C-100A
®
CUTSKILL
PLASMA CUTTING
SYSTEM
Operation Manual
Rev. AA.01 Issue Date: March 26, 2007 Manual 0-4686
Operating Features:
PLASMA
100
230
460
400
v
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
®
SL100™ 1Torch™
Operation Manual Number 0-4686
Covered under U.S. Patents.
Published by:
Thermadyne Corporation
82 Benning Street
West Lebanon, New Hampshire, USA 03784
(603) 298-5711
www.thermal-dynamics.com
©Copyright 2005, 2006, 2007 by
Thermal Dynamics Corporation
All rights reserved.
Reproduction of this work, in whole or in part, without written permission of the publisher is prohibited.
The publisher does not assume and hereby disclaims any liability to any party for any loss or damage
caused by any error or omission in this Manual, whether such error results from negligence, accident, or
any other cause.
Printed in the United States of America
Publication Date: March 26, 2007
Record the following information for Warranty purposes:
Where Purchased:____________________________________
Purchase Date:_______________________________________
Power Supply Serial #:________________________________
Torch Serial #:________________________________________
TABLE OF CONTENTS
SECTION 1:
GENERAL INFORMA TION ................................................................................................ 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:
INTRODUCTION .............................................................................................................. 2-1
2.01 Overview ...................................................................................................... 2-1
2.02 General Specifications.................................................................................. 2-1
2.03 Features ....................................................................................................... 2-2
2.04 Torch Specifications ..................................................................................... 2-2
2.05 System Contents.......................................................................................... 2-3
2.06 T ransporting Methods ................................................................................... 2-3
SECTION 3:
INST ALLATION................................................................................................................. 3-1
3.01 Site Selection ............................................................................................... 3-1
3.02 Electrical Input Connections ......................................................................... 3-1
3.03 Compressed Air Connection ......................................................................... 3-3
3.04 T orch ............................................................................................................ 3-3
SECTION 4:
OPERATION...................................................................................................................... 4-1
4.01 Front Control Panel ....................................................................................... 4-1
4.02 Preparations For Operating ........................................................................... 4-2
SECTION 5:
SERVICE .......................................................................................................................... 5-1
5.01 General Maintenance .................................................................................... 5-1
5.02 Basic T roubleshooting Guide......................................................................... 5-1
Appendix 1: Operating Sequence, Block Diagram ..................................................................... 5-1
Appendix 2: Torch Connection ................................................................................................... 5-2
Appendix 3: Replacement Hand Torch Parts List ........................................................................ 5-4
Appendix 4: System Schematic ................................................................................................ 5-6
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:
Antimony Chromium Mercury
Arsenic Cobalt Nickel
Barium Copper Selenium
Beryllium Lead Silver
Cadmium Manganese Vanadium
• Always read the Material Safety Data Sheets
(MSDS) that should be supplied with the material
you are using. These MSDSs will give you the information regarding the kind and amount of fumes
and gases that may be dangerous to your health.
• For information on how to test for fumes and gases
in your workplace, refer to item 1 in Subsection 1.03,
Publications in this manual.
• Use special equipment, such as water or down draft
cutting tables, to capture fumes and gases.
• Do not use the plasma torch in an area where combustible or explosive gases or materials are located.
• Phosgene, a toxic gas, is generated from the vapors
of chlorinated solvents and cleansers. Remove all
sources of these vapors.
• This product, when used for welding or cutting, produces fumes or gases which contain chemicals
known to the State of California to cause birth defects and, in some cases, cancer. (California Health
& Safety Code Sec. 25249.5 et seq.)
ELECTRIC SHOCK
Electric Shock can injure or kill. The plasma arc process
uses and produces high voltage electrical energy. This
electric energy can cause severe or fatal shock to the operator or others in the workplace.
• Never touch any parts that are electrically “live” or
“hot.”
Manual 0-4686 1-1 GENERAL 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 Protective Suggested
Arc Current Shade No. Shade No.
Less Than 300* 8 9
300 - 400* 9 12
400 - 800* 10 14
* These values apply where the actual arc is clearly
seen. Experience has shown that lighter filters may
be used when the arc is hidden by the workpiece.
1.03 Publications
Refer to the following standards or their latest revisions
for more information:
1. OSHA, SAFETY AND HEALTH STANDARDS, 29CFR
1910, obtainable from the Superintendent of Documents,
U.S. Government Printing Office, Washington, D.C.
