C-20A
®
CUTSKILL
PLASMA CUTTING
SYSTEM
Service Manual
Rev. AA.01 Issue Date: March 26, 2007 Manual 0-4697
Operating Features:
PLASMA
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
©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
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
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 operating area.
1.02 Important Safety Precautions
WARNINGS
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
follow all warnings, safety precautions and instructions before using the equipment. Call 1-603-2985711 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 chlorinated 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.
Manual 0-4697 1-1 GENERAL 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.
• 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 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 material 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 underwater or while using a water table. DO NOT cut alu-
minum 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.
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 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 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
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 workplace.
• 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 Subsection 1.03, Publications, in this manual.
GENERAL INFORMATION 1-2 Manual 0-4697
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 Superintendent 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, obtainable 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 Standards 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
CONTAINERS 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,
obtainable from the National Fire Protection Association, Batterymarch 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
obtainable from the National Welding Supply Association, 1900 Arch Street, Philadelphia, PA 19103
14. American Welding Society Standard AWSF4.1, RECOMMENDED 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
PROTECTION, obtainable from American National
Standards Institute, 1430 Broadway, New York, NY
10018
Manual 0-4697 1-3 GENERAL INFORMATION
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
GENERAL INFORMATION 1-4 Manual 0-4697
SECTION 2:
Frequency
50/60H z
No Load Voltage
330V
Output Current 120V
15-20 Amps
Output Current 230V
15-25 Amps
6.6 scfm
at A m bi ent A i r Temperatu res
at A m bi ent A i r Temperatu res
at A m bi ent A i r Temperatu res
s
@ 20 Amps
8.3" x 20" x 14. 8"
CUT
4
INTRODUCTION
OFF
25A
2.01 Overview
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.
2.02 General Specifications
System Description C-20A
Max im um Output 25 Amps @ 230V
Input Voltage & Phase
Input power 2.4 (kVA)
Current Input fuse 20 Amps
Load Voltage 88V
Post Flow Time 10 Seconds
Operating Air P res s ure
Maximum Air Pressure
Air flow
System Duty Cycle Ratings*
of 40° C / 104° F.
System Duty Cycle Ratings*
of 40° C / 104° F.
System Duty Cycle Ratings*
of 40° C / 104° F.
Cutting Capacity 115V
Cutting Capacity 230V
@ 25 Amps
115 - 230,
Single Phase
65 psi (4.5 bar)
(.45 Mpa)
125 ps i (8. 6 bar)
(.86 Mpa)
400 scfh
(188.7 lpm)
30% @ 20A m ps
60% @ 15A m ps
100% @ 10A mp
1/4" (6m m )
3/8" (10mm )
15A
10A
30% (3 min)
CUT
60% (6 min)
OFF
CUT
100% (10 min)
NOTE:
*Duty Cycle is the percentage of time the system can be operated without overheating. Duty
cycle is reduced if primary input voltage (AC) is
low or the DC voltage is higher than shown in
previous chart.
Certain cutting conditions using 120V input
power may cause nuisance tripping of 20 Amp
Input fuse.
2.03 Features
• PORT ABLE AND POWERFUL - Weighing just 44
lbs., (20 kg) it is easily moved from location to
location. This inverter based power supply automatically links the unit to primary voltage from
115 to 230V single phase 50/60 Hz.
• POWERFUL CUTTING PERFORMANCE - 115V
cutting capacity is 1/4” (6mm) and for 230V it’s
3/8” (10 mm).
• CUTS MOST METALS - Useful for most metals
such as stainless steel, aluminum, mild steel, copper and alloys.
• NO HIGH FREQUENCY - Starts without highfrequency so it won’t interfere with controls or
computers.
• MORE TORCH, LESS MONEY - The SL60™
1T orch™ pr ovides state of the art technology and
performance of more expensive torches.
