Victor 100 ULTRA-CUT Operating Manual
100
™
ULTRA-CUT
PLASMA CUTTING SYSTEM
W/AUTOMATED GAS CONTROL
Operating Manual
Art # A-08579_AB
Rev. AL Date: March 13, 2013 Manual # 0-5132
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 worldwide service network. To locate your nearest distributor or service agency call 1-800-426-1888, 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 market-leading, 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® 100
Automated Gas Contol, DFC-3000
Operating Manual No. 0-5132
Published by:
Thermadyne Corporation
82 Benning Street
West Lebanon, New Hampshire, USA 03784
(603) 298-5711
www.thermal-dynamics.com
© Copyright 2009,2010, 2011, 2012 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.
Licensed under U. S. Patent No. 5,070,227
Publication Date: June 24, 2009
Revision Date: March 13, 2013
Record the following information for Warranty purposes:
Where Purchased: ___________________________________
Purchase Date:______________________________________
Power Supply Serial #:_______________________________
Torch Serial #:_____________________________________
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 .................................................................................................. 1-2
1.04 Note, Attention et Avertissement .................................................................. 1-3
1.05 Precautions De Securite Importantes ........................................................... 1-3
1.06 Documents De Reference ............................................................................. 1-5
1.07 Declaration of Conformity ............................................................................. 1-6
1.08 Statement of Warranty .................................................................................. 1-7
SECTION 2: SPECIFICATIONS ................................................................................................. 2-1
2.01 General Description Of The System .............................................................. 2-1
2.02 Plasma Power Supply ................................................................................... 2-1
2.03 Remote Arc Starter ...................................................................................... 2-1
2.04 Gas Control Module ...................................................................................... 2-1
2.05 Precision Plasma Cutting Torch .................................................................... 2-1
2.06 Specifications & Electrical Requirements ..................................................... 2-2
2.07 System Component Layout .......................................................................... 2-2
2.08 Power Supply Dimensions ............................................................................ 2-3
2.09 Power Supply Rear Panel Features ............................................................... 2-4
2.10 Gas Requirements ........................................................................................ 2-5
2.11 Gas Applications .......................................................................................... 2-5
2.12 XTTM-300 Torch Specifications .................................................................... 2-6
SECTION 3: INSTALLATION ...................................................................................................... 3-1
3.01 Installation Requirements ............................................................................. 3-1
3.02 System Layout ............................................................................................. 3-2
3.03 Cables & Leads Identification ....................................................................... 3-3
3.04 Lift the Power Supply .................................................................................... 3-4
3.05 Remove the Connections Cover ................................................................... 3-5
3.06 Connect Work Cable and Pilot and Negative Leads....................................... 3-8
3.07 Ground Connections ..................................................................................... 3-9
3.08 Connect Coolant Leads ................................................................................3-12
3.09 Connect Control Cables for CNC, Remote Arc Starter, and DMC-3000 ........ 3-13
3.10 Connect TSC-3000 Cable and DMC-3000 Fiber Optic Cable to CCM............ 3-14
3.11 Set Switches on the Command - Control Module ......................................... 3-16
3.12 Height Control Connections ......................................................................... 3-18
3.13 DMC-3000 Gas Manifold Control Installation ................................................ 3-18
3.14 DPC-3000 Gas Pressure Control Installation ............................................... 3-22
3.15 Fiber Optic Cable Installation from CCM to DMC-3000. ............................... 3-25
3.16 Fiber Optic Cable Installation From DMC-3000 to DPC-3000........................ 3-28
3.17 Install TSC-3000 Touch Screen Control ........................................................ 3-30
3.18 Install Remote Arc Starter ...........................................................................3-31
3.19 Connecting Torch ......................................................................................... 3-40
3.20 Install Consumable Torch Parts ....................................................................3-41
3.21 Complete the Installation ............................................................................. 3-45
TABLE OF CONTENTS (continued)
SECTION 4: OPERATION .......................................................................................................... 4-1
4.01 Power Supply Control Panel .......................................................................... 4-1
4.02 Start-Up Sequence ....................................................................................... 4-2
4.03 TSC-3000 Navigation Functions ................................................................... 4-2
4.04 TSC-3000 Initial Setup ONLY ........................................................................ 4-3
4.05 TSC-3000 Selecting New Process ................................................................ 4-4
4.06 TSC-3000 Selecting Recently Used Process ................................................ 4-5
4.07 TSC-3000 Creating a Custom Process ......................................................... 4-6
4.08 Back up and Restoration of Custom Processes. ........................................... 4-8
4.09 Sequence of Operation ................................................................................ 4-11
4.10 Gas Selection .............................................................................................. 4-14
4.11 Power Supply Status Codes ........................................................................ 4-16
