Thermal Dynamics CUTSKILL C-35C Service Manual

C-35C

®

CUTSKILL

PLASMA CUTTING
SYSTEM

Service Manual

Art # A-09400

Rev. AB Date: November 17, 2009 Manual 0-4745

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

®

PCH-42
Service Manual Number 0-4745

Covered under U.S. Patents.

Published by:
Thermadyne Corporation
82 Benning Street
West Lebanon, New Hampshire, USA 03784
[phone]

www.thermal-dynamics.com

©Copyright 2006, 2007, 2008, 2009 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: November

17, 2009

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 Declaration of Conformity ............................................................................. 1-4

1.05 Statement of Warranty .................................................................................. 1-5

SECTION 2.0

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

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

2.02 GENERAL SPECIFICATION ......................................................................... 2-1

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

2.04 Torch Specifications ..................................................................................... 2-2

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

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

SECTION 3.0

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

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

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

3.03 Torch ............................................................................................................ 3-1

SECTION 4.0

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

SECTION 6:

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

6.01 Normal 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 ........................................................ 6-5

6.06 Torch Tests ................................................................................................... 6-9

SECTION 7:

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

7.01 Parts List Power Supply ................................................................................ 7-2

7.02 Replacement Hand Torch Parts With Ergonomic Handle ................................ 7-6

TABLE OF CONTENTS (Con't)

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 230V CE ................................................................................. A-4

Appendix 5: System Schematic 230V ....................................................................................... A-6

GLOBAL CUSTOMER SERVICE CONTACT INFORMATION .............................. Inside Rear Cover

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

• 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 danger

•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.)

ous to your health.

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 1-603-298-5711 or your local
distributor if you have any questions.

GASES AND FUMES

Gases and fumes produced during the plasma cutting process can be
dangerous and hazardous to your health.

• Keep all fumes and gases from the breathing area. Keep your
head out of the welding fume plume.

ELECTRIC SHOCK

Electric Shock can injure or kill. The plasma arc process uses and
produces high voltage electrical energy. This electric energy can cause
severe or fatal shock to the operator or others in the workplace.

• Never touch any parts that are electrically “live” or “hot.”

• Wear dry gloves and clothing. Insulate yourself from the work
piece or other parts of the welding circuit.

• Repair or replace all worn or damaged parts.

• Extra care must be taken when the workplace is moist or damp.

• Install and maintain equipment according to NEC code, refer to
item 9 in Subsection 1.03, Publications.

• Disconnect power
pairs.

• 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.

source before performing any service or re-

Manual 0-4745 1-1 GENERAL INFORMATION

•Provide a fire watch when working in an area where fire hazards
may exist.

• Hydrogen gas may be formed and trapped under aluminum
workpieces when they are cut underwater or while using a water
table. DO NOT cut aluminum alloys underwater or on a water
table unless the hydrogen gas can be eliminated or dissipated.
Trapped hydrogen gas that is ignited will cause an explosion.

1.03 Publications

Refer to the following standards or their latest revisions for more infor-
mation:

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 Subsec-
tion 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 ar
booths, screens or shields.

• Use the shade of lens as suggested in the following per ANSI/
ASC Z49.1:

Arc Current Shade No. Shade No.

Less Than 300* 8 9

300 - 400* 9 12

400 - 800* 10 14

* These values apply where the actual arc is clearly seen.
Experience has shown that lighter filters may be used
when the arc is hidden by the workpiece.

LEAD WARNING

This product contains chemicals, including lead, or otherwise pro­duces chemicals known to the State of California to cause cancer, birth
defects and other reproductive harm. Wash hands after handling.
(California Health & Safety Code § 25249.5 et seq.)

ea from the arc rays. Use protective

Minimum Protective Suggested

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 Fir e Pr otection 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

GENERAL INFORMATION 1-2 Manual 0-4745

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

• Montez et maintenez le matériel conformément au Code électrique
national des Etats-Unis. (Voir la page

• Débranchez l’alimentation électrique avant tout travail d’entretien
ou de réparation.

• Lisez et respectez toutes les consignes du Manuel de consignes.

5,

article 9.)

