Victor ULTRA-CUT 100 User manual

VictorThermalDynamics.com
100 200 400300 400V
ULTRA-CUT 100,
200, 300, 400 XT™
PLASMA CUTTING SYSTEM
Operating
Manual
Revision: AF Issue Date: October 2, 2014 Manual No.: 0-5264

WE APPRECIATE YOUR BUSINESS!
Congratulations on your new Victor 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 distribu-
tor 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
Victor 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 Pre-
cautions. 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.
Victor Thermal Dynamics is a Global Brand of manual and automation Plasma Cutting Products for
Victor Technologies.
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, excel-
lent 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 XT™ 100/200/300/400
Operating Manual No. 0-5264
Published by:
Victor Technologies, Inc.
82 Benning Street
West Lebanon, New Hampshire, USA 03784
[phone]
www.thermal-dynamics.com
© Copyright 2013 by
Victor Technologies International, Inc.
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.
Original Publication Date: April 18, 2013
Revision Date: October 2, 2014
Record the following information for Warranty purposes:
Where Purchased: ___________________________________
Purchase Date:______________________________________
Power Supply Serial #:_______________________________
Torch Serial #:_______________________________________

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 ............................................................................... 1-6
1.07 Declaration of Conformity............................................................................... 1-7
1.08 Statement of Warranty.................................................................................... 1-9
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 Power Supply Dimensions.............................................................................. 2-4
2.08 Power Supply Rear Panel Features ................................................................. 2-5
2.09 Gas Requirements .......................................................................................... 2-6
2.10 Gas Applications............................................................................................. 2-8
2.11 XT Torch Specifications ................................................................................. 2-9
SECTION 3: INSTALLATION ............................................................................... 3-1
3.01 Installation Requirements............................................................................... 3-1
3.02 System Layout 100 - 200 Amp ...................................................................... 3-2
3.03 System Layout 300 Amp................................................................................. 3-2
3.04 System Layout 400 Amp................................................................................. 3-3
3.05 Recommended Gas Supply Hose.................................................................... 3-3
3.06 Leads and Cables All Amperage...................................................................... 3-4
3.07 Lift the Power Supply ..................................................................................... 3-5
3.08 Connect Input Power and Ground Cables ....................................................... 3-6
3.09 Connect Work Cable and Pilot and Negative Leads......................................... 3-7
3.10 Ground Connections....................................................................................... 3-7
3.11 Connect Coolant Leads ................................................................................. 3-10
3.12 Connect Cables for CNC, Remote Arc Starter, GCM and HE 400................... 3-11
3.13 Handling and Installation of Fiber Optics ...................................................... 3-11
3.14 Set Switches on the Command - Control Module ......................................... 3-14
3.15 Height Control Connections.......................................................................... 3-16
3.16 Gas Control Module Installation.................................................................... 3-16
3.17 Fiber Optic Cable Installation ........................................................................ 3-18
3.18 Gas Control Module: Control, Input, and Output Connections ...................... 3-19
3.19 HE400XT COOLER ........................................................................................ 3-21
3.20 Install Remote Arc Starter............................................................................. 3-23
3.21 Torch Valve Installation................................................................................. 3-30
3.22 Connecting Torch.......................................................................................... 3-31
3.23 Install Consumable Torch Parts .................................................................... 3-33
3.24 Voltage Divider for iHC Torch Height Control................................................ 3-35
3.25 Complete the Installation .............................................................................. 3-37

