Thermal Dynamics C-70A CUTSKILL Service Manual
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Thermal Dynamics C-70A CUTSKILL Service Manual

Plasma cutting system
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C-70A

Service Manual

CUTSKILL
PLASMA CUTTING
SYSTEM
Rev. AA.01
Issue Date: March 26, 2007
Operating Features:
PLASMA
®
Manual 0-4699
400
70
v

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Summary of Contents for Thermal Dynamics C-70A CUTSKILL

  • Page 1: Service Manual

    C-70A CUTSKILL ® PLASMA CUTTING SYSTEM Service Manual Rev. AA.01 Issue Date: March 26, 2007 Manual 0-4699 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 0-4699...

  • Page 13: Introduction

    SECTION 2: INTRODUCTION 2.01 Overview Plasma is a gas which has been heated to an extremely high temperature and ionized so that it becomes elec- trically conductive. The plasma arc cutting process uses this plasma to transfer an electrical arc to the work- piece.

  • Page 14: Torch Specifications

    If you have questions or concerns regarding your sys- MPa) tem, please contact: 400 scfh 6.6 scfm Minimum Gas Flow (188.7 lpm) Thermal Dynamics Technical Service Dept. Plasma Power C-70A Tel: 1-800-752-7622 (1-800-PLASMA2) Supply Used With: Fax: 1-800-221-4401 e-mail address: tdc-tech@thermadyne.com 2.06 Transporting Methods...

  • Page 15: Installation

    3.03 Compressed Air Connection SECTION 3: INSTALLATION • An air compressor is required and should be con- nected to rear panel of power source by air hose. • Air pressure should be 75 psi (5.2 bar)(.52 MPa) 3.01 Site Selection and air should be dry and clean.
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  • Page 17: Operation

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

  • Page 18: 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 19 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 and the torch set at the indicated standoff height.
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  • Page 21: Section 5: Maintenance

    SECTION 5: MAINTENANCE 5.01 General Maintenance Maintain more often Warning! if used under severe Disconnect input power before maintaining. conditions Each Use Visual check of torch tip and electrode Weekly Visually inspect the cables and leads. Replace as needed Visually inspect the torch body tip, electrode and shield cup 3 Months Replace all...

  • Page 22: Maintenance - Torch O-Rings

    5.02 Maintenance - Torch O-Rings O-rings on the Torch require lubrication on a regular basis, depending on how frequently the torch shield cup is disconnected and re-connected. This will allow the O-rings to remain pliable and provide a proper seal. The O-rings will dry out, becoming hard and cracked, if the O-ring lubricant is not used on a regular basis.

  • Page 23: Troubleshooting

    SECTION 6: TROUBLESHOOTING WARNING There are extremely dangerous voltage and power levels present inside this unit. Do not attempt to diagnose or repair unless you have had training in power electronics measurement and troubleshooting techniques. NOTE: All procedures are done with the cover removed. 6.01 Setup and Operation Connect the unit to air supply and power.

  • Page 24: Basic Trouble Shooting Guide

    6.02 Basic Trouble Shooting Guide Problem - Symptom Possible Cause Recommended Action Power Switch is on 1. Improper electrical connection. 1. Check input power source and fuse. Check input cable and but the A/C Indicator 2. System was overloaded. connections. does not light 3.
  • Page 25 Spring-Loaded Spring-Loaded Cylinder at Cylinder at Rest / Full Compression 1/8” Full Extension Art # A-07069 Start Cartridge New Electrode Worn Electrode Art # A-03284 Electrode Example Good Tip Worn Tip A-03406 Tip Example Make a clean work cable connection to the work- piece or cutting table Work Cable And Clamp...

  • Page 26: Control Pcb Indicators

    6.03 Control PCB Indicators Turn the switch located on the front panel, to the "On" position. The A/C indicator on the front panel should light and the cooling fan should be running. Locate the Control PCB behind the front panel and the PWM PCB behind that. LD2 LED's on both PCB's should be "ON".

  • Page 27: Open Circuit Voltage Check

    6.04 Open Circuit Voltage Check Attach shop air to unit. Remove torch consumables from torch head and replace the shield cup. Turn unit power on. (220VAC 1PH). LD2 on both the Control Board and the PWM Board should be on and the cooling fan running.

  • Page 28: Fault Finding Tests

    6.05 Fault Finding Tests A. Diode Testing Basics WARNING Disconnect primary power at the source before disassembling the power supply, torch, or torch leads. Testing of diode modules requires a digital volt/ohmmeter that has a diode test scale. Remember that even if the diode module checks good, it may still be bad.
  • Page 29 6. Reverse the meter leads across the diode for reverse bias testing (refer to following figure). A properly functioning diode will block in the reverse bias direction and depending on the meter function will indicate an open or “OL”. Art # A-00306 Reverse Bias Diode Not Conducting VR COM...
  • Page 30 B. Component Tests WARNING Disconnect primary power at the source before taking any resistance checks. 1. Input Diode Module Board Circuit Test Check Input Diode for short per schematic located in Appendix 4. Use the following photo with call-outs for test points. Diode Outputs IGBT Outputs Art # A-07055...
  • Page 31 2. IGBT Module Test With an ohmmeter set on the diode range remove P5 from the upper and lower IGBTs and make the following IGBT checks: Gate PCB J5 IGBT Check White + DD (1.020) White + Open After Charging Black - Open After Charging Black -...

