Thermal Dynamics C-20A Cutskill Manuel utilisateur

PLASMA

CUTSKILL®

Service Manual

C-20A

PLASMA CUTTING

SYSTEM

Rev. AA.01 Issue Date: March 26, 2007 Manual 0-4697

Operating Features:

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 0-4697

Covered under U.S. Patents.

Published by:

Thermadyne Corporation

82 Benning Street

West Lebanon, New Hampshire, USA 03784

(603) 298-5711

www.thermal-dynamics.com

Thermal Dynamics Corporation

Reproduction of this work, in whole or in part, without written permission of the publisher is prohibited.

The publisher does not assume and hereby disclaims any liability to any party for any loss or damage

caused by any error or omission in this Manual, whether such error results from negligence, accident, or

any other cause.

Printed in the United States of America

Publication Date: March 26, 2007

Record the following information for Warranty purposes:

Where Purchased:____________________________________

Purchase Date:_______________________________________

Power Supply Serial #:________________________________

Torch Serial #:________________________________________

TABLE OF CONTENTS

SECTION 1:

GENERAL INFORMATION ................................................................................................ 1-1

1.01 Notes, Cautions and Warnings ...................................................................... 1-1

1.02 Important Safety Precautions ....................................................................... 1-1

1.03 Publications .................................................................................................. 1-2

1.04 Statement of Warranty .................................................................................. 1-4

SECTION 2:

INTRODUCTION ............................................................................................................... 2-1

2.01 Overview ...................................................................................................... 2-1

2.02 General Specifications .................................................................................. 2-1

2.03 Features ....................................................................................................... 2-1

2.04 Torch Ratings ................................................................................................ 2-2

2.05 System Contents .......................................................................................... 2-2

2.06 Transporting Methods ................................................................................... 2-2

SECTION 3:

INSTALLATION .................................................................................................................. 3-1

3.01 Site Selection ............................................................................................... 3-1

3.02 Electrical Input Connections ......................................................................... 3-1

3.03 Compressed Air Connection ......................................................................... 3-1

SECTION 4:

OPERATION ...................................................................................................................... 4-1

4.01 Front Control Panel ....................................................................................... 4-1

4.02 Preparations For Operating ........................................................................... 4-2

SECTION 5: MAINTENANCE .................................................................................................... 5-1

5.01 General Maintenance .................................................................................... 5-1

5.02 Maintenance - Torch O-Rings ........................................................................ 5-2

SECTION 6:

TROUBLESHOOTING ....................................................................................................... 6-1

6.01 Setup and Operation .................................................................................... 6-1

6.02 Basic Trouble Shooting Guide ....................................................................... 6-2

6.03 Control PCB Indicators ................................................................................. 6-3

6.04 Open Circuit Voltage Check .......................................................................... 6-4

6.05 Detailed Fault Finding / Error Indicators ........................................................ 6-4

6.06 Torch Tests ................................................................................................... 6-8

SECTION 7:

PARTS LIST ...................................................................................................................... 7-1

Replacement Hand Torch Parts ............................................................................. 7-8

Appendix 1: Operating Sequence, Block Diagram ..................................................................... A-1

Appendix 2: Torch Connection ................................................................................................... A-2

Appendix 3: Microchip Pin-Out .................................................................................................. A-3

Appendix 4: System Schematic ................................................................................................ A-4

Manual 0-4697 1-1 GENERAL INFORMATION

SECTION 1:

GENERAL INFORMATION

1.01 Notes, Cautions and Warnings

Throughout this manual, notes, cautions, and warnings

are used to highlight important information. These high-

lights are categorized as follows:

NOTE

An operation, procedure, or background informa-

tion which requires additional emphasis or is help-

ful in efficient operation of the system.

CAUTION

A procedure which, if not properly followed, may

cause damage to the equipment.

WARNING

A procedure which, if not properly followed, may

cause injury to the operator or others in the oper-

ating area.

1.02 Important Safety Precautions

WARNINGS

OPERATION AND MAINTENANCE OF

PLASMA ARC EQUIPMENT CAN BE DAN-

GEROUS AND HAZARDOUS TO YOUR

HEALTH.

Plasma arc cutting produces intense electric and

magnetic emissions that may interfere with the

proper function of cardiac pacemakers, hearing aids,

or other electronic health equipment. Persons who

work near plasma arc cutting applications should

consult their medical health professional and the

manufacturer of the health equipment to determine

whether a hazard exists.

To prevent possible injury, read, understand and

follow all warnings, safety precautions and instruc-

tions before using the equipment. Call 1-603-298-

5711 or your local distributor if you have any ques-

tions.

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.

• Use an air-supplied respirator if ventilation is not

adequate to remove all fumes and gases.