TABLE OF CONTENTS
SECTION 4: OPERATION................................................................................... 4-1
4.01 Power Supply Control Panel ........................................................................... 4-1
4.02 System Operation ........................................................................................... 4-2
4.03 Gas Selection.................................................................................................. 4-4
4.04 GCM 2010 Gas Control Module Operation...................................................... 4-6
4.05 GCM 2010 First Time Operation Matching Gas Control to Lead Length........ 4-10
4.06 GCM 2010 Sequence Of Operation ............................................................... 4-10
4.07 Power Supply Status Codes.......................................................................... 4-13
4.08 Remote Arc Starter Trouble Shooting ........................................................... 4-20
SECTION 5: MAINTENANCE ............................................................................... 5-1
5.01 General Maintenance ...................................................................................... 5-1
5.02 External Coolant Filter Cleaning Procedure ..................................................... 5-1
5.03 Coolant Replacement Procedure..................................................................... 5-2
SECTION 6: REPLACEMENT ASSEMBLIES & PARTS ................................................. 6-1
6.01 Replacement Power Supply............................................................................ 6-1
6.02 System Layout 100 - 200 Amp ....................................................................... 6-2
6.03 System Layout 300 Amp................................................................................. 6-2
6.04 System Layout 400 Amp................................................................................. 6-3
6.05 Recommended Gas Supply Hose.................................................................... 6-3
6.06 Leads And Cables All Amperages.................................................................... 6-4
6.07 Power Supply External Replacement Parts .................................................... 6-6
6.08 Power Supply Replacement Parts - Upper Right Side..................................... 6-7
6.09 Power Supply Replacement Parts - Lower Right Side ................................... 6-8
6.10 Power Supply Replacement Parts - Rear Panel .............................................. 6-9
6.11 Power Supply Replacement Parts - Left Side................................................ 6-10
6.12 Gas Control Module (GCM-2010) Replacement Parts................................... 6-11
6.13 Gas Control Module (GCM-2010) Replacement Parts................................... 6-12
6.14 Remote Arc Starter (RAS-1000 XT) Replacement Parts ............................... 6-13
6.15 HE400XT Heat Exchanger - Replacement Parts ............................................ 6-14
SECTION 7: TORCH MAINTENANCE................................................................... 7-1
7.01 Consumable Removal..................................................................................... 7-1
7.02 O-Ring Lubrication ......................................................................................... 7-2
7.03 Parts Wear...................................................................................................... 7-2
7.04 Torch Consumables Installation...................................................................... 7-3
7.05 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 PLUMBING DIAGRAM....................................... A-4
APPENDIX 4: GAS CONTROL MODULE PCB LAYOUT................................................. A-5
APPENDIX 5: GAS CONTROL DISPLAY MODULE PCB LAYOUT ..................................... A-6
APPENDIX 6: CNC - CONTROL MODULE PCB CONNECTIONS....................................... A-7

TABLE OF CONTENTS
APPENDIX 7: CNC ......................................................................................... A-8
CNC functions............................................................................................................... A-8
CNC Input / Output Descriptions................................................................................. A-10
Simplified CNC Circuit................................................................................................. A-12
CNC Connections........................................................................................................ A-14
APPENDIX 8: SERIAL COMMUNICATIONS ............................................................A-15
A8.01 Cables and Switch Settings for 2 and 4 Wire ............................................... A-15
APPENDIX 9: CCM CPU PCB LAYOUT..................................................................A-18
APPENDIX 10: CCM I/O PCB LAYOUT..................................................................A-20
APPENDIX 11: PILOT PCB LAYOUT ....................................................................A-22
APPENDIX 12: RELAY AND INTERFACE PCB LAYOUT ...............................................A-24
APPENDIX 13: DISPLAY PCB LAYOUT .................................................................A-26
APPENDIX 14: SYSTEM BIAS PCB LAYOUT...........................................................A-28
APPENDIX 15: MAIN INVERTER BOTTOM PCB LAYOUT ............................................A-30
APPENDIX 16: MAIN INVERTER TOP PCB LAYOUT ..................................................A-32
APPENDIX 17: CONTROL AND FAULT PCB LAYOUT .................................................A-34
APPENDIX 18: CAP BIAS BOTTOM PCB LAYOUT.....................................................A-36
APPENDIX 19: CAP BIAS TOP PCB LAYOUT ..........................................................A-37
APPENDIX 20: SUPPRESSOR PCB LAYOUT...........................................................A-38
APPENDIX 21: COOLING DIAGRAM ....................................................................A-39
APPENDIX 22: SYSTEM SCHEMATIC 100A, 380-415V PG 1 ........................................A-40
APPENDIX 23: SYSTEM SCHEMATIC 100A, 380-415V PG 2 ........................................A-42
APPENDIX 24: SYSTEM SCHEMATIC 200A, 380-415V PG 1 ........................................A-44
APPENDIX 25: SYSTEM SCHEMATIC 200A, 380-415V PG 2 ........................................A-46
APPENDIX 26: SYSTEM SCHEMATIC 300A, 380-415V PG 1 ........................................A-48
APPENDIX 27: SYSTEM SCHEMATIC 300A, 380-415V PG 2 ........................................A-50
APPENDIX 28: SYSTEM SCHEMATIC 400A, 380-415V PG 1 ........................................A-52
APPENDIX 29: SYSTEM SCHEMATIC 400A, 380-415V PG 2 ........................................A-54
APPENDIX 30: ADVANCED TROUBLESHOOTING.....................................................A-56
APPENDIX 31: PUBLICATION HISTORY................................................................A-94

