Thermal Dynamics CutSkill PCH-42 Torch User manual

PLASMA
CUTSKILL®
Operation Manual
C-35C
PLASMA CUTTING
SYSTEM
Rev. AA.01 Issue Date: March 26, 2007 Manual 0-4688
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®
PCH-42 Torch
Operation Manual Number 0-4688
Covered under U.S. Patents.
Published by:
Thermadyne Corporation
82 Benning Street
West Lebanon, New Hampshire, USA 03784
[phone]
www.thermal-dynamics.com
©Copyright 2005, 2006, 2007 by
Thermal Dynamics 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 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
SECTION1:
GENERALINFORMATION ................................................................................................ 1-1
1.01 Notes,CautionsandWarnings ...................................................................... 1-1
1.02 Important Safety Precautions ....................................................................... 1-1
1.03 Publications.................................................................................................. 1-2
1.04 StatementofWarranty .................................................................................. 1-4
SECTION2.0
INTRODUCTION .............................................................................................................. 2-1
2.01 INTRODUCTION .......................................................................................... 2-1
2.02 GENERALSPECIFICATION......................................................................... 2-1
2.03 Features ....................................................................................................... 2-1
2.04 Torch Specifications ..................................................................................... 2-2
2.05 System Contents.......................................................................................... 2-2
2.06 TransportingMethods ................................................................................... 2-2
SECTION3.0
INSTALLATION................................................................................................................. 3-1
3.01 Site Selection ............................................................................................... 3-1
3.02 ElectricalInputConnections ......................................................................... 3-1
3.03 Torch ............................................................................................................ 3-1
SECTION4.0
OPERATION...................................................................................................................... 4-1
4.01 FrontControlPanel ....................................................................................... 4-1
4.02 PreparationsFor Operating ........................................................................... 4-2
SECTION5:0
SERVICE .......................................................................................................................... 5-1
5.01 BasicTroubleshootingGuide......................................................................... 5-1
Appendix1: OperatingSequence,BlockDiagram ..................................................................... 5-1
Appendix2: TorchConnection ................................................................................................... 5-2
Appendix 3: System Schematic 230V Non CE .......................................................................... 5-3
Appendix 4: System Schematic 230V CE ................................................................................. 5-4

Manual 0-4688 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.
• Never touch any parts that are electrically “live” or
“hot.”

GENERAL INFORMATION 1-2 Manual 0-4688
• 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.
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. 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 0-4688 1-3 GENERAL INFORMATION
6. ANSI Standard Z49.2, FIRE PREVENTION IN THE USE
OF CUTTING AND WELDING PROCESSES, obtain-
able 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. NFPA Standard 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 0-4688
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 Componants
(Parts and Labor) Torch and Leads (Parts and Labor)
20C 1 Year 1 Year
35C 1 Year 1 Year
This warranty does not apply to:
1. Consumable Parts, such as tips, electrodes, shield cups, o - rings, start 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 May 31, 2005

