ULTRA-CUT® INTEGRATED SYSTEMS

THE NEXT GENERATION OF HIGH
PRECISION PLASMA CUTTING
Thermal Dynamics
®
ULTRA-CUT XT
®
INTEGRATED SYSTEMS
O
ur next generation of high precision plasma cutters works the
way you do – intelligently. Ultra-Cut XT systems give you the
flexibility to increase cutting power and the assurance of superior
quality, higher productivity and lower cutting costs. Ultra-Cut XT
systems are available in 100-400 Amp outputs for cutting plate
up to 2" (50 mm) thick. And because its Modular Power Technology
allows adding 100 Amp modules, the system grows with your business.
We Bring Intelligence to the Table.
TM
Thermal Dynamics
®
ULTRA-CUT XT SYSTEMS
®
The new Ultra-Cut XT technology provides the next generation of higher productivity, increased
flexibility and confidence in high precision plasma cutting. Their performance will meet or beat
anyone on mild steel, and they are superior on non-ferrous metals. With the ability to grow
with your business, you can expand from one system to the next higher in minutes. The
Ultra-Cut XT systems utilize StepUp™ modular power technology, allowing units to be easily
upgraded - ensuring you'll always have the right amount of power today - and tomorrow.
Higher Productivity Delivers Greater Profits
Ultra-Cut XT high precision systems deliver superior
cut quality, at superior cutting speeds.
• Outstanding parts life to reduce down time and
lower the overall cost of ownership.
Superior Cut Quality Means Greater Efficiency
The Ultra-Cut XT systems’ superior cut quality means
that parts can go directly from the cutting table to
welding, painting or assembly without expensive
secondary operations.
Ultra-Cut XT high precision plasma systems cut with:
• Excellent dross-free cuts using oxygen (O2) plasma
on mild steel.
• Unmatched cut quality on non-ferrous metals using
unique Water Mist Secondary (WMS®) process.
Ultra-Cut Cut Bevel Comparison
1
0
• Shorter switching time between marking and
cutting process for higher daily throughput.
• Highest cut speed in its class on stainless steel –
up to 3 times faster than similar cutting systems.
Relative Cutting Speed
5080
150
3810
100
2540
50
1270
mm/min
IPM
1/2 "
(12 mm)
100
130
150
200
Oxyfuel
1 1/2"
40 mm
1 1/4"
35 mm
25 mm
1"
25 mm
1"
25 mm
3/4"
• Lower current draw to reduce cutting cost.
Ultra-Cut 400 XT
1"
20 mm
20 mm
12 mm
1/2"
3/4"
20 mm
3/8"
3/4"
• Reduced downtime during parts changes with
the Speedlok cartridge design.
200
12 mm
2
1/2"
12 mm
3
3/8"
10 mm
ISO Class
4
Thermal Dynamics Ultra-Cut
Competitor
1/2"
10 mm
5
• Highest kW output for maximized duty cycle and
cut speed.
250
260
300
300
400
400
3/4 "
(20 mm)
1"
(25 mm)
1 ¼"
(35 mm)
1 ½"
1 ¾"
(40 mm)
(45 mm)
2"
(50 mm)
400
Current Level
PLATE THICKNESSES: 3/8" - 1 1/2"
• ISO 9013:2002 (E). Class 3 (depending on cut
thickness angles below 3 deg) or better cut angles
for true High Precision cuts.
• Minimal heat affected zone (HAZ) to improve
welding quality.
• 3DPro technology sets the new standard in robotic
cutting thin gauge material.
HeavyCut Technology Cuts Cost By Length on Mild Steel
$0.5000
$0.4500
$0.4000
$0.3500
$0.3000
$0.2500
$0.2000
$0.1500
$0.1000
$0.0500
$0.0000
Ultra-Cut 400 XT
0.500"
12.7 mm
0.625"
15.9 mm
Competitor A
0.75"
19.0 mm
Competitor B
1.0"
25.4 mm
Thickness
1.5"
38.1 mm
2.0"
50.8 mm
We Bring Intelligence to the Table.
TM
Now More Energy Efficient
“Bolt Ready” Holes with Diameter PRO™
Compared to previous systems, Ultra-Cut XT systems
draw about 20% less current and have an average
electrical efficiency of more than 92%. They meet
European Union Level V Efficiency Standards, and
they will help companies everywhere lower utility bills.
Diameter PRO produces the industry’s most precise
holes optimized for a diameter-to-thickness ratio of
1:1 or greater.
Intelligent Solutions Set Us Apart
It is the ideal process for a precision hole or radius with
minimal-to-no taper on mild steel from 10 gauge (3 mm)
to 2" (50 mm), or 1" (25 mm) on aluminum.