20402
2. ANSI Standard Z49.1, SAFETY IN WELDING AND
CUTTING, obtainable from the American Welding 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 INFORMATION 1-2 Manual 0-4686
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 0-4686 1-3 GENERAL 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 INFORMATION 1-4 Manual 0-4686
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-20A 1 Year 1 Year
C-35A 1 Year 1 Year
C-70A 1 Year 1 Year
C-100A 1 Year 1 Year
This warranty does not apply to:
1. Consumable Parts, such as tips, electrodes, shield cups, o - rings, starter cartridges, gas distributors, fuses, filters.
2. Equipment that has been modified by an unauthorized party, improperly installed, improperly operated or misused
based upon industry standards.
In the event of a claim under this warranty, the remedies shall be, at the discretion of Thermadyne Corporation:
1. Repair of the defective product.
2. Replacement of the defective product.
3. Reimbursement of reasonable costs of repair when authorized in advance by Thermadyne.
4. Payment of credit up to the purchase price less reasonable depreciation based on actual use.
These remedies may be authorized by Thermadyne and are FOB West Lebanon, NH or an authorized Thermadyne service station. Product
returned for service is at the owner’s expense and no reimbursement of travel or transportation is authorized.
LIMITATION OF LIABILITY: Thermadyne Corporation shall not under any circumstances be liable for special or consequential damages
such as, but not limited to, damage or loss of purchased or replacement goods or claims of customer of distributors (hereinafter
“Purchaser”) for service interruption. The remedies of the Purchaser set forth herein are exclusive and the liability of Thermadyne with
respect to any contract, or anything done in connection therewith such as the performance or breach thereof, or from the manufacture, sale,
delivery, resale, or use of the goods covered by or furnished by Thermadyne whether arising out of contract, negligence, strict tort, or under
any warranty, or otherwise, shall not, except as expressly provided herein, exceed the price of the goods upon which liability is based.
This warranty becomes invalid if replacement parts or accessories are used which may impair the safety or performance of any
Thermadyne product.
This warranty is invalid if the Thermadyne product is sold by non - authorized persons.
Effective January 25, 2005
Manual 0-4686 1-5 GENERAL INFORMATION
This Page Left Blank
GENERAL INFORMATION 1-6 Manual 0-4686
SECTION 2:
Maximum Output
100 Amps
Frequency
50/60Hz
87/45 Amps
31 Amps
48/25 Amps
Input Fus e 230V ± 10% 1P has e
50 Amp Slow Blow
Input Fus e 460V ± 10% 3P has e
30 Amp Slow Blow
30 Amp Slow Blow
Load Voltage
120V
Output Current
30 - 100 A m p
(8.6 bar)
400 s c f h, 6. 6 s c fm
40° C / 104 ° F.
40° C / 104 ° F.
40° C / 104 ° F.
12.5" x 27. 5" x 20. 5"
INTRODUCTION
2.01 Overview
2.02 General Specifications
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.
Model Desc ript i on C-100A
230V, 1 / 3 phase
Input Voltage & P hase
Input P ower 230V 1/3 P has e
Input Power 400V 3 Phase
Input P ower 460V 1/3 P has e
Input Fus e 230V ± 10% 3P has e
Input Fus e 400V ± 10% 32 Amp S l ow Blow
Input Fus e 460V ± 10% 1P has e
No Load Voltage 240V
Post Flow Time 10 Seconds
Operating Air P ress ure
Max im um Input Ai r Pres s ure
400V, 3 phas e
460V, 1 / 3 phase
(20/18 kV A )
(21.5 kV a)
(22/20 kV a)
30 Amp Slow Blow
72 psi (.5MPa)
(5 ba r)
125 ps i (. 86MP a)
Air Flow
Sy s t em Duty Cy c le Rat ing* at
Am bient A ir Tem peratures of
Sy s t em Duty Cy c le Rat ing* at
Am bient A ir Tem peratures of
Sy s t em Duty Cy c le Rat ing* at
Am bient A ir Tem peratures of
Genui ne Cut t in g Capacit y 1 1/4" (30mm )
Maximum Cutting Capacity 1 1/2" (40mm)
Dime ns i on (W x D x H)
Net We igh t 122 lbs . (85 kg)
(188.7 lpm)
35% @ 100A m p
60% @ 85A m p
100% @ 70A mp
(318mm x 699mm x
520mm)
Manual 0-4686 2-1 Introduction
1
00A
CUT
7
Torch Leads Length
20 feet / 6.1 m
Temperature
40° C
@ 400 sc f h
Straight Polarity
peak
st ream through torch
in Torch Head
Compre s sed A i r O nl y
(8. 6 b ar)
300 SCFH (142 lpm)
SL100™ 1Torch™ Ratings
2.04 Torch Specifications
OFF
CUT
85A
CUT
70A
35% (3.5 min)
60% (6 min)
OFF
100% (10 min)
2.03 Features
• PORT ABLE - Four wheels and two handles along
with two lifting eyes on top for easy manuvering
or pick up.