4.12 DMC-3000 Status Codes ............................................................................. 4-19
4.13 DPC-3000 Status Codes .............................................................................. 4-21
SECTION 5: MAINTENANCE .................................................................................................... 5-1
5.01 General Maintenance .................................................................................... 5-1
5.02 External Coolant Filter Cleaning Procedure ................................................... 5-1
5.03 Internal Coolant Filter Cleaning Procedure .................................................... 5-2
5.04 Coolant Replacement Procedure ................................................................... 5-2
5.05 Remote Arc Starter: Service Chart .............................................................. 5-3
5.06 Remote Arc Starter: Spark Gap Adjustment ................................................ 5-4
SECTION 6: REPLACEMENT ASSEMBLIES & PARTS ........................................................... 6-1
6.01 Main Component / System Replacement ...................................................... 6-1
6.02 System Layout ............................................................................................. 6-2
6.03 Recommended Gas Supply Hose ................................................................. 6-2
6.04 Leads and Cables ......................................................................................... 6-3
6.05 Power Supply External Replacement Parts .................................................. 6-10
6.06 Power Supply Replacement Parts - Right Side ............................................ 6-11
6.07 Power Supply Replacement Parts - Right Side ............................................ 6-12
6.08 Power Supply Replacement Parts - Right Side ............................................ 6-13
6.09 Power Supply Replacement Parts - Front Panel ........................................... 6-14
6.10 Power Supply Replacement Parts - Front Panel ........................................... 6-15
6.11 Power Supply Replacement Parts - Right Side ............................................ 6-16
6.12 Power Supply Replacement Parts - Rear Panel ............................................ 6-17
6.13 Power Supply Replacement Parts - Right Side ............................................ 6-18
6.14 Power Supply Replacement Parts ................................................................ 6-19
6.15 Power Supply Replacement Parts - Right Side ............................................ 6-20
6.16 Power Supply Replacement Parts ................................................................ 6-21
6.17 Power Supply Replacement Parts - Right Side ............................................ 6-22
6.18 DFC-3000 Automated Gas Control System Replacement Componants ........6-23
6.19 DMC-3000 Gas Control Module Replacement Parts ..................................... 6-24
6.20 DPC-3000 Gas Control Module Replacement Parts ..................................... 6-25
6.21 TSC-3000 Touch Screen Control Remote and Internal Replacement Parts ... 6-26
6.22 Remote Arc Starter (RAS-1000) Replacement Parts.................................... 6-27
6.23 Remote Arc Starter (RAS-1000) Replacement Parts.................................... 6-28
6.24 Command & Control Module For Auto Gas Control - Replacement Parts ..... 6-29
TABLE OF CONTENTS (continued)
SECTION 7. TORCH MAINTENANCE.................................................................................... 7-1
7.01 Consumable Removal ................................................................................... 7-1
7.02 O-Ring Lubrication ........................................................................................ 7-2
7.03 Parts Wear................................................................................................... 7-3
7.04 Torch Consumables Installation .................................................................... 7-4
7.05 Coolant Leak Trouble-Shooting ...................................................................... 7-6
APPENDIX 1: Remote Arc Starter Schematic .......................................................................... A-1
APPENDIX 2: DMC-3000 PCB Layout ...................................................................................... A-2
APPENDIX 3: DPC-3000 PCB Layout ...................................................................................... A-3
APPENDIX 4: TSC-3000 PCB Layout ...................................................................................... A-4
APPENDIX 5: CCM Input / Output PCB Layout ........................................................................ A-5
APPENDIX 6: CCM CPU PCB Layout ..................................................................................... A-6
APPENDIX 7: CNC .................................................................................................................... A-8
A7.01 CNC functions ............................................................................................ A-8
A7.02 CNC Input / Output Descriptions................................................................. A-9
A7.03 Simplified CNC Circuit. ............................................................................. A-10
A7.04 CNC Connections. .................................................................................... A-11
APPENDIX 8: SERIAL COMMUNICATIONS ........................................................................... A-12
A8.01 Cables and Switch Settings for 2 and 4 Wire ............................................ A-12
APPENDIX 9: Schematic, 230-460V, Chopper Pilot ................................................................. A-14
APPENDIX 9: Schematic, 230-460V, Chopper Pilot Cont. ........................................................ A-16
APPENDIX 10: Schematic, CCC 400V, w/ Chopper Pilot ......................................................... A-18
APPENDIX 10: Schematic, CCC 400V, w/ Chopper Pilot Cont. ................................................ A-20
APPENDIX 11: Schematic, CE 400V, Chopper Pilot ................................................................ A-22
APPENDIX 11: Schematic, CE 400V, Chopper Pilot Cont. ....................................................... A-24
APPENDIX 12: Schematic, CSA 600V, Chopper Pilot .............................................................. A-26
APPENDIX 12: Schematic, CSA 600V, Chopper Pilot Cont. ..................................................... A-28
APPENDIX 13: Schematic, DFC-3000 Auto Gas Box System ................................................. A-30
APPENDIX 14: PUBLICATION HISTORY................................................................................ A-32
TABLE OF CONTENTS (continued)
NOTE
provided separately.
