C-20C 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 0-4687 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 Notes, Cautions and Warnings ...................................................................... Important Safety Precautions ....................................................................... Publications .................................................................................................. Statement of Warranty ......
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 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.
2.0 INTRODUCTION 2.03 Features • COMPACT and LIGHT - Designed for easy transportation. 2.01 INTRODUCTION • ENERGY EFFICIENCY - Advanced technology reduces power consumption. 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 2.05 System Contents 3 in (76.2 mm) 10.5 in (266.7 mm) Introduction ITEMS Model 20C PCH-42, with 20' (6.1 m) Torch Set leads Air Regulator Work Cable Accessories & Manual Consumables Torch Electrodes Torch Tips 3 Meter NEMA 10 AWG / Input Power 4.8 mm2 with 6 - 50 P Cable molded plug Art # A-04653 PCH-42 Torch Ratings Torch Head at 70° to Torch Configuration Torch Handle Torch Leads Length 20 feet / 6.
3.0 Installation 3.03 Torch • Make sure that the torch cable and torch switch terminals are connected to the power supply. 3.01 Site Selection • Place in a clean and dry area. • Make sure the Work Cable is connected properly to the power supply. • Provide adequate ventilation and fresh air supply. • Before activating, turn torch away from yourself and others. • Ideal ambient temperature should not exceed 40°C / 104°F. Temperatures exceeding that may diminish cutting capacity or quality.
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B. BUTTONS 4.0 OPERATION • Torch Switch Latch Button 4.01 Front Control Panel 16 17 18 19 14 8 10 O 11 12 13 14 10 12 15 23 24 21 22 18 20 16 20C 115VAC 230VAC Torch Switch Latch Button A • Air Set Button Air Set Button Current Control Knob AC Power Indicator Air Vents to cool down heated torch. C. MAIN CURRENT CONTROL KNOB Torch Connection Work Lead Connection To adjust cutting current.
D. Torch Operation 4.02 Preparations For Operating • Wear gloves and protective goggles. At the start of each operating session: • Do not place bare hand on work piece. 1. For drag cutting, keep the torch in contact with the workpiece. WARNING 2. For standoff cutting, hold the torch 1/8 - 3/8 in (3-9 mm) from the workpiece as shown below. Disconnect primary power at the source before assembling or disassembling power supply, torch parts, or torch and leads assemblies. A.
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 torch held at the indicated standoff height. Maximum Travel Speed Recommended Travel Speed Inches per Milimeters Inches per Milimeters per minute per minute minute minute C-20C Drag Only (10GA) 0.135" (3mm) 42.7 1067 34.1 853 C-20C Drag Only (7GA) 0.
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SECTION 5: SERVICE C. No air flow at torch when air check switch is turned on. 1. Internal connection is disconnected or loose. a. Check all air line connections and fittings. 2. Internal air supply / compressor not working. 5.01 Basic Troubleshooting Guide a. Return to an authorized service center for repair. WARNING There are extremely dangerous voltage and power levels present inside this unit.
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 switch latch button doesn't work properly. 1. Torch Switch Latch button on front panel faulty. a. Return to an authorized service center for repair. 2. Control PCB faulty. a.
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 Air Set Switch "On" Red Air Indicator More air flow is required for Torch to Pilot than to run the power supply. Compressor not functioning properly need to be repaired by a Qualified Technician Compressor Starts and Air Flows at Torch. Turn Air Set Switch "Off" Check Torch parts alignment.
Appendix 2: Torch Connection Disconnect power and air. Lay unit on its side. Remove two screws and access plate.
Manual 0-4687 Input AC 115/230V 1PH Art # A-04700 A-3 Compressor Compressor Input Selector Fan Filter & Input Selector Pressure Sensor Diode Main IGBT Temp Air Power Error Error Hold Panel Board Control Board IGBT Air Check Hold Main Transformer Torch Filter Torch Pilot Work Piece Air Plazma 20C Pilot Relay Conduit Coil H/V Board Reactor Current Sensor Art # A-04700 Appendix 3: System Schematic APPENDIX
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Corporate Headquarters 16052 Swingley Ridge Road Suite 300 St. Louis, MO 63017 Telephone: 636-728-3000 Email: TDCSales@Thermadyne.com www.thermadyne.
