Thermal Dynamics Ultra-cut 300 User manual

300
Operating Manual
PLASMA CUTTING SYSTEM
ULTRA-CUT™
Rev. AG.01 Date: July 10, 2007 Manual # 0-4819
OperatingFeatures:
Art # A-04816

WE APPRECIATE YOUR BUSINESS!
Congratulations on your new Thermal Dynamics product. We are proud
to have you as our customer and will strive to provide you with the
best service and reliability in the industry. This product is backed by
our extensive warranty and world-wide service network. To locate your
nearest distributor or service agency call 1-800-426-1888, or visit us
on the web at www.thermal-dynamics.com.
This Operating Manual has been designed to instruct you on the cor-
rect use and operation of your Thermal Dynamics product. Your satis-
faction 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-lead-
ing, dependable products that have stood the test of time. We pride
ourselves on technical innovation, competitive prices, excellent deliv-
ery, 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 judge-
ment, the Manufacturer assumes no liability for its use.
Plasma Cutting Power Supply, Ultra-Cut® 300
Operting Manual No. 0-4819
Published by:
Thermadyne Corporation
82 Benning Street
West Lebanon, New Hampshire, USA 03784
[phone]
www.thermal-dynamics.com
© Copyright 2005,2006,2007 by
Thermadyne Corporation
All rights reserved.
Reproduction of this work, in whole or in part, without written permission of the
publisher is prohibited.
The publisher does not assume and hereby disclaims any liability to any party for
any loss or damage caused by any error or omission in this Manual, whether
such error results from negligence, accident, or any other cause.
Printed in the United States of America
Licensed under U. S. Patent No. 5,070,227
Publication Date: July 10, 2007
Record the following information for Warranty purposes:
Where Purchased: ___________________________________
Purchase Date:______________________________________
Power Supply Serial #:_______________________________
Torch Serial #:_______________________________________

This page intentionally blank

TABLE OF CONTENTS
SECTION 1:
GENERAL INFORMATION ................................................................................................ 1-1
1.01 Notes, Cautions and Warnings ...................................................................... 1-1
1.02 Important Safety Precautions ....................................................................... 1-1
1.03 Publications .................................................................................................. 1-3
1.04 Declaration of Conformity ............................................................................. 1-5
1.05 Statement of Warranty .................................................................................. 1-6
SECTION 2: SPECIFICATIONS ................................................................................................. 2-1
General Description Of The System ...................................................................... 2-1
Plasma Power Supply ........................................................................................... 2-1
Remote Arc Starter............................................................................................... 2-1
Gas Control Module .............................................................................................. 2-1
Precision Plasma Cutting Torch ............................................................................ 2-1
Specifications & Electrical Requirements ............................................................. 2-2
System Component Layout .................................................................................. 2-2
Power Supply Dimensions .................................................................................... 2-3
Power Supply Rear Panel Features ....................................................................... 2-4
Gas Requirements ................................................................................................ 2-5
Gas Applications .................................................................................................. 2-5
XTTM-300 Torch Specifications ............................................................................ 2-6
SECTION 3: INSTALLATION ...................................................................................................... 3-1
A. Installation Requirements ............................................................................. 3-1
B. Cooling System Requirements ...................................................................... 3-1
C. System Layout ............................................................................................. 3-2
D. Cables & Leads Identification ....................................................................... 3-3
D. Lift the Power Supply .................................................................................... 3-4
E -1. Set Switches on the Command - Control Module (Type 1 Module) ................ 3-5
E -2. Set Switches on the Command - Control Module (Type 2 Module) ................ 3-7
F. Remove the Connections Cover ................................................................... 3-9
G. Connect Work Cable and Pilot and Negative Leads ...................................... 3-10
H. Check / Adjust Input Voltage Configuration .................................................. 3-11
I. Connect Input Power and System Ground Cables ........................................ 3-12
J. Ground Connections .................................................................................... 3-13
K. Connect Coolant Leads ................................................................................3-15
L. Connect Control Cables for CNC, Remote Arc Starter, and GCM ................. 3-16
M. Gas Control Module Installation ................................................................... 3-19
N. Fiber Optic Cable Installation .......................................................................3-20
O. Gas Control Module: Control, Input, and Output Connections.......................3-22
P. Install Remote Arc Starter ........................................................................... 3-23
Q. Original & XTL Torch Valve Installation ......................................................... 3-32
R. Connecting Torch ......................................................................................... 3-33
S. Install Consumable Torch Parts.................................................................... 3-34
T. Complete the Installation ............................................................................. 3-37

