Tweco Ultima 150 User Manual

Plasma Welding

P o wer Supply

Ultima 150

Operating Manual

October 4, 2002 Manual No. 0-2472

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.

UL TIMA-150 Plasma W elding Operating Manual
Number 0-2472

Published by:
Thermal Dynamics Corporation
82 Benning Street
W est Lebanon, New Hampshire, USA 03784
[phone]

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: INTRODUCTION.................................................................................................... 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: GENERAL INFORMATION .................................................................................... 9

2.01 Scope of this Manual ..................................................................................... 9

2.02 ULTIMA-150 Power Supply Description ......................................................... 9

2.03 ULTIMA-150 Power Supply Specifications..................................................... 9

2.04 The ULTIMA-150 System............................................................................. 10

2.05 Requirements to Complete System ............................................................. 10

2.06 Options, Accessories, and Replacement Parts............................................ 10

2.07 Introduction to Plasma Arc Welding ............................................................. 10

2.08 Theory of Operation ..................................................................................... 11

SECTION 3: INSTALLATION..................................................................................................... 13

3.01 Introduction .................................................................................................. 13

3.02 Site Location ................................................................................................ 13

3.03 Unpacking .................................................................................................... 13

3.04 Primary Input Power Connections................................................................ 13

3.05 Voltage Changeover..................................................................................... 15

3.06 Work Cable Connection ............................................................................... 16

3.07 Plasma and Shield Gas Connections........................................................... 16

3.08 Torch Connection ......................................................................................... 17

3.09 Remote Connections ................................................................................... 17

3.10 Filling Coolant Reservoir .............................................................................. 17

SECTION 4: OPERATION ........................................................................................................ 19

4.01 Introduction .................................................................................................. 19

4.02 Operating Controls and Indicators ............................................................... 19

4.03 Basic Operation ........................................................................................... 21

4.04 Torch Operation............................................................................................ 22

SECTION 5: GENERAL MAINTENANCE ................................................................................. 23

5.01 Introduction .................................................................................................. 23

5.02 General Maintenance................................................................................... 23

5.03 Basic Troubleshooting .................................................................................. 25

5.04 Basic Parts Replacement............................................................................. 28

TABLE OF CONTENTS (continued)

SECTION 6: PARTS REPLACEMENT ...................................................................................... 31

6.01 Introduction .................................................................................................. 31

6.02 Returns ........................................................................................................ 31

6.03 Ordering Information .................................................................................... 31

6.04 Complete Systems....................................................................................... 31

6.05 Power Supply Only....................................................................................... 32

6.06 Replacement Torches .................................................................................. 32

6.07 Options and Accessories ............................................................................. 33

APPENDIX I: CIRCUIT PROTECTION & WIRING ................................................................... 35

APPENDIX II: QUICK DISCONNECT LEADS ASSIGNMENT ................................................. 36

APPENDIX III: REMOTE WIRING ............................................................................................ 37

APPENDIX IV: OPERATIONAL FLOWCHART ......................................................................... 38

APPENDIX V: HOSE DIAGRAM ............................................................................................... 39

APPENDIX VI: TORCH PARTS................................................................................................. 40

APPENDIX VII: TORCH PARTS TABLE .................................................................................... 41

APPENDIX VIII: SCHEMATIC DIAGRAM ................................................................................. 42

APPENDIX VIII: SCHEMATIC DIAGRAM ................................................................................. 43

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
HEALTH.

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 processes. Y ou
must be very careful when cutting or welding any
metals which may contain one or more of the fol­lowing:

Antimony Chromium Mer-

cury

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.

Date: No v ember 15, 2001 1 GENERAL INFORMATION

• Never touch any parts that are electrically “live”
or “hot.”

• W ear 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.

• V entilate 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.

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 pr otected.

• T o 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

NOISE

2. ANSI Standard Z49.1, SAFETY IN WELDING AND
CUTTING, obtainable from the American Welding So­ciety, 550 N.W . LeJeune Rd, Miami, FL 33126

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.

