Tweco 35A User Manual

Art # A-09778

AMP

PHASE

35A

™

CUTSKILL

PLASMA CUTTING SYSTEM

Operating Manual

Rev. AA Issue Date: January 7, 2011 Manual # 0-5180 Operating Features:

WE APPRECIATE YOUR BUSINESS!

Congratulations on your new Thermal Dynamics product. We are proud to have you as our customer and will strive to provide you with the best service and reliability in the industry. This product is backed by our extensive war ranty and world-wide service network. To locate your nearest distributor or service provider visit us on the web

(Americas and Europe).

This Operating Manual has been designed to instruct you on the correct use and operation of your Thermal Dynamics product. Your satisfaction with this product and its safe operation is our ultimate concern. There fore please take the time to read the entire manual, especially the Safety Precautions. They will help you to avoid potential hazards that may exist when working with this product.

at www.thermal-dynamics.com

YOU ARE IN GOOD COMPANY!

The Brand of Choice for Contractors and Fabricators Worldwide.

Thermal Dynamics is a Global Brand of manual and automation Plasma Cutting Products for Thermadyne Industries Inc.

We distinguish ourselves from our competition through market-leading, dependable products that have stood the test of time. We pride ourselves on technical innovation, competitive prices, excellent delivery, superior customer service and technical support, together with excellence in sales and marketing expertise.

Above all, we are committed to developing technologically advanced products to achieve a safer working environment within the welding industry.

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™ 35A SL40 1Torch™ Operating Manual Number 0-5180

Published by: Thermal Dynamics Corporation 82 Benning Street West Lebanon, New Hampshire, USA 03784 (603) 298-5711

www.thermal-dynamics.com

WARNINGS

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.

Publication Date: January 7, 2011

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

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

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

SECTION 2 SYSTEM:INTRODUCTION ...................................................................................................... 2-1

2.01 Working Principle .....................................................................................................

2.02 Power Supply Speciﬁcations ....................................................................................

2.03 Input Wiring Speciﬁcations ...................................................................................... 2-2

2.04 Power Supply Features ............................................................................................. 2-3

SECTION 2TORCH:INTRODUCTION .......................................................................................................

2T.01 Scope of Manual

2T.02 Speciﬁcations ........................................................................................................ 2T-1

2T.03 Introduction to Plasma ........................................................................................... 2T-2

SECTION 3:INSTALLATION ....................................................................................................................... 3-1

3.01 Unpacking ................................................................................................................ 3-1

3.02 Lifting Options .......................................................................................................... 3-1

3.03 Primary Input Power Connections ............................................................................ 3-1

3.04 Air Supply Connections ............................................................................................ 3-2

SECTION 4 SYSTEM:OPERATION .............................................................................................................. 4-1

4.01 Control Panel ............................................................................................................

4.02 Preparations For Operating....................................................................................... 4-2

4.03 Sequence of Operation ............................................................................................. 4-5

4.04 Cut Quality ................................................................................................................ 4-7

4.05 General Cutting Information ..................................................................................... 4-8

..................................................................................................... 2T-1

2-1 2-1

2T-1

4-1

SECTION 5 SYSTEM: SERVICE .................................................................................................................

5.01 General Maintenance ................................................................................................ 5-1

5.02 Basic Troubleshooting Guide .................................................................................... 5-2

SECTION 5 TORCH:SERVICE ................................................................................................................... 5T-1

5T.01 General Maintenance .............................................................................................. 5T-1

5T.02 Inspection and Replacement of Consumable Torch Parts ....................................... 5T-1

SECTION 6:PARTS LISTS ..........................................................................................................................

6.01 Introduction .............................................................................................................. 6-1

6.02 Ordering Information ................................................................................................ 6-1

APPENDIX 1:CIRCUIT DIAGRAM .............................................................................................................A-1

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

5-1

6-1

cutskill 35A

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 ef ﬁcient operation of the system.

CAUTION

A procedure which, if not properly followed, may cause damage to the equipment.

A procedure which, if not properly followed, may cause injury to the operator or others in the operating area.

WARNING

or welding any metals which may contain one or more of the following:

Antimony Chromium Mercury

Arsenic Cobalt Nickel Barium Copper Selenium Beryllium Lead Silver Cadmium Manganese Vanadium

• Always read the Material Safety Data Sheets (MSDS) that should be supplied with the material you are using. These MSDSs will give you the information regarding the kind and amount of fumes and gases that may be dangerous to your health.

