Thermal Dynamics cutskill 35A User manual

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AMP
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Art # A-09203
CUTSKILL™
PLASMA CUTTING SYSTEM
35A
Operating Manual
Rev. AA Issue Date: June 30, 2009 Manual # 0-5063
Operating Features:
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WE APPRECIATE YOUR BUSINESS!
Congratulations on your new Thermal Dynamics product. We are
proud to have you as our customer and will strive to provide you
with the best service and reliability in the industry. This product is
backed by our extensive warranty and world-wide service network.
To locate your nearest distributor or service provider visit us on
the web at www.cigweld.com.au (Asia Pacific) www.thermal-
dynamics.com (Americas and Europe).
This Operating Manual has been designed to instruct you on the
correct use and operation of your Thermal Dynamics product. Your
satisfaction with this product and its safe operation is our ultimate
concern. Therefore please take 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 competition through market-
leading, dependable products that have stood the test of time.
We pride ourselves on technical innovation, competitive prices,
excellent delivery, superior customer service and technical support,
together with excellence in sales and marketing expertise.
Above all, we are committed to developing technologically advanced
products to achieve a safer working environment within the welding
industry.
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Plasma Cutting Power Supply
CutSkill™ 35A
SL60 1Torch™
Operating Manual Number 0-5063
Published by:
Thermal Dynamics Corporation
82 Benning Street
West Lebanon, New Hampshire, USA 03784
[phone]
www.thermal-dynamics.com
Copyright 2009 by
Thermadyne Corporation
All rights reserved.
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 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 #:___________________________________ ___________
!
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.
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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.............................................................................................................. 1-3
1.04 Declaration of Conformity ........................................................................................ 1-4
1.05 Statement of Warranty ............................................................................................. 1-5
SECTION 2 SYSTEM: INTRODUCTION ..................................................................................................... 2-1
2.01 Working Principle..................................................................................................... 2-1
2.02 Power Supply Specifications .................................................................................... 2-1
2.03 Input Wiring Specifications ...................................................................................... 2-2
2.04 Power Supply Features............................................................................................. 2-3
SECTION 2 TORCH: INTRODUCTION ..................................................................................................... 2T-1
2T.01 Scope of Manual..................................................................................................... 2T-1
2T.02 Specifications ........................................................................................................ 2T-1
2T.03 Introduction to Plasma........................................................................................... 2T-2
SECTION 3: INSTALLATION ..................................................................................................................... 3-1
3.01 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: SERVICE.................................................................................................................. 5T-1
5T.01 General Maintenance.............................................................................................. 5T-1
5T.02 Inspection and Replacement of Consumable Torch Parts....................................... 5T-1
SECTION 6: PARTS LISTS ......................................................................................................................... 6-1
6.01 Introduction.............................................................................................................. 6-1
6.02 Ordering Information................................................................................................ 6-1
APPENDIX 1: CIRCUIT DIAGRAM ............................................................................................................ A-1
GLOBAL CUSTOMER SERVICE CONTACT INFORMATION...................................................Inside Rear Cover
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cutskill 35A
June 30, 2009 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 highlights are categorized
as follows:
NOTE
An operation, procedure, or background information
which requires additional emphasis or is helpful 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 operat-
ing area.
1.02 Important Safety Precautions
!
WARNING
OPERATION AND MAINTENANCE OF PLASMA ARC
EQUIPMENT CAN BE DANGEROUS 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 fol-
low all warnings, safety precautions and instructions
before using the equipment. Call 1-603-298-5711 or
your local distributor if you have any questions.
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 metals which may contain one or more of the
following:
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 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 combustible
or explosive gases or materials are located.
• Phosgene, a toxic gas, is generated from the vapors of chlo-
rinated solvents and cleansers. Remove all sources of these
vapors.
• This product, when used for welding or cutting, produces
fumes or gases which contain chemicals known to the State
of California to cause birth defects 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 operator or others in the
workplace.
• 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 service or
repairs.
• Read and follow all the instructions in the Operating Manu-
al.
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 material in the
workplace. Any material that cannot be removed must be
protected.
• Ventilate all flammable or explosive vapors from the work-
place.
• Do not cut or weld on containers that may have held com-
bustibles.
• 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 underwater or while using a
water table. DO NOT cut aluminum alloys underwater or on
a water table unless the hydrogen gas can be eliminated or
dissipated. Trapped hydrogen gas that is ignited will cause
an explosion.
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cutskill 35A
GENERAL INFORMATON 1-2 June 30, 2009
NOISE
Noise can cause permanent hearing loss. Plasma arc processes can
cause noise levels to exceed safe limits. You must protect your ears
from loud noise to prevent permanent loss of hearing.
• To protect your hearing from loud noise, wear protective
ear plugs and/or ear muffs. Protect others in the work-
place.
• Noise levels should be measured to be sure the decibels
(sound) do not exceed safe levels.
• For information on how to test for noise, see item 1 in Sub-
section 1.03, Publications, in this manual.
PLASMA ARC RAYS
Plasma Arc Rays can injure your eyes and burn your skin. The
plasma arc process produces very bright ultra violet and infrared
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 helmet or shield.
Also always wear safety glasses with side shields, goggles
or other protective eye wear.
• Wear welding gloves and suitable clothing to protect 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 protec-
tive 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.
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 reproductive harm. Wash hands after
handling. (California Health & Safety Code § 25249.5 et seq.)
