
LeJeune Rd, Miami, FL 33126
8. NFPA Standard 51, OXYGEN-FUEL GAS SYSTEMS
FOR WELDING, CUTTING AND ALLIED PROCESSES, obtainable from the National Fire Protection
Association, Batterymarch Park, Quincy, MA 02269
9. NFPA Standard 70, NATIONAL ELECTRICAL CODE,
obtainable from the National Fire Protection Association, Batterymarch Park, Quincy, MA 02269
10. NFP A Standard 51B, CUTTING AND WELDING PROCESSES, obtainable from the National Fire Protection
Association, Batterymarch Park, Quincy, MA 02269
11. CGA Pamphlet P-1, SAFE HANDLING OF COMPRESSED GASES IN CYLINDERS, obtainable from the
Compressed Gas Association, 1235 Jefferson Davis
Highway, Suite 501, Arlington, VA 22202
12. CSA Standard W1 17.2, CODE FOR SAFETY IN WELDING AND CUTTING, obtainable from the Canadian
Standards Association, Standards Sales, 178 Rexdale
Boulevard, Rexdale, Ontario, Canada M9W 1R3
13. NWSA booklet, WELDING SAFETY BIBLIOGRAPHY
obtainable from the National Welding Supply Association, 1900 Arch Street, Philadelphia, PA 19103
14. American Welding Society Standard A WSF4.1, RECOMMENDED SAFE PRACTICES FOR THE PREPARATION FOR WELDING AND CUTTING OF CONT AINERS AND PIPING THAT HA VE HELD HAZARDOUS
SUBSTANCES, obtainable fr om the American Welding
Society, 550 N.W. LeJeune Rd, Miami, FL 33126
ATTENTION
Toute procédure pouvant résulter
l’endommagement du matériel en cas de nonrespect de la procédur e en question.
AVERTISSEMENT
Toute procédure pouvant provoquer des blessures
de l’opérateur ou des autres personnes se trouvant
dans la zone de travail en cas de non-respect de la
procédure en question.
1.05 Precautions De Securite
Importantes
AVERTISSEMENTS
L’OPÉRATION ET LA MAINTENANCE DU
MATÉRIEL DE SOUDAGE À L’ARC AU JET
DE PLASMA PEUVENT PRÉSENTER DES
RISQUES ET DES DANGERS DE SANTÉ.
Coupant à l’arc au jet de plasma produit de l’énergie
électrique haute tension et des émissions
magnétique qui peuvent interférer la fonction
propre d’un “pacemaker” cardiaque, les appareils
auditif, ou autre matériel de santé electronique.
Ceux qui travail près d’une application à l’arc au
jet de plasma devrait consulter leur membre
professionel de médication et le manufacturier de
matériel de santé pour déterminer s’il existe des
risques de santé.
15. ANSI Standard Z88.2, PRACTICE FOR RESPIRATO RY
PROTECTION, obtainable from American National
Standards Institute, 1430 Broadway, New York, NY
10018
1.04 Note, Attention et
Avertissement
Dans ce manuel, les mots “note,” “attention,” et
“avertissement” sont utilisés pour mettre en relief des
informations à caractère important. Ces mises en relief
sont classifiées comme suit :
NOTE
Toute opération, procédure ou renseignement
général sur lequel il importe d’insister davantage
ou qui contribue à l’efficacité de fonctionnement
du système.
Date: No v ember 15, 2001 3 GENERAL INFORMATION
Il faut communiquer aux opérateurs et au personnel TOUS les dangers possibles. Afin d’éviter les
blessures possibles, lisez, comprenez et suivez tous
les avertissements, toutes les précautions de sécurité
et toutes les consignes avant d’utiliser le matériel.
Composez le + 603-298-5711 ou votr e distributeur
local si vous avez des questions.
FUMÉE et GAZ
La fumée et les gaz produits par le procédé de jet de
plasma peuvent présenter des risques et des dangers de
santé.