TABLE OF CONTENTS (continued)
SECTION 4: OPERATION .......................................................................................................... 4-1
Power Supply Control Panel .................................................................................. 4-1
Start-Up Sequence ............................................................................................... 4-2
Gas Control Module Operation .............................................................................. 4-3
Sequence Of Operation ........................................................................................ 4-7
Gas Selection ...................................................................................................... 4-10
Power Supply Status Codes ................................................................................ 4-11
Remote Arc Starter: Service Chart ..................................................................... 4-14
Remote Arc Starter: Spark Gap Adjustment ....................................................... 4-15
SECTION 5: MAINTENANCE .................................................................................................... 5-1
External Coolant Filter Cleaning Procedure ........................................................... 5-1
Internal Coolant Filter Cleaning Procedure ............................................................ 5-2
Coolant Replacement Procedure ........................................................................... 5-2
SECTION 6: REPLACEMENT ASSEMBLIES & PARTS ........................................................... 6-1
System Layout ..................................................................................................... 6-2
Leads and Cables ................................................................................................. 6-3
Optional Gas Supply Leads .................................................................................. 6-8
Power Supply External Replacement Parts ........................................................... 6-9
Power Supply Replacement Parts - Right Side ..................................................... 6-10
Power Supply Replacement Parts - Right Side ..................................................... 6-11
Power Supply Replacement Parts - Right Side ..................................................... 6-12
Power Supply Replacement Parts - Front Panel ................................................... 6-13
Power Supply Replacement Parts - Front Panel ................................................... 6-14
Power Supply Replacement Parts - Right Side ..................................................... 6-15
Power Supply Replacement Parts - Rear Panel .................................................... 6-16
Power Supply Replacement Parts - Right Side ..................................................... 6-17
Power Supply Replacement Parts ........................................................................ 6-18
Power Supply Replacement Parts - Right Side ..................................................... 6-19
Power Supply Replacement Parts ........................................................................ 6-20
Power Supply Replacement Parts - Right Side ..................................................... 6-21
Power Supply Replacement Parts - Right Side ..................................................... 6-22
Gas Control Module (GCM-2010) Replacement Parts .......................................... 6-23
Gas Control Module (GCM-2010) Replacement Parts .......................................... 6-24
Remote Arc Starter (RAS-1000) Replacement Parts ............................................6-25
Remote Arc Starter (RAS-1000) Replacement Parts ............................................6-26
Command & Control Module Type 1- Replacement Parts .................................. 6-27
Command & Control Module Type 2 - Replacement Parts ................................. 6-28
Torch Valve Assembly Replacement Parts ...........................................................6-29
XTL Torch Valve Assembly External Replacement Parts ......................................6-30
XTL Torch Valve Assembly Internal Replacement Parts .......................................6-31

