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
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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-

ULTRA-CUT 300 XT
Manual 0-5305 GENERAL INFORMATION 1-3
able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PRO-
CESSES, obtainable from the National Fire Protection
Association,BatterymarchPark,Quincy,MA02269
11. CGAPamphlet P-1, SAFE HANDLING OF COMPRESSED
GASES IN CYLINDERS, obtainable from the Compressed
GasAssociation,1235JeffersonDavisHighway,Suite501,
Arlington, VA ���0�
12. CSAStandardW117.2,CODEFORSAFETYINWELDING
AND CUTTING, obtainable from the Canadian Standards
Association,StandardsSales,178RexdaleBoulevard,Rex-
dale,Ontario,CanadaM9W1R3
13. NWSAbooklet,WELDINGSAFETYBIBLIOGRAPHY
obtainablefromtheNationalWeldingSupplyAssociation,
1900 Arch Street, Philadelphia, PA 19103
14. AmericanWeldingSocietyStandardAWSF4.1,RECOM-
MENDED SAFE PRACTICES FOR THE PREPARATION
FORWELDINGANDCUTTINGOFCONTAINERSAND
PIPINGTHATHAVEHELDHAZARDOUSSUBSTANC-
ES,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
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’efficacité de fonctionnement
du système.
ATTENTION
Toute procédure pouvant résulter
l’endommagement du matériel en cas de non-
respect de la procédure en question.
!
AVERTISSEMENT
Toute procédure pouvant provoquer des blessures
de l’opérateur ou des autres personnes se trouvant
dans la zone de travail en cas de non-respect de la
procédure en question.
1.05 Precautions De Securite
Importantes
AVERTISSEMENTS
L’OPÉRATION ET LA MAINTENANCE DU MATÉRIEL
DE SOUDAGE À L’ARC AU JET DE PLASMA PEU-
VENT 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 travail
près d’une application à l’arc au jet de plasma devrait
consulter leur membre professionel de médication
et le manufacturier de matériel de santé pour déter-
miner s’il existe des risques de santé.
Il faut communiquer aux opérateurs et au person-

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.
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respi-
ration.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:

ULTRA-CUT 300 XT
1-4 GENERAL INFORMATION Manual 0-5305
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.
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pro-
tecteurappropriépourprotégervotrepeaucontre
lesétincellesetlesrayonsdel’arc.
• Maintenezvotrecasqueetvoslunettesdeprotection
enbonétat.Remplaceztoutelentillesaleou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:

ULTRA-CUT 300 XT
Manual 0-5305 GENERAL INFORMATION 1-5
Nuance Minimum Nuance Suggerée
Courant Arc Protective Numéro Numéro
Moins de 300* 8 9
 300-400* 9 12
 400-800* 10 14
* Ces valeurs s’appliquent ou l’arc actuel est observé
clairement. L’experience a démontrer que les filtres
moins foncés peuvent être utilisés quand l’arc est
caché par moiceau de travail.
BRUIT
Lebruitpeutprovoquerunepertepermanentedel’ouïe.
Lesprocédésdesoudageàl’arcdeplasmapeuvent
provoquerdesniveauxsonoressupérieursauxlimites
normalementacceptables.Vousdú4ezvousprotéger
lesoreillescontrelesbruitsforts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.
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 PRO-
TECTION DE LA SANTÉ, �9CFR 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 OPÉRA-
TIONS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PRO-
TECTION 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SOUD-
AGE,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 Associa-
tion,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 ���0�
12. NormeCSAW117.2,CODEDESÉCURITÉPOURLESOUD-
AGEETLA COUPE,disponibleauprèsdel’Association
desNormesCanadiennes,StandardsSales,178Rexdale
Boulevard,Rexdale,Ontario,Canada,M9W1R3
13. LivretNWSA,BIBLIOGRAPHIESURLASÉCURITÉDU
SOUDAGE,disponibleauprèsdel’AssociationNationale
deFournituresdeSoudage(NationalWeldingSupplyAs-
sociation), 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 RENFERMÉ DES
PRODUITS DANGEREUX , disponible auprès de laAmeri-
canWeldingSociety,550N.W.LeJeuneRd.,Miami,FL33126
15. NormeANSIZ88.2,PRATIQUESDEPROTECTIONRES-
PIRATOIRE,disponibleauprèsde l’AmericanNational
StandardsInstitute,1430Broadway,NewYork,NY10018