Manual 0-4745 1-3 GENERAL INFORMATION

1.04 Declaration of Conformity

Manufacturer : Ther mal Dynamics Cor poration
Address: 82 Benning Str eet

West Lebanon, New Hampshire 03784
USA

The equipment described in this manual confor ms to all applicable aspects and r egulations of the ‘Low Voltage Directive’
(European Council Dir ective 73/23/EEC as amended by Council Dir ective 93/68/EEC) and to the National legislation for the
enforcement of this Dir ective.

The equipment described in this manual confor ms to all applicable aspects and r egulations 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 descr iption, parts used to manufactur e a unit and
date of manufacture.

National Standard and Technical Specifications

The product is designed and manufactur ed to a number of standards and technical r equirements. Among them ar e:

* CSA (Canadian Standards Association) standar d C22.2 numbe

* UL (Underwriter s Laboratory) rating 94VO flammability testing for all pr inted-circuit boar ds used.

* CENELEC EN50199 EMC Product Standar d 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 envir onments with increased hazard of electr ical shock, Power Supplies bearing the 'S' mark confor m to EN50192 when

used in conjunction with hand torches with exposed cutting tips, if equipped with pr operly installed standoff guides.

* Extensive product design ver ification is conducted at the manufacturing facility as par t of the routine design and manufactur-

ing process. This is to ensur e the product is safe, when used according to instr uctions in this manual and related industry
standards, and perfo
tured pr oduct meets or exceeds all design specifications.

Thermal Dynamics has been manufacturing products for more than 30 year s, and will continue to achieve excellence in our ar ea
of manufacture.

Manufacture r s responsible repr esentative: Steve Ward

rms as specified. Rigorous testing is incorpor ated into the manufacturing pr ocess to ensure the manufac-

Operations Director
Thermadyne Eur ope
Europa Building
Chorley N Industr ial Park
Chorley, Lancashire,
England PR6 7BX

r 60 for Arc welding equipment.

GENERAL INFORMATION 1-4 Manual 0-4745

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 o
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)

r components that fail due to defects in material or workmanship within the time

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 par ty, improperly installed, improper ly 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 ar
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, o
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.

e FOB West Lebanon, NH or an authorized Thermadyne service station. Product returned for

r anything done in connection

Effective August 28, 2005

Manual 0-4745 1-5 GENERAL INFORMATION

GENERAL INFORMATION 1-6 Manual 0-4745

SECTION 2.0

2.03 Features

INTRODUCTION

2.01 INTRODUCTION

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 SPECIFICATION

Model Desc ription 35C

Maximum output 35 Amps

Input Voltage & Phas e

Frequency 50/60Hz

Input power 8.3 kVA

Current Input fuse

No Load Voltage 330V

Load Voltage 94V

Output Current 10 - 35 Amps

Post flow time 15 Seconds

Duty cycle @ 104°F /

40° C Ambient

Genuine Cutting

Capacity

Maximum Cutting

Capacity

Dimension (W * D * H)

Gross Weight 57 lbs. (26 kg )

230V,

Single Phase

U.S. / Canada 40

Amps

All others 16A Slow

Blow Fuse

35% @ 35A @

94vdc

60% @ 27A @

91vdc

100% @ 20A @

88 vdc

3/8"

(10 m m )

5/8"

(15 m m )

10.5"x15.5"x11"

(267 mm x 394 mm

x 279 mm )

• COMPACT and LIGHT - Designed for easy trans­portation.

• ENERGY EFFICIENCY - Advanced technology
reduces power consumption.

• HIGH SPEED GENUINE CUTTING - The con­stricted plasma arc provides high speed cutting
as well as a good quality genuine, narrow cut.

• LOW COST WITH COMPRESSED AIR - The 35C
operates on compressed air.

• ALL KINDS OF METALS - Useful for most met­als such as stainless steel, aluminum, mild steel,
copper and their alloys.

• PILOT ARC IGNITION FROM TORCH - The Pi­lot 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 - Pilot Arc
ignition allows the 35C to cut painted materials.

• EXTENDED PARTS LIFE - Consumable parts life
is longer.

NOTE:

Refer to Local and National Codes or local au­thority having jurisdiction for proper wiring re­quirements.

