®

Ultima 150

1/3 50 Hz
PAW PHASE
60

INVERTER

208 230 400 460 575
V

V

V

V

V

DC CC 150
AMP

Repeatable welds again, and again, and again
5 Year*Ultima®150 comes with:• Ultima 150 unit
• Quick Change Torch**• Torch spare parts kit• Coolant

Quick Specifications#
Processes
Plasma Arc Welding (PAW)
Industrial Applications
Automation
Appliance Manufacturing
Metal Furniture Manufacturing
Electrical Manufacturing
Aerospace/Aircraft
Computer/Office Equipment
Medical Services
Fabrication
Input Voltage
208-460 VAC 1/3 Phase
575 VAC 3 Phase w/optional module
Rated Output
100A@18V 100% Duty Cycle
150A@25V 50% Duty Cycle
Amperage Range
0.5 – 15 Amps
5 – 150 Amps
Weight130 lb (59 kg)
Order Information
See ordering information pagefor details.

* Limited warranty. Refer to warranty schedule.
**Refer to ordering information for torch selection.
# Subject to change without notification.

Quick Change Torch!
No tools required.
Cost Savings! The Ultima 150 ispriced competitively with automated
TIG systems. Plasma welding ismeasurably the lower cost process withsavings gained through increased
productivity, reduced scrap, reduced
down time and fewer electrodechanges.

Multiple Voltage! 208-460 VAC in
1 or 3 phase power at 50 or 60 Hz with
575 VAC optional module.
Simple to Set-Up! The Ultima 150
is a self contained unit, which requires
attaching input power and gasses, thenmounting the torch.
Smart Logic®! Prevents damage tothe internal components if installed to
improper voltage.

Wide Current Range!
0.5 – 150amp current range for quality
performance over a wide variety of
applications.

Current Limiter! Limits powersource output to torch capability to
avoid torch damage.

Very Smooth Arc! Ultra smooth DC
arc for repetitive, high quality welds.

Preview Set Current! Allows you todisplay actual current/voltage and avoid
costly test set-ups.

Repeatable Arc Starting! Pilot arc
allows for repeatable arc starts,
reducing defects and rework.

Easy to Use! Simple interface for
automated or manual control.

Customer Care - USA

Thermadyne Canada

International Customer Care

www.thermalarc.com

Tel: 800 255 5846

Tel: 905 827 1111

Tel: 905 827 9777

Ultima 150

Fax: 800 332 0946

Fax: 905 827 0813

Fax: 905 827 9797

Form No.: 84-2659

®

Ultima 150

1/3 50 Hz
PAW PHASE
60

INVERTERDC CC 150
AMP

208 230 400 460 575
V

V

V

V

V

What is Plasma Welding?#
Plasma Welding is a superior variation of the TIG

Used Tig ElectrodeProtected Electrodeprocess that offers many advantages over TIG:
• Increases productivity by reducing down time
• Reduces scrap by providing consistent arc starting every time
• Improved process control for repeatable, high quality welds• Reduces interference (noise) with computers, phone systems,
CNC controllers

New Electrode

Used Plasma Electrode
Simply stated, plasma welding is a variation to GTAW (TIG) that
encloses the tungsten electrode in a protected environment(Fig. 1) and delivers the arc through a cooled copper tip.
Enclosing the electrode protects it from contamination, thus
substantially extending electrode life. The consistent arc
shape of plasma results in consistent welds for 8 hours or moreof operation as compared to automated TIG welding, where
deterioration of the exposed TIG electrode (Fig. 2) can resultin weld arc variations (Fig. 3) in one hour or less of operation.
Plasma welding uses a pilot arc (Fig. 4) to consistently transfer
the arc to the work without the repeated use of high frequency
current. The Ultima 150 pilot arc circuit results in repetitive
starting and reduces problems of high frequency interferencewith CNC controls, phones and computers which are common
with the TIG process.

Figure 1

Figure 2

Tig Weld Sample

Pilot

Figure 4

Figure 3

Typical Plasma/TIG Welding Productivity Benefit Analysis
TIG
Time

Total Parts
at 100% Cap.

Tig Electrode
Changes

PLASMA

Minutes toChange ElectrodeParts Lost
with TIG

Plasma Electrode
Changes

Parts Lost
with Plasma

Net Gain Plasma
over TIG

Hour

208

1

5

17

0

0

17

Day

4,992

24

120

416

3

52

364

Week

24,960

120

600

2,080

15

260

1,820

Month

108,160

520

2,600

9,013

65

1,127

7,887

Year

1,297,920

6,240

31,200108,160

780

13,52094,640Shift Hours per Day

24

Value Per Part:

1

Days worked per Week

5

Production Parts/Dollars Gained with Plasma:

94,640Application: Outside corner welds home appliance
Note: 4 welds required on each part. For more information, contact Thermal Arc or your Authorized Thermal Arc Distributor.