• Eloignez toute fumée et gaz de votre zone de respiration. Gardez votre tête hors de la plume de fumée
provenant du chalumeau.
• Utilisez un appareil respiratoire à alimentation en air
si l’aération fournie ne permet pas d’éliminer la fumée
et les gaz.
• Ne touchez jamais une pièce “sous tension” ou “vive”;
portez des gants et des vêtements secs. Isolez-vous
de la pièce de travail ou des autres parties du circuit
de soudage.
• Réparez ou remplacez toute pièce usée ou
endommagée.
• Les sortes de gaz et de fumée provenant de l’arc de
plasma dépendent du genre de métal utilisé, des
revêtements se trouvant sur le métal et des différ ents
procédés. Vous devez prendre soin lorsque vous
coupez ou soudez tout métal pouvant contenir un ou
plusieurs des éléments suivants:
antimoine cadmium mercure
argent chrome nickel
arsenic cobalt plomb
baryum cuivre sélénium
béryllium manganèse vanadium
• Lisez toujours les fiches de données sur la sécurité
des matières (sigle américain “MSDS”); celles-ci
devraient être fournies avec le matériel que vous
utilisez. Les MSDS contiennent des renseignements
quant à la quantité et la nature de la fumée et des gaz
pouvant poser des dangers de santé.
• Pour des informations sur la manière de tester la
fumée et les gaz de votre lieu de travail, consultez
l’article 1 et les documents cités à la page 5.
• Utilisez un équipement spécial tel que des tables de
coupe à débit d’eau ou à courant descendant pour
capter la fumée et les gaz.
• N’utilisez pas le chalumeau au jet de plasma dans une
zone où se trouvent des matières ou des gaz combustibles ou explosifs.
• Le phosgène, un gaz toxique, est généré par la fumée
provenant des solvants et des produits de nettoyage
chlorés. Eliminez toute source de telle fumée.
• Ce produit, dans le procéder de soudage et de coupe,
produit de la fumée ou des gaz pouvant contenir des
éléments reconnu dans L’état de la Californie, qui
peuvent causer des défauts de naissance et le cancer .
(La sécurité de santé en Californie et la code sécurité
Sec. 25249.5 et seq.)
CHOC ELECTRIQUE
• Prenez des soins particuliers lorsque la zone de travail est humide ou moite.
• Montez et maintenez le matériel conformément au
Code électrique national des Etats-Unis. (V oir la page
5, article 9.)
• Débranchez l’alimentation électrique avant tout travail d’entretien ou de réparation.
• Lisez et respectez toutes les consignes du Manuel de
consignes.
INCENDIE ET EXPLOSION
Les incendies et les explosions peuvent résulter des scories
chaudes, des étincelles ou de l’arc de plasma. Le procédé
à l’arc de plasma produit du métal, des étincelles, des
scories chaudes pouvant mettre le feu aux matières combustibles ou provoquer l’explosion de fumées
inflammables.
• Soyez certain qu’aucune matière combustible ou inflammable ne se trouve sur le lieu de travail. Protégez
toute telle matière qu’il est impossible de retirer de la
zone de travail.
• Procurez une bonne aération de toutes les fumées
inflammables ou explosives.
• Ne coupez pas et ne soudez pas les conteneurs ayant
pu renfermer des matières combustibles.
• Prévoyez une veille d’incendie lors de tout travail dans
une zone présentant des dangers d’incendie.
• Le gas hydrogène peut se former ou s’accumuler sous
les pièces de travail en aluminium lorsqu’elles sont
coupées sous l’eau ou sur une table d’eau. NE PAS
couper les alliages en aluminium sous l’eau ou sur
une table d’eau à moins que le gas hydrogène peut
s’échapper ou se dissiper . Le gas hydrogène accumulé
explosera si enflammé.
Les chocs électriques peuvent blesser ou même tuer. Le
procédé au jet de plasma requiert et produit de l’éner gie
électrique haute tension. Cette énergie électrique peut
produire des chocs graves, voire mortels, pour l’opérateur
et les autres personnes sur le lieu de travail.