Art # A-0450
Dimensions (W x D x H)
Net We ight 44 lbs . (20 k g )
Manual 0-4697 2-1 Introduction
(210 mm x 510
mm x 350 mm )
2.04 Torch Ratings
Temperature
40° C
@ 400 sc f h
Straight Polarity
peak
st ream through torch
in Torch Head
Com p ressed A ir O n ly
6
1
(.86 Mpa)
Supply Used
SL6 0™ 1T orc h™ Rat ings f or C-20A
Items
Description
Q'ty
leads
1
Accessories &
1
1
1
2
2.05 System Contents
Torc h Conf igurat ion
Torch Leads Length 20 feet / 6.1 m
Ambient
Torch Duty Cyc le
Maximum Current
Voltage (V
Arc S t riking Volt age 7kV
Type of Cooling
Parts-in-Place:
Gas Requ irem ent :
Input
Gas Pressure
Minimum Gas Flow
Plasma Power
)500V
Torch Head at 75° to
Torch Handle
104° F
100% @ 60 A mps
60 Amps, DC,
Am bient air and gas
Built-in Switch
Single Gas,
5 psi (4.5 bar)
(.4 5 Mpa )-
25 psi (8.6 bar)
400 sc fh - 6.6 s c fm
(188.7 lpm)
C-20A
Power Sourc e Mode l C-20A 1
Torch Set
SL 60™, wit h 20' (6.1m)
Air Regulator
Work Cable
Consumables
Input Power
Cable
Manual
Torch Electrodes
Torch Tips
12/3 AWG SOW with
molded 5-20 plug
3
1
If you have questions or concerns regarding your system, please contact:
Thermal Dynamics Technical Service Dept.
Tel: 1-800-752-7622 (1-800-PLASMA2)
Fax: 1-800-221-4401
e-mail address: tdc-tech@thermadyne.com
2.06 Transpor ting 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.
F ALLING EQUIPMENT can cause serious personal injury and equipment damage.
Introduction 2-2 Manual 0-4697
SECTION 3:
Connect
INSTALLATION
3.01 Site Selection
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.
• Place in a clean and dry area.
• Provide adequate ventilation and fresh air supply.
• 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,
firm surface so that it stands firmly.
3.02 Electrical Input Connections
CAUTION
Check your power source for correct voltage before plugging in or connecting the unit. The
primary power source, fuse, and any extension
cords used must conform to local electrical code
and the recommended circuit protection and wiring requirements as specified in Section 2.0.
• This power supply includes an input power cord
and plug suitable for 115 VAC, 20 Amp, Single Phase input power .
3.03 Compressed Air Connection
• An air compressor is requir ed and should be connected to rear panel of power source by air hose.
To replace fittings, use 1/4” NPT.
• Air pressure should be 65 psi (4.5 bar) (.45 MPa)
and air should be dry and clean.
• Air flow should be 400 scfh - 6.6 scfm (188.7 lpm)
minimum.
Air Here
Input
Power
A-04488
For 208 / 230 VAC input power, replace the supplied
power plug. Use only an approved replacement input
power plug with ground.
Replace the plug as follows:
1. Cut the original cord close to the plug.
2. Strip back the outer cord cover as needed to connect the inner conductors to the replacement plug.
3. Connect conductors to the plug contacts according
to the plug manufacturer's instructions. All three
conductors must be connected to the plug.
115 V, 20A, 1Ø
Art # A-04485
DANGER
Do not cut in humid or wet surroundings.
• Before you maintain or replace torch parts, wait
for the post flow air cycle (approximately 10 seconds), to stop, then turn the machine off.
• Always use original manufacturers parts. The use
of aftermarket parts could result in shorter parts
life and in unsatisfactory cutting results. Any warranty claims would be waived.
NOTE
Repairs must be done by skilled and qualified
personnel only.
Manual 0-4697 3-1 Installation
This Page Left Blank
Installation 3-2 Manual 0-4697
SECTION 4:
O
2
Inner numbers
t
OPERATION
B. Buttons
• Torch Switch Latch Button
4.01 Front Control Panel
Overheating
Indicator
"On / Off"
Switch
AC Power
Indicator
Air Vents
Work Lead
Connection
A. Indicator Lamp
• Power Indicator
Lights when primary power switch is turned
on.
• TEMPERA TURE Indicator
Air Error Indicator
I
20A
O
Art # A-04427
18
7
1
1
6
9
1
14
2
5
1
0
1
6
2
2
4
1
1
1
2
2
18
13
0
23
1
2
1
24
2
1
0
8
1
2
0
5
115VAC
1
230VAC
A
Torch Switch
Latch Indicator
Torch Switch
Latch Button
Air Set
Button
Current
Control Knob
Torch
Connection
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.