ULTRA-CUT 100 XT/200 XT/300 XT/400 XT
Manual 0-5264 GENERAL INFORMATION 1-1
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 infor-
mation which requires additional emphasis or is
helpful in ecient 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
WARNING
OPERATION AND MAINTENANCE OF
PLASMA ARC EQUIPMENT CAN BE DAN-
GEROUS AND HAZARDOUS TO YOUR
HEALTH.
Plasma arc cuing produces intense electric and
magnetic emissions that may interfere with the
proper function of cardiac pacemakers, hear-
ing aids, or other electronic health equipment.
Persons who work near plasma arc cuing ap-
plications 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
 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in-
formation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com-
bustible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.
• WARNING: This product contains chemicals,
includinglead,knowntotheStateofCaliforniato
causebirthdefectsandotherreproductiveharm.
Wash hands after handling.
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.

ULTRA-CUT 100 XT/200 XT/300 XT/400 XT
1-2 GENERAL INFORMATION Manual 0-5264
• 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, Publica-
tions.
• Disconnectpowersourcebeforeperformingany
serviceorrepairs.
• ReadandfollowalltheinstructionsintheOperat-
ing 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ammablemate-
rialintheworkplace.Anymaterialthatcannotbe
removedmustbeprotected.
• Ventilateallammableorexplosivevaporsfrom
theworkplace.
• Donotcutorweldoncontainersthatmayhave
held combustibles.
• Providearewatchwhenworkinginanarea
whererehazardsmayexist.
• Hydrogengasmaybeformedandtrappedunder
aluminumworkpieceswhentheyarecutunder-
water 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 dis-
sipated. 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pro-
tective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hel-
met 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
lters may be used when the arc is hidden by the
workpiece.
!
WARNING
WARNING: This product contains chemicals,
including lead, known to the State of California to
cause birth defects and other reproductive harm.
Wash hands after handling.
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 Docu-
ments,U.S.GovernmentPrintingOfce,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SuperintendentofDocuments,U.S.Govern-
mentPrintingOfce,Washington,D.C.20402
4. ANSIStandardZ87.1,SAFEPRACTICESFOROC-
CUPATION 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SAFE-
TY-TOEFOOTWEAR,obtainablefromtheAmerican

