C-100A CUTSKILL® PLASMA CUTTING SYSTEM Operation Manual Rev. AA.
WARNINGS Read and understand this entire Manual and your employer’s safety practices before installing, operating, or servicing the equipment. While the information contained in this Manual represents the Manufacturer's best judgement, the Manufacturer assumes no liability for its use. Plasma Cutting Power Supply CutSkill® SL100™ 1Torch™ Operation Manual Number 0-4686 Covered under U.S. Patents. Published by: Thermadyne Corporation 82 Benning Street West Lebanon, New Hampshire, USA 03784 (603) 298-5711 www.
TABLE OF CONTENTS SECTION 1: GENERAL INFORMATION ................................................................................................ 1-1 1.01 1.02 1.03 1.04 1.05 Notes, Cautions and Warnings ...................................................................... Important Safety Precautions ....................................................................... Publications ..................................................................................................
SECTION 1: GENERAL INFORMATION 1.01 Notes, Cautions and Warnings GASES AND FUMES Gases and fumes produced during the plasma cutting process can be dangerous and hazardous to your health. • Keep all fumes and gases from the breathing area. Keep your head out of the welding fume plume. Throughout this manual, notes, cautions, and warnings are used to highlight important information.
• Wear dry gloves and clothing. Insulate yourself from the work piece or other parts of the welding circuit. • Repair or replace all worn or damaged parts. • Extra care must be taken when the workplace is moist or damp. • Install and maintain equipment according to NEC code, refer to item 9 in Subsection 1.03, Publications. PLASMA ARC RAYS Plasma Arc Rays can injure your eyes and burn your skin. The plasma arc process produces very bright ultra violet and infra red light.
6. ANSI Standard Z49.2, FIRE PREVENTION IN THE USE OF CUTTING AND WELDING PROCESSES, obtainable from American National Standards Institute, 1430 Broadway, New York, NY 10018 7. AWS Standard A6.0, WELDING AND CUTTING CONTAINERS WHICH HAVE HELD COMBUSTIBLES, obtainable from American Welding Society, 550 N.W. LeJeune Rd, Miami, FL 33126 8.
1.04 Declaration of Conformity Manufacturer: Thermal Dynamics Corporation Address: 82 Benning Street West Lebanon, New Hampshire 03784 USA The equipment described in this manual conforms to all applicable aspects and regulations of the ‘Low Voltage Directive’ (European Council Directive 73/23/EEC as amended by Council Directive 93/68/EEC) and to the National legislation for the enforcement of this Directive.
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.
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SECTION 2: INTRODUCTION 2.02 General Specifications 2.01 Overview Plasma is a gas which has been heated to an extremely high temperature and ionized so that it becomes electrically conductive. The plasma arc cutting process uses this plasma to transfer an electrical arc to the workpiece. The metal to be cut is melted by the heat of the arc and then blown away.
2.04 Torch Specifications CUT OFF CUT OFF 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 @ 400 scfh 100 Amps, DC, Maximum Current Straight Polarity Voltage (V peak ) 500V Arc Striking Voltage 7kV Ambient air and gas Type of Cooling stream through torch Built-in Switch Parts-in-Place: in Torch Head Single Gas, Gas Requirement: Compressed Air Only 65 psi (.45MPa) Input (4.
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 400V (CE) 1-1600-4 Qty 1 1 1 1 1 2 3 0 1 2.06 Transporting Methods Lift unit using the two lifting eyes on the top of the case.
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SECTION 3: INSTALLATION 2. Input Power Connection The power supply requires a customer-supplied input power cord suitable for the input power in use. 1. Remove the power supply cover. 3.01 Site Selection • Place in a clean and dry area. • Provide adequate ventilation and fresh air supply. • Ideal ambient temperature should not exceed 40°C / 104°F. Higher temperatures may diminish cutting capacity or quality. • The cutting machine must be placed on an even, firm surface so that it stands securely.
4. Connect the cord to the input power terminal block as shown for single or three phase. Input connections 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; refer to the power supply upper horizontal panel for proper ground wire connection location.
3.03 Compressed Air Connection DANGER • An air compressor is required and should be connected by an air hose to the air regulator on the rear panel of the power supply . Do not cut in humid or wet surroundings. • Air flow should be 400 scfh / 6.6 scfm (188.7 lpm) minimum. • Before you maintain or replace torch parts, wait for the post flow air cycle (approximately 10 seconds), to stop, then turn the machine off. • Always use original manufacturers parts.
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SECTION 4: OPERATION B. Switches • 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 trigger.
D. Torch Operation 4.02 Preparations For Operating • Refer to Section 1 for necessary safety precautions. At the start of each operating session: WARNING Trigger Disconnect primary power at the source before assembling or disassembling power supply, torch parts, or torch and leads assemblies. 1 2 Trigger Release A. Torch Parts Selection Check the torch for proper assembly and appropriate torch parts.
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.
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SECTION 5: SERVICE 5.01 General Maintenance 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. This can lead to potential performance problems. 1. Basic Troubleshooting, Overview This guide covers basic troubleshooting.
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 on power supply. a. Check current setting. Check the Electrode and Tip for excess wear. 2. Torch tip, start cartridge, or electrode missing. a. Turn off power supply. Remove shield cup. Install missing parts. New Electrode 3. Start cartridge is stuck. a. Turn off power supply.
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 workpiece or cutting table Work Cable And Clamp Art # A-04389 3. Current sensor or PWM PCB faulty. a. Return to an authorized service center for repair. F. Air flows continuously and torch latch switch doesn't work properly. 1. Torch Latch Switch on front panel faulty. a. Return to an authorized service center for repair. 2. Control PCB faulty. a.
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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 run the power supply. Re-check regulator setting. Air Set Switch "On" Red Air Indicator Air Flows at Torch. Set Air Pressure Then Turn Air Set Switch "Off" Check Torch parts alignment.
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.
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Appendix 3: Replacement Hand Torch Parts List Item #QtyDescription Catalog # 1 1 Torch Handle Replacement Kit (include items no. 2 & 3) 9-7030 2 1 Trigger Assembly Replacement Kit 9-7034 3 1 Handle Screw Kit (5 each, #6-32 x 1/2" cap screw, and wrench) 9-8062 4 1 Torch Head Assembly Replacement Kit (includes items No.
7 1 2 4 5 6 3 8 7 A-07060 Manual 0-4686 6-5 APPENDIX
APPENDIX 6-6 Fan Pressure Sensor Solenoid V/V Input Selection AC460 AC230 Input AC 230V / 460V 1/3 Phase Art # A-04696 Filter Fan Fuse 3A Diode Main Hold Air Power Temp Check IGBT IGBT Air Hold Error Main Transformer Reactor Pilot Relay Current Sensor Torch Pilot Work Piece Appendix 4: System Schematic Manual 0-4686
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GLOBAL CUSTOMER SERVICE CONTACT INFORMATION Thermadyne USA Thermadyne Asia Sdn Bhd 2800 Airport Road Denton, Tx 76207 USA Telephone: (940) 566-2000 800-426-1888 Fax: 800-535-0557 Email: sales@thermalarc.
Corporate Headquarters 16052 Swingley Ridge Road Suite 300 St. Louis, MO 63017 Telephone: 636-728-3000 Email: TDCSales@Thermadyne.com www.thermadyne.
