Thermal Arc ULTIMA 150 Page 2 Service Manual Download

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Summary of Contents for ULTIMA 150

Page 1: ...February 9 2005 Manual No 0 2503 Plasma Welding Power Supply ULTIMA 150 Service Manual...

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Page 3: ...yright 1995 by Thermal Dynamics Corporation All rights reserved Reproduction of this work in whole or in part without written permission of the publisher is prohibited The publisher does not assume an...

Page 4: ...150 Power Supply Specifications 9 2 06 The ULTIMA 150 System 10 2 07 Requirements to Complete System 10 2 08 Options Accessories and Replacement Parts 11 SECTION 3 SERVICE TROUBLESHOOTING 13 3 01 Intr...

Page 5: ...er Assembly Replacement 33 4 09 Hose Assembly Replacements 33 4 10 Internal Parts Replacement 34 4 11 Front Panel Parts Replacement 39 4 12 Rear Panel Assembly Parts Replacement 41 SECTION 5 PARTS LIS...

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Page 7: ...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...

Page 8: ...s in this manual PLASMAARC RAYS PlasmaArc 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...

Page 9: ...ble 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 avertissement sont utilis s pour mettre en...

Page 10: ...r ou m me tuer Le proc d au jet de plasma requiert et produit de l nergie lectrique haute tension Cette nergie lectrique peut produire des chocs graves voire mortels pour l op rateur et les autres per...

Page 11: ...e les d cibels le bruit ne d passent pas les niveaux s rs Pour des renseignements sur la mani re de tester le bruit consultez l article 1 page 5 1 06 Documents De Reference Consultez les normes suivan...

Page 12: ...CURIT POUR LE SOUDAGE ET LA COUPE disponible aupr s de l Association des Normes Canadiennes Stan dards Sales 178 Rexdale Boulevard Rexdale Ontario Canada M9W 1R3 13 Livret NWSA BIBLIOGRAPHIE SUR LA S...

Page 13: ...ion standard C22 2 number 60 forArc welding equipment UL Underwriters Laboratory rating 94VO flammability testing for all printed circuit boards used ISO IEC 60974 1 BS 638 PT10 EN 60 974 1 EN50192 EN...

Page 14: ...as follows with the exception of XL Plus Series CutMaster Series Cougar and DRAG GUN A maximum of three 3 years from date of sale to an authorized distributor and a maximum of two 2 years from date of...

Page 15: ...quipment C Customer Operator Responsibilities It is the customer operator s responsibility to main tain the equipment and peripheral accessories pro vided by Thermal Dynamics in good operating order i...

Page 16: ...the system Coolant and power supply overtemperature of the power supply or coolant will immediately disable the power supply output The recirculator pump remains running for system and coolant cool d...

Page 17: ...erformance For more information refer to Section 5 Parts Replace ment Quick Disconnect Adapter Kit for use with older model Thermal Arc torches The Adapter Kit retro fits the torch for direct connecti...

Page 18: ...SECTION 2 INTRODUCTION 12 Manual 0 2503...

Page 19: ...bleshooting and parts replacement procedures This manual should be your first resource for trouble shooting if the problem cannot be remedied using the Operating Manual refer to the advanced troublesh...

Page 20: ...ct torch with correct torch parts installed Con sult appropriate torch manual for details if required 3 Turn on Plasma and Shield gas supplies Set both pres sure regulators to provide 35 psi 4 Install...

Page 21: ...enable the weld ing arc Refer to the Ultima 150 Operating Manual for more information 3 07 AC Indicator Light Status Under normal operating conditions the AC Indicator light is green Complete the fol...

Page 22: ...r a Check J7 connection at Transformer located in front of the Output PC Board for proper con nection b Measure the output voltages at J4 on the Trans former at Logic PC Board for the following Pins V...

Page 23: ...nnection is not open replace FET Assem bly A If connection is open reconnect J2Ato the Logic PC Board and proceed to step e e Check continuity of FET Heatsink Assembly B Temperature Switch between J2B...

Page 24: ...e Plasma and Shield Gas Flow meters on the front panel to desired flow rate Gas should be flowing through to the torch Con sult torch manual for proper flow rates to use If there are no Flowmeter read...

Page 25: ...the OFF position Unplug J3 from Logic PC Board to disable DC out put circuit Connect the primary power and place the Primary Power ON OFF Switch to the ON position A COOLANT Light Red not blinking 1...

Page 26: ...without optional Coolant Pressure Gauge installed For units with optional Coolant Pressure Gauge in stalled see note at end of this subsection a If Motor Fan rotates check coolant pressure b Remove H...