Manual 0-4745 2-1 Introduction

2.04 Torch Specifications

g

g

y

p

g

y

10.5 in (266.7 mm)

PCH-42 Torch Ratin

Torch Configuration

Torch Leads Len

Duty Cycle

Ambient

Temperature

Maximum Current

Voltage (V

Arc Striking Voltage 12kV

Type of Cooling

Parts -in-Plac e

Gas Requirement

Gas Pressure

Minimum Gas Flow

Direct Contact Hazard

Plasma Power

Supply Used With

eak

Input

Torch Head at 70° to

th 20 feet / 6.1 m

100% @ 40 Amps

)500V

Ambient air and gas

st ream through torc h

Compressed Air Only

For operation with

recommended standoff

1/8 - 3/8" (3-9 mm).

s

Torch Handle

@ 200 scfh

104° F

40° C

40 Amps, DC,

Strai

ht Polarit

Built-in Switch

in Torch Head

Single Gas,

65 psi (4.5 bar)

(.45MPa)-

125 psi (8.6 bar)

(.86MPa)

130 scfh (61 lpm)

exposed tip the

height is

35C

3 in

(76.2 mm)

Art # A-04653

2.05 System Contents

Description ITEMS Q't

Power source Model Drag-Gun Plus 1

PCH-42, with 20'

Torch Set

Accessories &

Consumables

Input Power
Cable U.S. /
CAN.

Input Power
Cable Outside
of U. S. / CA N.

(6.1 m) leads 1

Work Cable

Manual

Torch Electrodes

Torch Tips

3 Meter NEMA 10 AWG /

2

4.8 mm

with 6 - 50 P

molded plug

3 Meter 3x2.5 sq mm
rubber wire

1
1
2
3

1

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 per­sonal injury and equipment damage.

Introduction 2-2 Manual 0-4745

SECTION 3.0

3.03 Torch

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,
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

• 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 (approximately
15 seconds), then turn the machine off.

• Always use original manufacturers parts. The use
of aftermarket parts could result in lower parts
life and in unsatisfactory cutting results. Any war­ranty claims would be waived.

• Recycle worn parts according to local require­ments.

NOTE

Repairs must be done by skilled and qualified
personnel only.

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.

Manual 0-4745 3-1 Installation

This Page Left Blank

Installation 3-2 Manual 0-4745

SECTION 4.0

!

OPERATION

B. BUTTONS

• Torch Switch Latch Button - For

4.01 Front Control Panel

Overheating
Indicator

I

"On / Off"

35C

O

Switch

AC Power
Indicator

Air Vents

Work Lead
Connection

Art # A-04715

A. INDICATOR LAMP

• Power Indicator - Lights when primary

power switch is turned on.

• TEMPERATURE Indicator - Indicator is nor-

mally OFF. Indicator is ON when internal tem­perature exceeds normal limits. Shut unit OFF;
let the unit cool before continuing operation.

Air Error Indicator

Torch Switch

20

2

1

22

1
8

23

2

20

4

2

5

A

Latch Indicator

Torch Switch

18

7
1

1
9

16

14

15

1
6

12

14

13

0
1

12

8

11

115VAC

10

230VAC

Latch Button

Air Set
Button

Current
Control Knob

Torch
Connection

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 check for proper air

setting and to cool down heated torch.

C. MAIN CURRENT CONTROL KNOB

To adjust cutting current. Turning clockwise in­creases the cutting current and counter clock­wise decreases the cutting current.

20

15

10

25

30

35

A

Art # A-04387

D. PRIMARY POWER SWITCH, ON / OFF

• 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 op­erate 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.

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.

Manual 0-4745 4-1 Operation

4.02 Preparations For Operating

D. Torch Operation

At the start of each operating session:

WARNING

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 (35 amps maximum).
Use only genuine manufacturer’s parts with this
torch.

Electrode, No. 9-6542

Gas Distributor,

No. 9-6507

• 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 be­low.

Torch

Shield Cup

Standoff Distance

1/8" - 3/8" (3 - 9mm)

Torch Head Assembly

Tip, No. 9-6501

Art # A-04655

Shield Cup, No. 9-6003

B. Torch Connection

Check that the torch is properly connected.

