150
™
ULTRA-CUT
PLASMA CUTTING SYSTEM
Art # A-04816
Operating Manual
Rev. AJ Date: October 29, 2007 Manual # 0-4800
Operating Features:
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 1-800426-1888, 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 for Thermadyne Industries Inc.
We distinguish ourselves from our competition through marketleading, dependable products that have stood the test of time.
We pride ourselves on technical innovation, competitive prices,
excellent 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.
!
WARNINGS
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, Ultra-Cut® 150
Operting Manual No. 0-4800
Published by:
Thermadyne Corporation
82 Benning Street
West Lebanon, New Hampshire, USA 03784
(603) 298-5711
www.thermal-dynamics.com
© Copyright 2005, 2006,2007 by
Thermadyne 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
Licensed under U. S. Patent No. 5,070,227
Publication Date: October 29, 2007
Record the following information for Warranty purposes:
Where Purchased: ___________________________________
Purchase Date:______________________________________
Power Supply Serial #:_______________________________
Torch Serial #:_____________________________________
This page intentionally blank
TABLE OF CONTENTS
SECTION 1:
GENERAL INFORMATION ................................................................................................ 1-1
1.01 Notes, Cautions and Warnings ...................................................................... 1-1
1.02 Important Safety Precautions ....................................................................... 1-1
1.03 Publications .................................................................................................. 1-3
1.04 Declaration of Conformity ............................................................................. 1-5
1.05 Statement of Warranty .................................................................................. 1-6
SECTION 2: SPECIFICATIONS ................................................................................................. 2-1
General Description Of The System...................................................................... 2-1
Plasma Power Supply ........................................................................................... 2-1
Remote Arc Starter ............................................................................................... 2-1
Gas Control Module .............................................................................................. 2-1
Precision Plasma Cutting Torch ............................................................................ 2-1
Specifications & Electrical Requirements ............................................................. 2-2
System Component Layout .................................................................................. 2-2
Power Supply Dimensions .................................................................................... 2-3
Power Supply Rear Panel Features ....................................................................... 2-4
Gas Requirements ................................................................................................ 2-5
Gas Applications .................................................................................................. 2-5
XTTM-300 Torch Specifications ............................................................................ 2-6
SECTION 3: INSTALLATION ...................................................................................................... 3-1
A. Installation Requirements ............................................................................. 3-1
B. Cooling System Requirements ...................................................................... 3-1
C. System Layout ............................................................................................. 3-2
D. Cables & Leads Identification ....................................................................... 3-3
D. Lift the Power Supply .................................................................................... 3-4
E -1. Set Switches on the Command - Control Module (Type 1 Module) ................ 3-5
E -2. Set Switches on the Command - Control Module (Type 2 Module) ................ 3-7
F. Remove the Connections Cover ................................................................... 3-9
G. Connect Work Cable and Pilot and Negative Leads...................................... 3-10
H. Check / Adjust Input Voltage Configuration .................................................. 3-11
I. Connect Input Power and System Ground Cables ........................................ 3-12
J. Ground Connections ....................................................................................3-13
C. Creating An Earth Ground ............................................................................3-16
K. Connect Coolant Leads ................................................................................ 3-17
L. Connect Control Cables for CNC, Remote Arc Starter, and GCM ................. 3-18
M. Gas Control Module Installation ................................................................... 3-21
N. Fiber Optic Cable Installation .......................................................................3-22
O. Gas Control Module: Control, Input, and Output Connections .......................3-25
P. Install Remote Arc Starter ...........................................................................3-26
Q. Original & XTL Torch Valve Installation.........................................................3-35
R. Connecting Torch ......................................................................................... 3-37
S. Install Consumable Torch Parts .................................................................... 3-38
T. Complete the Installation .............................................................................3-41
TABLE OF CONTENTS (continued)
SECTION 4: OPERATION .......................................................................................................... 4-1
Power Supply Control Panel .................................................................................. 4-1
Start-Up Sequence ............................................................................................... 4-2
Gas Control Module Operation .............................................................................. 4-3
Sequence Of Operation ........................................................................................ 4-7
