Thermal Dynamics cutskill 35A, Operating Manual

Page 1: ...35 AMP 1 PHASE DC Art A 09203 cutskill plasma cutting system 35A Operating Manual Rev AA Issue Date June 30 2009 Manual 0 5063 Operating Features A R C W E L D I N G S U P P L I E S 0 7 8 4 7 7 8 7 0 ...

Page 2: ...e the time to read the entire manual especially the Safety Precautions They will help you to avoid po tential hazards that may exist when working with this product YOU ARE IN GOOD COMPANY The Brand of Choice for Contractors and Fabricators Worldwide Thermal Dynamics is a Global Brand of manual and automation Plasma Cutting Products for Thermadyne Industries Inc We distinguish ourselves from our co...

Page 3: ...ether such error results from negli gence accident or any other cause Publication Date June 30 2009 Record the following information for Warranty purposes Where Purchased ____________________________________________ Purchase Date _______________________________________________ Power Supply Serial _________________________________________ Torch Serial _______________________________________________...

Page 4: ... 01 Unpacking 3 1 3 02 Lifting Options 3 1 3 03 Primary Input Power Connections 3 1 3 04 Gas Connections 3 2 SECTION 4 SYSTEM OPERATION 4 1 4 01 Control Panel 4 1 4 02 Preparations For Operating 4 2 4 03 Sequence of Operation 4 4 4 04 Cut Quality 4 7 4 05 General Cutting Information 4 8 SECTION 5 SYSTEM SERVICE 5 1 5 01 General Maintenance 5 1 5 02 Basic Troubleshooting Guide 5 3 SECTION 5 TORCH S...

Page 5: ... These MSDSs will give you the information regarding the kind and amount of fumes and gases that may be dangerous to your health For information on how to test for fumes and gases in your workplace refer to item 1 in Subsection 1 03 Publications in this manual Use special equipment such as water or down draft cutting tables to capture fumes and gases Do not use the plasma torch in an area where co...

Page 6: ...ggested Arc Current Shade No Shade No Less Than 300 8 9 300 400 9 12 400 800 10 14 These values apply where the actual arc is clearly seen Experience has shown that lighter filters may be used when the arc is hidden by the workpiece LEAD WARNING This product contains chemicals including lead or otherwise produces chemicals known to the State of California to cause cancer birth defects and other re...

Page 7: ... SYSTEMS FOR WELDING CUTTING AND ALLIED PROCESSES obtainable from the National Fire Protection Association Batterymarch Park Quincy MA 02269 9 NFPA Standard 70 NATIONAL ELECTRICAL CODE obtain able from the National Fire Protection Association Bat terymarch Park Quincy MA 02269 10 NFPA Standard 51B CUTTING AND WELDING PROCESSES obtainable from the National Fire Protection Association Batterymarch P...

Page 8: ... testing for all printed circuit boards used CENELEC EN50199 EMC Product Standard for Arc Welding Equipment ISO IEC 60974 1 BS 638 PT10 EN 60 974 1 EN50192 EN50078 applicable to plasma cutting equipment and associated accessories AS60974 1 Arc Welding Equipment Welding Power Sources For environments with increased hazard of electrical shock Power Supplies bearing the mark conform to EN50192 when u...

Page 9: ...arter cartridges gas distributors fuses filters 2 Equipment that has been modified by an unauthorized party improperly installed improperly operated or misused based upon industry standards In the event of a claim under this warranty the remedies shall be at the discretion of Thermadyne Company 1 Repair of the defective product 2 Replacement of the defective product 3 Reimbursement of reasonable c...

Page 10: ...A R C W E L D I N G S U P P L I E S 0 7 8 4 7 7 8 7 0 ...

Page 11: ...an shown in this chart 2 Air supply must be free of oil moisture and other contaminants Excessive oil and moisture may cause double arcing rapid tip wear or even complete torch failure Contaminants may cause poor cutting perfor mance and rapid electrode wear Optional filters provide increased filtering capabilities NOTE IEC Rating is determined as specified by the International Electro Technical C...

Page 12: ...wer Input Current Input Current Input Suggested Sizes See Note Voltage Freq kVA Max Amps Ieff Amps Fuse Amps Volts Hz 1 Ph 1 Ph 1 Ph 1 Ph 240 50 3 4 27 3 14 20 Line Voltages with Suggested Circuit Protection Motor start fuses or thermal circuit breakers are recommended for this application Check local requirements for your situation in this regard NOTE Refer to Local and National Codes or local au...