GENERAL INFORMATION 4 Date: Nov ember 15, 2001
RAYONS D’ARC DE PLASMA
Les rayons provenant de l’arc de plasma peuvent blesser
vos yeux et brûler votre peau. Le procédé à l’arc de
plasma produit une lumière infra-rouge et des rayons
ultra-violets très forts. Ces rayons d’arc nuiront à vos
yeux et brûleront votre peau si vous ne vous protégez
pas correctement.
• Pour protéger vos yeux, portez toujours un casque ou
un écran de soudeur . Portez toujours des lunettes de
sécurité munies de parois latérales ou des lunettes de
protection ou une autre sorte de protection oculair e.
• Portez des gants de soudeur et un vêtement protecteur
approprié pour protéger votre peau contre les
étincelles et les rayons de l’arc.
• Maintenez votre casque et vos lunettes de protection
en bon état. Remplacez toute lentille sale ou
comportant fissure ou rognure.
• Protégez les autres personnes se trouvant sur la zone
de travail contre les rayons de l’arc en fournissant des
cabines ou des écrans de protection.
• Utilisez la nuance de lentille qui est suggèrée dans le
recommendation qui suivent ANSI/ASC Z49.1:
Nuance Minimum Nuance Suggerée
Courant Arc Protective Numéro Numéro
Moins de 300* 8 9
300 - 400* 9 12
400 - 800* 10 14
* Ces valeurs s’appliquent ou l’arc actuel est observé
clairement. L ’experience a démontrer que les filtres
moins foncés peuvent être utilisés quand l’arc est
caché par moiceau de travail.
1.06 Documents De Reference
Consultez les normes suivantes ou les révisions les plus
récentes ayant été faites à celles-ci pour de plus amples
renseignements :
1. OSHA, NORMES DE SÉCURITÉ DU TRA VAIL ET DE
PROTECTION DE LA SANTÉ, 29CFR 1910,
disponible auprès du Superintendent of Documents,
U.S. Government Printing Office, Washington, D.C.
20402
2. Norme ANSI Z49.1, LA SÉCURITÉ DES
OPÉRATIONS DE COUPE ET DE SOUDAGE,
disponible auprès de la Société Américaine de
Soudage (American Welding Society), 550 N.W.
LeJeune Rd., Miami, FL 33126
3. NIOSH, LA SÉCURITÉ ET LA SANTÉ LORS DES
OPÉRATIONS DE COUPE ET DE SOUDAGE À
L’ARC ET AU GAZ, disponible auprès du Superintendent of Documents, U.S. Government Printing
Office, Washington, D.C. 20402
4. Norme ANSI Z87.1, PRATIQUES SURES POUR LA
PROTECTION DES YEUX ET DU VISAGE AU TRAV AIL ET DANS LES ECOLES, disponible de l’Institut
Américain des Normes Nationales (American National Standards Institute), 1430 Broadway, New Y ork,
NY 10018
5. Norme ANSI Z41.1, NORMES POUR LES
CHAUSSURES PROTECTRICES, disponible auprès
de l’American National Standards Institute, 1430
Broadway, New York, NY 10018
BRUIT
Le bruit peut provoquer une perte permanente de l’ouïe.
Les procédés de soudage à l’arc de plasma peuvent
provoquer des niveaux sonores supérieurs aux limites
normalement acceptables. V ous dú4ez vous pr otéger les
oreilles contre les bruits forts afin d’éviter une perte
permanente de l’ouïe.
• Pour protéger votre ouïe contre les bruits forts, portez
des tampons protecteurs et/ou des protections
auriculaires. Protégez également les autres personnes
se trouvant sur le lieu de travail.
• Il faut mesurer les niveaux sonores afin d’assurer que
les décibels (le bruit) ne dépassent pas les niveaux
sûrs.
• Pour des renseignements sur la manière de tester le
bruit, consultez l’article 1, page 5.