• For information on how to test for fumes and gases in your workplace, refer to item 1 in Subsection 1.03, Publications in this manual.

• Use special equipment, such as water or down draft cutting tables, to capture fumes and gases.

• Do not use the plasma torch in an area where combustible or explosive gases or materials are located.

• Phosgene, a toxic gas, is generated from the vapors of chlo rinated solvents and cleansers. Remove all sources of these vapors.

• This product, when used for welding or cutting, produces fumes or gases which contain chemicals known to the State of California to cause birth defects and, in some cases, cancer. (California Health & Safety Code Sec. 25249.5 et seq.)

1.02 Important Safety Precautions

WARNING

OPERATION AND MAINTENANCE OF PLASMA ARC EQUIPMENT CAN BE DANGEROUS AND HAZARDOUS TO YOUR HEALTH.

Plasma arc cutting produces intense electric and magnet ic 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.

• 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

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.

Fire and explosion can be caused by hot slag, sparks, or the plasma arc.

ELECTRIC SHOCK

• 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

• Be sure there is no combustible or ﬂammable material in the workplace. Any material that cannot be removed must be protected.

• Ventilate all ﬂammable or explosive vapors from the work place.

• Do not cut or weld on containers that may have held combus tibles.

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

Manual 0-5180 1-1 GENERAL INFORMATION

cutskill 35A

Pb!

Eye protection ﬁlter shade selector for welding or cutting

(goggles or helmet), from AWS A6.2-73.

Welding or Cutting

Operation

Electrode Size

Metal Thickness

Filter

Shade

Welding or Cutting

Operation

Electrode Size

Metal Thickness

Filter

Shade

Torch soldering 2

Gas metal-arc welding (MIG)

Torch brazing 3 or 4 Non-ferrous base metal All 11

Oxygen Cutting Non-ferrous base metal All 12

Light Under 1 in., 25 mm 3 or 4 Gas tungsten arc welding All 12

Medium 1 to 6 in., 25-150 mm 4 or 5 (TIG) All 12

Heavy Over 6 in., 150 mm 5 or 6 Atomic hydrogen welding All 12

Gas welding Carbon arc welding All 12

Light Under 1/8 in., 3 mm 4 or 5 Plasma arc welding

Medium 1/8 to 1/2 in., 3-12 mm 5 or 6 Carbon arc air gouging

Heavy Over 1/2 in., 12 mm 6 or 8 Light 12

Shielded metal-arc

welding

(stick) electrodes

Under 5/32 in., 4 mm 10 Heavy 14

5/32 to 1/4 in.,

4 to 6.4 mm

12 Plasma arc cutting

Over 1/4 in., 6.4 mm 14 Light Under 300 Amp 9

Medium 300 to 400 Amp 12

Heavy Over 400 Amp 14

• 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.

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 infrared light. These arc rays will damage your eyes and burn your skin if you are not properly protected.

• To protect your eyes, always wear a welding helmet or shield. Also always wear safety glasses with side shields, goggles or

other protective eye wear.

• Wear welding gloves and suitable clothing to protect your skin from the arc rays and sparks.

• Keep helmet and safety glasses in good condition. Replace lenses when cracked, chipped or dirty.

• Protect others in the work area from the arc rays. Use 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.

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.)

GENERAL INFORMATON 1-2 Manual 0-5180

Table 1-1

cutskill 35A

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

6. ANSI Standard Z49.2, TING AND WELDING PROCESSES, obtainable from American National Standards Institute, 1430 Broadway, New York, NY 10018

7. AWS Standard A6.0, ERS WHICH HAVE HELD COMBUSTIBLES, obtainable from American Welding Society, 550 N.W. LeJeune Rd, Miami, FL 33126

8. NFPA Standard 51, OXYGEN-FUEL GAS SYSTEMS FOR WELD ING, CUTTING AND ALLIED PROCESSES, obtainable from the National Fire Protection Association, Batterymarch Park, Quincy, MA 02269

FIRE PREVENTION IN THE USE OF CUT-

WELDING AND CUTTING CONTAIN-

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, Bat terymarch 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 As sociation, 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, RECOM MENDED SAFE PRACTICES FOR THE PREPARATION FOR WELDING AND CUTTING OF CONTAINERS AND PIPING THAT HAVE HELD HAZARDOUS SUBSTANCES, obtainable from the American Welding Society, 550 N.W. LeJeune Rd, Miami, FL 33126