Page 13: ...ure Regulator Filter Assembly Control Panel Torch Lead RUN SET CURRENT A 25 35 READY AIR OVERHEAT POWER 240V AC Power Source Work Cable and Clamp Art A 09175 Gas Pressure Regulator Filter Assembly Gas Pressure Gauge Art A 09176 A R C W E L D I N G S U P P L I E S 0 7 8 4 7 7 8 7 0 ...

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Page 15: ...s 10 ft 3 m C Torch Parts Starter Cartridge Electrode Tip Shield Cup D Parts In Place PIP Torch Head has built in switch 12 vdc circuit rating E Type Cooling Combination of ambient air and gas stream through torch F Torch Ratings SL60 Torch Ratings Ambient Temperature 104 F 40 C Duty Cycle 100 60 Amps 400 scfh Maximum Current 60 Amps Voltage Vpeak 500V Arc Striking Voltage 7kV G Current Ratings SL...

Page 16: ...concentration of heat to a small area The stiff constricted plasma arc is shown in Zone C Direct current DC straight polarity is used for plasma cutting as shown in the illustration Zone A channels a secondary gas that cools the torch This gas also assists the high velocity plasma gas in blowing the molten metal out of the cut allowing for a fast slag free cut A 00002 Workpiece Power Supply _ C B ...

Page 17: ...ndle for hand lifting only Be sure unit is lifted and transported safely and securely WARNING Do not touch live electrical parts Disconnect input power cord before moving unit FALLING EQUIPMENT can cause serious personal injury and can damage equipment HANDLE is not for mechanical lifting Only persons of adequate physical strength should lift the unit Lift unit by the handle using two hands Do not...

Page 18: ...fe work voltage range it will shorten the power source life span 3 04 Air Supply Connections A Connecting Air Supply to Unit The connection is the same for compressed air or industrial compressed air in gas cylinders 1 Connect the gas line to the compressed air input inlet port at the appropriate pressure The illustration shows typical fittings as an example NOTE For a secure seal apply thread sea...

Page 19: ...of oil grease or any foreign material Briefly open each cylinder valve to blow out any dust which may be present 3 The cylinder must be equipped with an adjustable high pressure regulator capable of outlet pressures up to 100 psi 6 9 bar maximum and flows of at least 300 scfh 141 5 lpm 4 Connect gas supply hose to the cylinder NOTE Pressure should be set at 100 psi 6 9 bar at the high pressure gas...

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Page 21: ...setting gas pressure and purging lines 3 A Output Current Control Sets the desired output current If the overload protection fuse or circuit breaker on the input power circuit opens frequently either reduce cutting output reduce the cutting time or connect the unit to more adequate input power Refer to Section 2 for input power requirements 4 Power ON Indicator AC Indicator Steady light indicates ...

Page 22: ...ies A Torch Parts Selection Check the torch for proper assembly and appropriate torch parts The torch parts must correspond with the type of operation and with the amperage output of this power supply 35 amps maximum Use only genuine Thermal Dynamics parts with this torch Art A 03409_AB Large O Ring Cat No 8 3487 Small O Ring Cat No 8 3486 Electrode Cat No 9 8215 Start Cartridge Cat No 9 8213 Shie...

Page 23: ...le to the workpiece or cutting table The area must be free from oil paint and rust Con nect only to the main part of the workpiece do not connect to the part to be cut off Art A 03387 F Power On Place the power supply ON OFF switch to the ON I position Power indicator turns on Art A 09181 RUN SET CURRENT A 15 25 35 READY AIR OVERHEAT POWER Front Panel With Power ON OFF Indicator G Set Operating Pr...

Page 24: ...sequence of operation for this power supply Refer to Appendix 1 for block diagram 1 Plug the input power cord into an active circuit a AC power is available at the power supply 2 Place the ON OFF switch on the power supply to ON up position a AC indicator turns on fan turns on NOTE Gas will automatically flow from torch for 4 seconds this is a safety circuit that makes sure the torch tip is proper...

Page 25: ...orch head for maximum control or near the back end for maximum heat protection Choose the hold ing technique that feels most comfortable and allows good control and movement NOTE The tip should never come in contact with the workpiece except during drag cutting operations B Depending on the cutting operation do one of the following a For edge starts hold the torch perpendicular to the workpiece wi...

Page 26: ...he output current B The torch can be comfortably held in one hand or steadied with two hands Position the hand to press the Trigger on the torch handle With the hand torch the hand may be positioned close to the torch head for maximum control or near the back end for maximum heat protection Choose the hold ing technique that feels most comfortable and allows good control and movement C Keep the to...

Page 27: ... Build Up Top Spatter A 00007 Cut Quality Characteristics Cut Surface The desired or specified condition smooth or rough of the face of the cut Nitride Build Up Nitride deposits can be left on the surface of the cut when nitrogen is present in the plasma gas stream These buildups may create difficulties if the material is to be welded after the cutting process Bevel Angle The angle between the sur...