C. Connect Work Cable

Make a clean work cable
connection to the work­piece or cutting table

Work Cable
And Clamp

Art # A-04389

A-00024_AB

3. With the torch in starting position, press and
hold the Torch Trigger. After an initial two sec­ond 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 released a gas post­flow 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 4-2 Manual 0-4745

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

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

Material

Thi c knes s

Recommended Travel SpeedMaximum Travel Speed

ipm mm/m ipm mm/m

NOTE:

Drag or Drag mode refers to the torch tip being in contact with the work piece at all times.

Manual 0-4745 4-3 Operation

This Page Left Blank

Operation 4-4 Manual 0-4745

SECTION 5: MAINTENANCE

5.01 General Maintenance

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 0-4745 5-1 Maintenance

This Page Left Blank

Maintenance 5-2 Manual 0-4745

SECTION 6:

TROUBLESHOOTING

6.01 Normal Setup and Operation

1. Connect the unit to 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

lights and the cooling fan comes on.

4. Select the correct current setting for the material being cut.

5. Squeeze the torch trigger. The pilot arc and compressor start.

6. Transfer arc to work surface within 3-5 seconds before the pilot arc turns off. If arc was lost before transfer to
work surface, release the torch trigger and squeeze the trigger again to establish the pilot arc.

7. When the torch trigger is released, the compressor will continue to run for post flow, approximately 15 seconds.

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 troubleshooting techniques. Disconnect primary
power at the source before disassembling the power supply, torch, or torch leads.

NOTE:

All procedures are done with the cover removed.

Manual 0-4745 6-1 TROUBLE SHOOTING

6.02 Basic Trouble Shooting Guide

Problem - SymptomPossible Cause Recommended Action

Power Swit ch 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 replacement

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. Internal connection is loose or
disconnected.

2. Internal air supply / compressor
not working.

3. Control PCB faulty

1. Air pressure too high or too
low.

2. Torch consumables missing.

3. Worn or faulty torch parts

4. Thermal Switch activated

1. Torch removed from work piece
or moved away from metal being
cut

1. Worn torch parts.

2. Poor Work Lead connection.

3. Current sensor o

r 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 replacement

1. Check all air line connections and fittings.

2. Return to an authorized service center for repair.

3. Return to an authorized service center for repair.

1. There is no adjustment, return to an authorized service
center for repair..

2. Turn off power supply. Remove shield cup. Install missing
parts.

3. Inspect torch consumable parts. Replace if necessary.

4. 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

1. Check current setting. Check the Electrode and Tip for
excess wear.

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 SHOOTING 6-2 Manual 0-4745

6.03 Control PCB Indicators

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 troubleshooting techniques.

NOTE:

All procedures are done with the cover removed.

1. Turn the switch located on the front panel, to the "On" position. The A/C indicator on the front panel

lights and the cooling fan comes on.

2. Locate the Control PCB behind the front panel. LD2 (EN) LED should be "ON".

3. Press the Air Set Button . The the air compressor should come on causing air to flow through the torch

and LD1 (SOL) LED should light. Press the Air Set Button again and the air compressor stops and the LED goes
out.

4. Squeeze the torch trigger. The pilot arc and compressor start. LD2 (EN) should brighten and LD1 (SOL) LED
and LD4 (H/V) should be on.

5. Transfer the arc to the work surface within 3-5 seconds. LD4 goes off and LD3 comes on so that three LEDs are
on.

If no transfer of arc occurs, check the work lead connection.

Manual 0-4745 6-3 TROUBLE SHOOTING

Illustration 6-1, Control PCB

NOTE:

6.04 Open Circuit Voltage Check

1. Unplug the CN1 connector on the H/V (spark gap) PCB.

2. Turn unit power on.

3. Measure terminal TB2, Pins 1 and 3. It should be 230VAC.

4. Measure output voltage on Input diode (+ and -). It should be 325VDC.

5. Depress and hold the torch trigger for each of the following checks /steps, numbers 6 - 9. Each check has to be
done within the 3-5 second pilot arc time. If not, then the trigger will have to be releaed and then depressed
again.