ULTRA-CUT 100 XT/200 XT/300 XT/400 XT
Manual 0-5264 GENERAL INFORMATION 1-3
National Standards Institute, 1430 Broadway, New
York,NY10018
6. ANSIStandardZ49.2,FIRE PREVENTION IN THE USE
OF CUTTING AND WELDING PROCESSES, obtain-
able fromAmerican National Standards Institute, 1430
Broadway,NewYork,NY10018
7. AWSStandardA6.0,WELDING AND CUTTING CON-
TAINERS 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PRO-
CESSES, 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 Associa-
tion,BatterymarchPark,Quincy,MA02269
10.NFPAStandard51B,CUTTINGANDWELDINGPRO-
CESSES, obtainable from the National Fire Protection
Association,BatterymarchPark,Quincy,MA02269
11. CGA Pamphlet P-1, SAFE HANDLING OF COM-
PRESSED 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WELD-
ING 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Associa-
tion, 1900 Arch Street, Philadelphia, PA 19103
14.AmericanWeldingSocietyStandardAWSF4.1,REC-
OMMENDED SAFE PRACTICES FOR THE PREPARA-
TIONFORWELDINGANDCUTTINGOFCONTAIN-
ERSANDPIPINGTHATHAVEHELDHAZARDOUS
SUBSTANCES,obtainablefromtheAmericanWelding
Society,550N.W.LeJeuneRd,Miami,FL33126
15.ANSIStandardZ88.2,PRACTICEFORRESPIRATORY
PROTECTION, obtainable from American National
StandardsInstitute,1430Broadway,NewYork, NY
10018
1.04 Note, Attention et
Avertissement
Danscemanuel,lesmots“note,”“attention,”et“aver-
tissement”sontutiliséspourmettreenreliefdesinfor-
mations à caractère important. Ces mises en relief sont
classiéescommesuit:
NOTE
Toute opération, procédure ou renseignement
général sur lequel il importe d’insister davantage
ou qui contribue à l’ecacité 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
AVERTISSEMENT
L’OPÉRATION ET LA MAINTENANCE DU
MATÉRIEL DE SOUDAGE À L’ARC AU JET
DE PLASMA PEUVENT PRÉSENTER DES
RISQUES ET DES DANGERS DE SANTÉ.
Coupant à l’arc au jet de plasma produit de l’énergie
électrique haute tension et des émissions magné-
tique qui peuvent interférer la fonction propre d’un
“pacemaker” cardiaque, les appareils auditif, ou
autre matériel de santé electronique. Ceux qui tra-
vail 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 person-
nel TOUS les dangers possibles. An 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.

ULTRA-CUT 100 XT/200 XT/300 XT/400 XT
1-4 GENERAL INFORMATION Manual 0-5264
FUMÉEetGAZ
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respira-
tion.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ches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.
• AVERTISSEMENT : Ce produit contient des produits
chimiques, notamment du plomb, reconnu par l'État
de la Californie pour causer des malformations con-
génitalesetd'autresdommagestouchantlesystème
reproductif. Se laver les mains après manipulation.
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endom-
magée.
• Prenezdessoinsparticulierslorsquelazonedetravail
est humide ou moite.
• Montezetmaintenezlematérielconformémentau
CodeélectriquenationaldesEtats-Unis.(Voirlapage
5, article 9.)
• Débranchezl’alimentationélectriqueavanttouttra-
vail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inammables.
• Soyezcertainqu’aucunematièrecombustibleouin-
ammable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
inammables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enammé.

ULTRA-CUT 100 XT/200 XT/300 XT/400 XT
Manual 0-5264 GENERAL INFORMATION 1-5
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étince-
llesetlesrayonsdel’arc.
• Maintenezvotrecasqueetvoslunettesdeprotection
enbonétat.Remplaceztoutelentillesaleoucom-
portantssureourognure.
• Protégezlesautrespersonnessetrouvantsurlazone
detravailcontrelesrayonsdel’arcenfournissantdes
cabinesoudesécransdeprotection.
• Utilisezlanuancedelentillequiestsuggèréedansle
recommendationquisuiventANSI/ASCZ49.1:
Nuance Minimum Nuance Suggerée
Courant Arc Protective Numéro Numéro
Moins de 300* 8 9
300 - 400* 9 12
400 - 800* 10 14
* Ces valeurs s’appliquent ou l’arc actuel est observé
clairement. L’experience a démontrer que les ltres
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and’éviteruneperte
permanentedel’ouïe.
• Pourprotégervotreouïecontrelesbruitsforts,portez
destamponsprotecteurset/oudesprotectionsau-
riculaires.Protégezégalementlesautrespersonnes
setrouvantsurlelieudetravail.
• Ilfautmesurerlesniveauxsonoresan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.
AVERTISSEMENT
AVERTISSEMENT : Ce produit contient des produits
chimiques, notamment du plomb, reconnus par
l'État de Californie comme pouvant causer des
malformations congénitales et d'autres troubles
de la reproduction. Se laver les mains après toute
manipulation.