• The kinds of fumes and gases from the plasma arc

depend on the kind of metal being used, coatings

on the metal, and the different processes. You must

be very careful when cutting or welding any met-

als which may contain one or more of the follow-

ing:

Antimony Chromium Mercury

Arsenic Cobalt Nickel

Barium Copper Selenium

Beryllium Lead Silver

Cadmium Manganese Vanadium

• Always read the Material Safety Data Sheets

(MSDS) that should be supplied with the material

you are using. These MSDSs will give you the in-

formation 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 com-

bustible or explosive gases or materials are located.

• Phosgene, a toxic gas, is generated from the vapors

of chlorinated solvents and cleansers. Remove all

sources of these vapors.

• This product, when used for welding or cutting, pro-

duces fumes or gases which contain chemicals

known to the State of California to cause birth de-

fects and, in some cases, cancer. (California Health

& Safety Code Sec. 25249.5 et seq.)

ELECTRIC SHOCK

Electric Shock can injure or kill. The plasma arc process

uses and produces high voltage electrical energy. This

electric energy can cause severe or fatal shock to the op-

erator or others in the workplace.

GENERAL INFORMATION 1-2 Manual 0-4697

• 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.

• Install and maintain equipment according to NEC

code, refer to item 9 in Subsection 1.03, Publications.

• Disconnect power source before performing any ser-

vice or repairs.

• Read and follow all the instructions in the Operat-

ing Manual.

FIRE AND EXPLOSION

Fire and explosion can be caused by hot slag, sparks, or

the plasma arc.

• Be sure there is no combustible or flammable mate-

rial in the workplace. Any material that cannot be

removed must be protected.

• Ventilate all flammable or explosive vapors from

the workplace.

• Do not cut or weld on containers that may have held

combustibles.

• Provide a fire watch when working in an area where

fire hazards may exist.

• Hydrogen gas may be formed and trapped under

aluminum workpieces when they are cut underwa-

ter or while using a water table. DO NOT cut alu-

minum alloys underwater or on a water table un-

less the hydrogen gas can be eliminated or dissipated.

Trapped hydrogen gas that is ignited will cause an

explosion.

NOISE

Noise can cause permanent hearing loss. Plasma arc pro-

cesses can cause noise levels to exceed safe limits. You

must protect your ears from loud noise to prevent per-

manent loss of hearing.

• To protect your hearing from loud noise, wear pro-

tective ear plugs and/or ear muffs. Protect others

in the workplace.

• Noise levels should be measured to be sure the deci-

bels (sound) do not exceed safe levels.

• For information on how to test for noise, see item 1

in Subsection 1.03, Publications, in this manual.

PLASMAARC 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. These arc rays will damage your eyes

and burn your skin if you are not properly protected.

• To protect your eyes, always wear a welding hel-

met or shield. Also always wear safety glasses with

side shields, goggles or other protective eye wear.

• Wear welding gloves and suitable clothing to pro-

tect your skin from the arc rays and sparks.

• Keep helmet and safety glasses in good condition.

Replace lenses when cracked, chipped or dirty.

• Protect others in the work area from the arc rays.

Use protective booths, screens or shields.

• Use the shade of lens as suggested in the following

per ANSI/ASC Z49.1:

Minimum Protective Suggested

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.

1.03 Publications

Refer to the following standards or their latest revisions

for more information:

1. OSHA, SAFETY AND HEALTH STANDARDS, 29CFR

1910, obtainable from the Superintendent of Documents,

U.S. Government Printing Office, Washington, D.C.