15. ANSI Standard Z88.2, PRACTICE FOR RESPIRATORY PRO TECTION, obtainable from American National Standards Institute, 1430 Broadway, New York, NY 10018

16. Safety in Welding and Allied Processes Part 2: Electrical, AS1674.2-2007 from SAI Global Limited, www.saiglobal. com

Manual 0-5180 1-3 GENERAL INFORMATION

cutskill 35A

1.04 Declaration of Conformity

Manufacturer: Thermadyne Company Address: 82 Benning Street West Lebanon, New Hampshire 03784 USA

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

The equipment described in this manual conforms to all applicable aspects and regulations of the "EMC Directive" (European Council Directive 89/336/EEC) and to the National legislation for the enforcement of this Directive.

Serial numbers are unique with each individual piece of equipment and details description, parts used to manufacture a unit and date of manufacture.

National Standard and Technical Speciﬁcations

The product is designed and manufactured to a number of standards and technical requirements. Among them are:

* CSA (Canadian Standards Association) standard C22.2 number 60 for Arc welding equipment.

* UL (Underwriters Laboratory) rating 94VO ﬂammability testing for all printed-circuit boards used.

* CENELEC EN50199 EMC Product Standard for Arc Welding Equipment.

* ISO/IEC 60974-1 (BS 638-PT10) (EN 60 974-1) (EN50192) (EN50078) applicable to plasma cutting equipment and associated accessories.

* AS60974.1 Arc Welding Equipment Welding Power Sources.

For environments with increased hazard of electrical shock, Power Supplies bearing the conjunction with hand torches with exposed cutting tips, if equipped with properly installed standoff guides.

* Extensive product design veriﬁcation is conducted at the manufacturing facility as part of the routine design and manufacturing process. This is to ensure the product is safe, when used according to instructions in this manual and related industry standards, and performs as speciﬁed. Rigorous testing is incorporated into the manufacturing process to ensure the manufactured product meets or exceeds all design speciﬁcations.

Thermadyne has been manufacturing products for more than 30 years, and will continue to achieve excellence in our area of manufacture.

Manufacturers responsible representative in Europe: Steve Ward

Thermadyne Europe Europa Building Chorley N Industrial Park Chorley, Lancashire, England PR6 7BX

Operations Director

mark conform to EN50192 when used in

GENERAL INFORMATON 1-4 Manual 0-5180

cutskill 35A

1.05 Statement of Warranty

LIMITED WARRANTY: Subject to the terms and conditions established below, Thermadyne Company warrants to the original retail purchaser that new

Thermal Dynamics CUTSKILL™ plasma cutting systems sold after the effective date of this warranty are free of defects in material and workmanship. Should any failure to conform to this warranty appear within the applicable period stated below, Thermadyne Company shall, upon notiﬁcation thereof and substantiation that the product has been stored operated and maintained in accordance with Thermadyne’s speciﬁcations, instructions, recommendations and recognized industry practice, correct such defects by suitable repair or replacement.

This warranty is exclusive and in lieu of any warranty of merchantability or ﬁtness for a particular purpose.

Thermadyne will repair or replace, at its discretion, any warranted parts or components that fail due to defects in material or workmanship within the time periods set out below. Thermadyne Company must be notiﬁed within 30 days of any failure, at which time Thermadyne Company will provide instructions on the warranty procedures to be implemented.

Thermadyne Company will honor warranty claims submitted within the warranty periods listed below. All warranty periods begin on the date of sale of the product to the original retail customer or 1 year after sale to an authorized Thermadyne Distributor.

LIMITED WARRANTY PERIOD

Product

Power Supply Components

(Parts and Labor)

Torch and Leads

(Parts and Labor)

CUTSKILL 35A 2 Year 1 Year

This warranty does not apply to:

1. Consumable Parts, such as tips, electrodes, shield cups, o - rings, starter cartridges, gas distributors, fuses, ﬁlters.

2. Equipment that has been modiﬁed by an unauthorized party, improperly installed, improperly operated or misused based upon industry standards.

In the event of a claim under this warranty, the remedies shall be, at the discretion of Thermadyne Company:

1. Repair of the defective product.

2. Replacement of the defective product.

3. Reimbursement of reasonable costs of repair when authorized in advance by Thermadyne.

4. Payment of credit up to the purchase price less reasonable depreciation based on actual use.

These remedies may be authorized by Thermadyne and are FOB West Lebanon, NH or an authorized Thermadyne service station. Product returned for service is at the owner’s expense and no reimbursement of travel or transportation is authorized.

