Thermal Dynamics CUTSKILL C-35A Operator's Manual
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Thermal Dynamics CUTSKILL C-35A Operator's Manual

Thermal Dynamics CUTSKILL C-35A Operator's Manual

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C-35A

Operator Manual

CUTSKILL
PLASMA CUTTING
SYSTEM
Revision No.: AB.01
Operating Features:
®
Issue Date: March 26, 2007
PLASMA
Manual 0-4678

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Summary of Contents for Thermal Dynamics CUTSKILL C-35A

  • Page 1: Operator Manual

    C-35A CUTSKILL ® PLASMA CUTTING SYSTEM Operator Manual Revision No.: AB.01 Issue Date: March 26, 2007 Manual 0-4678 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 No. 0-4678...

  • 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- 75 psi (5.2 bar) (.52MPa) - Input tem, please contact: 125 psi (8.6 bar) (.86MPA) Gas Pressure Thermal Dynamics Technical Service Dept. 400 scfh / 6.6 scfm Minimum Gas Flow (188.7 lpm) Tel: 1-800-752-7622 (1-800-PLASMA2) Plasma Power...

  • 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) (.52MPa) 3.01 Site Selection and air should be dry and clean.
  • Page 16 This Page Left Blank Installation Manual 0-4678...

  • 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 torch. Release the torch trigger and the torch Air Error Indicator will continue to cut without depressing the torch Overheating Torch Switch...

  • 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 used in the Drag mode or standoff height indicated.
  • Page 20 This Page Left Blank Operation Manual 0-4678...

  • Page 21: 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 22 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 23: Contact Information

    Return to an authorized service center for re- pair. 2. Control PCB faulty. a. Return to an authorized service center for re- pair. 5.03 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 Manual 0-4678 SERVICE...
  • Page 24 This Page Left Blank SERVICE Manual 0-4678...

  • Page 25: 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 Red Air Indicator Air Set Switch "On"...

  • Page 26: 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 27: Appendix 3: Microchip Pin-Out

    Appendix 3: Microchip Pin-Out 40 Pin Microchip 9 10 11 12 Socket on 24 22 20 18 16 14 12 10 Control 23 21 19 17 15 13 11 9 10 11 12 Manual 0-4678 APPENDIX...

  • Page 28: Appendix 4: Replacement Hand Torch Parts List

    Appendix 4: 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 29 A-07060 Manual 0-4678 APPENDIX...

  • Page 30: Appendix 5: System Schematic Rev A

    Appendix 5: System Schematic Rev A 230 VAC DIODE IGBT IGBT Black INPUT White Filter Board AC230V C1 C2 1 PH No.40276003 To Ground Connection 230 VAC 230 VAC E1 G2 TW TW TW TW B W G R B W G R G4 E3 1 2 3 4 1 2 3 4...
  • Page 31 Piloting Current Cutting Current Current Sensor Main Transformer WORK VC_1 VD_1 OU_1 OU_2 194VAC GN_1 C/T 1 O.C.V. 325 Pilot 130 Cutting 110 REACTOR TORCH Pilot Relay Twisted PILOT +12VDC VC_1 -12VDC VD_1 OU_1 P.B. CN10 Enable VC_2 GN_1 +12VDC to engage CN12 Pilot Relay...

  • Page 32: Appendix 6: System Schematic Rev Ab

    Appendix 6: System Schematic Rev AB 230 VAC DIODE IGBT IGBT INPUT Filter Board AC230V C1 C2 1 PH No.40276003 To Ground Connection 230 VAC E1 G2 Ω TW TW TW TW B W G R B W G R G4 E3 1 2 3 4 1 2 3 4...
  • Page 33 Piloting Current Cutting Current Current Sensor Main Transformer WORK VC_1 VD_1 OU_1 OU_2 194VAC GN_1 C/T 1 O.C.V. 325 Pilot 130 Cutting 110 REACTOR TORCH Pilot Relay Twisted PILOT +12VDC VC_1 -12VDC VD_1 OU_1 P.B. CN10 Enable VC_2 GN_1 +12VDC to engage CN12 Pilot Relay...
  • Page 34 This Page Left Blank APPENDIX A-10 Manual 0-4678...

  • Page 35: 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 36 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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