C-35A CUTSKILL ® PLASMA CUTTING SYSTEM Operator Manual Revision No.: AB.
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® SL60™ 1Torch™ Operation Manual Number 0-4678 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 CUT OFF CUT OFF 35A 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. CUT 20A 35% (3.5 min) 2.
2.04 Torch Specifications 2.05 System Contents ITEMS Description Power Source Model C-35A SL60™, with 20' leads Torch Set (6.1m) Air Regulator Work Cable Accessories & Manual Consumables Torch Electrodes Torch Tips Input Power 3 Meter NEMA 10 AWG / Cable For 4.8 mm2 with 6 - 50 P Systems molded plug 1-1635-1 Input Power Cable For 2 Meter Cord With No Systems Plug 1-1635-4 (CE) SL60™ 1Torch™ Ratings for C-35A Torch Head at 75° to Torch Configuration Torch Handle Torch Leads Length 20 feet ( 6.
SECTION 3: INSTALLATION 3.03 Compressed Air Connection • An air compressor is required and should be connected to rear panel of power source by air hose. • Air pressure should be 75 psi (5.2 bar) (.52MPa) and air should be dry and clean. 3.01 Site Selection • Air flow should be 400 scfh / 6.6 scfm (188.7 lpm) minimum. • Place in a clean and dry area. • Provide adequate ventilation and fresh air supply. • Ideal ambient temperature should not exceed 40°C / 104°F.
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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 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 and the torch used in the Drag mode or standoff height indicated. Unit C-35A C-35A C-35A C-35A C-35A Material Maximum Travel Speed Recommended Travel Speed Thickness (ipm , mm/m) (imp , mm/m) Drag (10GA) 0.135" ( 3mm) 94.7 2367 75.7 1893 Drag (7GA) 0.
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SECTION 5: SERVICE 5.01 General Maintenance 1. Basic Troubleshooting Overview This guide covers basic troubleshooting. It is helpful for 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 for repair. O-rings on the Torch require lubrication on a regular basis, depending on how frequently the torch shield cup is disconnected and re-connected.
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. NOTE It is possible to have enough air pressure to operate the power supply but not enough air flow to operate the torch. New Electrode 2. Torch tip, start cartridge, or electrode missing. 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 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.
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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 Red Air Indicator More air flow is required for Torch to Pilot than to run the power supply. Re-check regulator setting. Air Set Switch "On" Air Flows at Torch. Set Air Pressure Then Turn Air Set Switch "Off" Check Torch parts alignment.
Appendix 2: Torch Connection Art # A-04445 Disconnect power and air. Lay unit on its side. Remove access plate.
Appendix 3: Microchip Pin-Out P2 CPU Socket on Control PCB P1 P3 Manual 0-4678 40 Pin Microchip 1 2 3 4 5 6 7 8 24 22 20 18 16 14 12 10 23 21 19 17 15 13 11 9 1 2 3 4 A-3 5 6 7 8 9 10 11 12 8 7 6 5 4 3 2 1 9 10 11 12 APPENDIX
Appendix 4: 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 0-4678 A-5 APPENDIX
Appendix 5: System Schematic Rev A 230 VAC DIODE L INPUT AC230V 1 PH N Black NFB W TB1 White IGBT N/C TB2 Filter Board IGBT Red C1 C2 No.40276003 G CN2 To Ground Connection R1 W CN1 BL DC 325 W B W BR 230 VAC 230 VAC G3 E3 G4 E4 TW TW B WGR TW TW B WGR FAN B B G1 E1 G2 E2 N.C SW W E2 G2 E1 G1 1 2 3 4 1 2 3 4 CN6 CN8 +12VDC W TH E4 G4 E3 G3 2 1 LD1 SOL CN5 T1 BL AC12 AC230 AC18 BL BK R N/C N/C Control Board CN1 No.
R2 218 VAC C3 Cutting Current Piloting Current Current Sensor Main Transformer WORK R3 C4 VC_1 VD_1 OU_1 GN_1 194VAC C/T 1 R4 R5 O.C.V. 325 Pilot 130 Cutting 110 C5 C6 W REACTOR 1 2 CN10 3 4 5 +12VDC to engage Pilot Relay TORCH PILOT +12VDC -12VDC LD2 Enable W Pilot Relay W Twisted CN9 OU_2 1 CN12 2 +12VDC CN3 VC_1 VD_1 OU_1 VC_2 GN_1 S/W P.B. Y Y W 2 1 S/W BR Red V Y G W Torch Filter PCR Jumper CN11 N/C To Current Sensor Panel Board No.
Appendix 6: System Schematic Rev AB 230 VAC DIODE L INPUT AC230V 1 PH N Bk NFB TB1 W TB2 Filter Board IGBT R W IGBT N/C C1 C2 No.40276003 G CN2 1 3 CN4 1 3 CN1 1 3 To Ground Connection W Bk DC 325 W R Bk W R1 W CN3 1 3 W R1 230 VAC 580 Ω Bk Bk G1 E1 G2 E2 G3 E3 G4 E4 TW TW B WGR TW TW B WGR E4 G4 E3 G3 E2 G2 E1 G1 1 2 3 4 1 2 3 4 CN6 CN8 FAN N/C 230 VAC +12VDC W TH W 2 1 LD1 SOL CN5 T1 BL AC12 AC230 BL AC18 AC18 BK N/C N/C Control Board CN1 R No.
R2 218 VAC C3 Cutting Current Piloting Current Current Sensor Main Transformer WORK R3 C4 VC_1 VD_1 OU_1 GN_1 194VAC C/T 1 R4 R5 O.C.V. 325 Pilot 130 Cutting 110 C5 C6 W REACTOR 1 2 CN10 3 4 5 +12VDC to engage Pilot Relay TORCH PILOT +12VDC -12VDC LD2 Enable W Pilot Relay W Twisted CN9 OU_2 1 CN12 2 +12VDC CN3 VC_1 VD_1 OU_1 VC_2 GN_1 Red V Y G S/W Y W W Torch Filter PCR Jumper CN11 N/C To Current Sensor Panel Board No.
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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.
