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:____________________________________
Appendix 3: 230 V olt System Schematic................................................................................... A-4
Appendix 4: 400 Volt CE System Schematic.............................................................................A-6
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:
• 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.
• Never touch any parts that are electrically “live” or
“hot.”
Manual 0-46991-1GENERAL INFORMATION
• 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.
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.
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 ProtectiveSuggested
Arc CurrentShade No.Shade No.
Less Than 300*89
300 - 400*912
400 - 800*1014
* 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 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
GENERAL INFORMATION1-2Manual 0-4699
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 0-46991-3GENERAL INFORMATION
1.04 Declaration of Conformity
Manufacturer: Thermal Dynamics Corporation
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.
* For environments with increased hazard of electrical shock, Power Supplies bearing the S 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.
Thermal Dynamics has been manufacturing products for more than 30 years, and will continue to achieve excellence
in our area of manufacture.
Manufacturers responsible representative: Steve Ward
Operations Director
Thermadyne Europe
Europa Building
Chorley N Industrial Park
Chorley, Lancashire,
England PR6 7BX
GENERAL INFORMATION1-4Manual 0-4699
1.05 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)
C-20A1 Year 1 Year
C-35A1 Year 1 Year
C-70A1 Year 1 Year
C-100A1 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 September, 2005
Manual 0-46991-5GENERAL INFORMATION
This Page Left Blank
GENERAL INFORMATION1-6Manual 0-4699
SECTION 2:
Output Current
25-70 A m ps
Post-Flow time
10 Sec onds
CUT
6
INTRODUCTION
OFF
70A
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
Sy s t em Des c riptionsC-70A
Maximum Output70 Amps
Input V oltage 230V
Input V oltage 400V CEThree Phase
Frequency50/60Hz
Input P ower 230V 1 P hase
Input P ower 230V 3 P hase
Input P ower Fuse, 1 P has e
Input P ower Fuse, 3 P has e
Input P ower 400V24 Amps (9.6 k V A )
Input Power Fuse, 3 Phase400V - 30 Amp
No Load Voltage250V
Load Voltage108V
Operating Air Pres s ure
Maximum Air Pressure
Air flow
Sy s t em *Dut y Cy c le Ratings
at A m bi ent A i r Tem pe ratu res
of 40° C / 104° F.
Sy s t em *Dut y Cy c le Ratings
at A m bi ent A i r Tem pe ratu res
of 40° C / 104° F.
Sy s t em *Dut y Cy c le Ratings
at A m bi ent A i r Tem pe ratu res
of 40° C / 104° F.
Max im um Cutti ng Capacity1" (25mm )
Dimensions (W x D x H)
Net Weight66 lbs. (30 k g)
Single and
Three Phase
67 Amps (15.4 kVA )
37 Amps ( 8.5 kVA )
230V - 80 Am p
230V - 40 Am p
75 psi (5.2 bar)(.52
Mpa)
125 psi (8.6 bar)(.86
Mpa)
400 sc fh
6.6 s cf m
(188.7 lpm)
35% @ 70A mps
60% @ 60A mps
100% @ 50A m ps
9.7" x 21. 7" x 16.5"
(245 mm x 550 mm x
420 mm )
CUT
60A
CUT
50A
35% (3.5 min)
60% (6 min)
OFF
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.
2.03 Features
• RELIABLE AND POWERFUL - This inverter
based power supply operates on standard 230V
single or three phase power.
• POWERFUL CUTTING PERFORMANCE Maximum cutting capacity is 1” (25mm).
• 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 SL100™
1T orch™ pr ovides state of the art technology and
performance of more expensive torches.
Art # A-0450
Introduction2-1Manual 0-4699
2.04 Torch Specifications
Torch Handle
Torch Leads Lengt h
20 feet (6.1 m )
Tem perature
40° C
@ 400 s c fh
peak
Compres s ed A ir Only
MPa)
4
Supply Us ed W ith:
SL100™ 1T orch™ Rat ings for C-70A
ITEMS
Description
Q'ty
1
1
1
2
1-1670-3
2.05 System Contents
Torch Configuration
Ambient
Torc h Duty Cycle
Maximum Current
Voltage (V
Arc S trik ing Volt age 7k V
Ty pe of Cooling
Parts -in-Place:
Gas Requirement:
Input
Gas Pressure
Minim um Gas Flow
Plas m a P ower
)500V
Torch Head at 75° to
104° F
100% @ 100 A m ps
100 Am ps , DC,
St raight Polarity
Am bient air and gas
st ream t hrough torch
Built-in S witc h
in Torch Head
Single G as ,
75 psi (5.2 bar) (.52
MPa)125 psi (8.6 bar) (.86
00 sc f h 6.6 s c fm
(188.7 lpm)
C-70A
Power Sourc e Mo del C-70A1
Torch S etSL100™, 20' (6.1m)1
Air Regulator
Added
Features
Work Cable
Manual
Torch Electrodes
Torch Tips
3
Input Power
Cable F or
Systems
1-1670-1
2 Meter 6 AWG SOW with
6 - 50 P molded pl ug
1
Input Power
Cable F or
Systems
1-1670-4 (CE)
2 Meter Cord With No Plug
1
If you have questions or concerns regarding your system, please contact:
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.