LIMITATION OF LIABILITY: Thermadyne Company shall not under any circumstances be liable for special or consequential damages such as, but not limited to, damage or loss of purchased or replacement goods or claims of customer of distributors (hereinafter “Purchaser”) for service interruption. The remedies of the Purchaser set forth herein are exclusive and the liability of Thermadyne with respect to any contract, or anything done in connection therewith such as the performance or breach thereof, or from the manufacture, sale, delivery, resale, or use of the goods covered by or furnished by Thermadyne whether arising out of contract, negligence, strict tort, or under any warranty, or otherwise, shall not, except as expressly provided herein, exceed the price of the goods upon which liability is based.

This warranty becomes invalid if replacement parts or accessories are used which may impair the safety or performance of any Thermadyne product.

This warranty is invalid if the Thermal Dynamics product is sold by non - authorized persons.

Effective December 10, 2010

Manual 0-5180 1-5 GENERAL INFORMATION

SECTION 2 SYSTEM:

Rectiﬁer

Inverter

Transformer

Rectiﬁer

Reduce pressure, ﬁlter

Gas valve Cutting torch

Workpiece

Compressed air

Art # A-09204_AB

INTRODUCTION

2.01 Working Principle

2.02 Power Supply Speciﬁcations

CutSkill 35A Power Supply Speciﬁcations

Input Power 230 VAC (± 15%), Single-Phase, 50 Hz Output Current 15-35 Amps, continuously variable

CutSkill 35A Power Supply Duty Cycle (Note 1)

Ambient Temperature 104° F (40° C) Duty Cycle Current 35 Amps

SL 40 Torch Gas Requirements (see section 2T.03)

1. Duty Cycle is the percentage of time the system can be operated without overheating. Duty cycle is re duced if primary input voltage (AC) is low or the DC voltage is higher than shown in this chart.

2. Air supply must be free of oil, moisture, and other contaminants. Excessive oil and moisture may cause double-arcing, rapid tip wear, or even complete torch failure. Contaminants may cause poor cutting perfor mance and rapid electrode wear. Optional ﬁlters provide increased ﬁltering capabilities.

30%

Notes

NOTE

cutskill 35A

IEC Rating is determined as speciﬁed by the International Electro-Technical Commission. These speciﬁca

tions include calculating an output voltage based upon power supply rated current. To facilitate comparison between power supplies, all manufacturers use this output voltage to determine duty cycle.

TDC Rating is determined using an output voltage representative of actual output voltage during cutting with a TDC torch. This voltage may be more or less than IEC voltage, depending upon choice of torch, consumables, and actual cutting operation.

Manual 0-5180 2-1 INTRODUCTION

cutskill 35A

26lb / 11.8kg

5 1/4"

133 mm

16 1/2"

419 mm

N T

(

)

2 5

E A

I R

11"

280 mm

Art # A-09174

Figure 2-1 Power Supply Dimensions & Weight

NOTE

Weight includes torch & leads, input power cord, and work cable with clamp.

CAUTION

Provide clearance for proper air ﬂow through the power supply. Operation without proper air ﬂow will inhibit proper cooling and reduce duty cycle.

2.03 Input Wiring Speciﬁcations

CutSkill 35A Input Power Requirements

Input Power Input Current Input Current Input

Voltage Freq. (kVA) Max (Amps) Ieff (Amps) Fuse (Amps)

(Volts) (Hz) 1-Ph 1-Ph 1-Ph 1-Ph

230 50 3.4 27.3 14 16 Line Voltages with Suggested Circuit Protection. Motor start fuses or thermal circuit breakers are recommended for this application. Check

local requirements for your situation in this regard.

NOTE

Refer to Local and National Codes or local authority having jurisdiction for proper wiring requirements. Cable size is de-rated based on the Duty Cycle of the equipment.

The suggested sizes are based on ﬂexible power cable with power plug installations.

Suggested Sizes

(See Note)

Cable conductor temperature used is 167° F (75° C).

INTRODUCTION 2-2 Manual 0-5180

+ 28 hidden pages

Tweco 35A User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

1.01 Notes, Cautions and Warnings

1.02 Important Safety Precautions

1.03 Publications

1.04 Declaration of Conformity

1.05 Statement of Warranty

2.01 Working Principle