• Air Set Button
To adjust air pressure and to cool down heated
torch.
Art # A-04503
Air will flow from gap
next to shield cup.
C. Main Current Control Knob
T o adjust cutting current. T urning clockwise increases the cutting current and counter clockwise decreases the cutting current.
Indicator is normally OFF. Indicator is ON
when internal temperature exceeds normal
limits.
• 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. Indicator is normally off.
NOTE
It is possible to have enough air pressure to operate the power supply but not enough air flow
to operate the torch.
D. Primary Power Switch, ON / OFF
uter numbers
30V Input
13
Art # A-04428
14
12
15
12
10
11
10
16
8
18
17
14
115VAC
230VAC
19
115V Inpu
20
16
21
22
18
23
24
20
25
A
The power switch is located on the front panel.
Placing the primary power switch to the “ON”
position energizes the power source and activates the Power Indicator .
• Torch Switch Latch Indicator
This indicator lights when the Torch Switch
Latch Button has been pressed for continuous
cutting.
When the power source is overloaded, the switch
turns to the OFF position automatically. DO
W ARNING
NOT TURN ON BY FORCE.
Manual 0-4697 4-1 Oper ation
4.02 Preparations For Operating
Make a clean work cable
W
A
Art # A-04389
3
D. Torch Operation
At the start of each operating session:
W ARNING
Disconnect primary power at the source before
assembling or disassembling power supply, torch
parts, or torch and leads assemblies.
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 (25 amps maximum).
Use only genuine manufactured parts with this
torch.
• Refer to Section 1 for necessary safety precautions.
Trigger
1
2
Trigger Release
3
4
Art # A-0338
Electrode
9-8215
Start Cartridge
9-8213
Tip
9-8206
Art # A-04429
Shield Cup
9-8218
B. Torch Connection
Check that the torch is properly connected.
C. Connect Work Cable
connection to the workpiece or cutting table
ork Cable
nd Clamp
Operation 4-2 Manual 0-4697
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.
Unit Standoff
C-20A Drag Only (10GA) 0.135" (3mm ) 42.7 1067 34.1 853
C-20A Drag Only (7GA) 0. 179" (4. 5mm ) 26.2 655 21.0 524
C-20A Drag Only 1/4" (6m m ) 16.0 401 12.8 321
Material
Thickness
Max im um Travel S peed
Inch e s p er
minute
Milimeters
per minute
Rec om mended Travel S p eed
Inch e s p er
minute
Mi l imet ers per
NOTE:
Drag or Drag mode refers to the torch tip being in contact with the work piece at all times.
minute
Manual 0-4697 4-3 Oper ation
This Page Left Blank
Operation 4-4 Manual 0-4697
SECTION 5: MAINTENANCE
5.01 General Maintenance
Warning!
Disconnect input power before maintaining.
Visual check of
regulator and pressure
Visually inspect the torch body
tip, electrode and shield cup
Maintain more often
if used under severe
conditions
Each Use
Visual check of
torch tip and electrode
Weekly
Visually inspect the
cables and leads.
Replace as needed
Replace all
broken parts
3 Months
Gas and
air lines
6 Months
Visually check and
Carefully clean the
interior
Clean
exterior
of power supply
Art # A-04929
Manual 0-4697 5-1 Maintenance
5.02 Maintenance - Torch O-Rings
g
U
i
C
U
w
M
O-rings on the Torch require lubrication on a regular basis, depending on how frequently the torch shield cup
is disconnected and re-connected. This will allow the O-rings to remain pliable and provide a proper seal. The
O-rings will dry out, becoming hard and cracked, if the O-ring lubricant is not used on a regular basis. This can
lead to potential performance problems.
Remove and apply a very light film of O-ring lubricant (Catalog # 8-4025) to the O-rings on a weekly basis.
NOTE
DO NOT use other lubricants or grease on the torch O-rings. They may not be designed to operate
within high temperatures or may contain “unknown elements” that may react with the atmosphere.