From superior technology for cutting heavy metal to
better plasma marking, Thermal Dynamics® offers
intelligent high precision solutions for automated plasma
cutting applications. The XT Series provides access for
these powerful cutting resources.
HeavyCut™ Technology
When cutting parts thicker than 3/4" (20 mm), rely on
HeavyCut Technology to provide the best cut quality, precision
and parts life with XTremeLife™ Consumables. Heavy-Cut 300A
and 400A electrodes
with multiple Hafnium
inserts increase parts
life at high current
applications.
Multiple Hafnium
Water Mist Secondary (WMS)
optimizes non-ferrous metal cutting
• Excellent non-ferrous metal cut quality using N2 as
plasma gas and ordinary tap water as the secondary.
Inserts
• Lowest operating cost.
• Dross-free cutting from gauge (1.0 mm) to 1 1/2" (40 mm).
• Oxide-free cut face surface.
• Wide parameter window.
LongerLife
Partswith
Life with
XTremeLife™™ Consumables
Longer Parts
XTremeLife
Consumables
• Higher cut speeds compared to H35 cutting.
5000
300A
400A
Stainless Steel Cutting Speed Comparison
160
3000
1000
10
20
30
Cut Duration (seconds)
O2 / Air on Mild Steel
40
50
4000
3500
300A
140
2000
Competitor H35/N2
Ultra-Cut ® N 2 /H 2 0
3000
120
100
100A
80
60
260A
80A
2500
300A
260A
400A
400A
2000
1500
40
1000
20
500
0
1/4"
(6 mm)
3/8"
(10 mm)
5/8"
(15 mm)
Material Thickness
1"
(25 mm)
0
Speed (mm/min)
200A
Speed (in/min)
Number of Starts
100A
4000
Thermal Dynamics
®
ULTRA-CUT XT SYSTEMS
®
With StepUp™ Modular
Power Technology, your
system has the flexibility
to grow with your business.
You can start with an
Ultra-Cut 100 XT, and
when you are ready,
expand to a 200, 300
or 400 Amp system.
With the Ultra-Cut XT,
you never have to worry
about choosing the
right system.
StepUp Modular Power Technology Expand As Your Cutting Needs Grow
TM
Thermal Dynamics designed the
Ultra-Cut® XT with the flexibility to grow
with your business. It features modular
“inverter blocks” and a common cabinet
for all amperages. To expand a 100A
system into a 200A, 300A or 400A
system, additional blocks can be easily
installed.* A field technician can install
a new inverter block in less than
30 minutes.
The Thermal Dynamics intelligent approach means
never “under-buying” again. With Ultra-Cut XT systems,
you’ll always have the right amount of power today —
and tomorrow.
*Any existing system can be upgraded up to 400A.
Better Flow Control and Plasma Marking with
the DFC-3000 Automatic Gas Control
Good gas flow control enhances cut quality and extends
consumables life. Digital flow control with the DFC-3000
— when paired with the iCNC® XT controller — provides
a better level of quality control. Together, they instantly set
and control gas pressure, leading to faster cycle times
and more productive cutting.
And for plasma marking with argon,
the DFC-3000 and Ultra-Cut XT
minimizes the purge cycle between
marking and cutting, as well as the
changeover time associated with
manual controls. Change seamlessly
between cutting and marking to:
• Indicate part numbers • Drill or hole points
• Weld locations • Lot numbers • Bend or cut lines
Easy-to-Service
Reliability – Performance You Can Rely On
The Ultra-Cut XT high precision system’s modular design
is not only easier to upgrade, but also easier to maintain.
• The Amperage/Error display indicates the status of
the XT system to accelerate trouble shooting.
Thermal Dynamics rigorously tests its plasma cutters to
ensure flawless performance. Should your Ultra-Cut XT
need service, our modular approach minimizes parts
inventory and repair time. Even when one inverter
block malfunctions, cutting is still possible with the
remaining blocks.
• Common components in the XT system minimize inventory.
We Bring Intelligence to the Table.
TM
XT Torch Technology – The New Standard
for High Precision Plasma Cutting Systems
™
Multiple Hafnium inserts improve parts
life also at 300A and 400A.
Speedlok Technology gives the fastest
consumable change over in the industry.
Water cooled shield cup
provides outstanding durability
even at 2" (50 mm) piercing.
At 300A and 400A, better cooling for
consistent cut quality until the end of life.
No Tools Required
Precision Cuts on All Metals
Unlike other torches,
no tools are required to
change either the torch
consumables or major
components in the
torch head.
The XT-Torch dual gas technology provides one of the
highest arc density plasma stream in the industry for
precision cuts on mild steel, stainless steel, aluminum
and other non-ferrous materials, and Ar for marking with
the DFC 3000. Choices for plasma gas include - Air, N2,
O2, Ar-H2 and Ar for marking with the DFC 3000. Shield
gas choices include - Air, N2, O2, or Ar-H2 and H2O.