Page 28: ...ickly as possible Direction of Cut In the torches the plasma gas stream swirls as it leaves the torch to maintain a smooth column of gas This swirl effect results in one side of a cut being more square than the other Viewed along the direction of travel the right side of the cut is more square than the left Right Side Cut Angle Left Side Cut Angle A 00512 Side Characteristics Of Cut To make a squa...

Page 29: ... Source must be returned to an Accredited CIGWELD Service Provider for repair Each Use Visual check of torch tip and electrode Weekly Visually inspect the torch body tip electrode start cartridge and shield cup Visually inspect the cables and leads Replace as needed 3 Months 6 Months Replace all broken parts Visually check and Carefully clean the interior Maintain more often if used under severe c...

Page 30: ... 1 Common Faults symptom A Gas regulator leakage 1 Gas regulator on a Reset the regulator to 0 PSI and re adjust it to 65 PSI 4 5 bar B AC indicator OFF 1 Main input power cord does not connect to power distribution net a Connect the power cord 2 Power ON OFF switch in OFF down position a Turn switch to ON up position 3 Actual input voltage does not correspond to voltage of unit a Verify that the ...

Page 31: ...orking cable not connected to work piece or connection is poor a Make sure that work cable has a proper connection to a clean dry area of the work piece 3 Faulty components in unit a Return for repair or have qualified technician repair per service manual 4 Faulty torch a Return for repair or have qualified technician repair G Torch cuts but not adequately 1 Incorrect setting of output current con...

Page 32: ...ted TEMP indicator ON a Let unit cool down for at least 5 minutes Make sure the unit has not been operated beyond duty cycle limit 2 Fan blades blocked TEMP indicator ON a Check and clear blades 3 Air flow blocked a Check for blocked air flow around the unit and correct condition 4 Gas pressure is too low Air indicator ON when torch trigger is activated a Check gas source It should be set to at le...

Page 33: ...spection and Replacement of Consumable Torch Parts WARNING Disconnect primary power to the system before disassembling the torch or torch leads DO NOT touch any internal torch parts while the AC indicator light of the Power Supply is ON Remove the consumable torch parts as follows NOTE The shield cup holds the tip and starter cartridge shield cup in place Position the torch with the shield cup fac...

Page 34: ...cessive wear Refer to the following figure Worn Electrode New Electrode Art A 03284 Electrode Wear 6 Reinstall the electrode by pushing it straight into the torch head until it clicks 7 Reinstall the desired starter cartridge and tip into the torch head 8 Hand tighten the shield cup until it is seated on the torch head If resistance is felt when install ing the cup check the threads before proceed...

Page 35: ...sure Switch 9 0136 7 1 Current Transformer 9 0138 1 3 4 2 5 Art A 09192_AB 6 7 B Returns If a product must be returned for service contact your distributor Materials returned without proper authorization will not be accepted 6 02 Ordering Information Order replacement parts by catalog number and complete description of the part or assembly as listed in the parts list for each type item Also includ...

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Page 37: ...e in Microfarads UF TITLE SCHEMATIC 35A 240V SINGLE PHASE 50 60 Hz Date By Rev Revision PILOT WORK T O R C H WV OUTPUT BLACK RED FAN DC24V AC240V INPUT 50 60 Hz AC240V D T WV OUTPUT FEEDBACK SIGNAL N A DRIVE POWER OT AIR READY CURRENT CONTROL SET RUN DRIVE SIGNAL N A SOURCE TIP SIGNAL HF QF GAS SOLENOID TEST TORCH SW PRESSURE SW OVER TEMPERATURE 1 2 3 1 2 3 1 2 1 2 3 4 1 2 3 4 1 2 3 4 5 1 2 3 4 5 ...

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Page 39: ...ababeka VI Blok P No 3 Cikarang Bekasi 17550 Indonesia Telephone 62 21 8936071 Fax 62 21 8936067 6068 http www thermadyne com Thermadyne Asia Sdn Bhd Lot 151 Jalan Industri 3 5A Rawang Integrated Industrial Park Jln Batu Arang 48000 Rawang Selangor Darul Ehsan West Malaysia Telephone 603 6092 2988 Fax 603 6092 1085 Thermadyne Australia 71 Gower Street Preston Victoria Australia 3072 Telephone 61 3...

Page 40: ...acific Regional Headquarters 71 Gower Street Preston Victoria Australia 3072 Telephone 61 3 9474 7400 Fax 61 3 9474 7488 Email cigweldsales cigweld com au A R C W E L D I N G S U P P L I E S 0 7 8 4 7 7 8 7 0 ...