Introduction2-2Manual 0-4699
SECTION 3:
Connect Air
Art # A-04486
3.03 Compressed Air Connection
INSTALLATION
3.01 Site Selection
• 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.
W ARNING
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 or three phase.
• An air compressor is requir ed and should be connected to rear panel of power source by air hose.
• Air pressure should be 75 psi (5.2 bar)(.52 MPa)
and air should be dry and clean.
• Air flow should be 400 scfh / 6.6 scfm (188.7 lpm)
minimum.
Input Power
Here
Cable
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.
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.
• W orn parts should be r ecycled accor ding to local
requirements.
NOTE
Installation3-1Manual 0-4699
Repairs must be done by skilled and qualified
personnel only.
This Page Left Blank
Installation3-2Manual 0-4699
SECTION 4:
Overheating
r
r
T
L
ol
A
Art # A-04431
OPERATION
B. Buttons
• Torch Switch Latch Button
4.01 Front Control Panel
AC Power
Indicator
"On / Off"
Switch
orch Switch
atch Button
Air Set
Button
Work Lead
Connection
A. Indicator Lamp
• Power Indicator
Lights when primary power switch is turned
on.
• TEMPERA TURE Indicator
Indicator is normally OFF. Indicator is ON
when internal temperature exceeds normal
limits.
Indicator
I
O
Art # A-04430
Air Error Indicato
70A
50
40
60
30
70
20
A
Torch Switch
Latch Indicato
Current Contr
Knob
Air V ents
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
T o check for proper air setting 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.
40
50
60
70
• Air Error Indicator
This indicator lights when there is not enough
30
20
air pressure to operate the power supply.
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
The power switch is located on the front panel.
Placing the primary power switch to the “ON”
• Torch Switch Latch Indicator
position energizes the power source and activates the Power Indicator .
This indicator lights when the Torch Switch
Latch Button has been pressed for continuous
cutting.
When the power source is overloaded, the switch
W ARNING
turns to the OFF position automatically. DO
NOT TURN ON BY FORCE.
Operation4-1Manual 0-4699
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 (70 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
9-8231
Art # A-04432
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
Operation4-2Manual 0-4699
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 set at the indicated standoff height.
Warning!
Disconnect input power before maintaining.
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
Clean
exterior
of power supply
6 Months
Visually check and
Carefully clean the
interior
Art # A-06884
Manual 0-46995-1Maintenance
5.02Maintenance - 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
Maintenance5-2Manual 0-4699
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 and the cooling fan should be on.
4.Set the air pressure. Press the Air Set Button and set the regulator pressure to 75 psi (5.2 bar) (.52 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, check for low or no air pressure.
5.Squeeze the torch trigger (slight delay), pilot arc starts.
6.T o begin cutting, transfer arc to work surface before the pilot goes out.
Manual 0-46996- 1TROUBLE SHOOTING
6.02 Basic Trouble Shooting Guide
Problem - Symptom Possible CauseRecommended 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 faulty
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 authorized 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 p ower or incorrect power to
fan.
2. Faulty fan.
1. Input air connection is
disconn ected.
2. Air source is not on.
3. Internal connection is loose
4. Filter or Control 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 authorized service center for repair or replacemen t
1. Connect the input air.
2. Check the compressor and manufacturers manual for trouble
shooting and follow local maintenance p rocedures.
3. Check all air line connectio ns 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 of 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 SHOOTING6- 2Manual 0-4699
Spring-Loaded
A
Make a clean work cable
W
A
Art # A-04389
Cylinder at
Full Compression 1/8”
Spring-Loaded
Cylinder at Rest /
Full Extension
Art # A-07069
Start Cartridge
New Electrode
rt # A-03284
Worn Electrode
Electrode Example
Good Tip
Tip Example
Worn Tip
A-03406
connection to the workpiece or cutting table
Manual 0-46996- 3TROUBLE SHOOTING
ork Cable
nd Clamp
Work Lead Connection
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 and the cooling fan should be running.
2.Locate the Control PCB behind the front panel and the PWM PCB behind that. LD2 LED's on both PCB's should
be "ON".
Control PCBPWM PCB
3.Squeeze the torch trigger (slight delay), pilot arc starts. LD2 LED on both boards should brighten.
4.T ransfer the arc to the work surface and LD1 on both boar ds should come on so that all LEDs are on.
If no transfer of arc occurs, check the work lead connection.
TROUBLE SHOOTING6- 4Manual 0-4699
NOTE:
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. (220V AC 1PH). LD2 on both the Contr ol Board and the PWM Board should be on and the
cooling fan running.
4.Refer to the 230V schematic in Appendix. Measure terminal TB1, Pin 1 (Red) and pin 3 (Black), it should be 220
V AC (incoming voltage).