• To protect your hearing from loud noise, wear
protective ear plugs and/or ear muffs. Protect oth­ers in the workplace.

• Noise levels should be measured to be sure the

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 F ACE PRO­TECTION, obtainable from American National Stan­dards Institute, 1430 Broadway, New York, NY 10018

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 2 Date: Nov ember 15, 2001

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

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

NOTE

Toute opération, procédure ou renseignement
général sur lequel il importe d’insister davantage
ou qui contribue à l’efficacité de fonctionnement
du système.

ATTENTION

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 W117.2, 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 Standar d 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

15. ANSI Standard Z88.2, PRACTICE FOR RESPIRA TOR Y
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 :

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.

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

Date: No v ember 15, 2001 3 GENERAL INFORMATION

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.

• 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 vana-

dium

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.

• 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.

• 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.

• 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

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.

GENERAL INFORMATION 4 Date: Nov ember 15, 2001

RAYONS D’ARC DE PLASMA

• Pour des renseignements sur la manière de tester le
bruit, consultez l’article 1, page 5.

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.

BRUIT

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

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

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

(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

sûrs.

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 repr esentative: 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 Year 2 Years 1 Year
Original Main Power Rectifier 3 Years 1 Year 2 Years 1 Year
Control PC Board 3 Years 1 Year 2 Years 1 Year
All Other Circuits And Components Including, 1 Year 1 Year 1 Year 1 Year

But Not Limited To, Starting Circuit,
Contactors, Relays, Solenoids, Pumps,
Power Switching Semi-Conductors

Consoles, Control Equipment, Heat 1 Year 1 Year 1 Year
Exchanges, And Accessory Equipment

Torch And Leads

Maximizer 300 Torch 1 Year 1 Year
SureLok Torches 1 Year 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. Transportation
charges to send products to an authorized warranty repair facility shall be the responsibility of the customer. All returned goods shall
be at the customer’s risk and expense. This warranty supersedes all previous Thermal warranties.

Effective: November 15, 2001

GENERAL INFORMATION 8 Date: Nov ember 15, 2001

SECTION 2:

GENERAL INFORMATION

2.01 Scope of this Manual

This manual provides operating instructions and basic
maintenance procedures for the Thermal Arc ULTIMA­150® Plasma W elding Power Supply. Service of this equip­ment is restricted to Thermal Dynamics trained person­nel; unqualified personnel are strictly cautioned against
attempting repairs or adjustments not covered in this
manual, at the risk of voiding the warranty .

Read this manual thoroughly . A complete understanding
of the capabilities and functions of the equipment will
assure the dependable operation for which it was designed.

2.02 ULTIMA-150 Power Supply

Description

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 @ 40ºC, 150 amp output
100% Duty Cycle @ 40°C, 100 amp output

3. Pilot Arc Output

2-15 amp V ariable, Continuous Pilot Arc
Pilot Arc Output 100% Duty Cycle @ 40º 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.

The ULTIMA-150 Plasma Welding Power Supply is one
integrated unit providing power , pilot control inverter , and
coolant recirculator . W ith output ranges from 0.5-15 amps
and 5-150 amps, the power supply is ideally suited for all
low current gas tungsten arc welding (GTAW) and auto­mated welding applications. Suitable for use with all des­ignated Thermal Dynamics plasma welding torches.

2.03 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 Transformer Module
only)

• 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 - Over temperature 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 re-energized to initiate the pilot arc after a fault
shutdown.

E. Gas Supply

Plasma Gas - 0.5-3.0 scfh
Shield Gas - 5.0-30 scfh

F. Coolant Reservoir Capacity

2 gallon Coolant Reservoir; Thermal Arc© Coolant
only

G. Weight

130 lbs (59 kg) - UL TIMA-150 Power Supply only
150 lbs (68kg) - shipping weight (including coolant

and torch)

H. Dimensions

18" high (457 mm) x 15" wide (381 mm) x 28.5" deep
(724 mm)

Manual 0-2472 9 SECTION 2: GENERAL INFORMATION