Introduction 2-1 Manual 0-4688
SECTION 2.0
INTRODUCTION
2.01 INTRODUCTION
Plasma is a gas which has been heated to an extremely
high temperature and ionized so that it becomes elec-
tricallyconductive. Theplasmaarc cutting processuses
this plasma to transfer an electrical arc to the work-
piece. The metal to be cut is melted by the heat of the
arc and then blown away.
2.02 GENERAL SPECIFICATION
Model Description
35C
Maximum output
35 Amps
Input Voltage & Phase
230V,
Single Phase
Frequency
50/60Hz
Input power
8.3 kVA
Current Input fuse
U.S. / Canada 40
Amps
All others 16A Slow
Blow Fuse
No Load Voltage
330V
Load Voltage
94V
Output Current
10 - 35 Amps
Post flow time
15 Seconds
35% @ 35A @
94vdc
60% @ 27A @
91vdc
100% @ 20A @
88 vdc
Genuine Cutting
Capacity
3/8"
(10 mm)
Maximum Cutting
Capacity
5/8"
(15 mm)
Dimension (W * D * H) 10.5"x15.5"x11" (267 mm x 394 mm
x 279 mm )
Gross Weight 57 lbs. (26 kg
)
Duty cycle @ 104°F /
40° C Ambient
NOTE:
Refer to Local and National Codes or local au-
thority having jurisdiction for proper wiring re-
quirements.
2.03 Features
• COMPACT and LIGHT - Designed for easy trans-
portation.
• ENERGY EFFICIENCY - Advanced technology
reduces power consumption.
• HIGH SPEED GENUINE CUTTING - The con-
stricted plasma arc provides high speed cutting
as well as a good quality genuine, narrow cut.
• LOW COST WITH COMPRESSEDAIR - The35C
operates on compressed air.
• ALL KINDS OF METALS - Useful for most met-
als such as stainless steel, aluminum, mild steel,
copper and their alloys.
• PILOT ARC IGNITION FROM TORCH - The Pi-
lot Arc ignites the cutting arc.
• POWERFUL CUTTING PERFORMANCE -
Genuine cutting capacity is 3/8” (10 mm) and
5/8” (15 mm) for maximum cut.
• ABLE TO CUT PAINTED MATERIALS - PilotArc
ignition allows the 35C to cut painted materials.
• EXTENDED PARTS LIFE - Consumable parts life
is longer.

Introduction 2-2 Manual 0-4688
2.04 Torch Specifications
Art # A-0465
3
10.5 in (266.7 mm)
3 in
(76.2 mm)
Torch Configuration Torch Head at 70° to
Torch Handle
Torch Leads Length
20 feet / 6.1 m
Duty Cycle 100% @ 40 Amps
@ 200 scfh
Ambient
Temperature
104° F
40° C
Maximum Current 40 Amps, DC,
Straight Polarity
Voltage (V
peak
)500V
Arc Striking Voltage 12kV
Type of Cooling Ambient air and gas
stream through torch
Parts-in-Place Built-in Switch
in Torch Head
Gas Requirement Single Gas,
Compressed Air Only
Input
Gas Pressure
65 psi (4.5 bar)
(.45MPa)-
125 psi (8.6 bar)
(.86MPa)
Minimum Gas Flow 130 scfh (61 lpm)
Direct Contact Hazard
For operation with
exposed tip the
recommended standoff
height is
1/8 - 3/8" (3-9 mm).
Plasma Power
Supply Used With 35C
PCH-42 Torch Ratings
2.05 System Contents
Description
ITEMS
Q'ty
Power source Model 35C 1
Torch Set PCH-42, with 20' (6.1 m) leads 1
Accessories &
Consumables
Air Regulator
Work Cable
Manual
Torch Electrodes
Torch Tips
1
1
1
2
3
Input Power
Cable U.S. /
CAN.
3 Meter NEMA 10 AWG /
4.8 mm2with 6 - 50 P
molded plug 1
Input Power
Cable Outside
of U.S. / CAN.
3 Meter 3x2.5 sq mm
rubber wire 1
2.06 Transporting Methods
Lift unit with handle on top of case. Use handcart or
similar device of adequate capacity for transporting.
WARNINGS
ELECTRIC SHOCK can kill. DO NOT
TOUCH live electrical parts. Disconnect input
power from supply before moving the power
source.
FALLING EQUIPMENT can cause serious per-
sonal injury and equipment damage.

Installation 3-1 Manual 0-4688
SECTION 3.0
INSTALLATION
3.01 Site Selection
• Place in a clean and dry area.
• Provide adequate ventilation and fresh air sup-
ply.
• Ideal ambient temperature should not exceed
40°C / 104°F. Temperatures exceeding that may
diminish cutting capacity or quality.
• The cutting machine must be placed on an even,
flat surface so that it stands firmly.
WARNING
This equipment must be electrically connected
by a qualified electrician.
3.02 Electrical Input Connections
• Input voltage is 230V ± 10%, 50/60 Hz single
phase.
CAUTION
Check your power source for correct voltage be-
fore plugging in or connecting the unit. The
primary power source, fuse, and any extension
cords used must conform to local electrical code
andthe recommendedcircuitprotectionand wir-
ing requirements as specified in Section 2.
3.03 Torch
• Make sure that the torch cable and torch switch
terminals are connected to front panel.
• Make sure the Work Cable is connected properly
to front panel.
• Before activating, turn torch away from yourself
and others.
DANGER
Do not cut in humid or wet surroundings.
• Before you maintain or replace torch parts, wait
for the post flow air cycle to stop, then turn the
machine off.
• Always use original manufacturersparts. Theuse
of aftermarket parts could result in lower parts
lifeandinunsatisfactorycuttingresults. Anywar-
ranty claims would be waived.
• Recycle worn parts according to local require-
ments.
NOTE
Repairs must be done by skilled and qualified
personnel only.