‘Leakless’ Torch Head Design
Coolant doesn’t drip form the torch head when the
consumables cartridge is removed form the torch head.
The design prevents air from entering the system and
becoming trapped in the leads.
Self-Centering Components
Consumable parts and torch body are precisely
engineered to lock into place for absolute alignment
and remain positioned cut after cut. Independentlyaligned tip and electrode assures accurate re-centering
of the consumable cartridge after each parts change.
This guarantees best cut quality time and again.
Superior Warranty
Thermal Dynamics’ XT-Torch warranty covers
components and service for a full 1-year period.
Relaxed Cutting Parameters
With the XT-Torch the operating window permits wide
travel speed variance, which means you’ll get great cuts
more often with less wasted material and time.
• Less critical standoff height
• Wider ‘Operating Window’ for dross-free cutting
The Ultra-Cut XT is the latest addition to
Thermal Dynamics integrated automated
plasma system solution. The next
generation Ultra-Cut XT combines high
precision cutting with exceptional
cost-performance benefits to deliver a
more profitable plasma cutting operation.
Thermal Dynamics
®
ULTRA-CUT XT SYSTEMS
®
The XT System Technology
™
• Microprocessor controlled
for optimized cut quality
and parts life.
• Power upgrade. Inverter
blocks can be easily
added for higher cutting
capacity.
Auto Gas Control DFC 3000
Digital Flow Control for optimized
and easy set up for frequent
changes between materials and
thicknesses. A must for marking
with Argon and fast switching
between cutting and marking.
XT Torch
Fastest consumable changes
with Speedlok technology.
Manual Gas Control
New Arc Starter
GCM2010 for stable gas flow
and pressure control.
For reduced HF emission.
System Capabilities
MILD STEEL
Production Pierce
Maximum Pierce
Edge Start
Ultra-Cut® 100 XT
1/2" (12 mm)
5/8" (15 mm)
¾" (20 mm)
Ultra-Cut 200 XT
1" (25 mm)
1-1/2" (40 mm)
2-1/2" (65 mm)
Ultra-Cut 300 XT
1 1/2" (40 mm)
1-3/4" (45 mm)
3" (75 mm)
Ultra-Cut 400 XT
2" (50 mm)
2" (50 mm)
3-1/2" (90 mm)
STAINLESS STEEL
Production Pierce
Maximum Pierce
Edge Start
1/2" (12 mm)
5/8" (15 mm)
¾" (20 mm)
1" 1" 2" (25 mm)
(25 mm)
(50 mm)
1" (25 mm)
1-1/4" (30 mm)
2" (50 mm)
2" 2" 4" ALUMINUM
Production Pierce
Maximum Pierce
Edge Start
1/2" (12 mm)
5/8" (15 mm)
¾" (20 mm)
7/8" 1" 2" (20 mm)
(25 mm)
(50 mm)
1" (25 mm)
1-1/4" (30 mm)
2" (50 mm)
2"
(50 mm)
2-1/4" (60 mm)
3-1/2" (90 mm)
(50 mm)
(50 mm)
(100 mm)
We Bring Intelligence to the Table.
TM
Unit Specifications*
Rated Output
(Amps)
Output Range
(Amps)
Output (Volts)
Ultra-Cut® 100 XT
Ultra-Cut 200 XT
100 A
200 A
5-100 A
5-200 A
180 V
180 V
Input Volts
(Volts, Phase,
Hertz)
380 V, 3 ph, 50-60 Hz,
400 V, 3 ph, 50-60 Hz,
480 V, 3 ph, 50-60 Hz
380 V, 3 ph, 50-60 Hz,
400 V, 3 ph, 50-60 Hz,
480 V, 3 ph, 50-60 Hz
Input Amps
(Amps, Volts)
33 A @ 380 V
31 A @ 400 V
26 A @ 480 V
65 A @ 380 V
62 A @ 400 V
52 A @ 480 V
100% (20 kW)
100% (40 kW)
425 V
425 V
Plasma Gas
Air, O2, Ar-H2, N2 @ 120 psi
(8.3 bar) and Ar for marking
with DFC 3000
Air, O2, Ar-H2, N2 @ 120 psi
(8.3 bar) and Ar for marking
with DFC 3000
Shield Gas
Air, N2, O2 @ 120 psi (8.3 bar),
H20 @ 10 GPH (0.6 l/min)
Air, N2, O2 @ 120 psi (8.3 bar),