Gas Selection ......................................................................................................4-10
Power Supply Status Codes ................................................................................ 4-11
Remote Arc Starter: Service Chart ..................................................................... 4-14
Remote Arc Starter: Spark Gap Adjustment ....................................................... 4-15
SECTION 5: MAINTENANCE .................................................................................................... 5-1
External Coolant Filter Cleaning Procedure ........................................................... 5-1
Internal Coolant Filter Cleaning Procedure ............................................................ 5-2
Coolant Replacement Procedure ........................................................................... 5-2
SECTION 6: REPLACEMENT ASSEMBLIES & PARTS ........................................................... 6-1
System Layout ..................................................................................................... 6-2
Leads and Cables ................................................................................................. 6-3
Optional Gas Supply Leads .................................................................................. 6-8
Power Supply External Replacement Parts ........................................................... 6-9
Power Supply Replacement Parts - Right Side..................................................... 6-10
Power Supply Replacement Parts - Right Side..................................................... 6-11
Power Supply Replacement Parts - Right Side..................................................... 6-12
Power Supply Replacement Parts - Front Panel ...................................................6-13
Power Supply Replacement Parts - Front Panel ...................................................6-14
Power Supply Replacement Parts - Right Side..................................................... 6-15
Power Supply Replacement Parts - Rear Panel .................................................... 6-16
Power Supply Replacement Parts - Right Side..................................................... 6-17
Power Supply Replacement Parts ........................................................................6-18
Power Supply Replacement Parts - Right Side..................................................... 6-19
Power Supply Replacement Parts ........................................................................6-20
Power Supply Replacement Parts - Right Side..................................................... 6-21
Power Supply Replacement Parts - Right Side..................................................... 6-22
Gas Control Module (GCM-2010) Replacement Parts .......................................... 6-23
Gas Control Module (GCM-2010) Replacement Parts .......................................... 6-24
Remote Arc Starter (RAS-1000) Replacement Parts ............................................ 6-25
Remote Arc Starter (RAS-1000) Replacement Parts ............................................ 6-26
Command & Control Module Type 1- Replacement Parts .................................. 6-27
Command & Control Module Type 2 - Replacement Parts .................................6-28
Torch Valve Assembly Replacement Parts ........................................................... 6-29
XTL Torch Valve Assembly External Replacement Parts ...................................... 6-30
XTL Torch Valve Assembly Internal Replacement Parts ....................................... 6-31
TABLE OF CONTENTS (continued)
SECTION 7: TORCH MAINTENANCE .................................................................................... 7-1
A. Consumable Removal ................................................................................... 7-1
B. O-Ring Lubrication ........................................................................................ 7-2
C. Parts Wear .................................................................................................... 7-2
D. Torch Consumables Installation .................................................................... 7-3
E. Coolant Leak Trouble-Shooting ...................................................................... 7-5
APPENDIX 1: Remote Arc Starter Schematic .......................................................................... A-1
APPENDIX 2: Gas Control and Torch Valve Schematic ............................................................. A-2
APPENDIX 3: Gas Control Module............................................................................................ A-4
APPENDIX 4: Gas Control Module PCB Layout ....................................................................... A-5
APPENDIX 5: Gas Control Display Interface PCB Layout ........................................................ A-6
APPENDIX 6: CCM CPU PCB Layout ..................................................................................... A-7
APPENDIX 7: CCM Input / Output PCB Layout ........................................................................ A-8
APPENDIX 8: CNC - Control Module PCB Connections ............................................................ A-9
CNC functions. ................................................................................................... A-10
CNC Input / Output Descriptions ......................................................................... A-11
Simplified CNC Circuit. ....................................................................................... A-12
APPENDIX 9: Schematic: 230/460V Unit w/ Chopper Pilot w/ Diode ........................................ A-14
APPENDIX 10: Schematic: 230/460V Unit w/ Resistor Pilot ..................................................... A-16
APPENDIX 11: Schematic: CCC 400V Unit w/ Chopper Pilot ................................................... A-18
APPENDIX 12: Schematic: CE 400V Unit w/ Chopper Pilot ..................................................... A-20
APPENDIX 13: Schematic: CE 400V Unit w/ Resistor Pilot ..................................................... A-22
APPENDIX 14: Schematic: CSA 600V Unit w/ Chopper Pilot ................................................... A-24
APPENDIX 15: PUBLICATION HISTORY ................................................................................ A-26
Global Customer Service Contact Information ............................... Inside Rear Cover
NOTE
Section 8, Torch operation, is provided separately.