ULTRA-CUT 300 XT
1-6 GENERAL INFORMATION Manual 0-5305
1.07 Declaration of Conformity
Declaration of Conformity
Manufacturer: Victor Technologies International Inc.
Address:   16052SwingleyRidgeRoad      
Suite 300
    Chestereld,MO63033U.S.A.
Type of Equipment: Plasma Cutting Controller
Model/Number:  Ultra-Cut300XT
SerialNumber:  Serialnumbersareuniquewitheachindividualpieceofequipmentanddetailsdescription,
parts used to manufacture a unit and date of manufacture.
MarketReleaseDate: May1,2013
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

in those locations, due to conducted as well as radiated disturbances.
The product is designed and manufactured to a number of standards and technical requirements.
Thispriductiscertiedto:
• CAN/CSAE60974-1Issue:2011/12/01Ed:2ArcWeldingEquipment-Part1:WeldingPowerSources
• UL60974-1Issue:2005/03/17Ed:1ArcWeldingEquipment-Part1
Extensiveproductdesignverication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specied.Rigoroustestingisincorporatedintothemanufacturing
processtoensurethemanufacturedproductmeetsorexceedsalldesignspecications.
VictorTechnologies.hasbeenmanufacturingproductsformorethan30years,andwillcontinuetoachieveexcel-
lence in our area of manufacture.
Manufacturer’sAuthorizedRepresentative
JoeMuellerS.V.P.AmericasandGeneralManager
Address: Victor Technologies International Inc.
   16052SwingleyRidgeRoad  
Suite 300
   Chestereld,MO63033U.S.A
Date: January16,2014
Signature
   JoeMueller  
(Full Name)
S.V.P. Americas and General Manager
(Position)

ULTRA-CUT 300 XT
Manual0-5305 GENERALINFORMATION 1-7
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

in those locations, due to conducted as well as radiated disturbances.

ULTRA-CUT 300 XT
1-8 GENERAL INFORMATION Manual 0-5305
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 Victor 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 300 XT
Manual 0-5305 SPECIFICATIONS �-1
SECTION 2: SPECIFICATIONS
2.01 General Description Of The System
AtypicalUltra-CutXT™systemcongurationincludes:
• OnePowerSupply
• RemoteArcStarter
• GasControl-DigitalmanifoldControl(DMC)
• GasControl-DigitalPressureControl(DPC)
• PrecisionPlasmaCuttingTorch
• SetOfConnectingLeads
• TorchSparePartsKit
• TouchScreenControl(TSC),Optional
• HeatExchanger,Optional
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, 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.
2.06 Specifications & Electrical Requirements
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)

ULTRA-CUT 300 XT
�-� SPECIFICATIONS Manual 0-5305
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
480 50/60 63 77 150 #4 25
IEC 480 50/60 72 88 150 #4 25
NOTE
* Suggested wire size based on United States NFPA 70 National Electrical Code 2011 edition published by the

-
lation type may require larger wire size. De rate for higher ambient.

determination of correct wire type and size.
2.07 Power Supply Dimensions
Art # A-11980
35.97 inch
914 mm
27.6 inch
701 mm
47.77 inch
1213 mm
200A 465 lb / 211 kg

ULTRA-CUT 300 XT
Manual 0-5305 SPECIFICATIONS �-3
2.08 Power Supply Rear Panel Features
USER INPUT
HEIGHT CONTROL
F1 - 8A SB 230 VAC F2 - 8A SB 230 VAC
CB4 - 5A 120 VAC
CB3 - 5A 24 VAC
CB2 - 5A 120 VAC
J55 - GCM
J15 - CNC
J59 - RAS
J70 - HE
J54 - TSC /COMM
Art # A-11842
AC Power Lamp
Negative Return
Coolant Filter
C.C.M.
Circuit Breakers
Input Power
Ports
Arc Starter Connector
Coolant Return
Coolant Supply
7 Pin Connector
Customer
Optional
Ports
Pilot Lead
Work Lead
Fuse
CNC Connector
GCM Connector
TSC/Comm
2.09 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.
Ultra-Cut 300 XT™ Power Supply: Gas Pressures, Flows, and Quality Requirements
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)
Ar (Argon) 99.995% Purity
(gas recommended)
120 psi
8.3 bar / 827 kPa 150 scfh (4200 l/h)
H2O (Water) See Note 2 50 psi (3.5 bar) 10 gph (38 lph)

ULTRA-CUT 300 XT
2-4 SPECIFICATIONS Manual 0-5305
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.
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 3: Water Pressure Regulator if needed can be purchased at local plumbing supply.
2.10 Gas Applications
MATERIAL MILD STEEL STAINLESS STEEL ALUMINUM
GAS TYPE GAS TYPE GAS TYPE
OPERATION PREFLOW PLASMA SHIELD PREFLOW PLASMA SHIELD PREFLOW PLASMA SHIELD
30A Cut Air O2O2Air Air Air Air Air Air
N2N2H20 N2N2H20
50A Cut Air O2Air Air Air Air Air Air Air
N2N2H20 N2N2H20
70A Cut Air O2Air Air Air Air Air Air Air
N2N2H20 N2N2H20
100A Cut Air O2Air N2H35 N2N2H35 N2
N2N2H20 N2N2H20
150A Cut Air O2Air N2H35 N2N2H35 N2
N2N2H20 N2N2H20
200A Cut Air O2Air N2H35 N2N2H35 N2
N2N2H20 N2N2H20
250A Cut Air O2Air
300A Cut Air O2Air N2H35 N2N2H35 N2
N2N2H20 N2N2H20
Marking Air Ar Air/ O2* Air/ N2* Ar Air/ N2/
H20Air/ N2 * Ar Air/ N2/ H20
*Note: Depends on process used.