6. Check for illumination of the "SOL" LED and that the "EN" (Enable) LED brightens on the Logic PCB.

5

1

3

4

6

2

Art # A-06991

Illustration 6-2

7. Measure output to Main Transformer Input between points 5 and 6 in Illustration 6-2 above. It should be
220VAC.

8. Measure Main Transformer secondary voltage between points 3 and 4 in Illustration 6-2 above. It should be
190VAC.

9. Measure output OCV between points 1 and 2 in Illustration 6-2 above. It should be 325VDC.

10. Turn off the unit power and plug the connector back in to CN1, removed in step 1 above.

TROUBLE SHOOTING 6-4 Manual 0-4745

6.05 Detailed Fault Finding / Error Indicators

Problem 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

Torch doesn't Pilot and
the LD1 LED on the
Control PCB is
"CO" LED on Control
PCB comes on when
not transferring.

is

not

1 - Check air and electrical connections
to the internal air compressor
2 - Control PCB faulty
3 - Check the compressor relay

1 - Check torch consumables.
2 - Check all air supply related issues

on

before proceding.
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.

on

Check Cable Connection on PCB
(CN10) and Current Sensor.

1 - If connections are good, return
to an authorized service center for
repair.
2 - Replace the Control PCB
3 - Replace the relay if bad.

1 - Replace tor
needed.
2 - Change air related items as
needed.
3 - If OCV is not OK, follow OCV
check procedures in section 6.04
4 - If CN9 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

ch consumables as

A. Diode Testing Basics

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 troubleshooting techniques. Disconnect primary
power at the source before disassembling the power supply, torch, or torch leads. Discharge power at the H/V spark gap
using a metal tipped screw driver as shown:

Art # A-07116

Manual 0-4745 6-5 TROUBLE SHOOTING

Testing of diode modules requires 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-00307

0.75

Forward Bias

Diode Conducting

Diode Test Symbol

Anode

VR

+

COM

_

A

Cathode

Testing Diode Forward Bias

TROUBLE SHOOTING 6-6 Manual 0-4745

6. Reverse the meter leads across the diode for reverse bias testing (refer to following figure). A properly function­ing 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

Cathode

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.

Manual 0-4745 6-7 TROUBLE SHOOTING

B. Component Tests

WARNING

Disconnect primary power at the source before taking any resistance checks.

1. Input Diode Module Board Circuit Test

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 from the IGBT and make the following IGBT checks:

Gate PCB J5 IGBT Check

+-

E1 White + DD (1.020)

White + E1 Open After Charging

E1 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 White + DD (1.270)

White + 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
3G2 Green 3 Green
4 E2 Red 4 Red
5 G3 Black 1 Black
6 E3 White 2 White
7G4 Green 3 Green
8 E4 Red 4 Red

b. If reading is not as shown, replace both IGBT modules and Gate PCB.

c. Reconnect P5 connector.

TROUBLE SHOOTING 6-8 Manual 0-4745

Diode Test

Control Connector

TW

CN8

TW

TW

CN6

TW

Pin-out diagram

6.06 Torch Tests

2

1

WARNING

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. With 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. Shorted Torch Check

a. Disconnect input power 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 "Open". If it does not show

"Open", check that the correct consumables were installed per the consumables label on the unit cover.

d. Replace Torch as needed.

NOTE

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.

Manual 0-4745 6-9 TROUBLE SHOOTING

This Page Left Blank

TROUBLE SHOOTING 6-10 Manual 0-4745

SECTION 7:

PARTS LIST

General Information

This parts list covers the CutSkill
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 authoriza-
tion will not be accepted.

Contact Information

Thermal Dynamics Technical Service Dept.

Tel: [phone] (1-800-PLASMA2)

Fax: [phone]

e-mail address: [e-mail]

Replacement parts are shown on the following pages. Catalog numbers are shown below each part.