ULTRA-CUT 100 XT/200 XT/300 XT/400 XT
1-6 GENERAL INFORMATION Manual 0-5264
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Ofce,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Ofce,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
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As-
sociation,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Na-
tionaledeFournituresdeSoudage(NationalWeldingSupplyAssociation),1900ArchStreet,Philadelphia,PA
19103
14.NormeAWSF4.1del’AssociationAméricainedeSoudage,RECOMMANDATIONSDEPRATIQUESSURES
POUR LA PRÉPARATION À LA COUPE ET AU SOUDAGE DE CONTENEURS ET TUYAUX AYANT REN-
FERMÉ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

ULTRA-CUT 100 XT/200 XT/300 XT/400 XT
Manual0-5264 GENERALINFORMATION 1-7
1.07 Declaration of Conformity
Declaration of Conformity
We Victor Technologies International Inc.
of 16052 Swingley Ridge Road
Suite 300
Chestereld, MO 63033 U.S.A.
in accordance with the following Directive(s):
 •2006/95/EC The Low Voltage Directive
 •2004/108/EC The Electromagnetic Compatibility (EMC) Directive
hereby declare that:
Equipment: Plasma Cutting Power Source
Model Name/Number: UltraCut 100 XT, 200 XT, 300 XT, 400 XT
Market Release Date: January 16,2014
is in conformity with the applicable requirements of the following harmonized standards:
  •EN 60974-10:2007 Arc Welding Equipment - Part 10: Electromagnetic compatibility (EMC)
requirements
  •EN 60974-1:2012 Arc Welding Equipment - Part 1: Welding power sources.
Classification: The equipment described in this document is Class A and intended for industrial use.
Manufacturer’s Authorized Representative
Steve Ward V.P. Europe and General Manager
Address:Victor Technologies International Inc.
Europa Building
Chorley N Industrial Park
Chorley, Lancashire,
England PR6 7BX
Date: May 30, 2014
Steve Ward
(Full Name)
V.P. Europe and General Manager
(Position)
(Signature)
!
WARNING
This Class A equipment is not intended for use in residential locations where the electrical power is provided by the
public low-voltage supply system. There may be potential diculties in ensuring electromagnetic compatibility in
those locations, due to conducted as well as radiated disturbances.

ULTRA-CUT 100 XT/200 XT/300 XT/400 XT
1-8 GENERAL INFORMATION Manual 0-5264
Classication:TheequipmentdescribedinthismanualisClassAandintendedforindustrialuse.
!
WARNING
This Class A equipment is not intended for use in residential locations where the electrical power is provided
by the public low-voltage supply system. There may be potential difculties in ensuring electromagnetic
compatibility in those locations, due to conducted as well as radiated disturbances.

ULTRA-CUT 100 XT/200 XT/300 XT/400 XT
Manual 0-5264 GENERAL INFORMATION 1-9
1.08 Statement of Warranty
LIMITED WARRANTY:Victor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noticationthereofandsubstantiationthattheproducthasbeenstored,installed,operated,and
maintainedinaccordancewithThermal’sspecications,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 FOR A 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
Ultra-CutXT™ andAuto-CutXT™ PowerSuppliesandComponents 2Years 1Year
Torch And Leads
XTTM/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October23,2012

ULTRA-CUT 100 XT/200 XT/300 XT/400 XT
1-10 GENERAL INFORMATION Manual 0-5264
ThisPageIntentionallyBlank

ULTRA-CUT 100 XT/200 XT/300 XT/400 XT
Manual 0-5264 SPECIFICATIONS 2-1
SECTION 2: SPECIFICATIONS
2.01 General Description Of The System
A typical Ultra-Cut XT™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.
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ows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.