This reaction can leave contaminants inside the torch. Either of these conditions can lead to inconsistent performance or poor parts life.
Art # A-04394
pper Groove
ith V ent Holes
ust Remain Open
pper O-Ring
n Correct Groove
at. #8-3487
Threads
Lower O-Rin
Cat. #8-3486
Maintenance 5-2 Manual 0-4697
SECTION 6:
TROUBLESHOOTING
W ARNING
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 troubleshooting techniques.
NOTE:
All procedures are done with the cover removed.
6.01 Setup and Operation
1. Connect the unit to air supply and power .
2. Connect the work lead clamp to cleaned area of work surface.
3. Turn the switch located on the front panel, to the "On" position. The A/C indicator on the front panel
should light.
4. Set the air pressure. Press the Air Set Button and set the regulator pressure to 65 psi (4.5 bar) (.45 MPa).
Air should be flowing continuously . Pr ess the Air Set Button again to stop the air flow .
NOTE:
If the Air Error Indicator light is on, and or there is an audible beeping tone, check for low or no air pressure.
5. Squeeze the torch trigger (slight delay), pilot arc starts.
6. T ransfer arc to work surface before the ar c goes out.
Manual 0-4697 6- 1 TROUBLE SHOOTING
6.02 Basic Trouble Shooting Guide
Problem - Symptom Possible Cause Recommended Action
Power Switch is on
but the A/C Indicator
does not light
1. Improper electrical connection.
2. System was overloaded.
3. Switch may be fau lty
1. Check input power source and fuse. Check input cable and
connections.
2. Turn Primary Power Switch Off and then On again.
3. Return to autho rized service center for repair or replacemen t
Primary power
switch is on, but the
cooling fan does not
work.
No air flow at torch
when air check
switch is turned on.
Torch will not pilot
when torch switch is
activated.
Pilot / transfer arc
goes out and
doesn’t reactivate
Cut performance is
diminished.
Air flows
continuously and
torch switch latch
button doesn't work
properly.
1. No power or incorrect power to
fan.
2. Faulty fan.
1. Input air connection is
disconnected.
2. Air source is not on.
3. Internal connection is loose
4. Filter or Con trol PCB is faulty
1. Gas pressure too high or too
low.
2. Torch tip, start cartridge, or
electrode missing.
3. Start Cartridge is stuck
4. Wo rn or faulty torch parts
5. Thermal Switch activated
1. Torch removed from work piece
or moved away from metal being
cut
1. Wo rn torch parts.
2. Poor Work Lead connection.
3. Current sensor or PWM PCB
faulty.
1. Torch Switch Latch button on
front panel faulty.
2. Control PCB faulty.
1. Check electrical connections to fan.
2. Return to autho rized service center for repair or replacemen t
1. Connect the input air.
2. Check the compressor and manufacturers manual for trouble
shootin g and follow local maintenance procedures.
3. Check all air lin e connections and fittings.
4. Return to an authorized service center for repair.
1. Adjust gas pressure per pressure setting label on power
supply.
2. Turn off power supply. Remove shield cup. Install missing
parts.
3. Turn off power supply. Remove shield cup, tip, and start
cartridge. Check lower end fitting on start cartridge for free
movement. Replace cartridge if lower end fitting does not
move freely.
4. Inspect torch consumable parts. Replace if necessary.
5. Allow the cooling fan to run for 2 minutes or longer until it
will resume operation.
1. Release torch trigger and re-establish the pilot arc. See
block diagram Appendix 1
1a. Check current setting. Check the Electrode and Tip for
excess wear.
1b. Check that the lower end fitting on the start cartridge
moves freely. Replace any or all parts as needed.
2. Check the connection o f the Work Lead to the work piece.
3. Return to an authorized service center for repair or
replacement.
1. Return to an authorized service center for repair or
replacement.
2. Return to an authorized service center for repair or
replacement.
TROUBLE SHOOTING 6- 2 Manual 0-4697
6.03 Control PCB Indicators
1. Turn the switch located on the front panel, to the "On" position. The A/C indicator on the front panel
should light.
2. Locate the Control PCB behind the front panel. LD2 (EN) LED should be "ON".
Control PCB
3. Press the Air Set Button . The LD1 (SOL) LED should light. Press the Air Set Button again and it should
go out.
