Tweco CE Ultima 150 Manuel d'utilisateur

RA THERMADYNE¨ CompanyªManual No. 0-2530October 4, 2002Operating ManualPlasma WeldingPower SupplyCE Ultima 150

GENERAL INFORMATION 4 Date: November 15, 2001• Eloignez toute fumée et gaz de votre zone de respira-tion. Gardez votre tête hors de la plume de fumé

Date: November 15, 2001 5 GENERAL INFORMATIONultra-violets très forts. Ces rayons d’arc nuiront à vosyeux et brûleront votre peau si vous ne vous pr

GENERAL INFORMATION 6 Date: November 15, 20019. Norme 70 de la NFPA, CODE ELECTRIQUE NA-TIONAL, disponible auprès de la National Fire Pro-tection Ass

Date: November 15, 2001 7 GENERAL INFORMATION1.07 Declaration of ConformityManufacturer: Thermal Dynamics CorporationAddress: 82 Benning StreetWest L

GENERAL INFORMATION 8 Date: November 15, 20011.08 Statement of WarrantyLIMITED WARRANTY: Thermal Dynamics® Corporation (hereinafter “Thermal”) warra

Manual 0-2530 9 SECTION 2: GENERAL INFORMATIONSECTION 2:GENERAL INFORMATION2.01 Scope of this ManualThis manual provides operating instructions and b

SECTION 2: GENERAL INFORMATION 10 Manual 0-25302.04 The ULTIMA-150 SystemThe ULTIMA-150 Plasma Welding System includes thefollowing components:• ULTI

Manual 0-2530 11 SECTION 2: GENERAL INFORMATIONBy forcing the plasma gas and electric arc through a smallorifice, Thermal Arc torches deliver a high

SECTION 2: GENERAL INFORMATION 12 Manual 0-2530

Manual 0-2530 13 SECTION 3: INSTALLATIONSECTION 3:INSTALLATION3.01 IntroductionThis section describes installation procedures for the UL-TIMA-150 Powe

SECTION 3: INSTALLATION 14 Manual 0-2530AC Input Power ConnectionA-00814Figure 3-1 Rear Panel Input Power Connection3.05 Work Cable ConnectionHigh fr

Manual 0-2530 15 SECTION 3: INSTALLATION3.06 Plasma and Shield GasConnectionsThe ULTIMA-150 Power Supply comes with two gas sup-ply hoses. Plasma and

SECTION 3: INSTALLATION 16 Manual 0-25303.08 Remote ConnectionsA. Using the STANDARD (J20) ConnectorThe J20 connector on the rear panel of the ULTIMA-

Manual 0-2530 17 SECTION 4: OPERATIONSECTION 4:OPERATION4.01 IntroductionThis section provides a description of the Power Supplyoperating controls and

SECTION 4: OPERATION 18 Manual 0-253010. Status Indicator Lights DetailCOOL PILOT DCGASTEMPACA-00823Figure 4-3 Status Lightsa. AC Power IndicatorGREE

Manual 0-2530 19 SECTION 4: OPERATIONC. Rear Panel1516171819202122A-00824Figure 4-4 Rear Panel15. Quick Disconnect Torch ConnectorConnects a PWH/M qu

SECTION 4: OPERATION 20 Manual 0-25304.03 Basic OperationNOTEFrequently review the safety precautions at the frontof this manual.1. SetupMake sure the

Manual 0-2530 21 SECTION 4: OPERATIONIf the current is controlled with either a remote deviceor the front panel pot, the current will be 0-100% ofthe

SECTION 4: OPERATION 22 Manual 0-2530

Manual 0-2530 23 SECTION 5: GENERAL MAINTENANCE5.02 General MaintenanceA. Power Supply MaintenanceThe only routine maintenance required for the power

WARNINGSRead and understand this entire Operating Manual and your employer’s safety practices before install-ing, operating, or servicing the equipm

SECTION 5: GENERAL MAINTENANCE 24 Manual 0-2530B. Coolant Filter MaintenanceThe Ultima-150 has three filters in the cooling system: theCoolant Filter

Manual 0-2530 25 SECTION 5: GENERAL MAINTENANCE2. Flushing the SystemAs part of general maintenance, periodically thecooling system should be flushed