TABLE OF CONTENTS (continued)
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 background 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
OPERA TION 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 1-603-298-571 1 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 processes. Y ou must be very careful when cutting or welding any met als which may contain one
or more of the following:
Antimony Chromium Mercury Beryllium
Arsenic Cobalt Nickel Lead
Barium Copper Selenium Silve r
Cadmium Manganese V anadium
Manual 0-4800 1-1 GENERAL INFORMATION
• 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
St ate 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.”
• 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. Trapped 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. Y o u
must protect your ears from loud noise to prevent permanent loss of hearing.
• To protect your hearing from loud noise, wear protective ear plugs and/or ear muf fs. 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.
GENERAL INFORMATION 1-2 Manual 0-4800
PLASMA ARC RAYS
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 protected.
• 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:
Arc Current Shade No. Shade No.
Less Than 300* 8 9
300 - 400* 9 12
400 - 800* 10 14
Minimum Protective Suggested
* 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 HEALTH 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 HEAL TH 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 OCCUPATION AND EDUCATIONAL 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, obt ainable from the American National
Standards Institute, 1430 Broadway, New York, NY 10018
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 Standard 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.NFPA 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 St andard W1 17.2, CODE FOR SAFETY IN WELDING AND CUTTING, obtainable from the Canadian St andards
Association, Standards Sales, 178 Rexdale Boulevard, Rexdale, Ontario, Canada M9W 1R3
Manual 0-4800 1-3 GENERAL INFORMATION
13. NWSA booklet, WELDING SAFETY BIBLIOGRAPHY obtainable from the National Welding Supply Association,
1900 Arch Street, Philadelphia, PA 19103
14. American Welding Society Standard AWSF4.1, RECOMMENDED SAFE PRACTICES FOR THE PREPARATION
FOR WELDING AND CUTTING OF CONTAINERS AND PIPING THAT HAVE HELD HAZARDOUS SUBSTANCES,
obtainable from the American Welding Society, 550 N.W. LeJeune Rd, Miami, FL 33126
15.ANSI Standard Z88.2, PRACTICE FOR RESPIRATORY PROTECTION, obtainable from American National Standards Institute, 1430 Broadway, New York, NY 10018
GENERAL INFORMATION 1-4 Manual 0-4800
1.04 Declaration of Conformity
Manufacturer: Thermal Dynamics Corporation
Address: 82 Benning Street
West 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.
The equipment described in this manual conforms to all applicable aspects and regulations of the "EMC Directive"
(European Council Directive 89/336/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 requirements. 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 boards used.
* ISO/IEC 60974-1 (BS 638-PT10) (EN 60 974-1) (EN50192) (EN50078) applicable to plasma cutting equipment and
associated accessories.
* CENELEC EN50199 EMC Product Standard for Arc Welding Equipment
* For environments with increased hazard of electrical shock, Power Supplies bearing the S mark conform to
EN50192 when used in conjunction with hand torches with exposed tips, if equipped with properly installed standoff guides.
* Extensive product design verification is conducted at the manufacturing facility as part of the routine design and
manufacturing 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: Steve Ward
Operations Director
Thermadyne Europe
Europa Building
Chorley N Industrial Park
Chorley, Lancashire,
England PR6 7BX
Manual 0-4800 1-5 GENERAL INFORMATION
1.05 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 W ARRANTY OF MERCHANTABILITY OR FITNESS FOR A P ARTICULAR PURPOSE.
LIMITA TION 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 INV ALID IF REPLACEMENT P ARTS OR ACCESSORIES ARE USED WHICH MA Y IMP AIR THE SAFETY OR
PERFORMANCE OF ANY THERMAL PRODUCT .
THIS WARRANTY IS INV ALID 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).
AutoCut
Parts
©
and UltraCut© Power Supplies and Components 2 Years 1 Year
Labor
Torch And Leads
TM
XT
-300 / XTTM-301 T orch (Excluding Consumable Parts) 1 Y ear 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 transport ation 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 August 19, 2005
GENERAL INFORMATION 1-6 Manual 0-4800
SECTION 2: SPECIFICATIONS
General Description Of The System
A typical Ultra-Cut® 150 system configuration includes:
• One Power Supply
• Remote Arc Starter
• Gas Control Module
• Torch Valve Assembly
• Precision Plasma Cutting Torch
• Set Of Connecting Leads
• Torch Spare Parts Kit
The components are connected at installation.