4. Squeeze the torch trigger (slight delay), pilot arc starts. LD2 (EN) should brighten and LD1 (SOL) LED should
be on.
5. T ransfer the arc to the work surface and (LD3) should come on so that all three LEDs ar e on.
NOTE:
If no transfer of arc occurs, check the work lead connection.
Manual 0-4697 6- 3 TROUBLE SHOOTING
6.04 Open Circuit Voltage Check
1. Attach shop air to unit.
2. Remove torch consumables from torch head and replace the shield cup.
3. T urn unit power on.
4. Measure terminal TB2, Pins 1 and 3. It should be 115VAC or 220VAC depending on input.
5. Measure output voltage on bridge diode (red and black). It should be 337VDC with 1 10V AC input and 298VAC
with 220VAC input.
6. Depress the torch trigger .
7. Check for illumination of the "SOL" LED and that the "EN" (Enable) LED brightens on the Logic PCB.
8. Measure output to Main T ransformer Input. It should be 239V AC with 1 10VAC input and 210V AC with 220V AC
input.
9. Measure Main Transformer secondary voltage. It should be 207VAC with 110VAC input and 182VAC with
220V AC input.
10. Measure output O.C.V . to work. It should be 335VDC with 1 10V AC input and 291VAC with 220V AC input.
11. Turn off the unit power and replace the tor ch consumables removed in step 2 above.
6.05 Detailed Fault Finding / Error Indicators
Proble m Check / Test Recommended Action
Air Indicator is on
and or audible
intermitant tone
Torch doesn't Pilot
and the LD1 LED light
on the Control PCB
on
Torch doesn't Pilot
and the LD1 LED on
the Control PCB is
on
"CO" LED on Control
PCB comes on when
not transferring.
If the air supply and regulator setting
are OK, check the Pressure Switch
1 - Check torch consumables.
2 - Check all air supply related issues
before proceding.
is
3 - Check LD2 (EN) LED it should get
brighter with the torch trigger
depressed .
4 - Check OCV Voltage. If OCV Voltage
is OK check C/T 1 connection
Check all air supply related issues
before proceding.
not
Check Cable Connection (CN10) and
Current Sensor.
1 - Replace Pressure Switch if
needed.
2 - If the Pressure Switch is OK
then replace the Control PCB
1 - Replace torch consumables
as needed.
2 - Ch ange air related items as
needed.
3 - If OCV is not OK, follow OCV
check procedures in section
6.04
4 - If C/T 1 connection is OK,
replace the Control PCB
If there are no air related
issues, replace the Control PCB
If connection and Current
Sensor are OK, replace the
Control PCB
TROUBLE SHOOTING 6- 4 Manual 0-4697
A. Diode Testing Basics
7
C
W ARNING
Disconnect primary power at the source before disassembling the power supply, torch, or torch leads.
T esting of diode modules r equires a digital volt/ohmmeter that has a diode test scale. Remember that even if the
diode module checks good, it may still be bad. If in doubt, replace the diode module.
1. Remove AC power. Refer to Appendix 3 Wiring diagram.
2. Locate the IGBT diode module to be tested.
3. Remove P5 from IGBT module.
4. Set digital volt/ohmmeter to diode test scale.
5. Connect the volt/ohmmeter positive lead to the anode (+) of the diode and the negative lead to the cathode (-) of the
diode for forward bias testing (refer to following figure). A properly functioning diode will conduct in the forward
bias direction and indicate between 0.3 to 0.9 volts.
Art # A-0030
0.75
Forward Bias
Diode Conducting
Diode T est Symbol
Anode
athode
VR
+
COM
_
A
Testing Diode Forward Bias
Manual 0-4697 6- 5 TROUBLE SHOOTING
6. Reverse the meter leads across the diode for reverse bias testing (refer to following figure). A properly functioning
C
diode will block in the reverse bias direction and depending on the meter function will indicate an open or “OL”.
Art # A-00306
OL
Reverse Bias
Diode Not Conducting
athode
Anode
+
VR
COM
_
A
Testing Diode Reverse Bias
7 Using the Figures for each test, check each diode in the module. Each diode must be checked in forward bias (plus
to negative) and reverse bias (negative to plus) direction.