Page 27: ...ocal control of the PILOT ARC ON function but the user may replace this jumper with a switch if remote control is desired Under normal conditions the PILOT Indicator light is off until a pilot arc is...

Page 28: ...limits for the torch used If not correct them b Check for gas leaks as in Section 3 09 c If all settings are OK and pilot is still erratic disconnect primary power and place the Pri mary Power ON OFF...

Page 29: ...ce If there are no signs of physical damage or failure then proceed with the following test procedure 2 Disconnect lead 7 from the negative terminal of Input Diode D1 Assembly A 01103 R S T Wire 7 Wir...

Page 30: ...are not correct re place the affected FET and Capacitor Assembly Capacitors Heatsinks FET FET A 00837 Figure 3 10 FET Locations C Output PC Board Diode Bridge Assembly NOTE The Ultima 150 has been man...

Page 31: ...ap the first two folds of the band Wrap the adhesive side firmly around your wrist 2 Unroll the rest of the band and peel the liner from the copper foil at the opposite end 3 Attach the copper foil to...

Page 32: ...by reversing the above steps The PC Board Assembly snaps onto the PC Board sup ports NOTE Make sure that the PCB snaps into place when pushed down over the supports B Input PC Board Replacement 1 Remo...

Page 33: ...ment Output PC Board Assem bly by reversing the above steps Torque all screws to 35 in lbs D Pilot PC Board Replacement The Pilot PC Board Assembly consists of two PC Boards mounted to a vertical fram...

Page 34: ...lter Assembly Cap Coolant Reservoir Basket Deionizer Bag Inside Hose A 00825 Figure 4 4 Coolant Reservoir Replacement 3 Remove the Enclosure Cover per Section 4 04 4 Remove the hose connected to the b...

Page 35: ...3 Reinstall the replacement Coolant Reservoir by reversing the above steps NOTE Use thread sealant on all fittings when reinstall ing 14 Refill the Coolant Reservoir with the coolant re moved or fresh...

Page 36: ...e hose prior to removing 5 Remove Filter bowl from filter body 6 Remove filter body from Flow Switch Assembly 7 Remove Flow SwitchAssembly from Coolant Res ervoir Rotate Flow Switch Approximately 30o...

Page 37: ...mp Assembly Approximately 30o Counter Clockwise CCW Motor Assembly A 00842 Figure 4 7 Pump Assembly Orientation 5 Pull the Pump Assembly from the Motor Assem bly 6 Remove the Pump Assembly from the un...

Page 38: ...y note where the Motor wiring terminates 4 Locate the Hose Assembly attached to the upper radiator connection 5 Loosen the hose clamp and remove the Hose As sembly 6 Disconnect the Motor Assembly wiri...

Page 39: ...ssembly Replacement The Coolant Filter Assembly is located on a bracket on the rear panel of the unit 1 Remove the two coolant hose connections to the Filter Assembly 2 Remove the two elbow fittings o...

Page 40: ...seAssembly by revers ing the above steps 5 Refill the ULTIMA 150 Plasma Welder with Ther mal Arc Torch Coolant before applying power B Coolant Supply Hose Coolant Filter to Pump Assembly Replacement T...

Page 41: ...om the Radiator and out of the unit 6 Install the replacement Hose Assembly by reversing the above steps 4 10 Internal Parts Replacement This subsection describes the replacement of various in ternal...

Page 42: ...d Fig ure 4 14 shows the connections for Model B Bus Bar OUTPUT PC BOARD Current Sense Toroids Transformer Leads E1 E2 T1 T2 A 01322 Figure 4 13 Connections for Model A Output Diode Bridge Assembly OU...

Page 43: ...the Enclosure Cover per Section 4 04 2 Locate the Output PCB Diode Bridge Heatsink Assembly on the left side internal frame as viewed from the front of the unit 3 Note the location of all the cable co...

Page 44: ...a Gas Input Hose Shield Gas Input Hose T Fitting T Fitting Fitting Collar Fitting Collar Plasma Gas Output Hose Shield Gas Output Hose Plasma Gas Flow Meter Assembly Shield Gas Flow Meter Assembly Pla...

Page 45: ...Remove the Logic Display PC Board per para graph A above 3 The Logic Display PC Board is attached to a frame Tilt the frame forward to gain access to the FET Heatsink Capacitor PC Board assem blies 4...

