Full Product Manual

11
Section 1 Introduction and Specifications
NOTICE:
This manual has been compiled to give an overview of operation and is designed to offer information centered around safe, practi-
cal use of the plasma cutter. Welding and cutting operations are inherently dangerous. Only the operator of this Welder/Plasma
cutter can ensure that safe operating practices are being followed, through the exercise of common sense practices and training.
Do not operate this machine until you have fully read the manual, including the safety section. If you do not have the skill or
knowledge to safely operate this Welder/Plasma Cutter do not operate this unit until formal training is received. To prevent re,
always be aware of your surroundings.
GENERAL PRODUCT INFORMATION:
The Ultra-Arc 205 utilizes the latest in digital inverter design technology. This new design is an improvement over its predecessor,
the PowerUltra 205Pi. This unit redesign has incorporated more advanced Stick and TIG welding features and even now includes
a memory function with up to 9 memory slots to preserve favorite settings.
New features have been added to improve the TIG welding capabilities of the unit. The unit offers 3 TIG Pulse settings which have
been carefully selected for best operation in a variety of conditions where pulse may be helpful. In each pulse program, pulse is
adjustable up to 150Hz for optimal ne control by the user. The unit also features a spot weld timer to be used with the TIG
mode to allow a timed arc that can produce consistently sized large spot welds or tacks welds. The new Fast Tack feature pro-
vides a intense burst of welding power. This allows tacking of very small or thin parts without over melting the component or
seam. This is used in conjunction with the TIG torch switch in 2T mode.
Also, control over stick functions have been increased with the additions of hot start intensity and arc force control. However, this
unit is not rated for E6010 use however, or similar cellulosic rods.
POWER INPUT:
This unit may be operated on either 120V or 240V single phase input. No changeover of wiring is required. Simply plug the sup-
plied adapter to the NEMA 6-50 plug on the plasma cutter and the unit will automatically sense the voltage that is being supplied.
When operating on 120V input, please note the maximum output will be limited. For Wiring and Breaker requirements, consult
the Article 630 of the National Electric Code (NEC) for special information concerning proper wiring and breaker sizing of duty-
cycle limited welding/cutting machines. Use the I1
MAX
and I1
EFF
ratings supplied on page 10 in this manual to determine correct
breaker and wire sizing. Always consult a licensed electrician before wiring this unit to new or existing service. Never attempt to
adapt this unit to work with existing dryer or range plugs. Do not use on long or undersized extension cords. Use cords rated
for a minimum of 30 amps for 120V and 40A for 240V. Use lengths no more than 25 ft in length.
GENERAL MAINTENANCE AND CARE:
Care should be taken to keep the unit out of direct contact with water spray. The unit is rated IP21S, which rates it for light contact
with dripping water. It is a good idea to remove the Welder/Plasma Cutter from the vicinity of any water or moisture source to
reduce the possibility of electrocution or shock. Never operate this unit in standing water.
IMPORTANT: Before opening the unit for any reason, make sure the unit has been unplugged for at least 10 minutes to allow time
for the capacitors to fully discharge. Severe shock and/or death can occur.
Every 1-2 months, depending upon use, the unit should be unplugged, opened up and carefully cleaned with dry compressed or
canned air. To open, remove rear plastic cover and main cover. Do not remove the front plastic cover. Regular maintenance will
extend the life of the unit. Carefully descale metal particles from the fan blades to prevent vibration and fan damage (if buildup is
present).
• Do not restrict air flow or movement of air around the welder/plasma cutter. Allow a minimum clearance of at least
18” (500mm) on all sides.
• Lift and carry the unit by the handle. Do not mount in areas that are prone to severe shock or vibration.
• Do not operate the unit immediately next to the weld/cut area. Allow at least 6 feet separation.
• Do not direct metallic dust or any dirt intentionally toward the machine, particularly in grinding and cutting operations. Make
sure the control panel is protected from damage.