TROUBLE SHOOTING 6- 6 Manual 0-4697
B. Component Tests
W ARNING
Disconnect primary power at the source before taking any resistance checks.
1. Input Diode Module Board Circuit T est
a. Check Input Diode for short per schematic located in Appendix 4.
2. IGBT Module Test
a. With an ohmmeter set on the diode range remove P5 fr om the IGBT and make the following IGBT checks:
Gate PCB J5 IGBT Check
+-
E1 Red DD (1.020)
Red E1 Open After Charging
1 Black Open After Charging
Black E1 DD (1.270)
E1 G1 DD (.770)
G1 E1 DD (.770)
E2 G2 DD (.770)
G2 E2 DD (.770)
E3 Red DD (1.270)
Red E3 Open After Charging
E3 Black DD (.770)
Black E3 DD (.770)
G3 E3 DD (.770)
E3 G3 DD (.770)
G4 E4 DD (.770)
E4 G4 DD (.770)
P5 Gate Connector
1 G1 Black 1 Black
2 E1 White 2 White
3 G2 Green 3 Green
4E2 Red 4 Red
5 G3 Black 1 Black
6 E3 White 2 White
7 G4 Green 3 Green
8E4 Red 4 Red
b. If reading is not as shown, replace both IGBT modules and Gate PCB.
c. Reconnect P5 connector.
Manual 0-4697 6- 7 TROUBLE SHOOTING
Diode Test
Control Connector
TW
CN8
TW
TW
CN6
TW
Pin-out diagram
6.06 Torch Tests
2
1
W ARNING
Disconnect primary power at the source before disassembling the power supply, torch, or torch leads.
1. PIP and Torch Switch Adapter Check
a. Disconnect input power from power supply .
b. Confirm that the torch parts are in place and that they match the parts consumables label on the power supply
cover .
c. Refer to Appendix 2 for torch connection and access. W ith the power supply on it's side and the panel removed,
disconnect the Power Supply Adapter from the power supply.
d. While the torch trigger is depressed, complete an Ohm check on the two pins in the Power Supply Adapter . The
reading should show a short (less than 1 Ohm). Refer to diagram.
Negative / Plasma Lead
PIP
Switch
Torch
Switch
Torch Head
Black
Orange
Green
White
Pilot
Torch Leads
To Power
Supply Adapter
Continuity
Check
Pilot
Art # A-05557
2. Start Cartridge Check
a. Disconnect input power and air from power supply.
b. Disconnect the pilot lead (see previous diagram).
c. Perform an Ohm check of the pilot lead to the negative lead. This should show a short of less than 1 Ohm. If it
does not show a short, check the function of the start cartridge. The inner piece is spring loaded and should
move freely. Also check other consumables for proper wear and fit.
d. Connect the power supply to air and power .
e. Turn the switch located on the fr ont panel, to the "On" position.
f. Press the air/set button on the front of the power supply for air flow .
g. Repeat this same Ohm check of the pilot lead to the negative lead. It should now read open (no resistance).
h. T urn off the air flow and check again. The Ohm meter should show a short, less than 1 Ohm.
Every effort has been made to provide complete and accurate information in this manual. However, the
publisher does not assume and hereby disclaims any liability to any party for any loss or damage caused by
errors or omissions in this Manual, whether such errors result from negligence, accident, or any other cause.
TROUBLE SHOOTING 6- 8 Manual 0-4697
NOTE
SECTION 7:
PARTS LIST
General Information
This parts list covers the CutSkill® Model C-20A Plasma Cutting Power Supply. Do not use these instructions or parts
on any other equipment.
Provide the power supply model number and serial number when ordering parts.
If a product must be returned for service, contact your distributor. Materials returned without proper authorization will
not be accepted.
Contact Information
Thermal Dynamics Technical Service Dept.
Tel: 1-800-752-7622 (1-800-PLASMA2)
Fax: 1-800-221-4401
e-mail address: tdc-tech@thermadyne.com
Replacement parts are shown on the following pages. Catalog numbers are shown below each part.