6. Norme ANSI Z49.2, PRÉVENTION DES INCENDIES
LORS DE L ’EMPLOI DE PROCÉDÉS DE COUPE ET
DE SOUDAGE, disponible auprès de l’American National Standards Institute, 1430 Broadway, New Y ork,
NY 10018
7. Norme A6.0 de l’Association Américaine du Soudage
(AWS), LE SOUDAGE ET LA COUPE DE
CONTENEURS A YANT RENFERMÉ DES PRODUITS
COMBUSTIBLES, disponible auprès de la American
Welding Society, 550 N.W. LeJeune Rd., Miami, FL
33126
8. Norme 51 de l’Association Américaine pour la Protection contre les Incendies (NFPA), LES SYSTEMES
À GAZ AVEC ALIMENTATION EN OXYGENE
POUR LE SOUDAGE, LA COUPE ET LES
PROCÉDÉS ASSOCIÉS, disponible auprès de la National Fire Protection Association, Batterymar ch Park,
Quincy, MA 02269
Date: No v ember 15, 2001 5 GENERAL INFORMATION
9. Norme 70 de la NFPA, CODE ELECTRIQUE NATIONAL, disponible auprès de la National Fire Protection Association, Batterymarch Park, Quincy, MA
02269
10. Norme 51B de la NFPA, LES PROCÉDÉS DE
COUPE ET DE SOUDAGE, disponible auprès de la
National Fire Protection Association, Batterymarch
Park, Quincy, MA 02269
11. Brochure GCA P-1, LA MANIPULATION SANS
RISQUE DES GAZ COMPRIMÉS EN CYLINDRES,
disponible auprès de l’Association des Gaz
Comprimés (Compressed Gas Association), 1235
Jefferson Davis Highway, Suite 501, Arlington, VA
22202
12. Norme CSA W117.2, CODE DE SÉCURITÉ POUR
LE SOUDAGE ET LA COUPE, disponible auprès
de l’Association des Normes Canadiennes, Standards Sales, 178 Rexdale Boulevard, Rexdale,
Ontario, Canada, M9W 1R3
13. Livret NWSA, BIBLIOGRAPHIE SUR LA
SÉCURITÉ DU SOUDAGE, disponible auprès de
l’Association Nationale de Fournitures de Soudage
(National Welding Supply Association), 1900 Arch
Street, Philadelphia, PA 19103
14. Norme AWSF4.1 de l’Association Américaine de
Soudage, RECOMMANDATIONS DE PRATIQUES
SURES POUR LA PRÉPARA TION À LA COUPE ET
AU SOUDAGE DE CONTENEURS ET TUYAUX
AYANT RENFERMÉ DES PRODUITS
DANGEREUX , disponible auprès de la American
Welding Society, 550 N.W. LeJeune Rd., Miami, FL
33126
15. Norme ANSI Z88.2, PRA TIQUES DE PROTECTION
RESPIRATOIRE, disponible auprès de l’American
National Standards Institute, 1430 Broadway, New
York, NY 10018
GENERAL INFORMATION 6 Date: Nov ember 15, 2001
1.07 Declaration of Conformity
Manufacturer: Thermal Dynamics Corporation
Address: 82 Benning Street
W est Lebanon, New Hampshire 03784
USA
The equipment described in this manual conforms to all applicable aspects and regulations of the ‘Low Voltage Directive’
(European Council Directive 73/23/EEC as amended by Council Directive 93/68/EEC) and to the National legislation for
the enforcement of this Directive.
Serial numbers are unique with each individual piece of equipment and details description, parts used to manufacture a unit
and date of manufacture.
National Standard and Technical Specifications
The product is designed and manufactured to a number of standards and technical r equirements. Among them are:
* CSA (Canadian Standards Association) standard C22.2 number 60 for Arc welding equipment.
* UL (Underwriters Laboratory) rating 94VO flammability testing for all printed-circuit boar ds used.