Plasma Power Supply
The power supply provides the necessary current for cutting operations. The power supply also monitors system
performance, and cools and circulates the liquid coolant for the torch and leads.
Remote Arc Starter
This unit produces a temporary HF pulse to start the pilot arc. The pilot arc creates a path for the main arc to
transfer to the work. When the main arc is established, the pilot arc shuts off.
Gas Control Module
This module allows remote setting of gas selection, pressures, and flows together with setting of cutting current.
Precision Plasma Cutting Torch
The torch delivers the controlled current to the work through the main arc, causing the metal to be cut.
Manual No. 0-4800 2-1 SPECIFICATIONS
Specifications & Electrical Requirements
UItraCut 150 Specifications & Design Fea tures
Max OCV (U0) 380 vdc
Minim um Out put Current 10 Amps
Max Out put Current 150 Amps
Output V oltage 60 - 230 vdc
Duty Cy c l e Rati ng 100% @ 150A, 180V
Ambi ent Temperature
for Dut y Cy cl e Ra ting
Operating range 14°F to 122°F (-10°C to + 50°C)
Power Fac t or 0.70 @ 100 A DC Out put
Cooling Forced A i r (Class F)
Input Power Input Current
Volt age Freq. 3-Ph 3-Ph Fus e (Am ps) W i re (AWG)
(Volts ) (Hz) (kVA) (Amps ) 3-Ph 3-Ph
208 60 23 105 125
230602498110
40050285875
400 (CE) 50 28 58 75
46060265775
Line Voltages wi t h S ugges ted Circuit Prot ecti on and W i re S izes
Bas ed on Nati onal E l ectri c Code and Canadian Elec tric al Code
1
Extra Hard Usage Type SO, SOW, SOO, SOOW, ST, STW, STO, STOW, STOO, STOOW
2
Extra Hard Usage Type G, G-GC, W
104F° (40°C)
Ultr a-Cu t 150
Power Supply
Sugges t ed S i z es (See Not e)
2
#4
2
#4
1
#4
1
#4
1
#4
System Component Layout
125’ / 38.1 m Maximum Length
Pilot Return
Negative
Coolant Supply
Primary power
CNC
Art # A-07233
Power
Supply
P
F
Coolant Return
Control Cable
Fiber
Optic
Cable
Control
Cable
175’ / 53.3 m Maximum Length
L
K
F
Gas Control
Module
175’ / 53.3 m Maximum Length
A
B
Remote
C
D
E
Plasma Gas
Shield Gas
Preflow Gas
Control Cable
Water Shield
Work Cable
H
Q
R
S
T
O
Arc
Starter
Assembly
100’ / 30.5 m Maximum Length
Pilot Return
Shield
Coolant Supply
Coolant Return
F1
Plasma Gas
Torch
Valve
Shield Gas
Shield
I
J
Positioning Tube
Torch
Work
G
Manual No. 0-4800 2-2 SPECIFICATIONS
Power Supply Dimensions
41.25 inch
1050 mm
27 inch
680 mm
Art # A-07182
33 inch
840 mm
37.75 inch
960 mm
27.5 inch
700 mm
433 lb / 196 kg
Manual No. 0-4800 2-3 SPECIFICATIONS
Power Supply Rear Panel Features
Gas Control
Console Connector
CNC Connector
Remote Arc Starter
Connector
Coolant Connections
Coolant Filter
Pilot (Pos) Terminal
Circuit Breaker
Panel
RETURN
SUPPLY
Torch (Neg) Terminal
AC Power Lamp
Input Power
Terminals
Ground Terminals
Terminal Cover
Work Cable Terminal
Terminal Cover
Support Panel
Coolant Tank
Leads
Bracket
Art # A-04794
Manual No. 0-4800 2-4 SPECIFICATIONS
Gas Requirements
The customer will provide all gases and pressure regulators. Gases must be of high quality. Pressure regulators
shall be double stage.
