Victor ULTRA-CUT 300 XT User manual

VictorThermalDynamics.com
ULTRA-CUT 300 XT™
PLASMA CUTTING SYSTEM
AUTOMATED GAS CONTROL
Operating
Manual
Revision: AE Issue Date: May 2, 2014 Manual No.: 0-5305
8
4

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 distributor
or service agency call 1-800-426-1888, or visit us on the web at www.VictorThermalDynamics.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 with Automated Gas Control, Ultra-Cut 300 XT™
Operating Manual No. 0-5305
Published by:
Victor Technologies, Inc.
82 Benning Street
West Lebanon, New Hampshire, USA 03784
[phone]
www.victortechnologies.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: May 1, 2013
Revision Date: May 2, 2014
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.................................................................................................... 1-2
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.................................................................................... 1-8
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.............................................................................. 2-3
2.08 Power Supply Rear Panel Features ................................................................. 2-4
2.09 Gas Requirements .......................................................................................... 2-5
2.10 Gas Applications............................................................................................. 2-6
2.11 XT Torch Specifications ................................................................................. 2-7
SECTION 3: INSTALLATION ............................................................................... 3-1
3.01 Installation Requirements............................................................................... 3-1
3.02 System Layout ............................................................................................... 3-2
3.03 Recommended Gas Supply Hose.................................................................... 3-2
3.04 Leads and Cables All Amperage...................................................................... 3-3
3.05 Lift the Power Supply ..................................................................................... 3-4
3.06 Connect Input Power and Ground Cables ....................................................... 3-5
3.07 Connect Work Cable and Pilot and Negative Leads......................................... 3-6
3.08 Ground Connections....................................................................................... 3-6
3.09 Connect Coolant Leads ................................................................................... 3-9
3.10 Connect Cables for CNC, Remote Arc Starter, GCM and HE 400................... 3-10
3.11 Handling and Installation of Fiber Optics ...................................................... 3-11
3.12 Connect TSC-3000 Cable and DMC-3000 Fiber Optic Cable to CCM............. 3-15
3.13 Set Switches on the Command - Control Module ......................................... 3-17
3.14 Height Control Connections.......................................................................... 3-19
3.15 DMC-3000 Gas Manifold Control Installation................................................ 3-20
3.16 DPC-3000 Gas Pressure Control Installation ................................................ 3-24
3.17 Fiber Optic Cable Installation from CCM to DMC-3000................................. 3-27
3.18 Fiber Optic Cable Installation From DMC-3000 to DPC-3000........................ 3-29
3.19 Install TSC-3000 Touch Screen Control ........................................................ 3-31
3.20 Install Remote Arc Starter............................................................................. 3-32
3.21 Connecting Torch.......................................................................................... 3-39
3.22 Install Consumable Torch Parts .................................................................... 3-40
3.23 Voltage Divider for iHC Torch Height Control................................................ 3-43
3.24 Complete the Installation .............................................................................. 3-45

TABLE OF CONTENTS
SECTION 4: OPERATION................................................................................... 4-1
4.01 Power Supply Control Panel ........................................................................... 4-1
4.02 System Operation ........................................................................................... 4-1
4.03 TSC-3000 Navigation Functions...................................................................... 4-3
4.04 TSC-3000 Initial Setup ONLY.......................................................................... 4-4
4.05 TSC-3000 Selecting New Process .................................................................. 4-5
4.06 TSC-3000 Selecting Recently Used Process................................................... 4-6
4.07 TSC-3000 Creating a Custom Process............................................................ 4-7
4.08 Back up and Restoration of Custom Processes. ............................................. 4-9
4.09 Sequence of Operation.................................................................................. 4-12
4.10 Gas Selection................................................................................................ 4-15
4.11 CCM Status Codes........................................................................................ 4-17
4.12 DMC-3000 Status Codes .............................................................................. 4-24
4.13 DPC-3000 Status Codes ............................................................................... 4-26
4.14 Remote Arc Starter Trouble Shooting ........................................................... 4-29
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................................................................................................ 6-2
6.03 Recommended Gas Supply Hose.................................................................... 6-2
6.04 Leads And Cables All Amperages.................................................................... 6-3
6.05 Power Supply External Replacement Parts .................................................... 6-5
6.06 Power Supply Replacement Parts - Upper Right Side..................................... 6-6
6.07 Power Supply Replacement Parts - Lower Right Side ................................... 6-7
6.08 Power Supply Replacement Parts - Rear Panel .............................................. 6-8
6.09 Power Supply Replacement Parts - Left Side.................................................. 6-9
6.10 DFC-3000 Automated Gas Control System Replacement Components......... 6-10
6.11 DMC-3000 Gas Control Module Replacement Parts ..................................... 6-11
6.12 DPC-3000 Gas Control Module Replacement Parts ...................................... 6-12
6.13 TSC-3000 Touch Screen Control Remote and Internal Replacement Parts... 6-13
6.14 Remote Arc Starter (RAS-1000 XT) Replacement Parts ............................... 6-14
6.15 HE 400 Heat Exchanger - Replacement Parts ............................................... 6-15
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: CNC - CONTROL MODULE PCB CONNECTIONS....................................... A-1