* ISO/IEC 60974-1 (BS 638-PT10) (EN 60 974-1) (EN50192) (EN50078) applicable to plasma cutting equipment and associ-
ated accessories.
* Extensive product design verification is conducted at the manufacturing facility as part of the routine design and manufac-
turing process. This is to ensure the product is safe, when used according to instructions in this manual and related
industry standards, and performs as specified. Rigorous testing is incorporated into the manufacturing process to ensure
the manufactured product meets or exceeds all design specifications.
Thermal Dynamics has been manufacturing products for more than 30 years, and will continue to achieve excellence in our
area of manufacture.
Manufacturers responsible representative: Giorgio Bassi
Managing Director
Thermal Dynamics Europe
Via rio Fabbiani 8A
40067 Rastignano (BO)
Italy
Date: No v ember 15, 2001 7 GENERAL INFORMATION
1.08 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 stor ed, 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, corr ect such defects by suitable r epair 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
PAR TICULAR 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 Thermal products shall be as follows (with the exception of XL Plus Series, CutMaster Series , Cougar
and DRAG-GUN): 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 the further limitations on such two (2) year period (see chart below).
The limited warranty period for XL Plus Series and CutMaster Series shall be as follows: A maximum of four (4) years from date
of sale to an authorized distributor and a maximum of three (3) years from date of sale by such distributor to the Purchaser, and
with the further limitations on such three (3) year period (see chart below).
The limited warranty period for Cougar and DRAG-GUN shall be as follows: A maximum of two (2) years from date of sale to an
authorized distributor and a maximum of one (1) year from date of sale by such distributor to the Purchaser, and with the further
limitations on such two (2) year period (see chart below).
Parts
XL Plus & Parts Parts
PAK Units, Power Supplies CutMaster Series Cougar/Drag-Gun All Others Labor
Main Power Magnetics 3 Years 1 Y ear 2 Years 1 Year
Original Main Power Rectifier 3 Y ears 1 Year 2 Years 1 Year
Control PC Board 3 Y ears 1 Year 2 Years 1 Year
All Other Circuits And Components Including, 1 Year 1 Y ear 1 Y ear 1 Year
But Not Limited To, Starting Circuit,
Contactors, Relays, Solenoids, Pumps,
Power Switching Semi-Conductors
Consoles, Control Equipment, Heat 1 Y ear 1 Year 1 Year
Exchanges, And Accessory Equipment
Torch And Leads
Maximizer 300 To rch 1 Y ear 1 Year
SureLok T orches 1 Y ear 1 Year 1 Year
All Other Torches 180 Days 180 Days 180 Days 180 Days
Repair/Replacement Parts 90 Days 90 Days 90 Days None
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. T ransportation 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: November 15, 2001
GENERAL INFORMATION 8 Date: Nov ember 15, 2001
SECTION 2:
INTRODUCTION
2.01 Scope of Manual
This manual provides service instructions for the Thermal Arc® ULTIMA-150® Plasma Welding Power Supply.
Information in this edition is particularly applicable to
the troubleshooting and repair of the equipment. For information on operating procedures, please refer to the
ULTIMA-150 Plasma Welding Power Supply Operating
Manual (0-2472).
NOTE
Service of this equipment is restricted to properly
trained service technicians familiar with this equipment; unqualified personnel are strictly cautioned
against attempting repairs or adjustments not covered in this manual, at the risk of voiding the warranty.
Read both this manual and the Operating Manual thoroughly . A complete understanding of the capabilities and
functions of the equipment will assure obtaining the performance for which it was designed.
C. Customer/Operator Responsibilities
It is the customer/operator's responsibility to maintain the equipment and peripheral accessories provided by Thermal Dynamics in good operating order
in accordance with the procedures outlined in the
Operating Manual, and to protect the equipment from
accidental or malicious damage.
D. Repair Restrictions
The electronics consists of printed circuit board assemblies which must be carefully handled, and must
be replaced as units. No replacement of printed circuit solder-mounted components is allowed except as
noted in this manual.