Page 46: ...as Hoses 1 Turn Gas Regulators off 2 Remove the Enclosure Cover per Section 4 04 3 Locate the Gas Hose and Solenoid Pull the Hose from the Solenoid Fitting while pushing the fit ting collar towards th...

Page 47: ...re E Main ON OFF Switch Assembly Replacement 1 Remove the Enclosure Cover per Section 4 04 2 Label each wire connected to the terminals of the Main ON OFF Switch Assembly 3 Remove all wiring from the...

Page 48: ...ted Coil Spring inside the fitting does not fall out or get turned sideways 5 Install the replacement Shield Gas Fitting by re versing the above steps A 00858 Plasma Gas Supply Fitting Shield Gas Supp...

Page 49: ...n the TORCH Quick Disconnect Connec tor 4 On the TORCH connector remove the nut secur ing a wire ring to the fitting 5 Using a snap ring tool remove the Socket Retain ing Ring Clip from the Coolant Re...

Page 50: ...SECTION 4 REPAIRS REPLACEMENT 44 Manual 0 2503...

Page 51: ...5 05 Base Unit Replacement Parts Section 5 06 Rear Panel Replacement Parts NOTE Parts listed without item numbers are not illus trated but may be ordered by the catalog numbers shown B Returns If a p...

Page 52: ...nt Control Knob 9 4146 5 1 Front Panel Assembly 9 5945 6 1 Cover Not Shown 9 5947 7 1 Hose Radiator To Reservoir 9 5929 8 1 Hose Disconnect To Radiator 9 5928 9 1 Radiator Includes 6 Grommets 9 5941 1...

Page 53: ...eatsink Capacitor PC Board Assembly Includes 7 9 9 5975 7 1 Input Pc Board Assembly 9 5935 8 2 FET Cap Heatsink Assembly 9 5953 9 1 Diode 3 Phase W Scr 40A 1600V With Thermal Pad 9 5950 10 2 Cable Ass...

Page 54: ...Cat 1 1 Coolant Pressure Gauge Optional 9 6220 1 1 Pressure Gauge Plug 9 4583 2 1 Auxiliary Transformer 9 5921 3 1 Contactor 9 5920 4 1 Motor 9 5932a 5 1 Pump 9 6164 6 1 Pump Clamp 9 5942 7 1 Hose Pu...

Page 55: ...Manual 0 2503 49 SECTION 5 PARTS LISTS A 00853 To Quick Disconnect From Filter 4 8 7 1 9 5 3 2 6 1 Coolant Pressure Gauge optional 5 05 Base Unit Replacement Parts...

Page 56: ...1 In Line Filter 8 3460 9 1 Shield Supply Hose 9 5931 10 1 Plasma Supply Hose 9 5930 11 1 Rear Panel Assembly 9 5946 12 1 Standard Remote Assembly N A 9 5951 13 1 Quick Disconnect Body Assembly 9 5917...

Page 57: ...Manual 0 2503 51 SECTION 5 PARTS LISTS A 00855 Cable Assembly with Ground Clamp optional 1 2 4 3 5 6 7 8 19 18 9 10 11 12 19 5 06 Rear Panel Replacement Parts...

Page 58: ...SECTION 5 PARTS LISTS 52 Manual 0 2503...

Page 59: ...5 or 6 Heavy Over 1 2 in 12 mm 6 or 8 Shielded metal arc welding stick electrodes Light Under 5 32 in 4 mm 10 Medium 5 32 1 4 in 4 6 4 mm 12 Heavy Over 1 4 in 6 4 mm 14 Gas metal arc welding MIG Non f...

Page 60: ...0 2503 APPENDIX II QUICK DISCONNECT LEADS ASSIGNMENT Rear Panel Mounted Quick Disconnect Leads Assignment Viewed Looking at Rear Panel SHIELD GAS YELLOW COOLANT SUPPLY GREEN PLASMA GAS BLACK COOLANT...

Page 61: ...able the pilot arc when coolant conduc tivity level is high connect pin 12 to pin 24 and pin 13 to pin 23 3 Weld Arc On Detect for use with Synerweld 2100 is enabled with the following wiring connecti...

Page 62: ...APPENDIX 56 Manual 0 2503 APPENDIX IV SYSTEM SCHEMATIC A 00835...

Page 63: ...Manual 0 2503 57 APPENDIX A 00835...

Page 64: ...Assembly Radiator To In Line Filter Coolant Return Hose Assembly In Line Filter To Flow Switch Coolant Return Hose Assembly TORCH QD To Radiator Coolant Supply Hose Assembly Pump To TORCH QD Check Va...

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