Manual 0-4697 7-1 Parts List
7.01 Parts List Power Supply
Item Number Quantity Description Catalog Number
1 1 Cable Ground PG29 9-0382
2 1 Case, F ront 9-0323
3 1 Circui t Breaker 9-7176
4 1 PCB-Front 9-7117
5 1 Cover A s sembly 9-0293
6 1 Solenoi d A ssem bl y 9-0294
7 1 Cover, B ack 9-0295
8 1 Cable Ground PG21 9-0296
9 1 Ai r A s sembly 9-0297
10 1 Cooling Fan 9-7163
11 1 Connector 9-0305
12 1 Main Trans and Reactor A ssy 9-0325
13 1 Heat Si nk Assembly 9-0306
14 1 Case, Bott om 9-0298
15 1 Case, Terminal P l at e 9-0327
16 1 PCB-Torch Fil t er 9-7121
17 1 Case, Top 9-0299
18 1 PCB-Control 9-7115
19 1 PCB-Input Fi l t er 9-7126
20 1 Control Transformer 9-7150
21 1 Pil ot Relay Assem bly 9-0304
22 1 Current Sens or 9-7153
23 1 Bracket , Upper 9-0301
24 1 PCB-Input Capac it or A ssem bl y 9-7127
3
2
1
Art # A-07743
Parts List 7-2 Maual 0-4697
5
7
4
6
10
8
9
13
12
14
11
16
15
Art # A-07744
18
17
22
24
19
20
Art # A-07745
21
23
Manual 0-4697 7-3 Parts List
7.02 Replacement Hand Torch Parts
Item # Qty Description 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. 5 & 6) 9-8219
5 1 Large O-Ring 8-3487
6 1 Small O-Ring 8-3486
7 Leads Assemblies with O2B Connectors (includes switch assemblies)
1 SL60 / 30 Amp, 20 - foot Leads Assembly with O2B connectors 7-5240
8 1 Switch Kit 9-7031
Parts List 7-4 Maual 0-4697
7
1
2
4
5
6
3
8
7
A-07060
Manual 0-4697 7-5 Parts List
This Page Left Blank
Parts List 7-6 Maual 0-4697
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
More air flow is required
Red Air Indicator
Release Torch Switch
Air Set Switch "On"
Air Flows at Torch. Set Air Pressure Then Turn Air Set Switch "Off"
Check Torch parts
Air Flow at Torch Stops
alignment. PIP switches
need to be repaired by a
Qualified Technician
for Torch to Pilot than to
run the power supply.
Re-check regulator setting.
Pilot Arc goes out
Pilot Arc Ignition
Torch Tip to Work after Pilot Arc start
Start Cutting Operation
YES
Post Flow of Air, Approximately 10 Seconds Then Stops
Note: The Torch will be very hot! Do not set on or near flammable materials!
Power Supply On/Off Switch "Off"
Cutting Done ?
Torch Switch "Off"
Torch Switch "On"
No Pilot Arc
NO
Art # A-04390
Manual 0-4697 A-1 APPENDIX
Green Power Indicator "Off" and Fan Stops
Primary Input Power Switch "Off" or Unplugged
Appendix 2: Torch Connection
r
Art # A-04445
Disconnect power and air. Lay unit
on its side. Remove access plate.
DETAIL
Negative / Plasma Lead
Power Supply
Adapter
PIP
Switch
Torch
Switch
Torch Head
Negative / Plasma Lead
Black
Orange
Green
White
Pilot
Torch Leads
Pilot
Work Cable
To Power
Supply Adapte
Pilot
APPENDIX A-2 Manual 0-4697
Appendix 3: Microchip Pin-Out
40 Pin Microchip
123456789101112
24222018161412108642
2321191715131197531
CPU
Socket on
Control
PCB
P2
P1
P3 123456789101112
Manual 0-4697 A-3 APPENDIX
Appendix 4: System Schematic
INPUT
AC115/230V
1 PH
L
N
G
INPUT
DIODE
INPUT
DIODE
Input Capcitor
-
+
Red to
IGBT
W
W
337VDC at 115VAC input
298VDC at 220VAC input
B
Input Capcitor
From
Filter Board
-
-
-
+
Black to
IGBT
+
Red to
Input Diode
12VDC
2
CN5
1
Black to
Input
Diode
IGBT IGBT
No.40279011
G1
E2 G4
E1 G2
TW
E4 G3 G2
11
LD1
SOL
G3 E4E3
TW TW TW
W
G4 E3
22
CN6
WBBGG
R
3
4
CN8
(Gas Solenoid)
E1E2 G1
3
R
4
115VAC
220VAC
TB1
CN4 CN3
N/C
Filter Board
No.40279012
CN1
CN2
TB2
W
B
W
NFB
FAN
230
VAC
230VAC
AC
115
VAC
AC
AC0
AC115
AC230
T1
AC12
VAC
AC18
VAC
AC18
VAC
NC
TH
Art # A-05555
67Ω
(+)
Solenoid V/V
Pressure
Sensor
( )
PS
Closes At
30 PSI
NOTE:
Do Not attempt to adjust the POTs!