  • Page 32: Torch Tests

    6.06 Torch Tests WARNING Disconnect primary power at the source before disassembling the power supply, torch, or torch leads. 1. PIP and Torch Switch Adapter Check Disconnect input power from power supply. Confirm that the torch parts are in place and that they match the parts consumables label on the power supply cover.

  • Page 33: Parts List

    Provide the power supply model number and serial number when ordering parts. If a product must be returned for service, contact your distributor. Materials returned without proper authorization will not be accepted. Contact Information Thermal Dynamics Technical Service Dept. Tel: 1-800-752-7622 (1-800-PLASMA2) Fax: 1-800-221-4401 e-mail address: tdc-tech@thermadyne.com...
  • Page 34 7.01 Parts List Power Supply Item Number Quantity Description Catalog Number Side Cover-Right 9-7214 Cover Assembly 9-0329 Side Cover-Left 9-7213 Switch-Toggle 9-0333 Knob 9-0334 Cable Ground PG29 9-0291 Front Panel Assembly 9-0382 Circuit Breaker 9-7177 Volume 9-0335 Air Assembly 9-0330 Case, Back 9-0331 Cable Ground PG21 (CE Version Only)
  • Page 35 Manual 0-4699 Parts List...
  • Page 36 Parts List Manual 0-4699...
  • Page 37 MAGNET DISASSEMBLE MAGNET ASSEMBLY Manual 0-4699 Parts List...

  • Page 38: Replacement Hand Torch Parts

    7.02 Replacement Hand Torch Parts Item # Description 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. 5 & 6) 9-8219 Large O-Ring 8-3487...
  • Page 39 A-07060 Manual 0-4699 Parts List...
  • Page 40 This Page Left Blank Parts List Manual 0-4699...

  • Page 41: 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 42: Appendix 2: Torch Connection

    Appendix 2: Torch Connection Art # A-04445 Disconnect power and air. Lay unit on its side. Remove access plate. DETAIL Negative / Plasma Lead Power Supply Adapter Pilot Work Cable Negative / Plasma Lead To Power Black Supply Adapter Switch Orange Green Torch...
  • Page 43 This Page Left Blank Manual 0-4699 APPENDIX...

  • Page 44: Appendix 3: 230 Volt System Schematic

    Appendix 3: 230 Volt System Schematic 230VAC 1PH - R&Bk 3PH - R,W&Bk DIODE FILTER 103 3KV IGBT IGBT Input Power Connection 320VDC INPUT AC230V FUSE 1/3 PH 630V 104MF CONTROL 3A G1 E1 G2 E2 G3 E3 G4 E4 Bk,2 E4 G4 E3 G3 E2 G2 E1 G1...
  • Page 45 Current Sensor Main Transformer WORK VC_1 VC_2 VD_1 VD_2 OU_1 OU_2 220VAC GN_1 GN_2 C/T 1 O.C.V. 290 VDC Pilot 160 VDC Cutting 130 VDC Pilot Relay PILOT REACTOR TORCH Jumper VC_1 VD_1 OU_1 GN_1 12VDC Ω VC_2 VD_2 OU_2 GN_2 DC Output Pilot...

  • Page 46: Appendix 4: 400 Volt Ce System Schematic

    Appendix 4: 400 Volt CE System Schematic DIODE IGBT IGBT INPUT FILTER PCB AC400V 1 / 3 PH No.40276004 MAGNET DELAY PCB No.40279016 G2 E1 FUSE CONTROL 3A PWM DRIVE BOARD PW-1-0300-P-02 AC230 AC12 AC160 AC15 AC15 AC180 CONTROL BOARD Solenoid V/V No.40271006 Pressure...
  • Page 47 Current Sensor Main Transformer WORK VC_1 VC_2 VD_1 VD_2 OU_1 OU_2 GN_1 GN_2 C/T 1 Pilot Relay PILOT REACTOR TORCH VC_1 VD_1 OU_1 GN_1 VC_2 VD_2 OU_2 GN_2 Torch No.40276002 Air Plasma 70A (400V CE) No. 66001010 HOLD CHECK oct. 18. 2005 Art # A-06949 Manual 0-4699 APPENDIX...
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  • Page 49: Global Customer Service Contact Information

    GLOBAL CUSTOMER SERVICE CONTACT INFORMATION Thermadyne USA Thermadyne Asia Sdn Bhd 2800 Airport Road Lot 151, Jalan Industri 3/5A Denton, Tx 76207 USA Rawang Integrated Industrial Park - Jln Batu Arang 48000 Rawang Selangor Darul Ehsan Telephone: (940) 566-2000 West Malaysia 800-426-1888 Fax: 800-535-0557 Telephone: 603+ 6092 2988...
  • Page 50 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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