TABLE OF CONTENTS
APPENDIX 2: CNC ......................................................................................... A-2
CNC functions............................................................................................................... A-2
CNC Input / Output Descriptions................................................................................... A-4
Simplified CNC Circuit................................................................................................... A-6
CNC Connections.......................................................................................................... A-8
APPENDIX 3: DMC-3000 CONTROL PCB LAYOUT..................................................... A-9
APPENDIX 4: DPC-3000 CONTROL PCB LAYOUT....................................................A-10
APPENDIX 5: DMC-3000 / DPC-3000 POWER SUPPLY PCB LAYOUT.............................A-11
APPENDIX 6: TSC-3000 PCB LAYOUT.................................................................A-12
APPENDIX 7: CCM CPU PCB LAYOUT..................................................................A-14
APPENDIX 8: CCM I/O PCB LAYOUT ...................................................................A-16
APPENDIX 9: PILOT PCB LAYOUT ......................................................................A-18
APPENDIX 10: RELAY AND INTERFACE PCB LAYOUT ...............................................A-20
APPENDIX 11: DISPLAY PCB LAYOUT .................................................................A-22
APPENDIX 12: SYSTEM BIAS PCB LAYOUT...........................................................A-24
APPENDIX 13: MAIN INVERTER BOTTOM PCB LAYOUT ............................................A-26
APPENDIX 14: MAIN INVERTER TOP PCB LAYOUT ..................................................A-28
APPENDIX 15: CONTROL AND FAULT PCB LAYOUT .................................................A-30
APPENDIX 16: CAP BIAS BOTTOM PCB LAYOUT.....................................................A-32
APPENDIX 17: CAP BIAS TOP PCB LAYOUT ..........................................................A-33
APPENDIX 18: SUPPRESSOR PCB LAYOUT...........................................................A-34
APPENDIX 19: COOLING DIAGRAM ....................................................................A-35
APPENDIX 20: REMOTE ARC STARTER SCHEMATIC ................................................A-36
APPENDIX 21: SCHEMATIC, DFC-3000 AUTO GAS BOX SYSTEM ..................................A-38
APPENDIX 22: SYSTEM SCHEMATIC 300A, 480V PG 1..............................................A-40
APPENDIX 23: SYSTEM SCHEMATIC 300A, 480V PG 2..............................................A-42
APPENDIX 24: ADVANCED TROUBLESHOOTING.....................................................A-44
APPENDIX 25: PUBLICATION HISTORY................................................................A-82

TABLE OF CONTENTS
This Page Intentionally Blank

ULTRA-CUT 300 XT
Manual 0-5305 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 informa-
tion which requires additional emphasis or is help-
ful 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
WARNING
OPERATION AND MAINTENANCE OF PLASMA ARC
EQUIPMENT CAN BE DANGEROUS AND HAZARD-
OUS 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
 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 300 XT
1-� GENERAL INFORMATION Manual 0-5305
• 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 filters 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 Documents,
U.S.GovernmentPrintingOfce,Washington,D.C.20402
2. ANSIStandardZ49.1,SAFETYINWELDINGANDCUT-
TING,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
Ofce,Washington,D.C.20402
4. ANSIStandardZ87.1,SAFEPRACTICESFOROCCUPA-
TION 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Broad-
way,NewYork,NY10018
7. AWSStandardA6.0,WELDING AND CUTTING CON-
TAINERS WHICH HAVE HELD COMBUSTIBLES, obtain-