• VERSITLE - The 100A operates on 230V or 460V
1 or 3-phase input power.
• 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 100A
opperates on shop air for its cutting and cooling.
• ALL KIND 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 1 1/4” - (30 mm)
and 1 1/2” - (40 mm) for maximum cut.
• ABLILITY TO CUT UNPREPARED MATERIALS
- Pilot Arc ignition allows the 100A to cut painted,
coated or even rusted materials.
• EXTENDED P AR TS LIFE - Consumable parts life
is longer .
• LESS ELECTROMAGNETIC DISTURBANCE BY
PILOT ARC IGNITION FROM TORCH - Electromagnetic disturbance for electronic systems in the
vicinity of the cutting operation is less.
Art # A-0466
Torc h Conf igurat ion
Ambient
Duty Cycle
Maximum Current
Voltage (V
Arc S t riking Volt age 7kV
Type of Cooling
Parts-in-Place:
Gas Requ irem ent :
Input
Gas Pressure
Minimum Gas Flow
Plasma Power
Supply Used Wit h:
)500V
Torch Head at 75° to
Torch Handle
104° F
100% @ 100 Am ps
100 Am ps , DC,
Am bient air and gas
Built-in Switch
Single Gas,
65 psi (.45MPa)
(4. 5 b ar) 125 psi (.86MP a)
C-100A
Introduction 2-2 Manual 0-4686
2.05 System Contents
Description
Qty
Power sourc e
Model C-10 0A
1
Torch Set
SL100™, 20'
1
Torch Tips
1
1
1
2
3
230V/460V
400V Non CE
1-1600-3 and
400V (CE)
Items
Air Regulator
Added
Features
Input Power
Cable F or
Systems
1-1600-2
Input Power
Cable F or
Systems
Work Cable
Manual
Torch Electrodes
No In pu t P ower Cord 0
2 Meter Cord With No Plug 1
1-1600-4
2.06 Transpor ting Methods
Lift unit using the two lifting eyes on the top of the
case. Use hand cart or similar device of adequate capacity for transporting. On smooth surfaces, the supplied wheels are adequate 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.
Manual 0-4686 2-3 Introduction
This Page Left Blank
Introduction 2-4 Manual 0-4686
SECTION 3:
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. Higher temperatures may diminish cutting capacity or quality.
• The cutting machine must be placed on an even,
firm surface so that it stands securely. Block the
wheels or lower and secure the side rails along
the bottom of the base to keep the wheels from
rolling and the power supply stationary. The
power supply may also be fastened to supports
by passing hardware through the openings in the
same side rails.
W ARNING
2. Input Power Connection
The power supply requires a customer-supplied input
power cord suitable for the input power in use.
1. Remove the power supply cover.
2. Loosen, but do not remove, the through-hole protector on the power supply rear panel.
3. On the end being used to attach to the power supply, strip the outer layer of the input power cord
approximately 4” (10 cm) exposing the individual
wires. Strip the insulation from the individual wires
approximately 3/8” (9 mm) from the ends. Securely
fasten ring tongue terminals, that are compatible
with the input power , to the individual wires .
Pass the input power cord through the through-hole
protector, then upward through the power supply
upper horizontal panel.
This equipment must be electrically connected
by a qualified electrician.
3.02 Electrical Input Connections
1. Input Power Requirements
Model C-100A
230V (± 10%), 1 pha s e , 50/ 60 Hz
230V (± 10%), 3 pha s e , 50/ 60 Hz
Input Power
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 2.02.
400V (± 10%), 3 pha s e , 50/ 60 Hz
460V (± 10%), 1 pha s e , 50/ 60 Hz
460V (± 10%), 3 pha s e , 50/ 60 Hz
CAUTION
Power Supply
Rear Panel
Through-hole
Protector
Art # A-04651
Manual 0-4686 3-1 Installation
4. Connect the cord to the input power terminal block
jo
A
d
A
d
Bus Bars
as shown for single or three phase. Input connections must be connected oposite the red and the
black wires. The white wire is used for 3 Phase.