SECTION 8. TORCH OPERATION, is
ULTRA-CUT 100
!
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
• 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. You 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.)
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 1-603-298-5711 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.
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.
Manual 0-5132
1-1
ULTRA-CUT 100
• 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.
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
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.
• 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 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 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:
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.
LEAD WARNING
This product contains chemicals, including lead, or otherwise produces chemicals known to the State of California to cause cancer, birth
defects and other reproductive harm. Wash hands after handling.
(California Health & Safety Code § 25249.5 et seq.)
1-2
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 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, 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
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 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 Standard AWSF4.1, RECOMMENDED SAFE PRACTICES FOR THE PREPARATION FOR
WELDING AND CUTTING OF CONTAINERS AND PIPING
Manual 0-5132
THAT HAVE HELD HAZARDOUS SUBSTANCES, obtainable
!
from the American Welding Society, 550 N.W. LeJeune Rd,
Miami, FL 33126
ULTRA-CUT 100
FUMÉE et GAZ
15. ANSI Standard Z88.2, PRACTICE FOR RESPIRATORY 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.
ATTENTION
Toute procédure pouvant résulter l’endommagement du
matériel en cas de non-respect de la procédure 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.
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 différents 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.)
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 votre distributeur local si vous avez
des questions.
Manual 0-5132
CHOC ELECTRIQUE
Les chocs électriques peuvent blesser ou même tuer. Le procédé au jet de
plasma requiert et produit de l’énergie 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.
1-3
ULTRA-CUT 100
• Montez et maintenez le matériel conformément au Code électrique
national des Etats-Unis. (Voir la page
• 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.
5,
article 9.)
• 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
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. Vous dú4ez vous
protéger 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.
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 oculaire.
• 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.
PLOMB AVERTISSEMENT
Ce produit contient des produits chimiques, comme le plomb, ou
engendre des produits chimiques, reconnus par l’état de Californie
comme pouvant être à l’origine de cancer, de malformations fœtales ou
d’autres problèmes de reproduction. Il faut se laver les mains après
toute manipulation. (Code de Californie de la sécurité et santé,
paragraphe 25249.5 et suivants)
1-4
Manual 0-5132
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 TRAVAIL 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 TRAVAIL ET DANS LES ECOLES,
disponible de l’Institut Américain des Normes Nationales (American
National Standards Institute), 1430 Broadway, New York, 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
ULTRA-CUT 100
14. Norme AWSF4.1 de l’Association Américaine de Soudage,
RECOMMANDATIONS DE PRATIQUES SURES POUR LA
PRÉPARATION 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, PRATIQUES DE PROTECTION RESPIRATOIRE,
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 York, NY 10018
7. Norme A6.0 de l’Association Américaine du Soudage (AWS), LE
SOUDAGE ET LA COUPE DE CONTENEURS AYANT 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, Batterymarch Park, Quincy, MA 02269
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
Manual 0-5132
1-5
ULTRA-CUT 100
1.07 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’ (2006/95 EC) 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.
* CENELEC EN50199 EMC Product Standard for Arc Welding Equipment.
* ISO/IEC 60974-1 (BS 638-PT10) (EN 60 974-1) (EN50192) (EN50078) applicable to plasma cutting equipment and associated accessories.