Eye protection filter shade selector for welding or cutting
(goggles or helmet), from AWS A6.2-73.
Welding or Cutting
Operation
Electrode Size
Metal Thickness
Filter
Shade
Welding or Cutting
Operation
Electrode Size
Metal Thickness
Filter
Shade
Torch soldering 2 Gas metal-arc
welding (MIG)
Torch brazing 3 or 4 Non-ferrous base metal All 11
Oxygen Cutting Non-ferrous base metal All 12
Light Under 1 in., 25 mm 3 or 4 Gas tungsten arc welding All 12
Medium 1 to 6 in., 25-150 mm 4 or 5 (TIG) All 12
Heavy Over 6 in., 150 mm 5 or 6 Atomic hydrogen welding All 12
Gas welding Carbon arc welding All 12
Light Under 1/8 in., 3 mm 4 or 5 Plasma arc welding
Medium 1/8 to 1/2 in., 3-12 mm 5 or 6 Carbon arc air gouging
Heavy Over 1/2 in., 12 mm 6 or 8 Light 12
Shielded metal-arc
welding
(stick) electrodes
Under 5/32 in., 4 mm 10 Heavy 14
5/32 to 1/4 in.,
4 to 6.4 mm 12 Plasma arc cutting
Over 1/4 in., 6.4 mm 14 Light Under 300 Amp 9
Medium 300 to 400 Amp 12
Heavy Over 400 Amp 14
Table 1-1
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cutskill 35A
June 30, 2009 1-3 GENERAL INFORMATION
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 Society, 550 N.W.
LeJeune Rd, Miami, FL 33126
3. NIOSH, SAFETY AND HEALTH IN ARC WELDING AND GAS
WELDING AND CUTTING, obtainable from the Superin-
tendent of Documents, U.S. Government Printing Office,
Washington, D.C. 20402
4. ANSI Standard Z87.1, SAFE PRACTICES FOR OCCUPATION
AND EDUCATIONAL EYE AND FACE PROTECTION, obtain-
able from American National Standards Institute, 1430
Broadway, New York, NY 10018
5. ANSI Standard Z41.1, STANDARD FOR MEN’S SAFETY-TOE
FOOTWEAR, obtainable from the American National Stan-
dards Institute, 1430 Broadway, New York, NY 10018
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 CONTAIN-
ERS WHICH HAVE HELD COMBUSTIBLES, 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 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 Park, Quincy, MA 02269
11. CGA Pamphlet P-1, SAFE HANDLING OF COMPRESSED
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 WELDING
AND CUTTING, obtainable from the Canadian Standards
Association, Standards Sales, 178 Rexdale Boulevard,
Rexdale, Ontario, Canada M9W 1R3
13. NWSA booklet, WELDING SAFETY BIBLIOGRAPHY obtain-
able from the National Welding Supply Association, 1900
Arch Street, Philadelphia, PA 19103
14. American Welding Society Standard AWSF4.1, RECOM-
MENDED SAFE PRACTICES FOR THE PREPARATION FOR
WELDING AND CUTTING OF CONTAINERS 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 PRO-
TECTION, obtainable from American National Standards
Institute, 1430 Broadway, New York, NY 10018
16. Safety in Welding and Allied Processes Part 2: Electrical,
AS1674.2-2007 from SAI Global Limited, www.saiglobal.
com
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cutskill 35A
GENERAL INFORMATON 1-4 June 30, 2009
1.04 Declaration of Conformity
Manufacturer: Thermadyne Company
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.
The equipment described in this manual conforms to all applicable aspects and regulations of the "EMC Directive" (European Council Directive
89/336/EEC) and to the National legislation for the enforcement of this Directive.
Serial numbers are unique with each individual piece of equipment and details description, parts used to manufacture a unit and date of
manufacture.
National Standard and Technical Specifications
The product is designed and manufactured to a number of standards and technical requirements. Among them are:
* CSA (Canadian Standards Association) standard C22.2 number 60 for Arc welding equipment.
* UL (Underwriters Laboratory) rating 94VO flammability 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 used in
conjunction with hand torches with exposed cutting tips, if equipped with properly installed standoff guides.
* Extensive product design verification is conducted at the manufacturing facility as part of the routine design and manufacturing process.
This is to ensure the product is safe, when used according to instructions in this manual and related industry standards, and performs
as specified. Rigorous testing is incorporated into the manufacturing process to ensure the manufactured product meets or exceeds all
design specifications.
Thermadyne has been manufacturing products for more than 30 years, and will continue to achieve excellence in our area of manufacture.
Manufacturers responsible representative in Europe: Steve Ward
Operations Director
Thermadyne Europe
Europa Building
Chorley N Industrial Park
Chorley, Lancashire,
England PR6 7BX
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cutskill 35A
June 30, 2009 1-5 GENERAL INFORMATION
1.05 Statement of Warranty
LIMITED WARRANTY: Subject to the terms and conditions established below, Thermadyne Company warrants to the original retail purchaser
that new Thermal Dynamics CUTSKILL™ 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 Company 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 Company must be notified within 30 days of any failure, at which time Thermadyne Company will
provide instructions on the warranty procedures to be implemented.
Thermadyne Company 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)
CUTSKILL 35A 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 Company:
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 Company 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 Thermal Dynamics product is sold by non - authorized persons.
Effective June 30, 2009
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