Check for secure connections to the block. All cor d
installations require a ground wir e connection to the
power supply chassis; refer to the power supply
upper horizontal panel for proper ground wire connection location.
Negro
Blanco
Ro
NO SE
USA
Black
White
Re
Input Power
rt # A-04652
3 Phase
5. Provide a small amount of slack in the cord between
the terminal block and the through-hole protector.
Tighten the through-hole protector to the cord by
hand only. Do not overtighten or use a wrench.
Art # A-04670-S
Energía
Input Power
rt # A-04697
de Entrada
Monofásico,
1 alambre
Black
White
1 Phase
3 Wire
Re
For 230-Volt or 460-Volt Power Supplies Only:
6. Locate the input power bus bar block on the right
side of the power supply. Position the bars according to the input power in use.
Bus Bars
Art # A-04650
230V Input Power
460V Input Power
7. Reinstall the power supply covers. Tighten the har dware securely; do not overtighten.
Installation 3-2 Manual 0-4686
3.03 Compressed Air Connection
r
C
A
• An air compressor is requir ed and should be connected by an air hose to the air regulator on the
rear panel of the power supply .
• Air flow should be 400 scfh / 6.6 scfm (188.7 lpm)
minimum.
Input Powe
onnect
ir Here
Cable
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 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.
Art # A-04489
3.04 Torch
• Make sure that the torch cable and torch switch
terminals are connected through the front panel.
• Make sure the Work Cable is connected properly
through the front panel and the clamp to clean
work surface.
• Before activating, turn torch away from yourself
and others.
Manual 0-4686 3-3 Installation
This Page Left Blank
Installation 3-4 Manual 0-4686
SECTION 4:
100A
Overheating
r
or
T
S
l
Art # A-04483
0
A
Art # A-04484
OPERATION
B. Switches
• Torch Latch Switch
4.01 Front Control Panel
AC Power
Indicator
"On / Off"
Switch
orch Latch
witch
Air Set
Switch
Work Lead
A. Indicator Lamp
• Power Indicator
Indicator
I
100A
O
70
60
50
40
30
Air Error Indicato
80
90
100
A
Torch Latch
Switch Indicat
Current Contro
Knob
Air V ents
Torch
For continuous cutting performance. Depress
this switch ( 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 Switch
T o check for proper air setting and to cool down
heated torch.
C. Main Current Control Knob
T o adjust cutting current. T urning clockwise increases the cutting current and counter clockwise decreases the cutting current.
70
6
50
40
30
80
90
100
Lights when primary power switch is turned
on.
• TEMPERA TURE Indicator
D. Primary Power Switch, ON / OFF
The power switch is located on the front panel.
Indicator is normally OFF. Indicator is ON
when internal temperature exceeds normal
Placing the primary power switch to the “ON”
position energizes the power source.
limits.
• Air Error Indicator
This indicator lights 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
When the power source is overloaded, the switch
turns to the OFF position automatically. DO
NOT TURN ON BY FORCE.
W ARNING
to operate the torch.
• Torch Latch Switch Indicator
This indicator lights when the Torch Latch
Switch has been pressed for continuous cutting.
Manual 0-4686 4-1 Oper ation
4.02 Preparations For Operating
Make a clean work cable
W
A
Art # A-04389
3
D. Torch Operation
At the start of each operating session:
W ARNING
Disconnect primary power at the source before
assembling or disassembling power supply, torch
parts, or torch and leads assemblies.
A. Torch Parts Selection
Check the torch for proper assembly and appropriate torch parts. The torch parts must correspond
with the type of operation, and with the amperage
output of this Power Supply (100 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
9-8212
Art # A-04649
Shield Cup
9-8218
B. Torch Connection
Check that the torch is properly connected.
C. Connect Work Cable
connection to the workpiece or cutting table
ork Cable
nd Clamp
Operation 4-2 Manual 0-4686
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.