TABLE OF CONTENTS (continued)
SECTION 7: TORCH MAINTENANCE.................................................................................... 7-1
A. Consumable Removal ................................................................................... 7-1
B. O-Ring Lubrication ........................................................................................ 7-2
C. Parts Wear .................................................................................................... 7-2
D. Torch Consumables Installation .................................................................... 7-3
E. Coolant Leak Trouble-Shooting ...................................................................... 7-5
APPENDIX 1: Remote Arc Starter Schematic .......................................................................... A-1
APPENDIX 2: Gas Control and Torch Valve Schematic ............................................................. A-2
APPENDIX 3: Gas Control Module ............................................................................................ A-4
APPENDIX 4: Gas Control Module PCB Layout ....................................................................... A-5
APPENDIX 5: Gas Control Display Module PCB Layout ........................................................... A-6
APPENDIX 6: CCM CPU PCB Layout ...................................................................................... A-7
APPENDIX 7: CCM Input-Output PCB Layout .......................................................................... A-8
APPENDIX 8: CNC - Control Module PCB Connections ............................................................ A-9
CNC functions. ................................................................................................... A-10
CNC Input / Output Descriptions ......................................................................... A-11
Simplified CNC Circuit. ....................................................................................... A-12
APPENDIX 9: Schematic, 230-460V Power Supply .................................................................. A-14
APPENDIX 10: Schematic, CCC 400V Power Supply .............................................................. A-16
APPENDIX 11: Schematic, CE 400V Power Supply ................................................................. A-18
APPENDIX 12: Schematic, CSA 600V Power Supply .............................................................. A-20
APPENDIX 13: Publication History ......................................................................................... A-22
Global Customer Service Contact Information ...................................................... A-2
NOTE:
The Section 8 torch operaton
section is provided separately.

TABLE OF CONTENTS (continued)

Manual 0-4819 1-1 GENERAL INFORMATION
SECTION 1:
GENERAL INFORMATION
1.01 Notes, Cautions and Warnings
Throughout this manual, notes, cautions, and warnings are used to highlight important information. These highlights
are categorized as follows:
NOTE
An operation, procedure, or background information which requires additional emphasis or is helpful in
efficient operation of the system.
CAUTION
A procedure which, if not properly followed, may cause damage to the equipment.
WARNING
A procedure which, if not properly followed, may cause injury to the operator or others in the operating area.
1.02 Important Safety Precautions
WARNINGS
OPERATION AND MAINTENANCE OF PLASMA ARC EQUIPMENT CAN BE DANGEROUS AND HAZ-
ARDOUS 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.
• 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 Beryllium
Arsenic Cobalt Nickel Lead
Barium Copper Selenium Silver
Cadmium Manganese Vanadium

GENERAL INFORMATION 1-2 Manual 0-4819
• Always read the Material Safety Data Sheets (MSDS) that should be supplied with the material you are using.
These MSDSs will give you the information regarding the kind and amount of fumes and gases that may be
dangerous to your health.
• For information on how to test for fumes and gases in your workplace, refer to item 1 in Subsection 1.03,
Publications in this manual.
• Use special equipment, such as water or down draft cutting tables, to capture fumes and gases.
• Do not use the plasma torch in an area where combustible or explosive gases or materials are located.
• Phosgene, a toxic gas, is generated from the vapors of chlorinated solvents and cleansers. Remove all sources
of these vapors.
• This product, when used for welding or cutting, produces fumes or gases which contain chemicals known to the
State of California to cause birth defects and, in some cases, cancer. (California Health & Safety Code Sec.
25249.5 et seq.)
ELECTRIC SHOCK
Electric Shock can injure or kill. The plasma arc process uses and produces high voltage electrical energy. This
electric energy can cause severe or fatal shock to the operator or others in the workplace.
• Never touch any parts that are electrically “live” or “hot.”
• Wear dry gloves and clothing. Insulate yourself from the work piece or other parts of the welding circuit.
• Repair or replace all worn or damaged parts.
• Extra care must be taken when the workplace is moist or damp.
• Install and maintain equipment according to NEC code, refer to item 9 in Subsection 1.03, Publications.
• Disconnect power source before performing any service or repairs.
• Read and follow all the instructions in the Operating Manual.
FIRE AND EXPLOSION
Fire and explosion can be caused by hot slag, sparks, or the plasma arc.
• Be sure there is no combustible or flammable material in the workplace. Any material that cannot be removed
must be protected.
• Ventilate all flammable or explosive vapors from the workplace.
• Do not cut or weld on containers that may have held combustibles.
• Provide a fire watch when working in an area where fire hazards may exist.
• Hydrogen gas may be formed and trapped under aluminum workpieces when they are cut underwater or while
using a water table. DO NOT cut aluminum alloys underwater or on a water table unless the hydrogen gas can
be eliminated or dissipated. Trapped hydrogen gas that is ignited will cause an explosion.
NOISE
Noise can cause permanent hearing loss. Plasma arc processes can cause noise levels to exceed safe limits. 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 work-
place.
• 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.