®

Model C-35C Plasma Cutting Power Supply with Internal Air Compressor. Do

Manual 0-4745 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, Front 9-0309
3 1 PCB-Front 9-7117
4 1 Circuit Breaker 9-7143
5 1 Cover Ass embly 35C 9-0310
6 1 Cooling Fan 9-7163
7 1 Power Cord Strain Relief 9-0296
8 1 Case, Back 9-0311

9 1 Case, Top 9-0312
10 1 PCB-Control 9-7181
11 1 H/V PCB 9-7147
12 1 Relay 9-0319
13 1 Resistor 9-0300
14 1 Control Transformer 9-7144
15 1 Bracket, Capacitor 9-0302
16 1 Electrolytic Capacitor As sembly 9-0303
17 1 Bracket, Upper 9-0313
18 1 Compress or Part 9-0320
19 1 Current Sensor 9-7153
20 1 PCB-Input Filter (shown) 9-7128
20 1 PCB-Input Filter (CE) 9-7133
21 1 Heat Sink Assembly 9-0306
22 1 Case, Torch Cover 9-0314
23 1 Connector 9-0305
24 1 Pilot Relay Assembly 9-0304
25 1 Main Trans and Reactor As sy 9-0315
26 1 Compress or Assembly 9-0316
27 1 Rubber Bushing 9-0318
28 1 PCB-Torch Filter 9-7121
29 1 Case, Bottom 9-0317

PARTS LIST 7-2 Manual 0-4745

5

2

1

4

3

6

8

7

Art # A-07768

11

20

10

9

19

12

13

14

15

16

18

Art # A-07769

17

Manual 0-4745 7-3 PARTS LIST

22

21

23

24

25

Art

28

# A-07770

26

27

29

PARTS LIST 7-4 Manual 0-4745

This Page Left Blank

Manual 0-4745 7-5 PARTS LIST

7.02 Replacement Hand Torch Parts With Ergonomic Handle

Item # Qty Description Catalog #

1 1 Assembly, Basic Head

70° Head 9-8442

2 2 PIP (Parts - In - Place) Pins 9-5723

3 1 #6-32 x 3/16" Phillips Pan Head Screw See Note

4 1 #6 Internal Star Washer See Note

1 Ergonomic Handle, Split, with Trigger (includes items #5 - 12) 9-8076

5 1 Trigger, Lexan, Orange 9-8059

6 1 Handle 9-8060

7 1 Spring, 0.390 O.D. x 0.750 9-8061

8 1 Torch Handle Socket Head Cap Screw Kit (5 pcs 6-32 x 1/2" ) 9-8062

9 1 Assembly, Torch Switch 9-8063

10 1 Negative / Plasma Lead Insulation Sleeving 9-8056

11 3 Pin Housing (Used with item #12) 9-8111

12 3 Pin 9-8101

13 3 Socket Housing (Used with item #14) 9-8112

14 3 Socket 9-8102

15 1 Lead Assembly, including items No. 6, 8, and 9

20 ft (7.6 m) Length 4-2989

NOTE: Item can be purchased locally.

PARTS LIST 7-6 Manual 0-4745

10

6

13 & 14

4

3

9

11 & 12

7

1

5

6

8

2

15

Art # A-07061

Manual 0-4745 7-7 PARTS LIST

This Page Left Blank

PARTS LIST 7-8 Manual 0-4745

Appendix 1: Operating Sequence, Block Diagram

Primary Input Power "On" or Plugged in

Power Supply On/Off Switch "On"

Red Air Indicator

Release Torch Switch

Pilot Arc Ignition (3-5 seconds)

Pilot Arc goes out

Green Power Indicator "On" and Fan is Running

Air Set Switch "On"

Compressor Starts and Air Flows at Torch. Turn Air Set Switch "Off"

Check Torch parts

Air Flow at Torch Stops

Torch Switch "On"

Torch Tip to Work within 3-5 seconds of Pilot Arc start

Start Cutting Operation

alignment. PIP switches
need to be repaired by a
Qualified Technician

Release Torch Switch

More air flow is required
for Torch to Pilot than to
run the power supply.
Compressor not functioning
properly need to be repaired
by a Qualified Technician

No Pilot Arc

YES

Post Flow of Air, Approximately 15 Seconds Then Stops

Note: The Torch will be very hot! Do not set on or near flammable materials!

Art # A-04694

Manual 0-4745 A-1 APPENDIX

Cutting Done ?

Torch Switch "Off"

Power Supply On/Off Switch "Off"

Green Power Indicator "Off" and Fan Stops

Primary Input Power Switch "Off" or Unplugged

NO

Appendix 2: Torch Connection

Art # A-04695

Disconnect power and air. Lay unit
on its side. Remove two screws and
access plate.