# Subject to change without notification.

Customer Care - USA

Thermadyne Canada

International Customer Care

www.thermalarc.com

Tel: 800 255 5846

Tel: 905 827 1111

Tel: 905 827 9777

Ultima 150

Fax: 800 332 0946

Fax: 905 827 0813

Fax: 905 827 9797

Form No.: 84-2659

®

Ultima 150

1/3 50 Hz
PAW PHASE
60

INVERTER

208 230 400 460 575
V

V

V

V

V

DC CC 150
AMP

Features#Easy fill coolant
reservoir with built-in
deionizer bag.

Plasma & Secondarygas flow meter.

System status anderror indicator lights.

Digital welding/Pilot
current amp meter.

Quick disconnect
hand held or
automated torches
available.
#Subject to change without notification.

Customer Care - USA

Thermadyne Canada

International Customer Care

www.thermalarc.com

Tel: 800 255 5846

Tel: 905 827 1111

Tel: 905 827 9777

Ultima 150

Fax: 800 332 0946

Fax: 905 827 0813

Fax: 905 827 9797

Form No.: 84-2659

®

Ultima 150

1/3 50 Hz
PAW PHASE
60

INVERTER

208 230 400 460 575
V

V

V

V

V

DC CC 150
AMP

Specifications#

Ultima 150
Rated Output@ Duty Cycle

150A/25V @ 50%
208-460V, 1/3 Phase
100A/18V @ 100%
208-460V, 1/3 Phase
575V 3 Phase
w/optional module

Output Ranges

Low .5-15 A

Load Volts

12-25 VOCV

60 V DC

Input Hz50/60 Hz

Flow Meters

Plasma.5-3.0 SCFH (.25-1.5 lpm)

High 5-150A

Shield5-30 SCFH (2.5-15 lpm)
Contractor
Control

Remote Input

Current Control

Remote or Panel

Analog Control

0-10 Volts DC Input

Shipping Weight

154 lbs/72 kg

Input
Voltages
Power
(KVA)
Current (Amps)

208
1 ph
3 ph
1 ph
3 ph

Dimensions & Weight
Dimensions
HxWxD
Weight3720

208-575 Volt 1/3 Phase
230
380
415
8
6
34
–
–
19
12
12

460

575

–
11

–
9

18 x 15 x 28.5 in (457 x 381 x 724 mm)
130 lb (59 kg)#Subject to change without notification.

Customer Care - USA

Thermadyne Canada

International Customer Care

www.thermalarc.com

Tel: 800 255 5846

Tel: 905 827 1111

Tel: 905 827 9777

Ultima 150

Fax: 800 332 0946

Fax: 905 827 0813

Fax: 905 827 9797

Form No.: 84-2659

®

Ultima 150

1/3 50 Hz
PAW PHASE
60

INVERTER

208 230 400 460 575
V

V

V

V

V

DC CC 150
AMP

Control Panel#

3

5

4

6

7

8

9

10

2

1

11

1.

Primary On/Off Circuit Breaker

2.

Shield Gas Flow Control

3.

Plasma Gas Flow Control

4.

Pilot Arc On/Set

5.

Pilot Current Adjust

6.

Pilot Current Preview

7.

Weld Current Preview/Actual

8.

Weld Current Adjust

9.

Current Limiter Adjust

10. Weld Current Range
11. Remote/Panel Control

PANEL INDICATOR LIGHTS

1

2

3

4

5

6

1.

AC - indicates correct input voltage isapplied

2.

TEMP - over temperature indicator light3.

Gas - lights to indicate Plasma & Shieldgas pressure switches are satisfied

4.

Coolant - indicates proper coolant flow
to torch

5.

Pilot - indicates pilot arc is active

6.

DC - indicates output welding DC
current is active#Subject to change without notification.

Customer Care - USA

Thermadyne Canada

International Customer Care

www.thermalarc.com

Tel: 800 255 5846

Tel: 905 827 1111

Tel: 905 827 9777

Ultima 150

Fax: 800 332 0946

Fax: 905 827 0813

Fax: 905 827 9797

Form No.: 84-2659

®

Ultima 150

1/3 50 Hz
PAW PHASE
60

INVERTER

208 230 400 460 575
V

V

V

V

V

DC CC 150
AMP

Torch Specifications#

2A

3A

4A

Type

Torch
Lead Current
Part No. Length Rating

PWH-2A70°

2-2100 (H)2-2104 (H)

12.5 ft.
25 ft.

PWH-2A90°

2-2101 (H)
2-2105 (H)

12.5 ft.
25 ft.