Manual 0-4819 1-3 GENERAL INFORMATION
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.
1.03 Publications
Refer to the following standards or their latest revisions for more information:
1. OSHA, SAFETY AND HEALTH STANDARDS, 29CFR 1910, obtainable from the Superintendent of Documents,
U.S. Government Printing Office, Washington, D.C. 20402
2. ANSI Standard Z49.1, SAFETY IN WELDING AND CUTTING, obtainable from the American Welding Society, 550
N.W. LeJeune Rd, Miami, FL 33126
3. NIOSH, SAFETY AND HEALTH IN ARC WELDING AND GAS WELDING AND CUTTING, obtainable from the Super-
intendent 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 PROTEC-
TION, 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, ob-
tainable 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 Asso-
ciation, Batterymarch Park, Quincy, MA 02269
11. CGA Pamphlet P-1, SAFE HANDLING OF COMPRESSED GASES IN CYLINDERS, obtainable from the Com-
pressed 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

GENERAL INFORMATION 1-4 Manual 0-4819
13. NWSA booklet, WELDING SAFETY BIBLIOGRAPHY obtainable from the National Welding Supply Association,
1900 Arch Street, Philadelphia, PA 19103
14. American Welding Society Standard AWSF4.1, RECOMMENDED SAFE PRACTICES FOR THE PREPARATION
FOR WELDING AND CUTTING OF CONTAINERS AND PIPING THAT HAVE HELD HAZARDOUS SUBSTANCES,
obtainable from the American Welding Society, 550 N.W. LeJeune Rd, Miami, FL 33126
15. ANSI Standard Z88.2, PRACTICE FOR RESPIRATORY PROTECTION, obtainable from American National Stan-
dards Institute, 1430 Broadway, New York, NY 10018

Manual 0-4819 1-5 GENERAL INFORMATION
1.04 Declaration of Conformity
Manufacturer: Thermal Dynamics Corporation
Address: 82 Benning Street
West Lebanon, New Hampshire 03784
USA
The equipment described in this manual conforms to all applicable aspects and regulations of the ‘Low Voltage
Directive’ (European Council Directive 73/23/EEC as amended by Council Directive 93/68/EEC) and to the National
legislation for the enforcement of this Directive.
The equipment described in this manual conforms to all applicable aspects and regulations of the "EMC Directive"
(European Council Directive 89/336/EEC) and to the National legislation for the enforcement of this Directive.
Serial numbers are unique with each individual piece of equipment and details description, parts used to manufacture
a unit and date of manufacture.
National Standard and Technical Specifications
The product is designed and manufactured to a number of standards and technical requirements. Among them are:
* CSA (Canadian Standards Association) standard C22.2 number 60 for Arc welding equipment.
* UL (Underwriters Laboratory) rating 94VO flammability testing for all printed-circuit boards used.
* ISO/IEC 60974-1 (BS 638-PT10) (EN 60 974-1) (EN50192) (EN50078) applicable to plasma cutting equipment and
associated accessories.
* CENELEC EN50199 EMC Product Standard for Arc Welding Equipment
* For environments with increased hazard of electrical shock, Power Supplies bearing the
S
mark conform to
EN50192 when used in conjunction with hand torches with exposed tips, if equipped with properly installed stand-
off guides.
* Extensive product design verification is conducted at the manufacturing facility as part of the routine design and
manufacturing process. This is to ensure the product is safe, when used according to instructions in this manual and
related industry standards, and performs as specified. Rigorous testing is incorporated into the manufacturing
process to ensure the manufactured product meets or exceeds all design specifications.
Thermal Dynamics has been manufacturing products for more than 30 years, and will continue to achieve excellence
in our area of manufacture.
Manufacturers responsible representative: Steve Ward
Operations Director
Thermadyne Europe
Europa Building
Chorley N Industrial Park
Chorley, Lancashire,
England PR6 7BX