20402

2. ANSI Standard Z49.1, SAFETY IN WELDING AND

CUTTING, obtainable from the American Welding So-

ciety, 550 N.W. LeJeune Rd, Miami, FL 33126

3. NIOSH, SAFETY AND HEALTH IN ARC WELDING

AND GAS WELDING AND CUTTING, obtainable from

the Superintendent of Documents, U.S. Government

Printing Office, Washington, D.C. 20402

4. ANSI Standard Z87.1, SAFE PRACTICES FOR OCCU-

PATION AND EDUCATIONAL EYE AND FACE PRO-

TECTION, obtainable from American National Stan-

dards Institute, 1430 Broadway, New York, NY 10018

5. ANSI Standard Z41.1, STANDARD FOR MEN’S

SAFETY-TOE FOOTWEAR, obtainable from theAmeri-

can National Standards Institute, 1430 Broadway, New

York, NY 10018

Manual 0-4697 1-3 GENERAL INFORMATION

6. ANSI Standard Z49.2, FIRE PREVENTION IN THE

USE OF CUTTING AND WELDING PROCESSES, ob-

tainable from American National Standards Institute,

1430 Broadway, New York, NY 10018

7. AWS Standard A6.0, WELDING AND CUTTING

CONTAINERS WHICH HAVE HELD COMBUS-

TIBLES, obtainable from American Welding Society,

550 N.W. LeJeune Rd, Miami, FL 33126

8. NFPA Standard 51, OXYGEN-FUEL GAS SYSTEMS

FOR WELDING, CUTTING AND ALLIED PRO-

CESSES, obtainable from the National Fire Protection

Association, Batterymarch Park, Quincy, MA 02269

9. NFPA Standard 70, NATIONAL ELECTRICAL CODE,

obtainable from the National Fire Protection Associa-

tion, Batterymarch Park, Quincy, MA 02269

10. NFPAStandard 51B, CUTTING AND WELDING PRO-

CESSES, obtainable from the National Fire Protection

Association, Batterymarch Park, Quincy, MA 02269

11. CGA Pamphlet P-1, SAFE HANDLING OF COM-

PRESSED GASES IN CYLINDERS, obtainable from the

Compressed Gas Association, 1235 Jefferson Davis

Highway, Suite 501, Arlington, VA 22202

12. CSA Standard W117.2, CODE FOR SAFETY IN WELD-

ING AND CUTTING, obtainable from the Canadian

Standards Association, Standards Sales, 178 Rexdale

Boulevard, Rexdale, Ontario, Canada M9W 1R3

13. NWSA booklet, WELDING SAFETY BIBLIOGRAPHY

obtainable from the National Welding Supply Associa-

tion, 1900 Arch Street, Philadelphia, PA 19103

14. American Welding Society Standard AWSF4.1, RECOM-

MENDED SAFE PRACTICES FOR THE PREPARA-

TION FOR WELDING AND CUTTING OF CONTAIN-

ERS AND PIPING THAT HAVE HELD HAZARDOUS

SUBSTANCES, obtainable from the American Welding

Society, 550 N.W. LeJeune Rd, Miami, FL 33126

15. ANSI Standard Z88.2, PRACTICE FOR RESPIRATORY

PROTECTION, obtainable from American National

Standards Institute, 1430 Broadway, New York, NY

10018

GENERAL INFORMATION 1-4 Manual 0-4697

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. Should any failure to conform to this warranty appear within the applicable period stated below, Thermadyne

Corporation shall, upon notification thereof and substantiation that the product has been stored operated and maintained in accordance

with Thermadyne’s specifications, instructions, recommendations and recognized industry practice, correct such defects by suitable repair

or replacement.

This warranty is exclusive and in lieu of any warranty of merchantability or fitness for a particular purpose.

Thermadyne will repair or replace, at its discretion, any warranted parts or components that fail due to defects in material or workmanship

within the time periods set out below. Thermadyne Corporation must be notified within 30 days of any failure, at which time Thermadyne

Corporation will provide instructions on the warranty procedures to be implemented.

Thermadyne Corporation will honor warranty claims submitted within the warranty periods listed below. All warranty periods begin on the

date of sale of the product to the original retail customer or 1 year after sale to an authorized Thermadyne Distributor.

LIMITED WARRANTY PERIOD

Product Power Supply Components

(Parts and Labor) Torch and Leads

(Parts and Labor)

C-20A 1 Year 1 Year

C-35A 1 Year 1 Year

C-70A 1 Year 1 Year

C-100A 1 Year 1 Year

This warranty does not apply to:

1. Consumable Parts, such as tips, electrodes, shield cups, o - rings, starter 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 Corporation:

1. Repair of the defective product.

2. Replacement of the defective product.

3. Reimbursement of reasonable costs of repair when authorized in advance by Thermadyne.

4. Payment of credit up to the purchase price less reasonable depreciation based on actual use.

These remedies may be authorized by Thermadyne and are FOB West Lebanon, NH or an authorized Thermadyne service station. Product

returned for service is at the owner’s expense and no reimbursement of travel or transportation is authorized.

LIMITATION OF LIABILITY: Thermadyne Corporation shall not under any circumstances be liable for special or consequential damages

such as, but not limited to, damage or loss of purchased or replacement goods or claims of customer of distributors (hereinafter “Purchaser”)

for service interruption. The remedies of the Purchaser set forth herein are exclusive and the liability of Thermadyne with respect to any

contract, or anything done in connection therewith such as the performance or breach thereof, or from the manufacture, sale, delivery, resale,

or use of the goods covered by or furnished by Thermadyne whether arising out of contract, negligence, strict tort, or under any warranty,

or otherwise, shall not, except as expressly provided herein, exceed the price of the goods upon which liability is based.

This warranty becomes invalid if replacement parts or accessories are used which may impair the safety or performance of any

Thermadyne product.

This warranty is invalid if the Thermadyne product is sold by non - authorized persons.

Effective August 28, 2005

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