SECTION 5: GENERAL MAINTENANCE 26 Manual 0-2530C. Plasma/Shield Gas Problems1. Gas light not ona. Gas tank(s) empty; not connected properly; not turn

Manual 0-2530 27 SECTION 5: GENERAL MAINTENANCE2. No pilot arc /weak pilot arca. Pilot current too low• Increase current by adjusting the Pilot Arc C

SECTION 5: GENERAL MAINTENANCE 28 Manual 0-2530G. Welding ProblemsSee the appropriate torch manual for torch troubleshoot-ing.5.04 Basic Parts Replac

Manual 0-2530 29 SECTION 5: GENERAL MAINTENANCE3. Clean the old thread sealer from the threads of theelbow fittings.4. Apply a thin coating of liquid

SECTION 5: GENERAL MAINTENANCE 30 Manual 0-2530E. Hose Assembly ReplacementThis subsection describes the replacement of the variousHose Assemblies us

Manual 0-2530 31 SECTION 6: PARTS REPLACEMENTSECTION 6:PARTS REPLACEMENT6.01 IntroductionThis section provides a breakdown of all ULTIMA-150parts th

SECTION 6: PARTS REPLACEMENT 32 Manual 0-2530C. ULTIMA 150 with 4A TorchDescriptionPWH-4A 70° with 12.5 ft. leadsPWH-4A 70° with 25 ft. leadsPWH-4A 9

Manual 0-2530 33 SECTION 6: PARTS REPLACEMENT2. 3A TorchesCatalog # Description2-2527 PWH-3A 70° with 12.5 ft. leads2-2599 PWH-3A 70° with 25 ft. le

TABLE OF CONTENTSSECTION 1: INTRODUCTION ... 11.01

SECTION 6: PARTS REPLACEMENT 34 Manual 0-2530E. Weld Sequencer PackagesCatalog # Description7-3105 Weld Sequencer Package, includes:7-3100 WT-1 Weld

Manual 0-2530 35 APPENDICESAPPENDIX I: CIRCUIT PROTECTION & WIRINGRecommended Circuit Protection and Wire SizesInput Power Input Current Recommen

APPENDICES 36 Manual 0-2530APPENDIX II: QUICK DISCONNECT LEADS ASSIGNMENTRear Panel Mounted Quick Disconnect Leads AssignmentViewed Looking at Rear P

Manual 0-2530 37 APPENDICESAPPENDIX III: REMOTE WIRINGNotes:1. Welding Arc/ON disabled without clos-ing TB1-3 to TB1-4. This must be doneby direct

APPENDICES 38 Manual 0-2530APPENDIX IV: OPERATIONAL FLOWCHARTACTIONON/OFF switch to OFF.RESULTAll indicators off. Power Supply fan off.ACTIONON/SET

Manual 0-2530 39 APPENDICESAPPENDIX V: HOSE DIAGRAMCoolant Filter Assembly(Rear Panel)Pump AssemblyRadiatorTop (In)Bottom (Out)T-ConnectionCoolant Pr

APPENDICES 40 Manual 0-2530APPENDIX VI: TORCH PARTS1. Torch Head Assembly2. Shield Cup3. Tip4. Electrode5. Liner6. Gas Distributor7. Gas Diffuser8.

Manual 0-2530 41 APPENDICESAPPENDIX VII: TORCH PARTS TABLEITEM PARTTORCH TYPENUMBER DESCRIPTIONPWH-2A Torch PWH-3A Torch PWH-4A Torch1 Torch Head Ass

APPENDICES 42 Manual 0-2530A-00864APPENDIX VIII: SCHEMATIC DIAGRAM

Manual 0-2530 43 APPENDICESA-00864

TABLE OF CONTENTS (continued)SECTION 6: PARTS REPLACEMENT ... 316.

Date: November 15, 2001 1 GENERAL INFORMATIONSECTION 1:GENERAL INFORMATION1.01 Notes, Cautions and WarningsThroughout this manual, notes, cautions, a

GENERAL INFORMATION 2 Date: November 15, 2001• Wear dry gloves and clothing. Insulate yourselffrom the work piece or other parts of the weldingcircu

Date: November 15, 2001 3 GENERAL INFORMATION6. ANSI Standard Z49.2, FIRE PREVENTION IN THE USEOF CUTTING AND WELDING PROCESSES, obtain-able from Ame