DETAIL

Power Supply
Adapter Connections

Negative / Plasma Lead

To Power
Supply Adapter

Pilot

APPENDIX A-2 Manual 0-4745

Pilot

Black

Orange

Green
White

Negative / Plasma Lead

Pilot

Torch Leads

PIP
Switch

Torch
Switch

Torch Head

Appendix 3: Microchip Pin-Out

40 Pin Microchip

123456789101112

24222018161412108642
2321191715131197531

CPU

Socket on

Control

PCB

P2

P1

P3 123456789101112

Manual 0-4745 A-3 APPENDIX

Appendix 4: System Schematic 230V CE

L

INPUT
AC230V

N

1 PH

G

NOTE:
Do Not
attempt to
adjust the
PCB POTs!

W

Br

NFB

230 VAC

Bl

Bl

R

Bk

R

R

Bl

TB2

Bk

1

W

N/C

3

W

R

W,2

Located on IGBT
Heatsink

N/C

Or

Or

C3

Capacitor

W

W

Bk

11

230 VAC

TB1

2

Wh

3

Inrush Filter PCB

CN2

13 3 3 31

W

W

230 VAC

580

Ω

FAN

AC230

230 VAC

Lt

W

Bl

Br

N/C

3

1

Comp
Relay

4

N/C

Compressor Relay

R

75

Jumper

826

Bl

230 VAC

No.40276005

CN1 CN4THCN3

1

WW

Bk Bk

R1

Ω

50

T1

AC12

AC18

AC18

672Ω

MF 103K
630V

Pressure
Sensor

DIODE

DC
325

R2

C2

+

N/C
N/C

(-)

+12VDC

2
1

2
1

2
1

Red

C2

Bk

Bk,2

CN5

CN1

+25VDC

CN4

+12VDC

CN7

IGBT

C3

R2

E1 G2

G1

E2 G4

G3 E4E3

TW TW TW TW
B W G R B W G R

E4 G3 G2G4 E3 E1E2 G1

CN6

LD1
SOL

Control Board

No.40271005

LD3
CO

CN2

IGBT

CN8

Compressor

Art # A-06978

APPENDIX A-4 Manual 0-4745

CN1

Bl

C1

Bl

MAIN

POWER

Panel Board

No.40270601

TEMP

AIR

ERROR

ERROR

HOLD

No H.F.
On

220
VAC

Bk

LD2
Enable

Bk

C/T 1

CN9

Main Tra nsformer

W
Twi sted

+12VDC

-12VDC

CN10

190VAC

1
2

3
4
5

VC_1
VD_1
OU_1
OU_2
GN_1

C4

R3

Current Sensor

+

C5

R4

R5

C6

C7

R6

BR

Red

O
Y

(-)

VC_1
VD_1
OU_1
GN_1

REACTOR

1

3

CN1

R7

36VAC
10k Ω

O

F/G

G

Br

OU_2

Conduit Coil

C8

Spark Gap

H/V Board

No.40273003

R

Y

G

Pilot
Relay

WW

80

Ω

WORK

O.C.V. 325
Pilot 130
Cutting 80-100

(See Sec. 6 OCV
in Service Manual)

PILOT

TORCH

WW

PCR

H/V Contactor

+12VDC
to engage
Pilot Relay

LD4
H/V

HOLD

AIR
CHECK

CN11

CN12

+12VDC

CN3

2
1

1
2

2

1

W

W

NOTE:
Do Not attempt to
adjust the PCB
POTs!

Torc h
Filter

No. 40276002

Bk (1 only)

Y

Y

Air Plasma 35C (230V CE)

No. 66001012

oct. 19. 2005

S/W

S/W

Y

**PCB not removable from relay

Y

AA

Art # A-06978

Manual 0-4745 A-5 APPENDIX

Appendix 5: System Schematic 230V

INPUT
AC230V
1 PH

NOTE:
Do Not
attempt to
adjust the
PCB POTs!