PWM-2A 2-2102 (H)
180° Offset 2-2103 (M)2-2106 (H)2-2107 (M)12.5 ft.

PWH-3A70°

2-2110 (H)
2-2114 (H)

12.5 ft.
25 ft.

PWH-3A90°

2-2111 (H)
2-2115 (H)

12.5 ft.
25 ft.

PWM-3A 2-2112 (H)
180° Offset 2-2113 (M)2-2116 (H)
2-2117 (M)12.5 ft.

PWH-4A70°

2-2120 (H)2-2125 (H)

12.5 ft
25 ft.

PWH-4A90°

2-2119 (H)2-2126 (H)

12.5 ft.
25 ft.

PWM-4A 2-2121 (H)
180° Offset 2-2122 (M)2-2127 (H)2-2128 (M)12.5 ft.

PWM-4A1
180° Inline

12.5 ft.

2-2123 (H)2-2124 (M)2-2129 (H)2-2130 (M)Torch Dimensions

Coolant
Requirements

75
Amps(DCSP)

2,000 BTU/hr(504 K/Cal/hr)
1/4 gpm coolant flow
@ 50 PSI(0.9 lpm @3.7 kg/cm2)

150
Amps
(DCSP)

6,000 BTU/hr(1513 K/Cal/hr)
1/3 gpm coolant flow
@ 50 PSI(1.25 lpm @3.7 kg/cm2)

A

B

C

D

7-15/16"(202 mm)

1-11/16"(43 mm)

5/8"(16 mm)

7/8"(22 mm)7-3/4"(196 mm)

1-11/16"(43 mm)

5/8"(16 mm)

7/8"(22 mm)18-1/4"(463 mm)13/16"(21 mm)8-3/4"(222 mm)2-5/8"(67 mm)

7/8"(22 mm)1-1/16"(27 mm)8-1/2"(216 mm)2-5/8"(67 mm)

7/8"(22 mm)1-1/16"(27 mm)19-1/4"(489 mm)

1"(25 mm)12-1/2"(318 mm)3-3/16"(81 mm)1-1/4"(32 mm)1-3/8"(35 mm)12-1/4"311 mm)3-3/16"(81 mm)1-1/4"(32 mm)1-3/8"(35 mm)

18"(457 mm)

1-3/4'(44 mm)Min.
8-1/4"(209 mm)Max.
16"(406 mm)

1-3/8"(35 mm)1-1/4"(32 mm)21"(.53 m)1-3/4"(44 mm)Min.
11-1/4"(286 mm)Max.
19"(483 mm)

1-3/8"(35 mm)1-1/4"(32 mm)

25 ft.

25 ft.

25 ft.

200
Amps(DCSP)

8,000 BTU/hr(2017 K/Cal/hr)
1/2 gpm coolant flow
@ 50 PSI(1.9 lpm @3.7 kg/cm2)

25 ft.

Min.
7-1/8"(181 mm)Min.
9-1/4"(235 mm)Max.
15"(381 mm)Max.
16-3/4"(425 mm)E

1-3/8"(35 mm)1-3/8"(35 mm)NOTE: All torches listed incorporate a quick disconnect connector specifically for operation with the Ultima 150.
(H) designates torch with molded handle(M) designates torch with rack and pinion assembly#Subject to change without notification.

Customer Care - USA

Thermadyne Canada

International Customer Care

www.thermalarc.com

Tel: 800 255 5846

Tel: 905 827 1111

Tel: 905 827 9777

Ultima 150

Fax: 800 332 0946

Fax: 905 827 0813

Fax: 905 827 9797

Form No.: 84-2659

®

Ultima 150

1/3 50 Hz
PAW PHASE
60

INVERTER

208 230 400 460 575
V

V

V

V

V

DC CC 150
AMP

Torch Parts#

ITEM
NO.

PART
DESCRIPTION

SPARE
PARTS
KIT
5-2984

2A
TORCH

1

Torch Head
Assembly

8-2027 (70°)
8-2028 (90°)
8-2097 (180° offset)

2

Shield Cup

3

Tip

3A
TORCH

SPARE
PARTS
KIT
5-2985

TORCH

SPARE
PARTS
KIT
5-29861

8-4014 (70°)
8-4015 (90°)
8-4016 (180° offset)
8-4054 (180° inline)
8-40881

9-1890 (.062) 100A-lg
9-1891 (.093) 125A-lg
9-1892 (.125) 150A-lg*

5559-1827 (.187) std.
9-1834 (.187) ext.