Unit Standoff
C-100A 3/16" (5mm ) 1/2" (12mm ) 52 1308 42 1047
C-100A 3/16" (5mm ) 1/2" (12mm ) 58 1448 46 1159
C-100A 3/16" (5mm ) 3/4" (19mm ) 25 633 20 507
C-100A 3/16" (5mm ) 1" (25mm) 17 425 14 340
C-100A 3/16" (5mm ) 1" (25mm) 18 458 15 366
C-100A 3/16" (5mm ) 1 1/4" (32mm) 12 288 9 230
C-100A 3/16" (5mm ) 1 1/4" (32mm) 12 288 9 231
Material
Thickness
Max im um Travel S peed
(ipm , mm/m)
Recomm ended Travel Speed
(ipm , mm/m)
Manual 0-4686 4-3 Oper ation
This Page Left Blank
Operation 4-4 Manual 0-4686
SECTION 5:
g
U
i
C
U
w
M
SERVICE
5.01 General Maintenance
1. Basic Troubleshooting, Overview
This guide covers basic troubleshooting. It is helpful for
solving many of the common problems that can arise with
this system. If major complex subassemblies are faulty,
the unit must be returned to an authorized service center
for repair .
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
Follow all instructions as listed and complete each section in the order presented.
2. Common Symptoms
A. Primary power switch is ON, but power indicator
doesn’t light.
1. Improper electrical connection.
a. Check the input cable line & connection.
b. Check the input power that it is turned on.
c. Check the input power fuse.
2. System was overloaded.
a. Turn Primary Power Switch Off and then On
again.
3. Switch may be faulty.
a. Return to an authorized service center for re-
pair .
4. Fuse may be faulty.
a. Check and replace power supply input fuse as
needed
B. Primary power switch is on, but the cooling fan
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
5.02 Basic Troubleshooting Guide
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.
does not work.
1. No power / incorrect power to fan or failed fan.
a. Return to an authorized service center for re-
pair .
C . No air flow at torch when air check switch is turned
on.
1. Input air connection is disconnected.
a. Connect the input air.
2. Input air supply not working.
a. Check the manufacturers manuals for trouble
shooting or local maintenance procedures.
3. Internal connection is disconnected or loose.
a. Check all air line connections and fittings.
4. Filter or control PCB faulty.
a. Return to an authorized service center for re-
pair .
Manual 0-4686 5- 1 SERVICE
D. T orch will not pilot when torch switch is activated.
g
Start Cartridge
A
g
Start Cartridge
E. Cut performance is diminished.
1. Gas pressure too high or too low.
a. Adjust gas pressure per pressure setting label
on power supply .
2. Tor ch tip, start cartridge, or electrode missing.
a. Turn off power supply. Remove shield cup. In-
stall missing parts.
3. Start cartridge is stuck.
a. 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 .
Lower End Fittin
Art # A-03621
NOTE
1. Worn torch parts.
a. Check current setting. Check the Electrode and
Tip for excess wear .
New Electrode
rt # A-03284
Good Tip
Worn Electrode
Worn Tip
A-03406
b. Check that the lower end fitting on the start car-
tridge moves freely. Replace any or all parts as
needed.
When operating the torch in a normal condition, a
small amount of gas / air vents through the gap between the shield cup and torch handle. Do not attempt to over tighten the shield cup as irreparable
damage to internal components may result.
4. Worn or faulty torch parts.
a. Inspect torch consumable parts. Replace if nec-
essary.
5. Thermal Switch activated
a. Allow the cooling fan to run for 2 minutes or
longer until it will resume operation.
Lower End Fittin
Art # A-03621
SERVICE 5-2 Manual 0-4686
2. Poor Work Lead connection.
Make a clean work cable
W
A
Art # A-04389
a. Check the connection of the Work Lead to the
work piece.
connection to the workpiece or cutting table
ork Cable
nd Clamp
3. Current sensor or PWM PCB faulty.
a. Return to an authorized service center for re-
pair .
F . Air flows continuously and torch latch switch
doesn't work properly .
1. Tor ch Latch Switch on front panel faulty .
a. Return to an authorized service center for re-
pair .
2. Control PCB faulty.
a. Return to an authorized service center for re-
pair .
Manual 0-4686 5- 3 SERVICE
This Page Left Blank
SERVICE 5-4 Manual 0-4686
Appendix 1: Operating Sequence, Block Diagram
Primary Input Power "On" or Plugged in
Power Supply On/Off Switch "On"
Green Power Indicator "On" and Fan is Running
More air flow is required
Red Air Indicator
Release Torch Switch
Air Set Switch "On"
Air Flows at Torch. Set Air Pressure Then Turn Air Set Switch "Off"
Check Torch parts
Air Flow at Torch Stops
alignment. PIP switches
need to be repaired by a
Qualified Technician
for Torch to Pilot than to
run the power supply.
Re-check regulator setting.
Pilot Arc goes out
Pilot Arc Ignition (3-5 seconds)
Torch Tip to Work within 3-5 seconds of Pilot Arc start
Start Cutting Operation
YES
Post Flow of Air, Approximately 10 Seconds Then Stops
Note: The Torch will be very hot! Do not set on or near flammable materials!