230 VAC

NFB

L

N

G

Br

W

Bk

11

230 VAC

TB1

2

Wh

3

CN2

13 3 3 31

W

W

Filter Board

230 VAC

580

Ω

FAN

AC230

230 VAC

Lt

W

Bl

Br

N/C

3

1

Comp
Relay

4

N/C

Compressor Relay

R

75

Jumper

826

Bl

230 VAC

No.40276003

CN1 CN4THCN3

1

WW

Bk Bk

R1

Ω

50

T1

AC12

AC18

AC18

672Ω

MF 103K
630V

Pressure
Sensor

TB2

3

1

Bk

R

Bl

Bl

R

Bk

R

R

Bl

DIODE

W

N/C

W

C3

W,2

+

Capacitor

Located on IGBT
Heatsink

N/C

W

W

N/C
N/C

Or

Or

Compressor

DC
325

R2

C2

(-)

2
1

2
1

2
1

Red

C2

Bk

Bk,2

+12VDC

CN5

CN1

+25VDC

CN4

+12VDC

CN7

IGBT

C3

R2

E1 G2

G1

G3 E4E3

E2 G4

TW TW TW TW
B W G R B W G R

E4 G3 G2G4 E3 E1E2 G1

CN6

LD1
SOL

Control Board

LD3
CO

CN2

CN1

IGBT

CN8

No.40271005

Panel Board

No.40270601

Art # A-07024

APPENDIX A-6 Manual 0-4745

Bl

C1

Bl

MAIN

POWER

TEMP
ERROR

AIR
ERROR

HOLD

No H.F.
On

220
VAC

Bk

LD2
Enable

Bk

C/T 1

CN9

Main Tra nsformer

W
Twi sted

+12VDC

-12VDC

CN10

190VAC

1

2

3
4

5

VC_1
VD_1
OU_1
OU_2
GN_1

C4

R3

Current Sensor

+

C5

R4

R5

C6

C7

R6

BR

Red

O
Y

(-)

REACTOR

1

3

CN1

VC_1
VD_1
OU_1
GN_1

36VAC
10k Ω

O

R7

F/G

G

Br

OU_2

Conduit Coil

C8

Spark Gap

H/V Board

No.40273003

R

Y

G

Pilot
Relay

WW

80

Ω

WORK

O.C.V. 325
Pilot 130
Cutting 80-100

(See Sec. 6 OCV
in Service Manual)

PILOT

TORCH

WW

PCR

H/V Contactor

+12VDC

to engage

Pilot Relay

LD4
H/V

HOLD

AIR
CHECK

CN11

CN12

+12VDC

CN3

2
1

1
2

2

1

W

W

Torc h
Filter

No. 40276002

Bk (1 only)

Y

Y

S/W

S/W

**PCB not removable from relay

Y

Y

NOTE:
Do Not attempt to
adjust the PCB
POTs!

Air Plasma 35C (230V )

No. 66001008

oct. 19. 2005

AB

Art # A-07024

Manual 0-4745 A-7 APPENDIX

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APPENDIX A-8 Manual 0-4745

GLOBAL CUSTOMER SERVICE CONTACT INFORMATION

Thermadyne USA

2800 Airport Road
Denton, Tx 76207 USA
Telephone: [phone]
800-426-1888
Fax: [phone]
Email: [e-mail]

Thermadyne Canada

2070 Wyecroft Road
Oakville, Ontario
Canada, L6L5V6
Telephone: [phone]
Fax: [phone]

Thermadyne Europe

Europe Building
Chorley North Industrial Park
Chorley, Lancashire
England, PR6 7Bx
Telephone: [phone]
Fax: [phone]

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: [phone]
Fax: [phone]

Thermadyne Italy

OCIM, S.r.L.
Via Benaco, 3
20098 S. Giuliano
Milan, Italy
Tel: [phone]
Fax: [phone]

Thermadyne, China

RM 102A
685 Ding Xi Rd
Chang Ning District
Shanghai, PR, 200052
Telephone: [phone]
Fax: [phone]

Thermadyne International

2070 Wyecroft Road
Oakville, Ontario
Canada, L6L5V6
Telephone: [phone]
Fax: [phone]

Corporate Headquarters

16052 Swingley Ridge Road
Suite 300
St. Louis, MO 63017

Telephone: [phone]
Email: [e-mail]

www.thermadyne.com