GENERAL INFORMATION 1-6 Manual 0-4819
1.05 Statement of Warranty
LIMITED WARRANTY: Thermal Dynamics®Corporation (hereinafter “Thermal”) warrants that its products will be free of defects in workmanship
or material. Should any failure to conform to this warranty appear within the time period applicable to the Thermal products as stated below,
Thermal shall, upon notification thereof and substantiation that the product has been stored, installed, operated, and maintained in accordance
with Thermal’s specifications, instructions, recommendations and recognized standard industry practice, and not subject to misuse, repair,
neglect, alteration, or accident, correct such defects by suitable repair or replacement, at Thermal’s sole option, of any components or parts
of the product determined by Thermal to be defective.
THIS WARRANTY IS EXCLUSIVE AND IS IN LIEU OF ANY WARRANTY OF MERCHANTABILITY OR FITNESS FORA PARTICULAR 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 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).
Parts Labor
AutoCut© and UltraCut© Power Supplies and Components 2 Years 1 Year
Torch And Leads
XTTM-300 / XTTM-301 Torch (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 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 August 19, 2005

Manual No. 0-4819 2-1 SPECIFICATIONS
SECTION 2: SPECIFICATIONS
General Description Of The System
A typical Ultra-Cut®300 system configuration includes:
• One Power Supply
• Remote Arc Starter
• Gas Control Module
• Torch Valve Assembly
• Precision Plasma Cutting Torch
• Set Of Connecting Leads
• Torch Spare Parts Kit
The components are connected at installation.
Plasma Power Supply
The power supply provides the necessary current for cutting operations. The power supply also monitors system
performance, and cools and circulates the liquid coolant for the torch and leads.
Remote Arc Starter
This unit produces a temporary HF pulse to start the pilot arc. The pilot arc creates a path for the main arc to
transfer to the work. When the main arc is established, the pilot arc shuts off.
Gas Control Module
This module allows remote setting of gas selection, pressures, and flows together with setting of cutting current.
Precision Plasma Cutting Torch
The torch delivers the controlled current to the work through the main arc, causing the metal to be cut.

Manual No. 0-4819 2-2 SPECIFICATIONS
Specifications & Electrical Requirements
Max OCV (U0) 380 vdc
Minimum Output Current 10 Amps
Max Output Current 300 Amps
Output Voltage 60 - 230 vdc
Duty Cycle Rating 100% @ 300A, 180V, (54kW),
Ambient Temperature
for Duty Cycle Rating 104F° (40°C)
Operating range 14°F to 122°F (-10°C to + 50°C)
Power Factor 0.70 @ 300 A DC Output
Cooling Forced Air (Class F)
Ultra-Cut 300 Specifications & Design Features
Input Power Input Current Suggested Sizes (See Note)
Voltage Freq. 3-Ph 3-Ph Fuse (Amps) Wire (AWG)
(Volts) (Hz) (kVA) (Amps) 3-Ph 3-Ph
208 50/60 74 206 260 #3/0
230 50/60 72 181 230 #2/0
400 (Incl. CE) 50/60 75 109 135 #3
460 50/60 89 112 150 #2
Line Voltages with Suggested Circuit Protection and Wire Sizes
Based on National Electric Code and Canadian Electrical Code
Ultra-Cut 300 Power Supply
System Component Layout
Primary power
Work
CNC
Remote
Arc
Starter
Art # A-07234
Torch
Coolant Supply
Coolant Return
Control Cable
Coolant Supply
Coolant Return
Plasma Gas
Shield Gas
Fiber
Optic
Cable
Control
Cable
Gas Control
Module
300-A
Power
Supply
Torch
Valve
Assembly
Positioning Tube
Plasma Gas
Preflow Gas
Water Shield
Shield
Shield Gas
Negative Leads
Control Cable
Pilot Return Pilot Return
Work Cables
Shield
25’ / 7.6 m Maximum Length
125’ / 38.1 m Maximum Length
175’ / 53.3 m Maximum Length

