Plasma Cutting System Model FP-20A Art # A-04501 Operating Manual January 23, 2006 Manual 0-4680
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.
• Never touch any parts that are electrically “live” or “hot.” • 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. 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.
SECTION 2: INTRODUCTION CUT OFF 25A 15A 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 10A 30% (3 min) 2.
If you have questions or concerns regarding your system, please contact: 2.04 Torch Ratings Thermal Dynamics Technical Service Dept. SL60™ 1Torch™ Ratings for FP-20A Torch Head at 75° to Torch Configuration Torch Handle Torch Leads Length 20 feet / 6.
SECTION 3: INSTALLATION Connect the input power cord as follows: 1. Check the power source for correct voltage before plugging in the unit. 2. Connect the input power cable (or close the main disconnect switch) to supply power to the system. 3.01 Site Selection • Place in a clean and dry area. 3.03 Compressed Air Connection • Provide adequate ventilation and fresh air supply. • An air compressor is required and should be connected to rear panel of power source by air hose.
Installation 3-2 Manual 0-4680
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 only. Maximum Travel Speed Recommended Travel Speed Inches per Milimeters Inches per Milimeters per minute per minute minute minute FP-20A Drag Only (10GA) 0.135" (3mm) 42.7 1067 34.1 853 FP-20A Drag Only (7GA) 0.179" (4.
Operation 4-4 Manual 0-4680
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 0-4680 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 0-4680 A-5 APPENDIX
Appendix 5: System Schematic 337VDC at 115VAC input 298VDC at 220VAC input 115VAC 220VAC N/C NFB IGBT IGBT Filter Board B TB2 Input Capcitor TB1 INPUT AC115/230V N 1 PH B W No.40279012 G CN4 CN3 CN1 CN2 No.
R2 C3 Current Sensor Main Transformer WORK R3 239VAC at 115VAC input 210VAC at 220VAC input C4 VC_1 VD_1 OU_1 GN_1 207VAC at 115VAC input 182VAC at 220VAC input C/T 1 R4 OU_2 335VAC at 115VAC input O.C.V.