If the Printed Circuit Board is to be returned, the replaced Printed Circuit Board Assemblies must be properly packaged in protective material and returned intact per normal procedures.
2.03 Service Responsibilities
The Service T echnician should be familiar with the equipment and its capabilities and should be prepared to recommend arrangements of components which will provide
the most efficient layout, utilizing the equipment to its best
possible advantage.
W ARNING
There are extremely dangerous voltage and power
levels present inside this unit. Do not attempt to
diagnose or repair unless you have had training in
high power electronics measurement and troubleshooting.
2.02 General Service Philosophy
Several key points are essential to properly support the
application and operation of this equipment.
A. Application
Confirm that the equipment is capable of handling
the application desired. Specifications supplied and
described in Subsection 2.05 of this manual.
B. Modifications
No physical or electrical modifications other than selection of standard options and accessories are to be
made to this equipment.
Maintenance work should be accomplished in a timely
manner . If problems are encountered, or the equipment
does not function as specified, contact the Technical Service Department in W est Lebanon, NH for assistance.
2.04 ULTIMA-150 Power Supply
Description
The ULTIMA-150 Plasma Welding Power Supply is one
integrated unit providing power , pilot control inverter , and
coolant recirculator . The power supply has output ranges
from 0.5-15 amps and 5-150 amps. It is ideally suited for
all automated welding applications as well as all low current gas tungsten arc welding (GT AW) applications. The
ULTIMA-150 Power Supply is suitable for use with all
designated Thermal Dynamics plasma welding torches.
Manual 0-2503 9 SECTION 2: INTRODUCTION
2.05 ULTIMA-150 Power Supply
Specifications
A. Input Power
200 VAC ±10%50/60hz, 1 or 3 phase
208 VAC ±10%50/60hz, 1 or 3 phase
230 VAC ±10%50/60hz, 1 or 3 phase
380 VAC ±10%50/60hz, 1 or 3 phase
415 VAC ±10%50/60hz, 1 or 3 phase
460 VAC ±10%50/60hz, 1 or 3 phase
575 VAC ±10% 50/60hz 3 phase (available with optional T ransformer Module only)
B. Output Power
1. Output Amps
Range I - 0.5 to 15 amps DC straight polarity
Range II - 5 to 150 amps DC straight polarity
2. Duty Cycle
60% Duty Cycle @ 40°C, 150 amp output
100% Duty Cycle @ 40°C, 100 amp output
3. Pilot Arc Output
2-15 amp variable, continuous pilot arc
Pilot arc output 100% duty cycle @ 40° C
C. Fuse
3A, 500V (1FU) Fuse
D. Protection Features
A number of interlocks have been to provided to assure proper handling of fault conditions at all times.
E. Gas Supply
• Plasma Gas - 0.5-3.0 scfh (.25-1.8 lpm) @ 35 psi
• Shield Gas - 5.0-30 scfh (2.5-15 lpm) @ 35 psi
F. Coolant Reservoir Capacity
2 gal. (7.6 liters) Coolant Reservoir (use Thermal Arc
Coolant only)
G. Weight
130 lbs (59 kg) - unit only (coolant or torch not included)
150 lbs (68 kg) - shipping
H. Dimensions
18" (460 mm) high x 15" (380 mm) wide x 29" (0.74 m)
deep
2.06 The ULTIMA-150 System
The ULTIMA-150 Plasma Welding System includes the
following components:
• ULTIMA-150 Power Supply with 2 Gas Supply
Hoses
• Quick Disconnect Torch with leads (torch type and
lead length as ordered)
• T or ch Spare Parts Kit
• 2 gallons (7.6 liters) Thermal Arc Coolant
• 10 ft (304.8 cm) W ork Cable with Cable Lug Connector
• Coolant flow and level - monitored and shut down
the recirculator pump when below minimum levels.
• Pump operation - system shuts down due to air in
torch leads or in the system.
• Coolant and power supply - overtemperature of the
power supply or coolant will immediately disable
the power supply output. The recirculator pump
remains running for system and coolant cool down.