Installation 3-2 Manual 0-4688
This Page Left Blank

Operation 4-1 Manual 0-4688
SECTION 4.0
OPERATION
4.01 Front Control Panel
Overheating
Indicator
AC Power
Indicator
Air Error Indicator
Torch Switch
Latch Indicato
r
Torch Switc
h
Latch Butto
n
Air Set
Button
Air Vents
Work Lead
Connection
"On / Off"
Switch
Art # A-04715
Torch
Connection
I
O
115VAC
230VAC
8
10
12
14
10
11
12
13
14
15
17
18
19
20
21
22
23
24
25
A
35C
16
18
20
16
Current
Control Knob
A. INDICATOR LAMP
• Power Indicator - Lights when primary
power switch is turned on.
• TEMPERATUREIndicator -Indicator is nor-
mally OFF. Indicator is ON when internal tem-
peratureexceedsnormallimits. Shutunit OFF;
let the unit cool before continuing operation.
• Air Error Indicator - This indicator lights
and is accompanied by an intermittent audible
tone when there is not enough air pressure to
operate the power supply.
NOTE
It is possible to have enough air pressure to op-
erate the power supply but not enough air flow
to operate the torch.
• Torch Switch Latch Indicator -
This indicator lights when the Torch Switch
Latch Button has been pressed for continuous
cutting.
B. BUTTONS
• Torch Switch Latch Button - For
continuous cutting performance. Depress this
button(turn “On” ) while cutting with the torch.
Release the torch trigger and the torch will con-
tinue to cut without depressing the torch trig-
ger.
• Air Set Button - To check for proper air
setting and to cool down heated torch.
C. MAIN CURRENT CONTROL KNOB
To adjust cutting current. Turning clockwise in-
creases the cutting current and counter clock-
wise decreases the cutting current.
10
15
20
25
A
3
0
35
A
rt # A-04387
D. PRIMARY POWER SWITCH, ON / OFF
The power switch is located on the front panel.
Placing the primary power switch to the “ON”
position energizes the power source.
WARNING
When the power source is overloaded, the switch
turns to the OFF position automatically. DO
NOT TURN ON BY FORCE.

Operation 4-2 Manual 0-4688
4.02 Preparations For Operating
At the start of each operating session:
WARNING
Disconnect primary power at the source before
assemblingordisassembling power supply,torch
parts, or torch and leads assemblies.
A. Torch Parts Selection
Check the torch for proper assembly and appro-
priatetorchparts. Thetorchparts must correspond
with the type of operation, and with the amperage
output of this Power Supply (35 amps maximum).
Use only genuine manufacturer’s parts with this
torch.
Torch Head Assembly
Shield Cup, No. 9-6003
Gas Distributor,
No. 9-6507
Tip, No. 9-6501
Electrode, No. 9-6542
A
rt # A-04655
B. Torch Connection
Check that the torch is properly connected.
C. Connect Work Cable
Make a clean work cable
connection to the work-
piece or cutting table
W
ork Cable
A
nd Clamp
Art # A-04389
D. Torch Operation
• Wear gloves and protective goggles.
• Do not place bare hand on work piece.
1. For drag cutting, keep the torch in contact with
the workpiece.
2. For standoff cutting, hold the torch 1/8 - 3/8
in (3-9 mm) from the workpiece as shown be-
low.
A-00024
S
hield Cup
Torch
Standoff
Distance 1/8" - 3/
8"
3. With the torch in starting position, press and
hold the Torch Trigger. After an initial two sec-
ond pre-flow, the pilot arc will come on and
remain on until the cutting arc starts.
4. Once on, the cutting arc remains on as long as
the Torch Trigger is held down, unless the torch
is withdrawn from the work or torch motion is
too slow.
5. To shut off the torch simply release the Torch
Trigger. When the trigger is releasedagaspost-
flow will occur. If the Torch Trigger is pushed
during the post-flow, the cutting arc will restart
immediately when the torch is brought within
range of the workpiece.