* 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 cutting 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,
1-6
England PR6 7BX
Manual 0-5132
ULTRA-CUT 100
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 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 WARRANTY OF MERCHANT ABILITY OR FITNESS FOR A P ARTICULAR
PURPOSE.
LIMIT A 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 INVALID 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 Y ear
Labor
Torch And Leads
TM
XT
-300 / XTTM-301 T orch (Excluding Consumable Parts) 1 Year 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 transportation cost s 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 August 19, 2005
Manual 0-5132
1-7
ULTRA-CUT 100
1-8
Manual 0-5132
ULTRA-CUT 100
SECTION 2: SPECIFICATIONS
2.01 General Description Of The System
A typical Ultra-Cut® 100 system configuration will include:
• 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.
2.02 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.
2.03 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.
2.04 Gas Control Module
This module allows remote setting of gas selection, pressures, and flows together with setting of cutting current.
2.05 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. 0-5132 2-1 SPECIFICATIONS
ULTRA-CUT 100
2.06 Specifications & Electrical Requirements
Ultra-Cut 100 Specifications & Design Features
Input Power & Current 208/230V - 460V , 1/ 3 ph, 50 / 60 Hz
Max OCV (U
Minim um Out put Current 10 Amps
Max Out put Current 100 Amps
Output V oltage 60 - 230 vdc
Duty Cy c l e Rati ng 100% @ 100A, 180V
Ambi ent Temperature
for Dut y Cy cl e Rati ng
Operating range 14°F to 122°F (-10°C to + 50°C)
Power Factor 0. 70 @ 100 A DC Output
Cooling Forced A i r (Class F)
Input Power Input Current Sugges t ed S i z es (See Not e)
Vol tage Freq. 3-Ph 3-Ph Fuse (A mps ) W i re (AWG)
(Volts) (Hz) (kVA) (Amps) 3-Ph 3-Ph
208 50/60 23 64 80
230 50/60 24 60 75
40050284050
400 (CE) 50 28 40 50
460 50/60 26 33 40
600 50/60 25 24 30 #8
Line Voltages wit h S ugges ted Circui t P rot ect ion and Wire Si zes
Bas ed on Nati onal E l ec t ri c Code and Canadian Electri cal Code
1
Extra Hard Usage Type SO, SOW, SOO, SOOW, ST, STW, STO, STOW, STOO, STOOW
) 380 vdc
0
104F° (40°C)
Ultra-Cut 100 Power S upply
#4
#4
#6
#6
#8
1
1
1
1
1
2.07 System Component Layout
125’ / 38.1 m Maximum Length
Pilot Return
Negative
Coolant Supply
Primary power
CNC
To uch
Screen
Controller
Art # A-09124
Ultra-Cut
Power
Supply
W
P
V
Coolant Return
Control Cable
Fiber Optic
Control Cable
Ground Cable
Only When
DMC Mounted
On Top Of PS
L
K
DMC-3000
F
F
175’ / 53.3 m Maximum Length
Gas
Console
175’ / 53.3 m Maximum Length
A
B
Remote
C
D
Starter
E
Plasma Gas
Fiber Optic
Secondary
Preflow
Control Cable
Water Shield
Marking
Work Cable
H
L
Q
R
S
T
U
O
DPC-3000
100’ / 30.5 m Maximum Length
Pilot Return
Arc
Gas
Control
Coolant Supply
Coolant Return
Plasma Gas
Shield Gas
Shield
Shield
Positioning Tube
I
J
G
Torch
Work
SPECIFICATIONS 2-2 Manual No. 0-5132
2.08 Power Supply Dimensions
41.25 inch
1050 mm
ULTRA-CUT 100
27 inch
680 mm
Art # A-04793
33 inch
840 mm
37.75 inch
960 nm
27.5 inch
700 mm
343 lb / 156 kg
Manual No. 0-5132 2-3 SPECIFICATIONS
ULTRA-CUT 100
2.09 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
SPECIFICATIONS 2-4 Manual No. 0-5132
ULTRA-CUT 100
2.10 Gas Requirements
The customer will provide all gases and pressure regulators. Gases must be of high quality. Pressure regulators
shall be double stage. The chart includes gases which may not be used in all applications.