22
18-3030 (70°))8-3031 (90°)
8-3032 (180° offset)

4

Electrode

5
6
7
8

Liner
Gas Distributor(insulating sleeve)
Gas Diffuser
Collet Assembly

9

Back Cap

N/S
N/S

CollarO-ring (liner)

8-3236 (use w/ext. tip)
8-2071 (use w/std. tip)
8-2023 (.045) 35A-std
8-2024 (.062) 55A-std
8-2025 (.081) 75A-std
8-2079 (.031) 15A-lg
8-2080 (.045) 25A-lg
8-2082 (.062) 35A-lg
8-2083 (.081) 50A-lg
8-2033 (.093) std
8-2006 (.093) ext.
8-2044 (.040) std.
8-2046 (.040) ext.
N/A
8-2040 (.093-electrode)
8-2042 (.040-electrode)
N/A
8-2039 (.093-electrode)
8-2041 (.040-electrode)8-2032 (std-electrode)8-2030 (ext-electrode)
N/A
N/A

2

8-3040

N/S
N/S
N/S
N/S
N/S
N/S

O-ring (internal)
O-ring (back-cap)
Gasket (shield cup)
Gage/Wrench Assy
LubricantTool Box

N/A
8-20358-20368-20218-40258-3141NOTE:

The use of extended electrode requires an extended back cap.
Tip ratings @ minimum electrode setback.
*Tip maximum current rating not to exceed the maximum output of Ultima-150

9-1788 (.031) 35A-lg
9-1789 (.046) 50A-lg
9-1790 (.062) 75A-lg
9-1791 (.081) 100A-lg
9-1811 (.-093) 130A-lg

5

4A

5
5

5
5
8-2007 (.093) std.
9-1775 (.093) ext.

1

1
1
1

2

N/A
9-224018-40119-22048-30599-178018-4087
9-1876

9-1779 (std-electrode)9-1803 (ext-electrode)
N/A
N/A

8-4158 (std-electrode)9-1877 (ext-electrode)8-40248-0560N/A
8-05278-30579-18108-40258-31418-05288-05308-40699-18738-40258-3141

1
1
1

1
1
1

#Subject to change without notification.

Customer Care - USA

Thermadyne Canada

International Customer Care

www.thermalarc.com

Tel: 800 255 5846

Tel: 905 827 1111

Tel: 905 827 9777

Ultima 150

Fax: 800 332 0946

Fax: 905 827 0813

Fax: 905 827 9797

Form No.: 84-2659

®

Ultima 150

1/3 50 Hz
PAW PHASE
60

INVERTER

208 230 400 460 575
V

V

V

V

V

DC CC 150
AMP

Ordering Information
PRODUCTPART NO.

Ultima 150

3-2770DESCRIPTION

QTY

PRICE

Power source only inc. quick disconnect assemblyPART NO.
w/12.5ft torch & leads

PART NO.
w/25ft torch & leads

SYSTEM
DESCRIPTION

Ultima 150 System Torch (rating)
2A (75 Amps)

3A (150 Amps)

4A (200 Amps)

ACCESSORIES

1-1551-21

1-1552-21

PWH-2A, 70 degree

1-1551-22

1-1552-22

PWH-2A, 90 degree

1-1551-23

1-1552-23

PWH-2A, 180 degree

1-1553-23

1-1553-23

PWM-2A, 180 degree

1-1551-31

1-1552-31

PWH-3A, 70 degree

1-1551-32

1-1552-32

PWH-3A, 90 degree

1-1551-33

1-1552-33

PWH-3A, 180 degree

1-1553-33

1-1553-33

PWM-3A, 180 degree

1-1551-41

1-1552-41

PWH-4A, 70 degree

1-1551-42

1-1552-42

PWH-4A, 90 degree

1-1551-43

1-1552-43

PWH-4A, 180 degree

1-1551-53

1-1552-53

PWH-4A1, 180 degree

1-1553-43

1-1553-43

PWM-4A, 180 degree

1-1553-53

1-1553-53

PWM-4A1, 180 degree

PART NO.

Quick Disconnect Kit

5-2990Regulator - Argon

9-2722

Regulator - Argon/Hydrogen

9-3053

Foot Control

7-3080Hand Pendant

10-2005

Remote Interface Cable 10ft.

9-4063

Weld Process Controller - WC-1

600279Remote Hand Pendant 25ft.

600280

Cable Assembly (required for WC-1)

9-4129DESCRIPTION
Allows existing torches to be converted for use with Ultima 150

Requires 7-3316 adapter

TOTAL QUOTE PRICE

NOTE: PWH designates a torch with a molded handle; PWM designates a torch with rack and pinion.
Torch amperage rating based on minimum electrode set back.

Customer Care - USA

Thermadyne Canada

International Customer Care

www.thermalarc.com

Tel: 800 255 5846

Tel: 905 827 1111

Tel: 905 827 9777

Ultima 150

Fax: 800 332 0946

Fax: 905 827 0813

Fax: 905 827 9797

Form No.: 84-2659