• Plasma gas and shield gas - both have minimum
pressure switches that disable pilot arc operation.
• Pilot arc - always latched off in event of power supply interlock trip. The pilot must be disabled and
then reenergized to initiate the pilot arc after a fault
shutdown.
SECTION 2: INTRODUCTION 10 Manual 0-2503
Figure 2-1 The ULTIMA-150 System
2.07 Requirements to Complete
System
T o complete the system, the user needs the following:
• Remote signal to operate Arc ON/OFF via TB-1 interface or J-20 receptacle using accessory remote
device
• Gas Pressure Regulators. Both Argon Gas Regulator and Argon/Hydrogen Gas Regulators are available through Thermal Dynamics
• Power Input Cable
2.08 Options, Accessories and
Replacement Parts
Options and accessories are available for the ULTIMA150 Plasma W elding Power Supply to customize it for a
particular application or to further enhance performance.
For more information, refer to Section 5, Parts Replacement.
• Quick Disconnect Adapter Kit - for use with older
model Thermal Arc torches. The Adapter Kit retrofits the torch for direct connection to the quick disconnect receptacle on the Power Supply .
• Torch Spare Parts Kit - contains replacement front
end torch parts.
• 575-V olt Transformer Module - a step-down transformer which converts 575V primary power to 460V
for use with the ULTIMA-150 Plasma Welding
Power Supply .
• Remote Current Control Device - required for operation of the ULTIMA-150 Plasma Welding System.
• W eld Sequencer - an add-on accessory for controlling weld timing, pulsing, current slope, and gas
slope.
• Coolant Pressure Gauge Assembly Kit - This kit allows for easy monitoring and adjusting of coolant
pressure.
Manual 0-2503 11 SECTION 2: INTRODUCTION
SECTION 2: INTRODUCTION 12 Manual 0-2503
SECTION 3:
SERVICE
TROUBLESHOOTING
3.01 Introduction
This section provides service diagnostics for the UL TIMA150 Plasma Welding Power Supply allowing the technician to isolate any faulty subassemblies.
Under no circumstances are field repairs to be attempted
on subassemblies (including printed circuit boards) of this
unit. Evidence of unauthorized repairs will void the factory warranty.
NOTE
B. Advanced T roubleshooting
The UL TIMA-150 Plasma W elding Power Supply Service
Manual (No. 0-2503) provides advanced troubleshooting. This manual is helpful for solving many of the more
complex problems that can arise with the Power Supply.
T roubleshooting and repairing this unit is a process which
should be undertaken only by those familiar with high
voltage, high power electronic equipment.
The advanced troubleshooting covered in this service
manual does require disassembly and live measurements
of the power supply. If major complex assemblies are
faulty , the unit must be returned to an authorized service
center for repair.
WARNING
The troubleshooting contained in this manual is
for the UL TIMA-150 Power Supply only. Troubleshooting other parts of the system is covered in the
separate manuals for that product.
Refer to Section 4 Repairs & Replacement, for parts replacement instructions.
3.02 Periodic Inspection
These inspection procedures should be performed at periodic intervals as required:
A. Physical Inspection
Before beginning troubleshooting, visually inspect the
internal components for signs of overheating, fractures
and damage. Check that all cable connections are secure.
B. Cleaning
The only routine maintenance required for the power
supply is a thorough cleaning and inspection, with the
frequency depending on the usage and the operating environment. Refer to the appropriate torch manual for
information on torch maintenance.
3.03 Troubleshooting Information
A. Basic Tr oubleshooting
There are extremely dangerous voltage and power
levels present inside this unit. Do not attempt to
diagnose or repair unless you have had training in
high power electronics measurement and troubleshooting.
WARNING
Never use a rubber hose to supply gas to system;
moisture can impregnate rubber and damage the
torch parts and torch head.
The Gas pipeline should always be pressurized, otherwise the collection of moisture can result, causing severe torch parts damage.