Ultra-Cut 100 Power S uppl y: Gas Pressures, Fl ows, and Qua l i ty Require m ents
Gas Quality Minimum Press ure Flow
O
(Oxygen)
2
(Nitrogen)
N
2
99.5% Purity
(Liquid rec om mended)
99.5% Purity
(Liquid rec om mended)
<1000 ppm O
ppm H
2
O)
2
, <32
120 psi
8.3 bar / 827 k Pa
120 psi
8.3 bar / 827 k Pa
70 scfh (1982 l/h)
200 scfh (5700 l/h)
Compressed
or Bottled Air
H35 (Argon-Hydrogen)
H35 = 35% Hydrogen,
65% A rgon
Ar (A rg on)
O (Water) See Note 2 50 psi (3. 5 bar) 10 gph (38 lph)
H
2
: The air sourc e m ust be adequat el y filtered to remove all oil or greas e. Oi l or greas e
Note 1
Clean, Dry ,
Free of Oil (s ee Not e 1)
99.995% P uri ty
(gas recommended)
99-995% Puri ty
(gas rec om m ended)
120 psi
8.3 bar / 827 k Pa
120 psi
8.3 bar / 827 k Pa
80 psi
5.5 bar / 550 k Pa
244 scfh (6910 l/h)
90 scfh (2550 l/h)
21 scfh (600 l/h)
cont am i nation from c ompress ed or bot t l ed ai r can cause fires i n conjunc tion wi t h oxy gen.
For filt ering, a coal esc i ng fil t er abl e t o fil ter to 0. 01 m i crons should be placed as close as
possible to the gas inl et s on t he Gas Control M odul e.
: The tap water s ource does not need to be deionized, but in wat er s ys tems wit h extrem el y hi gh
Note 2
mineral content a water s oft ener is rec omm ended. Tap water with hi gh l evels of particulat e m at ter mus t be
filtered.
2.11 Gas Applications
Ultra-Cut-100 Gas A ppli c ations
MATERIAL
OPERATION
30A CUT
50 A CUT
70 A CUT
85A CUT
100 A CUT
PREFLOW PLASMA SHIELD PREFLOW PLASMA SHIELD PREFLOW PLASMA SHIELD
MILD ST EEL ST AINL ES S S T EEL ALUMI NUM
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
N
2
AirO
2
N
2
H35 N
N
2
H20N2N
2
N
2
2
2
2
H35 N
2
H20
H20
H20
2
H20
Manual No. 0-5132 2-5 SPECIFICATIONS
ULTRA-CUT 100
2.12 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
SPECIFICATIONS 2-6 Manual No. 0-5132
2.74"
69.55 mm
1.57"
39.96 mm
1.49"
37.8 mm
B. Torch Specifications
TM
XT
-300 Torch Rat i ngs
for us e wi th Ul tra-Cu t 100 Powe r Supply
Ambient
Tempera ture
104° F
40° C
Duty Cycl e 100% @ 100 Am ps
Maxi m um Current 100 Am ps
Volt age (V
)500V
peak
Arc S t ri k i ng V ol t age 10kV
Current
TM
-300 Torc h Gas Speci fic ations
XT
Up to 100 Amps, DC,
Straight Polarity
Compress ed A i r,
Plasma Gases:
Oxygen,
Nit rog en, H35
Compress ed A i r,
Shield Gases:
Oxygen,
Nitrogen, Water
Marking Gas
Argon
ULTRA-CUT 100
Operating P ressure
Maxi m um Input P res sure 135 psi / 9.3 bar
C. Leads Lengths
Gas Lead Assemblies
D. Torch Parts (Generic Parts Shown)
125 psi ± 10 ps i
8.6 bar ± 0.7 bar
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 Cup
Manual No. 0-5132 2-7 SPECIFICATIONS
Shield Cap
Shield Gas
Distributor
Plasma Gas
Tip
Distributor
Electrode
Cartridge
ULTRA-CUT 100
E. 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.
F. Type of Cooling
Combination of gas stream through torch and liquid
cooling.
SPECIFICATIONS 2-8 Manual No. 0-5132
SECTION 3: INSTALLATION
3.01 Installation Requirements
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.