Ultra-Cut 150 Pow er Supply: Gas Pre ssures, Flows, and Qual i ty Require m e nts
Gas Qualit y Mi nim um P res sure Flow
O
(Oxygen)
2
99.5% Purity
(Liquid recommended)
120 psi
8.3 bar / 827 k Pa
70 scfh (1982 l/h)
99.5% Purity
N
(Liquid recommended)
(Nitrogen)
2
Compressed
or Bottled Air
H35 (Argo n-Hydrogen)
H35 = 35% Hy drogen,
65% A rgon
O (Water) See Note 2 50 psi (3. 5 bar) 10 gph (38 lph)
H
2
: The air source must be adequately filtered to remove all oil or greas e. Oil or grease
Note 1
<1000 ppm O
ppm H
2
O)
2
, <32
Clea n, Dry,
Free of Oil (see Note 1)
99.995% P urity
(gas recommended)
120 psi
8.3 bar / 827 k Pa
120 psi
8.3 bar / 827 k Pa
120 psi
8.3 bar / 827 k Pa
204 scfh (5777 l/h)
244 scfh (6910 l/h)
90 scfh (2550 l/h)
cont am i nat ion from c om pres sed or bott led ai r c an c ause fires in conjunc t i on wit h oxygen.
For filtering, a coales cing filt er able to filter t o 0. 01 m i c rons should be plac ed as close as
pos sible to the gas inlets on the Gas Control Module.
: The tap water source does not need to be deionized, but in water systems with ex tremely
Note 2
high mineral content a wat er s oftener is recom m ended. Tap water with high l evels of partic ul at e
matter mus t be filtered.
: Water Pressure Regulator No. 8-6118 is recommended to ensure proper water pressure.
Note 3
Gas Applications
Ultra-Cut-150 Gas A ppli cati ons
MATERIAL
OPERATION
PREFLOW PLASMA SHIELD PREFLOW PLASMA SHIELD PREFLOW PLASMA SHIELD
30A CUT
50 A CUT
70 A CUT
85A CUT
100 A CUT
150A CUT
Manual No. 0-4800 2-5 SPECIFICATIONS
MILD STEEL ST AINL ES S S T EEL ALUMI N UM
GAS TYPEGAS TYPE GAS TYPE
Air
Air
Air
O
2
O
2
O
2
O
Air
Air
2
Air Air Air Air Air Air
N
2
N
2
H20N2N
Air Air Air Air Air Air
N
2
N
2
H20N2N
Air Air Air Air Air Air
N
2
N
2
H20N2N
Air Air Air
Air
Air O
N
2
2
AirO
Air
2
N
2
N
2
N
2
H
35
N
2
H
35
N
2
N
2
N
2
H20N2N
N
2
N
2
H20N2N
2
2
2
H
35
2
H
35
2
H20
H20
H20
N
H20
N
H20
2
2
XTTM-300 Torch Specifications
A. Torch Dimensions
End Cap
Art # A-04897
19.00"
482.68 mm
393.78 mm
15.50"
160.10 mm
6.30"
3.54"
89.87 mm
2.25"
57.15 mm
Mounting Tube
2.0"
50.8 mm
2.39"
60.81 mm
2.74"
69.55 mm
1.57"
39.96 mm
1.49"
37.8 mm
Manual No. 0-4800 2-6 SPECIFICATIONS
B. Torch Leads Lengths
Gas Lead Assemblies
C. Torch Parts (Generic Parts Shown)
Length
Feet Meters
10 3.05
15 4.6
25 7.6
35 10.6
50 15.2
75 22.8
100 30.4
125 38.2
150 45.7
175 53.3
Art # A-04741
Shield Gas
Distributor
Shield Cap
Shield Cup
Plasma Gas
Tip
Distributor
Electrode
Cartridge
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.
E. Type of Cooling
Combination of gas stream through torch and liquid cooling.
Manual No. 0-4800 2-7 SPECIFICATIONS
F. XTTM-300 Torch Data (with Ultra-CutTM 150 Power Supply)
TM
XT
-300 Torch Ratings
for use with Ul tra-Cut 15 0 P o wer Suppl y
Ambient
Tempera ture
Duty Cy c l e 100% @ 150 Am ps
Maxi m um Current 150 Amps
Volt age (V
)500V
peak
Arc Striking Voltage 10kV
Current
TM
-300 Torch Gas Specifications
XT
Plasma Gases:
Shield Gases:
Operating Pres sure
Maxi m um Input P res s ure 135 psi / 9. 3 bar
Gas flow 10 - 300 s cfh
104° F
40° C
Up to 150 Amps, DC,
Straight Polarity
Compress ed Ai r, Oxygen,
Nitrogen, H35
Compress ed Ai r, Oxygen,
Nitrogen, Wat er
125 ps i ± 10 psi
8.6 bar ± 0.7 bar
G. Plasma Power Supply Used With:
• Thermal Dynamics UltraCut®150
Manual No. 0-4800 2-8 SPECIFICATIONS
SECTION 3: INSTALLATION
A. Installation Requirements
1. Electric Supply
The electrical supply network, the gas and water supply system must meet local safety standards. This
conformity shall be checked by qualified personnel.
