Victor ULTRA-CUT 100 User Manual

Name: Victor ULTRA-CUT 100
Brand: Victor
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202 pages

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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

Default Chapter4
- Table of Contents4
Section 17
- General Information7
- Important Safety Precautions7
- Notes, Cautions and Warnings7
- Publications8
- Note, Attention Et Avertissement9
- Precautions de Securite Importantes9
- Documents de Reference12
- Declaration of Conformity13
- Statement of Warranty15
Section 2: Specifications17
- General Description of the System17
- Plasma Power Supply17
- Remote Arc Starter17
- Gas Control Module17
- Precision Plasma Cutting Torch17
- Specifications & Electrical Requirements18
- Power Supply Dimensions20
- Power Supply Rear Panel Features21
- Gas Requirements22
- Gas Applications24
- XT Torch Specifications25
Section 3: Installation27
- Installation Requirements27
- System Layout 100 - 200 Amp28
- System Layout 300 Amp28
- System Layout 400 Amp29
- Recommended Gas Supply Hose29
- Leads and Cables All Amperage30
- Lift the Power Supply31
- Connect Input Power and Ground Cables32
- Connect Work Cable and Pilot and Negative Leads33
- Ground Connections33
- Connect Coolant Leads36
- Connect Cables for CNC, Remote Arc Starter, GCM and HE 40037
- Handling and Installation of Fiber Optics37
- Correct Installation39
- Set Switches on the Command - Control Module40
- Height Control Connections42
- Gas Control Module Installation42
- Fiber Optic Cable Installation44
- Gas Control Module: Control, Input, and Output Connections45
- He400Xt Cooler47
- Install Remote Arc Starter49
  - Input Connections51
  - Output Connections53
- Torch Valve Installation56
- Connecting Torch57
- Install Consumable Torch Parts59
- Voltage Divider for Ihc Torch Height Control61
- Control Cable61
- Complete the Installation63
Section 4: Operation65
- Power Supply Control Panel65
- System Operation66
- Gas Selection68
- Functional Overview70
- GCM 2010 Gas Control Module Operation70
- GCM 2010 First Time Operation Matching Gas Control to Lead Length74
- GCM 2010 Sequence of Operation74
- Power Supply Status Codes77
- Remote Arc Starter Trouble Shooting84
Section 5: Maintenance85
- General Maintenance85
- External Coolant Filter Cleaning Procedure85
- Coolant Replacement Procedure86
Section 6: Replacement Assemblies & Parts87
- Replacement Power Supply87
- System Layout 100 - 200 Amp88
- System Layout 300 Amp88
- System Layout 400 Amp89
- Recommended Gas Supply Hose89
- Leads and Cables All Amperages90
- Power Supply External Replacement Parts92
- Power Supply Replacement Parts - Upper Right Side93
- Power Supply Replacement Parts - Lower Right Side94
- Power Supply Replacement Parts - Rear Panel95
- Power Supply Replacement Parts - Left Side96
- Gas Control Module (GCM-2010) Replacement Parts97
- Gas Control Module (GCM-2010) Replacement Parts98
- Remote Arc Starter (RAS-1000 XT) Replacement Parts99
- HE400XT Heat Exchanger - Replacement Parts100
Torch Maintenance101
- Consumable Removal101
- O-Ring Lubrication102
- Parts Wear102
- Torch Consumables Installation103
- Coolant Leak Trouble-Shooting105
Appendix 1: Remote Arc Starter Schematic107
Appendix 2: Gas Control and Torch Valve Schematic108
Appendix 3: Gas Control Module Plumbing Diagram110
Appendix 4: Gas Control Module Pcb Layout111
Appendix 5: Gas Control Display Module Pcb Layout112
Appendix 6: Cnc - Control Module Pcb Connections113
Appendix 7: Cnc114
- CNC Functions114
- CNC Input / Output Descriptions116
- Simplified CNC Circuit118
- CNC Connections120
Appendix 8: Serial Communications121
- A8.01 Cables and Switch Settings for 2 and 4 Wire121
Appendix 9: CCM Cpu Pcb Layout124
Appendix 10: CCM I/O Pcb Layout126
Appendix 11: Pilot Pcb Layout128
Appendix 12: Relay and Interface Pcb Layout130
Appendix 13: Display Pcb Layout132
Appendix 14: System Bias Pcb Layout134
Appendix 15: Main Inverter Bottom Pcb Layout136
Appendix 16: Main Inverter Top Pcb Layout138
Appendix 17: Control and Fault Pcb Layout140
Appendix 18: Cap Bias Bottom Pcb Layout142
Appendix 19: Cap Bias Top Pcb Layout143
Appendix 20: Suppressor Pcb Layout144
Appendix 21: Cooling Diagram145
Appendix 22: System Schematic 100A, 380-415V146
Appendix 23: System Schematic 100A, 380-415V148
Appendix 24: System Schematic 200A, 380-415V152
Appendix 25: System Schematic 200A, 380-415V Pg 2156
Appendix 25: System Schematic 200A, 380-415V Pg 2156
Appendix 26: System Schematic 300A, 380-415V156
Appendix 27: System Schematic 300A, 380-415V Pg 2160
Appendix 27: System Schematic 300A, 380-415V Pg 2160
Appendix 28: System Schematic 400A, 380-415V160
Appendix 29: System Schematic 400A, 380-415V Pg 2162
Appendix 29: System Schematic 400A, 380-415V Pg 2162
Appendix 30: Advanced Troubleshooting162
Appendix 31: Publication History200

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Victor ULTRA-CUT 100 Specifications

General

Efficiency	85%
Insulation Class	H
Output Current Range	20 - 100 A
Duty Cycle	60% @ 100 A
Gas Type	Air or Nitrogen
Gas Flow Rate	190 lpm
Protection Class	IP23
No Load Voltage	300V

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