Ultra-Cut 100 Power S upply
Input Power Input Current Sugges t ed S i z es (See Not e)
Vol tage Freq. 3-Ph 3-Ph Fuse (A mps ) W i re (AWG)
(Volts) (Hz) (kVA) (Amps) 3-Ph 3-Ph
208 50/60 23 64 80
230 50/60 24 60 75
40050284050
400 (CE) 50 28 40 50
460 50/60 26 33 40
600 50/60 25 24 30 #8
Line Voltages wit h S ugges ted Circui t P rot ect ion and Wire Si zes
Bas ed on Nati onal E l ec t ri c Code and Canadian Electri cal Code
1
Extra Hard Usage Type SO, SOW, SOO, SOOW, ST, STW, STO, STOW, STOO, STOOW
ULTRA-CUT 100
1
#4
1
#4
1
#6
1
#6
1
#8
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.
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.
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
7-3580 'Extra-Cool
7-3581 'Ultra-Cool
7-3582 'Ext reme Cool
* For mixing wit h D-I Cool
TM
'
TM
'
TM
' Concentrate* -76° F / -60° C
TM
7-3583
Manual No. 0-5132 3-1 INSTALLATION
25 / 75 10° F / -12° C
50 / 50 -27° F / -33° C
ULTRA-CUT 100
3.02 System Layout
Refer to section 3.05 for ground connections and ground cables.
175’ / 53.3 m Maximum Length
Primary power
F
F1
W
CNC
P
To uch
Screen
Controller
Art # A-09124_AC
Pilot Return
Ultra-Cut
Power
Supply
Fiber Optic
Control Cable
Ground Cable
Only When
DMC Mounted
On Top Of PS
V
125’ / 38.1 m Maximum Length
Negative
Coolant Supply
Coolant Return
Control Cable
L
K
DMC-3000
F
F
175’ / 53.3 m Maximum Length
Gas
Console
Plasma Gas
Fiber Optic
Shield Gas
Preflow
Control Cable
Water Shield
Marking
Work Cable
F1
100’ / 30.5 m Maximum Length
A
B
C
D
E
H
L
Q
R
S
T
U
O
Pilot Return
Remote
Arc
Starter
DPC-3000
Gas
Control
Shield
Coolant Supply
Coolant Return
Shield
Plasma Gas
Shield Gas
Positioning Tube
F
I
J
G
To rc h
Work
INSTALLATION 3-2 Manual No. 0-5132
3.03 Cables & Leads Identification
ULTRA-CUT 100
B
C
D
E
F
F1
G
#8 AWG Cable
A
#1 AWG Cable
Green
Red
14
Green / Yellow #4 AWG (16 mm2)
Green / Yellow 1/0 (50 mm2)
Green
Red
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-09125_AC
I
J
K
L
H, Q,
R, T, U
S,V
16 pin
O
P, W
37
14/11
1/0 Cable (50 mm2 )
Plasma Gas Lead,
Torch Valve to Torch
Shield Gas Lead,
Torch Valve to Torch
Control Cable,
From Power Supply
Fiber Optic Cable,
Power Supply to
DMC-3000
For use with
DFC-3000
S - Control Cable,
DMC-3000
V - TSC-3000 to PS
Work Cable
P - CNC Cable (14 Wire)
W - CNC Communitcation
Cable (11 Wire)
to
DPC-3000
Manual No. 0-5132 3-3 INSTALLATION
ULTRA-CUT 100
3.04 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. Ensure all panels and screws are
secure prior to lifting.
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.
INSTALLATION 3-4 Manual No. 0-5132
Art # A-04796
ULTRA-CUT 100
3.05 Remove the Connections Cover
The primary power cable must be supplied by the end user and connected to the power supply.
Remove the connections cover on the rear of the Power Supply. Use caution when removing the panel; there is a
ground wire connected to the inside of the panel. Do not disconnect this wire.
Connections Cover
(Removed)
Connection Panel
Art # A-04797
Manual No. 0-5132 3-5 INSTALLATION
ULTRA-CUT 100
Check / Adjust Input Voltage Configuration for 208/230 and 460V Systems
1. The 208/230 and 460 V power supply includes a voltage configuration board which must be positioned to
match the primary input voltage. Remove the power supply left side panel and locate the voltage configuration
board. The input voltage configuration is shown at the top of the board.
2. If necessary, disconnect the jumper at the top right corner of the board, remove the board and re-install it with
the correct input voltage shown at the top of the board.
3. Re-connect the jumper. Re-install the power supply side panel.
Inverter Module
1. Unplug connector
208/230V / 460V
Input Voltage Board
(Shown in 460V Position)
2. Remove bolts.
3. Invert board.
4. Re-install board.
5. Plug in connector.
Art # A-04856_AB
INSTALLATION 3-6 Manual No. 0-5132
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