Ultr a-Cu t 150
Input Power Input Current
Power Supply
Sugges t ed S i z es (See Not e)
Volt age Freq. 3-Ph 3-Ph Fus e (A m ps ) Wire (A WG)
(Volts ) (Hz) (kVA) (Amps ) 3-Ph 3-Ph
208 60 23 105 125
230602498110
40050285875
400 (CE) 50 28 58 75
46060265775
#4
#4
#4
#4
#4
2
2
1
1
1
Line Voltages wi t h S ugges ted Circuit Prot ecti on and Wire Si zes
Bas ed on Nati onal E l ectri c Code and Canadian Electri c al Code
1
Extra Hard Usage Type SO, SOW, SOO, SOOW, ST, STW, STO, STOW, STOO, STOOW
2
Extra Hard Usage Type G, G-GC, W
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.
2. Gas Supply
The customer must supply all gases and pressure regulators. Gases must be of high quality. Pressure
regulators 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.
B. 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 Capabilit i es
Cat. Number and Mixture Mixture Protects To
TM
7-3580 'Extra-Cool
7-3581 'Ultra-Cool
7-3582 'Ext reme Cool
* For mixing wit h D-I Cool
'
TM
'
TM
' Concent rate* -65° F / -51° C
TM
7-3583
Manual No. 0-4800 3-1 INSTALLATION
25 / 75 10° F / -12° C
50 / 50 -27° F / -33° C
C. System Layout
175’ / 53.3 m Maximum Length
Primary power
CNC
Art # A-07233
125’ / 38.1 m Maximum Length
Pilot Return
Negative
Coolant Supply
Power
Supply
P
F
Coolant Return
Control Cable
Fiber
Optic
Cable
Control
Cable
175’ / 53.3 m Maximum Length
L
Gas Control
K
F
Module
Plasma Gas
Shield Gas
Preflow Gas
Control Cable
Water Shield
Work Cable
A
B
Remote
C
D
E
H
Q
R
S
T
O
Arc
Starter
Torch
Assembly
100’ / 30.5 m Maximum Length
Pilot Return
Shield
Coolant Supply
Coolant Return
F1
Valve
Shield
Plasma Gas
Shield Gas
Positioning Tube
I
J
G
Torch
Work
Manual No. 0-4800 3-2 INSTALLATION
D. Cables & Leads Identification
B
D
E
F
F1
#8 AWG Cable
A
#1 AWG Cable
C
14
G
Green
Red
Green / Yellow # 4 AWG
Green / Yellow 1/0 (50 mm )
Green
Red
2
Pilot Return, Power Supply
to Arc Starter
Negative Lead, Power Supply
to Arc Starter
Coolant Supply Lead,
Power Supply to Arc Starter
Coolant Return Lead,
Power Supply to Arc Starter
Control Cable, Power Supply
to Arc Starter
Ground Cable
Ground Cable,
Remote Arc Starter
To Earth Ground
Shielded Torch Lead
Assembly, Remote
Arc Starter to Torch
Art # A-07473
I
J
K
L
H, Q,
R, S,T
O
P
37
14
1/0 Cable (1/0 (50 mm )
Plasma Gas Lead,
Torch Valve to Torch
Shield Gas Lead,
Torch Valve to Torch
Control Cable,
Power Supply to
Gas Control Module
Fiber Optic Cable,
Power Supply to
Gas Control Module
2
CNC Cable (14 Wire)
Work Cable
Manual No. 0-4800 3-3 INSTALLATION
D. Lift the Power Supply
WARNINGS
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 all four lifting eyes when using lifting 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-04796
Set the power supply on a solid, level surface. The installer may fasten the power supply to the floor or a
supporting fixture with hardware passing through the horizontal parts of the power supply feet.
