Thermal Dynamics CUTSKILL C-100A Operation Manual
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Thermal Dynamics CUTSKILL C-100A Operation Manual

Thermal Dynamics CUTSKILL C-100A Operation Manual

Plasma cutting system
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C-100A
CUTSKILL
®
PLASMA CUTTING
SYSTEM
Operation Manual
Rev. AA.01
Issue Date: March 26, 2007
Manual 0-4686
Operating Features:
230
400
100
460
v
PLASMA

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Summary of Contents for Thermal Dynamics CUTSKILL C-100A

  • Page 1 C-100A CUTSKILL ® PLASMA CUTTING SYSTEM Operation Manual Rev. AA.01 Issue Date: March 26, 2007 Manual 0-4686 Operating Features: PLASMA...
  • Page 3 (603) 298-5711 www.thermal-dynamics.com ©Copyright 2005, 2006, 2007 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 and hereby disclaims any liability to any party for any loss or damage caused by any error or omission in this Manual, whether such error results from negligence, accident, or any other cause.

  • Page 5: Table Of Contents

    TABLE OF CONTENTS SECTION 1: GENERAL INFORMATION ....................1-1 1.01 Notes, Cautions and Warnings ..............1-1 1.02 Important Safety Precautions ............... 1-1 1.03 Publications ....................1-2 1.04 Declaration of Conformity ................1-4 1.05 Statement of Warranty .................. 1-5 SECTION 2: INTRODUCTION ......................

  • Page 7: General Information

    SECTION 1: GASES AND FUMES GENERAL INFORMATION Gases and fumes produced during the plasma cutting process can be dangerous and hazardous to your health. 1.01 Notes, Cautions and Warnings • Keep all fumes and gases from the breathing area. Throughout this manual, notes, cautions, and warnings Keep your head out of the welding fume plume.

  • Page 8: Publications

    • Wear dry gloves and clothing. Insulate yourself from the work piece or other parts of the welding PLASMA ARC RAYS circuit. • Repair or replace all worn or damaged parts. Plasma Arc Rays can injure your eyes and burn your skin. •...
  • Page 9 6. ANSI Standard Z49.2, FIRE PREVENTION IN THE USE OF CUTTING AND WELDING PROCESSES, ob- tainable from American National Standards Institute, 1430 Broadway, New York, NY 10018 7. AWS Standard A6.0, WELDING AND CUTTING CONTAINERS WHICH HAVE HELD COMBUS- TIBLES, obtainable from American Welding Society, 550 N.W.

  • Page 10: Declaration Of Conformity

    Rigorous testing is incorporated into the manufacturing process to ensure the manufactured product meets or exceeds all design specifications. Thermal Dynamics has been manufacturing products for more than 30 years, and will continue to achieve excellence in our area of manufacture.

  • Page 11: Statement Of Warranty

    1.05 Statement of Warranty LIMITED WARRANTY: Subject to the terms and conditions established below, Thermadyne ® Corporation warrants to the original retail purchaser that new Thermadyne CutSkill Series plasma cutting systems sold after the effective date of this warranty are free of defects in material and workmanship.
  • Page 12 This Page Left Blank GENERAL INFORMATION Manual 0-4686...

  • Page 13: Introduction

    SECTION 2: 2.02 General Specifications INTRODUCTION 2.01 Overview Model Description C-100A Plasma is a gas which has been heated to an extremely Maximum Output 100 Amps high temperature and ionized so that it becomes elec- trically conductive. The plasma arc cutting process uses 230V, 1/3 phase this plasma to transfer an electrical arc to the workpiece.

  • Page 14: Features

    2.04 Torch Specifications 100A SL100™ 1Torch™ Ratings Torch Head at 75° to Torch Configuration Torch Handle Torch Leads Length 20 feet / 6.1 m Ambient 104° F Temperature 40° C 100% @ 100 Amps Duty Cycle 35% (3.5 min) 60% (6 min) @ 400 scfh 100% (10 min) 100 Amps, DC,...

  • Page 15: System Contents

    2.05 System Contents Items Description Power source Model C-100A Torch Set SL100™, 20' Air Regulator Work Cable Added Manual Features Torch Electrodes Torch Tips Input Power Cable For Systems No Input Power Cord 230V/460V 1-1600-2 Input Power Cable For Systems 400V Non CE 2 Meter Cord With No Plug 1-1600-3 and...
  • Page 16 This Page Left Blank Introduction Manual 0-4686...