5.Refer to following photo. Measure Output voltage of the Input Diode T erminals 1(Black) and 2 (White). It should
be 320 V AC.
6.Depress the torch trigger . Air should flow .
7.Check for illumination of the LD2 on both the Control Board and the PWM Board. They should both brighten.
8.Measure IGBT output to Main T ransformer between points 12 and 13. It should be 220 VAC
9.Measure output OCV between points 7 and 9. It should be 290 VAC.
10. Turn off the unit power and replace the tor ch consumables removed in step 2 above.
Art # A-07055
Input Diode
Output Diode
Diode Outputs
1
3
IGBT Outputs
2
(+)
P5
10
4
5
Thermal SW
6
7
P5
8
(-)
11
12
IGBT Output
13
O.C.V. Measured
between
9
these points
Manual 0-46996- 5TROUBLE SHOOTING
6.05 Fault Finding Tests
7
C
A. Diode Testing Basics
W ARNING
Disconnect primary power at the source before disassembling the power supply, torch, or torch leads.
T esting of diode modules requir es 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 W iring 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
VR
Anode
athode
Testing Diode Forward Bias
+
COM
_
A
TROUBLE SHOOTING6- 6Manual 0-4699
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
7Using 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.
Manual 0-46996- 7TROUBLE SHOOTING
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.
b.Use the following photo with call-outs for test points.
Art # A-07055
Input Diode
Output Diode
Diode Outputs
1
3
IGBT Outputs
2
(+)
P5
10
4
5
(-)
11
12
Thermal SW
6
IGBT Output
7
P5
8
13
O.C.V. Measured
between
9
these points
TROUBLE SHOOTING6- 8Manual 0-4699
2. IGBT Module Test
a.With an ohmmeter set on the diode range r emove P5 from the upper and lower IGBT s and make the following
IGBT checks:
Gate PCB J5 IGBT Check
+-
E1White +DD (1.020)
White +E1Open After Charging
E1Black -Open After Charging
Black -E1DD (1.270)
E1G1DD (.770)
G1E1DD (.770)
E2G2DD (.770)
G2E2DD (.770)
E3White +DD (1.270)
White +E3Open After Charging
E3Black -DD (.770)
Black -E3DD (.770)
G3E3DD (.770)
E3G3DD (.770)
G4E4DD (.770)
E4G4DD (.770)
Diode Test
P5 Gate Connector
4 G1 Black1 Black
TW
3 E1 White2 White
2G2 Green3Green
TW
Control Connector
P7
1 E2 Red4 Red
P5 Gate Connector
2 G3 Black1 Black
TW
1 E3 White2 White
4G4 Green3Green
TW
Control Connector
P8
3 E4 Red4 Red
Pin-out diagram
b. If reading is not as shown, replace both IGBT modules and Gate PCB.
c.Reconnect P5 connector.
Manual 0-46996- 9TROUBLE SHOOTING
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 tor ch 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. (See Start Cartridge illustration in 6.02) 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.Press the air/set button on the front of the power supply for air flow .
f.Repeat this same Ohm check of the pilot lead to the negative lead. It should now read open (no resistance).
g. Turn of f 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 SHOOTING6-10Manual 0-4699
NOTE
SECTION 7:
PARTS LIST
General Information
This parts list covers the CutSkill® Model C-70A 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 T echnical Service Dept.
T el: 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 0-46997- 1Parts List
7.01 Parts List Power Supply
Item Number QuantityDescriptionCatalog Number
11Side Cover-Right9-7214
21Cover As sembly9-0329
31Si de Cover-Left9-7213
41Switch-Toggle9-0333
51Knob9-0334
61Cable Ground PG299-0291
71Front Panel Assembly9-0382
81Circuit B reak er9-7177
91Volume9-0335
101Air As sembly9-0330
111Cas e, B ack9-0331
121Cable Ground PG21 (CE V ers i on Only)9-0296
131Fan9-7164
141C onnector9-0305
151Cas e, Torch Cover9-0337
161Cas e, B ot tom9-0336
171Capaci t or A ss embl y9-0350
181Heat S i nk Assem bl y9-0349
191R eactor9-7110
201Main Transformer Assem bl y9-0348
211PCB-Torc h Fi lt er9-7121
221Pilot Rel ay A ss em bly9-0340
231PCB-Control9-7189
241PCB-Input Filt er (CE Versi on)9-0363
241Termi nal B l oc k (Non CE Vers ion)9-0341
251PCB-PWM Drive9-7120
261Control Transformer 400V9-7151
271Solenoid Ass embl y9-0343
281Current Sensor9-7174
291R esistor9-0344
301PCB-input m agnet9-0346
311Bracket9-0345
321Magnet9-0347
331Cas e, Top9-0351
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Telephone: 44-1257-261755
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Australia, 3072
Telephone: 61-3-9474-7400
Fax: 61-3-9474-7510
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Milan, Italy
Tel: (39) 02-98 80320
Fax: (39) 02-98 281773
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RM 102A
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Shanghai, PR, 200052
Telephone: 86-21-69171135
Fax: 86-21-69171139