Operation 4-3 Manual 0-4688
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 torch held at the indicated standoff height.
Unit Standoff Material
Thickness ipm mm/m ipm mm/m
35C Drag (10 ga) 0.135" - (3mm) 94.7 2367 75.7 1893
35C Drag (7 ga) 0.179" - (4.5mm) 57.0 1425 45.6 1140
35C 1/8" - (3mm) 1/4" - (6mm) 36.3 908 29.1 727
35C 1/8" - (3mm) 3/8" - (9.5mm) 15.3 383 12.3 307
35C 1/8" - (3mm) 1/2" - (12mm) 9.7 242 7.7 193
Recommended Travel SpeedMaximum Travel Speed
NOTE:
Drag or Drag mode refers to the torch tip being in contact with the work piece at all times.

Operation 4-4 Manual 0-4688
This Page Left Blank

Manual0-4688 5-1 SERVICE
SECTION 5:0
SERVICE
5.01 Basic Troubleshooting Guide
WARNING
There are extremely dangerous voltage and power
levels present inside this unit. Do not attempt to
diagnose or repair unless you have had training in
power electronics measurement and troubleshoot-
ing techniques.
A. Basic Troubleshooting, Overview
This guide covers basic troubleshooting.It is helpful for
solvingmanyofthecommonproblemsthatcanarisewith
this system. If major complex subassemblies are faulty,
the unit must be returned to an authorized service center
forrepair.
Follow all instructions as listed and complete each sec-
tion in the order presented.
B. Common Symptoms
A. Primary power switch isON,but power indicator
doesn’tlight.
1. Improperelectricalconnection.
a. Check the input cable line & connection.
b. Checkthatinputpoweristurnedon.
c. Checktheinputpowerfuse.
2. System was overloaded.
a. Turn Primary Power Switch Off and then On
again.
3. Switch may be faulty.
a. Return to an authorized service center for re-
pair.
B. Primarypowerswitchison, but the coolingfan
doesnotwork.
1. No power / incorrect power to fan or failed fan.
a. Return to an authorized service center for re-
pair.
C. Noairflow at torchwhen air checkswitch is turned
on.
1. Internal connection is disconnected or loose.
a. Checkallairlineconnectionsandfittings.
2. Internal air supply / compressor not working.
a. Return to an authorized service center for re-
pair.
3. Control PCB faulty.
a. Return to an authorized service center for re-
pair.
D. Torchwillnotpilotwhentorchswitchisactivated.
1. Gas pressure too high or too low.
a. There is no adjustment. Return to authorized
servicecenter for repair.
2. Torch tip, gas distributor, or electrode missing.
a. Turn off power supply. Remove shield cup. In-
stall missing parts.
3. Worn or faulty torch parts
a. Inspect torchconsumableparts. Replace ifneces-
sary.
E. Cutperformanceisdiminished.
1. Worn torch parts.
a. Checkcurrentsetting. ChecktheElectrodeandTip
forexcesswear.
Worn Electrode
New Electrode
A
rt # A-03026
Good Tip Worn Tip
A-00323

SERVICE 5-2 Manual0-4688
2. Poor Work Lead connection.
a. Check the connection of the Work Lead to the
workpiece.
Make a clean work cable
connection to the work-
piece or cutting table
W
ork Cable
A
nd Clamp
Art # A-04389
3. Current sensor or PWM PCB faulty.
a. Return to an authorized service center for re-
pair.
F. Air flows continuouslyandtorchswitchlatch
buttondoesn'tworkproperly.
1. Torch Switch Latch button on front panel faulty.
a. Return to an authorized service center for re-
pair.
2. Control PCB faulty.
a. Return to an authorized service center for re-
pair.