Disconnect primary power to the system before
disassembling the unit.
NOTES
Many signals are transferred between Printed Circuit Board Assemblies on Ribbon Cables. If these
cables become faulty they can then cause various
problems. Do not forget about these cables when
troubleshooting.
The ULTIMA-150 Plasma Welding Power Supply Operating Manual (No. 0-2472.) provides information on basic troubleshooting and parts replacement procedures.
This manual should be your first resource for troubleshooting; if the problem cannot be remedied using the
Operating Manual, refer to the advanced troubleshooting in this Service Manual.
Manual 0-2503 13 SECTION 3: SERVICE TROUBLESHOO TING
3.04 How to Troubleshoot the
PILOT ARC
PREVIEW
ON
CURRENT
SET
A
A
CURRENT
0.5-15
5-150
PREVIEW
ARC
VOLTS
A / V
A
LIMIT
A
PANEL
REMOTE
A
COOL PILOT DCGASTEMPAC
A
V
RANGE
1012
1
2
3
A-01096
4
56
7
8
9
11
13 14
Ultima-150 Power Supply
The Ultima-150 Plasma Welding Power Supply is relatively simple to troubleshoot since it has a panel of indicator lights that continually provide feedback to the user .
Under normal conditions, all active indicator lights are
green. Blinking lights, red lights, and off lights are indicators of problems.
Should any light indicate a problem, refer to the appropriate troubleshooting section for that light. If more than
one light is faulty, complete testing procedures in the order presented in this guide. Each subsection of this guide
is set up as follows:
X. Symptom (bold type)
1. Cause (Italic Type)
a. Check/Remedy (Text Type)
3.06 Checking Basic Functions
The following routine checks the basic functions of the
Ultima-150 Power Supply . Use this r outine to verify that
the system is working correctly. Should any light fail to
display as described, refer to the appropriate troubleshooting section for that light and follow the instructions
provided.
Once a problem has been corrected, repeat the steps in
Section 3.06 Basic Functions, to ensure that the complete
problem has been remedied and that the power supply
functions properly.
Troubleshooting the power supply has been organized
as follows:
Section 3.06 - Checking Basic Functions
Section 3.07 - AC Power Problems
Section 3.08 - Temperature Problems
Section 3.09 - Gas Problems
Section 3.10 - Coolant Problems
Section 3.11 - PILOT Problems
Section 3.12 - DC Power Problems
Section 3.13 - A/V Display Status Problems
Section 3.14 - Static Test Procedures
3.05 Preparing to Troubleshoot
Before beginning to troubleshoot, connect the following:
1. Connect incoming voltage.
2. Connect torch with correct tor ch parts installed. (Consult appropriate torch manual for details, if requir ed.)
3. T urn on Plasma and Shield gas supplies. Set both pressure regulators to provide 35 psi.
4. Install optional remote or contact closure switch between TB1 terminals 3 and 4 (Weld Arc On). Closing
this switch turns weld arc on.
SECTION 3: SERVICE TROUBLESHOOTING 14 Manual 0-2503
Figure 3-1 Indicator Lights Panel
1. Make sure Primary Power ON/OFF Switch is in OFF
position.
2. Set Pilot Arc ON/SET switch (1) to SET .
3. Set RANGE switch (2) to 5-150.
4. Set PANEL/REMOTE switch (3) to PANEL.
5. Place Primary Power ON/OFF Switch to the ON position. Adjust Plasma and Shield Gas Flow meters on
the front of unit to desired flow rate. Indicator lights
should be:
Indicator Light Display
AC (4) on (green)
TEMP (5) on (green)
GAS (6) on
COOLANT (7) on (green)
AV Display (8) on (00)
PILOT (9) off
DC (10) off
6. Press the Pilot Arc Current PREVIEW Switch (11) to
display the pilot arc's current set point. It is factory
set for 7 amps. Consult the torch manual for other
settings. T o adjust the current set point, turn the Pilot
Arc CURRENT potentiometer (12) clockwise to increase.
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