Manual No. 0-4800 3-4 INSTALLATION
E -1. Set Switches on the Command - Control Module (Type 1 Module)
Compare the command - control module to the illustration. Follow instructions in this section for a module with an
external connection cover.
Remove the power supply right side. Set switches on the CCM (Command-Control Module) per the illustrations.
Switch settings and connection details are provided in the Appendix.
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.
O
N
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
2 = OFF, 3 = OFF, 4 = ON: 0.8 Seconds
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-3: Gas Preflow Time 1 = OFF, 2 = OFF: 2 Seconds (Factory default setting).
1 = ON, 2 = OFF: 4 Seconds
1 = OFF, 2 = ON: 6 Seconds
1 = ON, 2 = ON: 8 Seconds
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-5-1: Tip Saver 1 = OFF = Disabled (Factory default setting).
1 = ON = Enabled
SW-5-2: Off Plate 2 = OFF = Disabled (Factory default setting).
2 = ON = Enabled
SW 8-1: Pilot Time 1 = OFF = Short (85 ms.) (Factory default setting).
1 = ON = Long (3 s.)
SW 8-2: Remote Current 1 = ON (Remote Analog Current Control)
SW 8-3, SW 8-4: Reserved for Factory use.
SW1
1
3
2
SW3
1
4
2
1
SW4
SW5
1
2
2
SW8
4
1
3
2
Future Use
O
N
1
2
Active only when
SW-1-1 is set to ON.
Art # A-04819
Manual No. 0-4800 3-5 INSTALLATION
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
Art # A-07673
SW13
SW6: OK-to-Move: Contact closure, 120VAC @ 1A (Factory default setting) or
DC Volts (16-18vdc@ up to 100 ma.)
SW11: Analog Current Control. B = from Gas Control (Factory default setting) or A = from CNC.
Position A requires that SW-8-2 be ON.
SW12-1/2/3/4: Divided Arc signal
1 = ON = 16.6:1
2 = ON = 30:1
3 = ON = 40:1
4 = Not used.
SW13: TVA and XTL Switch positions
All = OFF = 50:1 (Factory default setting)
Only 1 on at a time.
1
2
TVA XTL TVA
SW13
1
2
Manual No. 0-4800 3-6 INSTALLATION
E -2. Set Switches on the Command - Control Module (Type 2 Module)
Compare the command - control module to the illustration. Follow instructions in this section for a module
without an external connection cover.
Remove the power supply right side. Set switches on the CCM (Command-Control Module) per the illustrations.
Switch settings and connection details are provided in the Appendix.
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.
Future Use
2
SW1
3
O
N
1
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
2 = OFF, 3 = OFF, 4 = ON: 0.8 Seconds
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-3: Gas Preflow Time 1 = Off, 2 = OFF: 2 seconds
1 = ON, 2 = OFF: 4 seconds
1 = OFF, 2 = ON: 6 seconds
1 = ON, 2 = ON: 8 seconds
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-5-1: Tip Saver 1 = OFF = Disabled (Factory default setting).
1 = ON = Enabled
SW-5-2: Off Plate 2 = OFF = Disabled (Factory default setting).
2 = ON = Enabled
SW 8-1: Pilot Time 1 = OFF = Short (85 ms.) (Factory default setting).
1 = ON = Long (3 s.)
SW 8-2: Remote Current 1 = ON (Remote Analog Current Control)
SW 8-3, SW 8-4: Reserved for Factory use.
SW3
1
4
2
1
SW4
SW5
1
2
2
SW8
4
1
3
2
1
O
N
2
Active only when
SW-1-1 is set to O
Art # A-06791
N.
Manual No. 0-4800 3-7 INSTALLATION
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
No external
connection cover
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: Analog Current Control. B = from Gas Control (Factory default setting) or A = from CNC.
Position A requires that SW-8-2 be ON.
SW-12-1/2/3/4: Divided Arc signal
1 = ON = 16.6:1
2 = ON = 30:1
3 = ON = 40:1
4 = Not used.
SW13: TVA and XTL Switch positions
All = OFF = 50:1 (Factory default setting)
Only 1 on at a time.
Art # A-06792
1
2
TVA XTL TVA
SW13
1
2
Manual No. 0-4800 3-8 INSTALLATION
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