ULTRA-CUT 100 XT/200 XT/300 XT/400 XT
2-2 SPECIFICTIONS Manual 0-5264
2.06 Specications&ElectricalRequirements
100 Amp System
Ultra-Cut 100 XT™ Specifications & Design Features
Max OCV (U0) 425 vdc
Minimum Output Current 5 Amps
Max Output Current 100 Amps
Output Voltage 60 - 180 vdc
Duty Cycle Rating 100% @ 100A, 200V, (20kW),
Ambient Temperature
for Duty Cycle Rating
104F° (40°C)
Operating range 14°F to 122°F (-10°C to + 50°C)
Power Factor 0.94 @ 100 A DC Output
Cooling Coolant and Forced Air (Class F)
200 Amp System
Ultra-Cut 200 XT™ Specifications & Design Features
Max OCV (U0) 425 vdc
Minimum Output Current 5 Amps
Max Output Current 200 Amps
Output Voltage 60 - 180 vdc
Duty Cycle Rating 100% @ 200A, 200V, (40kW),
Ambient Temperature
for Duty Cycle Rating
104F° (40°C)
Operating range 14°F to 122°F (-10°C to + 50°C)
Power Factor 0.94 @ 200 A DC Output
Cooling Coolant and Forced Air (Class F)
300 Amp System
Ultra-Cut 300 XT™ Specifications & Design Features
Max OCV (U0) 425 vdc
Minimum Output Current 5 Amps
Max Output Current 300 Amps
Output Voltage / IEC 60 - 180 vdc / 60 - 200 vdc
Duty Cycle Rating 100% @ 300A, 200V, (60kW),
Ambient Temperature
for Duty Cycle Rating
104F° (40°C)
Operating range 14°F to 122°F (-10°C to + 50°C)
Power Factor 0.94 @ 300 A DC Output
Cooling Coolant and Forced Air (Class F)
400 Amp System
Ultra-Cut 400 XT™ Specifications & Design Features
Max OCV (U0) 425 vdc
Minimum Output Current 5 Amps
Max Output Current 400 Amps
Output Voltage 60 - 200 vdc
Duty Cycle Rating 100% @ 400A, 200V, (80kW),
Ambient Temperature
for Duty Cycle Rating
104F° (40°C)
Operating range 14°F to 122°F (-10°C to + 50°C)
Power Factor 0.94 @ 400 A DC Output
Cooling Coolant and Forced Air (Class F)

ULTRA-CUT 100 XT/200 XT/300 XT/400 XT
Manual 0-5264 SPECIFICATIONS 2-3
Ultra-Cut 100 XT™ Power Supply
Input Power Input Current Suggested Sizes (See Note)
Voltage Freq. 3-Ph 3-Ph Fuse (Amps) Wire (AWG) Wire (mm2)
(Volts) (Hz) (kVA) (Amps) 3-Ph 3-Ph 3-Ph
400 50/60 21 31 40-45 #12 4
Ultra-Cut 200 XT™ Power Supply
Input Power Input Current Suggested Sizes (See Note)
Voltage Freq. 3-Ph 3-Ph Fuse (Amps) Wire (AWG) Wire (mm2)
(Volts) (Hz) (kVA) (Amps) 3-Ph 3-Ph 3-Ph
400 50/60 42 62 100 #6 16
Ultra-Cut 300 XT™ Power Supply
Input Power Input Current Suggested Sizes (See Note)
Voltage Freq. 3-Ph 3-Ph Fuse (Amps) Wire (AWG) Wire (mm2)
(Volts) (Hz) (kVA) (Amps) 3-Ph 3-Ph 3-Ph
400 50/60 63 93 150 #4 25
IEC
400 50/60 72 106 150 #4 25
Ultra-Cut 400 XT™ Power Supply
Input Power Input Current Suggested Sizes (See Note)
Voltage Freq. 3-Ph 3-Ph Fuse (Amps) Wire (AWG) Wire (mm2)
(Volts) (Hz) (kVA) (Amps) 3-Ph 3-Ph 3-Ph
400 50/60 93 137 200 #1 50
NOTE
* Suggested wire size based on United States NFPA 70 National Electrical Code 2011 edition pub-
lished by the National Fire Prevention Association. Listings are from table 400.5(A)(2) for exible cord
of certain types rated for 75 deg C in ambient temperatures up to 30 deg C. Using wires of lower tem-deg C in ambient temperatures up to 30 deg C. Using wires of lower tem-C in ambient temperatures up to 30 deg C. Using wires of lower tem-
perature rating or different insulation type may require larger wire size. De rate for higher ambient.
These are suggestions only. Always refer to your local and national codes that apply to your region for
nal determination of correct wire type and size.

ULTRA-CUT 100 XT/200 XT/300 XT/400 XT
2-4 SPECIFICTIONS Manual 0-5264
2.07 Power Supply Dimensions
Art # A-11487_AB
35.97 inch
914 mm
27.6 inch
701 mm
47.77 inch
1213 mm
100A 420 lb / 190 kg
200A 465 lb / 211 kg
300A 560 lb / 254 kg
400A 580 lb / 263 kg