1
CN1
7
R
BL
O
O
19VDC
2
1
2
1
CN4
12VDC
CN7
Control Board
No.40271002
LD3
CO
CN2
CN1
MAIN
(Transfer)
POWER
Panel Board
No.40270601
TEMP
ERROR
APPENDIX A-4 Manual 0-4697
A
239VAC at 115VAC input
210VAC at 220VAC input
C/T 1
Main Transformer
R2
R3
207VAC at 115VAC input
182VAC at 220VAC input
R4
R5
C3
Current Sensor
C4
VC_1
VD_1
OU_1
GN_1
OU_2
WORK
335VAC at 115VAC input
O.C.V.
291VAC at 220VAC input
Pilot 90
C5
C6
REACTOR
Pilot
Relay
WW
Cutting 110
PILOT
TORCH
S/W
S/W
(Power Supply)
AIR
ERROR
LD2
Enable
HOLD
CN9
+20VDC
to engage
Pilot Relay
HOLD
AIR
CHECK
+12VDC
-12VDC
CN10
CN12
14VDC
CN3
1
VC_1
VD_1
OU_1
VC_2
GN_1
Y
Y
BR
R
O
Y
G
W
W
PCR
2
3
4
5
1
2
W
2
W
1
Jumper
NOTE:
Do Not attempt to
adjust the POTs!
To Current
Sensor
Y
77
Ω
Pilot
Y
10.3 MF
630V
POWWEL ELECTRONIC IND.CO., LTD.
Air Plasma 20A
2005 / 01 / 12
Manual 0-4697 A-5 APPENDIX
Art # A-05555
This Page Left Blank
APPENDIX A-6 Manual 0-4697
GLOBAL CUSTOMER SERVICE CONTACT INFORMATION
Thermadyne USA
2800 Airport Road
Denton, Tx 76207 USA
Telephone: (940) 566-2000
800-426-1888
Fax: 800-535-0557
Email: sales@thermalarc.com
Thermadyne Canada
2070 Wyecroft Road
Oakville, Ontario
Canada, L6L5V6
Telephone: (905)-827-1111
Fax: 905-827-3648
Thermadyne Europe
Europe Building
Chorley North Industrial Park
Chorley, Lancashire
England, PR6 7Bx
Telephone: 44-1257-261755
Fax: 44-1257-224800
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
Cigweld, Australia
71 Gower Street
Preston, Victoria
Australia, 3072
Telephone: 61-3-9474-7400
Fax: 61-3-9474-7510
Thermadyne Italy
OCIM, S.r.L.
Via Benaco, 3
20098 S. Giuliano
Milan, Italy
Tel: (39) 02-98 80320
Fax: (39) 02-98 281773
Thermadyne, China
RM 102A
685 Ding Xi Rd
Chang Ning District
Shanghai, PR, 200052
Telephone: 86-21-69171135
Fax: 86-21-69171139
Thermadyne International
2070 Wyecroft Road
Oakville, Ontario
Canada, L6L5V6
Telephone: (905)-827-9777
Fax: 905-827-9797
Corporate Headquarters
16052 Swingley Ridge Road
Suite 300
St. Louis, MO 63017
Telephone: 636-728-3000
Email: TDCSales@Thermadyne.com
www.thermadyne.com
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