Power Supply On/Off Switch "Off"
Cutting Done ?
Torch Switch "Off"
Torch Switch "On"
NO
No Pilot Arc
Green Power Indicator "Off" and Fan Stops
Art # A-04673
Primary Input Power Switch "Off" or Unplugged
Manual 0-4686 6-1 APPENDIX
Appendix 2: Torch Connection
Art # A-04674
Work Cable
Disconnect power and air. Lay unit on its side.
Remove two screws and the access panel.
View from Bottom
Negative / Plasma Lead
Pilot
Power Supply
Adapter
NOTE: Work cable and torch leads must go through the access
panel and be secured with through hole protectors.
Negative / Plasma Lead
PIP
Switch
Torch
Switch
Torch Head
Pilot
Black
Orange
Green
White
Torch Leads
Pilot
To Power
Supply Adapter
APPENDIX 6-2 Manual 0-4686
This Page Left Blank
Manual 0-4686 6-3 APPENDIX
Appendix 3: Replacement Hand Torch Parts List
Item #QtyDescription Catalog #
1 1 Torch Handle Replacement Kit (include items no. 2 & 3) 9-7030
2 1 Trigger Assembly Replacement Kit 9-7034
3 1 Handle Screw Kit (5 each, #6-32 x 1/2" cap screw, and wrench) 9-8062
4 1 Torch Head Assembly Replacement Kit (includes items No. 5 & 6) 9-8219
5 1 Large O-Ring 8-3487
6 1 Small O-Ring 8-3486
7 Leads Assemblies with O2B Connectors (includes switch assemblies)
1 SL100 / 100Amp, 20 - foot Leads Assembly with O2B connectors 7-5243
8 1 Switch Kit 9-7031
APPENDIX 6-4 Manual 0-4686
7
1
2
4
5
6
3
8
7
A-07060
Manual 0-4686 6-5 APPENDIX
Work Piece
Current Sensor
Appendix 4: System Schematic
Pilot
To rc h
Pilot Relay
Reactor
IGBT
Diode
Filter
Main Transformer
Fuse 3A
IGBT
Hold
Air
Error
Te mp
Powe r
Air
Check
Hold
Main
Fan
Fan
Pressure
Sensor
Solenoid V/V
Art # A-04696
Input AC
230V / 460V
1/3 Phase
AC230
Input Selection
AC460
APPENDIX 6-6 Manual 0-4686
This Page Left Blank
Manual 0-4686 6-7 APPENDIX
GLOBAL CUSTOMER SERVICE CONTACT INFORMATION
Thermadyne USA
2800 Airport Road
Denton, Tx 76207 USA
Telephone: (940) 566-2000
800-426-1888
Fax: 800-535-0557
Email: sales@thermalarc.com
Thermadyne Canada
2070 Wyecroft Road
Oakville, Ontario
Canada, L6L5V6
Telephone: (905)-827-1111
Fax: 905-827-3648
Thermadyne Europe
Europe Building
Chorley North Industrial Park
Chorley, Lancashire
England, PR6 7Bx
Telephone: 44-1257-261755
Fax: 44-1257-224800
Thermadyne Asia Sdn Bhd
Lot 151, Jalan Industri 3/5A
Rawang Integrated Industrial Park - Jln Batu Arang
48000 Rawang Selangor Darul Ehsan
West Malaysia
Telephone: 603+ 6092 2988
Fax : 603+ 6092 1085
Cigweld, Australia
71 Gower Street
Preston, Victoria
Australia, 3072
Telephone: 61-3-9474-7400
Fax: 61-3-9474-7510
Thermadyne Italy
OCIM, S.r.L.
Via Benaco, 3
20098 S. Giuliano
Milan, Italy
Tel: (39) 02-98 80320
Fax: (39) 02-98 281773
Thermadyne, China
RM 102A
685 Ding Xi Rd
Chang Ning District
Shanghai, PR, 200052
Telephone: 86-21-69171135
Fax: 86-21-69171139
Thermadyne International
2070 Wyecroft Road
Oakville, Ontario
Canada, L6L5V6
Telephone: (905)-827-9777
Fax: 905-827-9797
Corporate Headquarters
16052 Swingley Ridge Road
Suite 300
St. Louis, MO 63017
Telephone: 636-728-3000
Email: TDCSales@Thermadyne.com
www.thermadyne.com
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