C-70A 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 0-4679 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 Input Voltage 230V Input Voltage 400V CE Frequency Input Power 230V 1 Phase Input Power 230V 3 Phase Input Power Fuse, 1 Phase Input Power Fuse, 3 Phase Input Power 400V Input Power Fuse, 3 Phase No Load Voltage Load Voltage Output Current Post-Flow time Operating Air Pressure Maximum Air Pressure Air flow System *Duty Cycle Ratings at Ambient Air Temperatures of 40° C / 104° F. System *Duty Cycle Ratings at Ambient Air Temperatures of 40° C / 104° F.
2.04 Torch Specifications SL100™ 1Torch™ Ratings for C-70A 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 Torch Duty Cycle @ 400 scfh 100 Amps, DC, Maximum Current Straight Polarity 500V Voltage (Vpeak ) 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 Input .5MPa (5 bar) Gas Pressure .
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 .5MPa (5 bar) 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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SECTION 4: OPERATION B. Buttons • 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 set at the indicated standoff height.
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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 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-04445 Disconnect power and air. Lay unit on its side. Remove access plate.
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Appendix 3: Replacement Hand Torch Parts List Item # Qty 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 0-4679 A-5 APPENDIX
Appendix 4: 230 Volt System Schematic TB1 1PH - R&Bk 3PH - R,W&Bk 230VAC FILTER R R DIODE 103 3KV C1 NFB 103 C4 C2 C3 Bk R4 C8 C7 Bk R7 Bk Input Power Connection W 320VDC W W Bk C12 INPUT AC230V 1/3 PH IGBT W Bk C5 Bk Bk IGBT R3 W R C6 W W W G 3KV W C13 P5 P5 G1 E1 G2 E2 G3 E3 G4 E4 FUSE 630V 104MF CONTROL 3A C7 R7 C8 W,2 + Bk,2 (-) E4 G4 E3 G3 E2 G2 E1 G1 P8 P7 Capacitor P5 TH 12 VDC PWM DRIVE BOARD 40272004 FAN G AC230 AC12 AC15 Bk AC15 Y AC160
Current Sensor Main Transformer Bk WORK W (2) R5 R1 C11 C10 W 220VAC C/T 1 R8 (2) VC_1 VD_1 OU_1 GN_1 VC_2 VD_2 OU_2 GN_2 O.C.V.
Appendix 5: 400 Volt CE System Schematic R10 DIODE NFB S FILTER PCB T R7 C9 C14 No.40276004 CN1 G CN2 R11 CN3 E4 G4 E3 G3 INPUT AC400V 1 / 3 PH IGBT R4 C8 C7 TB2 E2 G2 E1 G1 TB1 IGBT R3 R R9 C12 C13 MAGNET CN3 CN2 CN1 DELAY PCB No.40279016 FAN FUSE CONTROL 3A E4 G4 E3 G3 E2 G2 E1 G1 P6 P7 TH P5 PWM DRIVE BOARD PW-1-0300-P-02 P2 AC230 AC12 AC160 AC15 P11 AC15 AC180 T1 P9 Solenoid V/V P1 P4 P3 P8 CONTROL BOARD No.
Current Sensor Main Transformer WORK R5 C11 R1 C10 C/T 1 R8 VC_1 VD_1 OU_1 GN_1 VC_2 VD_2 OU_2 GN_2 C16 Pilot Relay PILOT REACTOR TORCH S/W P3 VC_1 VD_1 OU_1 GN_1 P4 VC_2 VD_2 OU_2 GN_2 P8 S/W P9 P6 P10 Torch S/W No.40276002 P3 Air Plasma 70A (400V CE) No. 66001010 HOLD AIR CHECK AB oct. 18.
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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.