H20 @ 10 GPH (0.6 l/min)
Power Supply
Weight
410 lbs (186 kg)
451 lbs (205 kg)
Certifications
48.0" x 27.5" x 40.6"
(1219 mm x 698 mm x 1031 mm)
CSA, CE, CCC
48.0" x 27.5" x 40.6"
(1219 mm x 698 mm x 1031 mm)
CSA, CE, CCC
Ultra-Cut 300 XT
Ultra-Cut 400 XT
300 A
400 A
5-300 A
5-400 A
Duty Cycle
(@ 104ºF / 40º C)
Max OCV
Dimensions
Rated Output
(Amps)
Output Range
(Amps)
Output (Volts)
180 V
200 V
Input Volts
(Volts, Phase,
Hertz)
380 V, 3 ph, 50-60 Hz,
400 V, 3 ph, 50-60 Hz,
480 V, 3 ph, 50-60 Hz
380 V, 3 ph, 50-60 Hz,
400 V, 3 ph, 50-60 Hz,
480 V, 3 ph, 50-60 Hz
Input Amps
(Amps, Volts)
97 A @ 380 V
93 A @ 400 V
77 A @ 480 V
144 A @ 380 V
137 A @ 400 V
114 A @ 480 V
100% (60 kW)
100% (80 kW)
425 V
425 V
Plasma Gas
Air, O2, Ar-H2, N2 @ 120 psi
(8.3 bar) and Ar for marking
with DFC 3000
Air, O2, Ar-H2, N2 @ 120 psi
(8.3 bar) and Ar for marking
with DFC 3000
Shield Gas
Air, N2, O2 @ 120 psi (8.3 bar),
H20 @ 10 GPH (0.6 l/min)
Air, N2, O2, Ar-H2 @ 120 psi (8.3
bar), H20 @ 10 GPH (0.6 l/min)
Power Supply
Weight
537 lbs (244 kg)
555 lbs (252 kg)
48.0" x 27.5" x 40.6"
(1219 mm x 698 mm x 1031 mm)
CSA, CE, CCC
48.0" x 27.5" x 40.6"
(1219 mm x 698 mm x 1031 mm)
CSA, CE, CCC
Duty Cycle
(@ 104ºF / 40º C)
Max OCV
Dimensions
Certifications
* Subject to change without notice
Thermal Dynamics
®
ULTRA-CUT XT SYSTEMS
®
Cutting Speed Chart For Ultra-Cut® XT Systems
Material
Thickness (in)
Speed
(IPM)
Mild Steel
10 ga.
1/4
1/4
3/8
1/2
3/4
1
3/4
1
1 1/4
1
1 1/2
2
50
100
145
90
60
65
48
100
70
50
80
45
30
16 ga.
14 ga.
3/16
1/4
1/4
1/2
3/4
1
1
1 1/4
1
1 1/2
3/4
1 1/2
1
2
4
205
170
50
50
95
50
50
35
40
30
35
25
90
30
45
17
3.5
0.052
1/4
3/8
1/2
3/4
1
1
1 1/4
1
3/4
1 1/2
1
2
150
70
70
40
90
50
60
40
85
90
55
90
30
Stainless
Steel
Aluminum
Amps
Plasma
/Shield
Thickness
(mm)
Speed
mm/min.
30
70
100
O2/O2
O2/Air
O2/Air
200
O2/Air
300
O2/Air
400
O2/Air
3
6
6
10
12
20
25
20
25
35
25
40
50
1340
2710
3940
2170
1690
1590
1250
2430
1830
1080
2100
1110
790
30
50
N2/H20
N2/H20
70
100
N2/H20
N2/H20
200
N2/H20
300
N2/H20
300
H35/N2
400
N2/H20
400
H35/N2
400
H35/H35
1.5
2
4
6
6
12
20
25
25
35
25
40
20
40
25
50
100
5500
4310
2410
1490
2670
1350
1190
910
1030
720
920
600
2286
760
1170
440
90
30
70
100
N2/H20
N2/H20
N2/H20
200
N2/H20
300
N2/H20
400
H35/N2
N2/H20
400
H35/N2
1.5
6
10
12
20
25
25
35
25
20
40
25
50
3210
2060
1660
1180
2170
1350
1560
760
2190
2170
1280
2330
810
Note: The cutting speed chart includes preliminary data and is subject to change without notice. Take care in comparison. The speeds noted above
are best cut quality speeds.Often, competitors show maximum cutting speeds. Although much higher speeds can be achieved, edge quality and
bevel angle may be compromised. The capabilities shown in this table were obtained by using new consumables, correct gas and current settings,
accurate torch height control and with the torch perpendicular to the workpiece. The operating chart does not list all processes available for the
Ultra-Cut XT systems. Please contact Thermal Dynamics® for more information.
U.S. Customer Care: 866-279-2628
Form No. 63-1305 (09/17/14)
•
Canada Customer Care: 905-827-4515
© 2014 Thermal Dynamics
•
International Customer Care: 940-381-1212
Thermal-Dynamics.com
Printed in U.S.A.
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