  • Page 17: Installation

    2. Input Power Connection SECTION 3: The power supply requires a customer-supplied input INSTALLATION power cord suitable for the input power in use. 1. Remove the power supply cover. 3.01 Site Selection 2. Loosen, but do not remove, the through-hole pro- tector on the power supply rear panel.
  • Page 18 4. Connect the cord to the input power terminal block as shown for single or three phase. Input connec- tions must be connected oposite the red and the black wires. The white wire is used for 3 Phase. Check for secure connections to the block. All cord installations require a ground wire connection to the power supply chassis;...

  • Page 19: Compressed Air Connection

    3.03 Compressed Air Connection DANGER • An air compressor is required and should be con- nected by an air hose to the air regulator on the Do not cut in humid or wet surroundings. rear panel of the power supply . •...
  • Page 20 This Page Left Blank Installation Manual 0-4686...

  • Page 21: Operation

    B. Switches SECTION 4: OPERATION • Torch Latch Switch 4.01 Front Control Panel For continuous cutting performance. Depress this switch ( turn “On” ) while cutting with the torch. Release the torch trigger and the torch will continue to cut without depressing the torch Overheating AC Power trigger.

  • Page 22: Preparations For Operating

    D. Torch Operation 4.02 Preparations For Operating • Refer to Section 1 for necessary safety precau- At the start of each operating session: tions. WARNING Trigger Disconnect primary power at the source before assembling or disassembling power supply, torch parts, or torch and leads assemblies. Trigger Release A.
  • Page 23 E. Typical Cutting Speeds Cutting speeds vary according to torch output, the type of material being cut, and operator skill. Speeds shown are typical for this cutting system using air plasma to cut mild steel, with output current at the highest setting.
  • Page 24 This Page Left Blank Operation Manual 0-4686...

  • Page 25: Service

    1. Basic Troubleshooting, Overview SECTION 5: This guide covers basic troubleshooting. It is helpful for SERVICE solving many of the common problems that can arise with this system. If major complex subassemblies are faulty, the unit must be returned to an authorized service center 5.01 General Maintenance for repair.
  • Page 26 D. Torch will not pilot when torch switch is activated. E. Cut performance is diminished. 1. Gas pressure too high or too low. 1. Worn torch parts. a. Adjust gas pressure per pressure setting label a. Check current setting. Check the Electrode and on power supply.
  • Page 27 2. Poor Work Lead connection. a. Check the connection of the Work Lead to the work piece. Make a clean work cable connection to the work- piece or cutting table Work Cable And Clamp Art # A-04389 3. Current sensor or PWM PCB faulty. a.
  • Page 28 This Page Left Blank SERVICE Manual 0-4686...

  • Page 29: Appendix 1: Operating Sequence, Block Diagram

    Appendix 1: Operating Sequence, Block Diagram Primary Input Power "On" or Plugged in Power Supply On/Off Switch "On" Green Power Indicator "On" and Fan is Running More air flow is required for Torch to Pilot than to Air Set Switch "On" Red Air Indicator run the power supply.

  • Page 30: Appendix 2: Torch Connection

    Appendix 2: Torch Connection Art # A-04674 Disconnect power and air. Lay unit on its side. Remove two screws and the access panel. View from Bottom Work Cable Negative / Plasma Lead Pilot Power Supply Adapter NOTE: Work cable and torch leads must go through the access panel and be secured with through hole protectors.
  • Page 31 This Page Left Blank Manual 0-4686 APPENDIX...

  • Page 32: Appendix 3: Replacement Hand Torch Parts List

    Appendix 3: Replacement Hand Torch Parts List Item #QtyDescription Catalog # Torch Handle Replacement Kit (include items no. 2 & 3) 9-7030 Trigger Assembly Replacement Kit 9-7034 Handle Screw Kit (5 each, #6-32 x 1/2" cap screw, and wrench) 9-8062 Torch Head Assembly Replacement Kit (includes items No.
  • Page 33 A-07060 Manual 0-4686 APPENDIX...

  • Page 34: Appendix 4: System Schematic

    Appendix 4: System Schematic APPENDIX Manual 0-4686...
  • Page 35 This Page Left Blank Manual 0-4686 APPENDIX...

  • Page 37: Global Customer Service Contact Information

    GLOBAL CUSTOMER SERVICE CONTACT INFORMATION Thermadyne Asia Sdn Bhd Thermadyne USA 2800 Airport Road Lot 151, Jalan Industri 3/5A Rawang Integrated Industrial Park - Jln Batu Arang Denton, Tx 76207 USA 48000 Rawang Selangor Darul Ehsan Telephone: (940) 566-2000 West Malaysia 800-426-1888 Fax: 800-535-0557 Telephone: 603+ 6092 2988...
  • Page 38 Corporate Headquarters 16052 Swingley Ridge Road Suite 300 St. Louis, MO 63017 Telephone: 636-728-3000 Email: TDCSales@Thermadyne.com www.thermadyne.com...

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