Manual No. 0-4819 2-3 SPECIFICATIONS
Power Supply Dimensions
Art # A-06939
33 inch
840 mm
27 inch
680 mm
37.75 inch
960 mm
52.25 inch
1030 mm
27.5 inch
700 mm
535 lb / 243 kg

Manual No. 0-4819 2-4 SPECIFICATIONS
Power Supply Rear Panel Features
Terminal Cover
Support Panel
Coolant Tank
Coolant Filter
Coolant Connections
Input Power
Terminals
Pilot (Pos) Terminal
Circuit Breaker
Panel
Terminal Cover
AC Power Lamp
Ground Terminals
Gas Control
Console Connector
RETURN SUPPLY
Art # A-04794
CNC Connector
Remote Arc Starter
Connector
Work Cable Terminal
Torch (Neg) Terminal
Leads
Bracket

Manual No. 0-4819 2-5 SPECIFICATIONS
Gas Requirements
The customer will provide all gases and pressure regulators. Gases must be of high quality. Pressure regulators
shall be double stage and installed within 3 meters from the Gas Console.
Gas Quality Minimum Pressure Flow
O2(Oxygen) 99.5% Purity
(Liquid recommended)
120 psi
8.3 bar / 827 kPa 200 scfh (5700 l/h)
N2(Nitrogen)
99.5% Purity
(Liquid recommended)
<1000 ppm O2, <32
ppm H2O)
120 psi
8.3 bar / 827 kPa 300 scfh (8496 l/h)
Compressed
or Bottled Air
Clean, Dry,
Free of Oil (see Note 1)
120 psi
8.3 bar / 827 kPa 450 scfh (12743 l/h)
H35 (Argon-Hydrogen)
H35 = 35% Hydrogen,
65% Argon
99.995% Purity
(gas recommended)
120 psi
8.3 bar / 827 kPa 200 scfh (5664 l/h)
H2O (Water) See Note 2 50 psi (3.5 bar) 10 gph (38 lph)
Note 3: Water Pressure Regulator No. 8-6118 is recommended to ensure proper water pressure.
Ultra-Cut 300 Power Supply: Gas Pressures, Flows, and Quality Requirements
Note 2: The tap water source does not need to be deionized, but in water systems with extremely high
mineral content a water softener is recommended. Tap water with high levels of particulate matter must be
filtered.
Note 1: The air source must be adequately filtered to remove all oil or grease. Oil or grease
contamination from compressed or bottled air can cause fires in conjunction with oxygen.
For filtering, a coalescing filter able to filter to 0.01 microns should be placed as close as
possible to the gas inlets on the Gas Control Module.
Gas Applications
M
ATERIA
L
O
PERATIO
N
PREFLOW PLASMA SHIELD PREFLOW PLASMA SHIELD PREFLOW PLASMA SHIELD
Air Air Air Air Air Air
N2N2H20N
2N2H20
Air Air Air Air Air Air
N2N2H20N
2N2H20
Air Air Air Air Air Air
N2N2H20N
2N2H20
85A Cut Air Air Air
N2H35 N2N2H35 N2
N2N2H20N
2N2H20
N2H35 N2N2H35 N2
N2N2H20N
2N2H20
300A Cut Air O2Air
100A Cut
150A Cut
O2Air
Air O2Air
50A Cut O2Air
Air
70A Cut O2Air
Air O2O2
Air
Air
MILD STEEL STAINLESS STEEL ALUMINUM
30A Cut
GAS TYPE GAS TYPE GAS TYPE

Manual No. 0-4819 2-6 SPECIFICATIONS
XTTM-300 Torch Specifications
A. Torch Dimensions
2.25"
57.15 mm
2.0"
50.8 mm
2.39"
60.81 mm
1.49"
37.8 mm
19.00"
482.68 mm
15.50"
393.78 mm
2.74"
69.55 mm
1.57"
39.96 mm
3.54"
89.87 mm
6.30"
160.10 mm
Art # A-04897