Tweco FP-35A User Manual

Plasma Cutting System

Model FP- 35A

Number the art as Art # A-044??

Art # A-04502

Operating Manual

January 23, 2006 Manual 0-4681

TABLE OF CONTENTS

SECTION 1:

GENERAL INFORMATION ................................................................................................ 1-1

1.01 Notes, Cautions and Warnings ...................................................................... 1-1

1.02 Important Safety Precautions ....................................................................... 1-1

1.03 Publications .................................................................................................. 1-2

1.04 Statement of Warranty .................................................................................. 1-4

SECTION 2:

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

2.01 Overview ...................................................................................................... 2-1

2.02 General Specifications .................................................................................. 2-1

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

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

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

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

SECTION 3:

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

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

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

3.03 Compressed Air Connection ......................................................................... 3-1

SECTION 4:

OPERATION ...................................................................................................................... 4-1

4.01 Front Control Panel ....................................................................................... 4-1

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

SECTION 5:

SERVICE .......................................................................................................................... 5-1

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

5.02 Basic Troubleshooting Guide ......................................................................... 5-1

5.03 Contact information ...................................................................................... 5-3

Appendix 1: Operating Sequence, Block Diagram ..................................................................... A-1

Appendix 2: Torch Connection ................................................................................................... A-2

Appendix 3: Microchip Pin-Out .................................................................................................. A-3

Appendix 4: Replacement Hand Torch Parts List ....................................................................... A-4

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

SECTION 1:

GENERAL INFORMATION

1.01 Notes, Cautions and Warnings

Throughout this manual, notes, cautions, and warnings
are used to highlight important information. These high­lights are categorized as follows:

NOTE

An operation, procedure, or background informa­tion which requires additional emphasis or is help­ful in efficient operation of the system.

CAUTION

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

WARNING

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

1.02 Important Safety Precautions

WARNINGS

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

Plasma arc cutting produces intense electric and
magnetic emissions that may interfere with the
proper function of cardiac pacemakers, hearing aids,
or other electronic health equipment. Persons who
work near plasma arc cutting applications should
consult their medical health professional and the
manufacturer of the health equipment to determine
whether a hazard exists.

To prevent possible injury, read, understand and
follow all warnings, safety precautions and instruc­tions before using the equipment. Call 1-603-298­5711 or your local distributor if you have any ques­tions.

GASES AND FUMES

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

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

• Use an air-supplied respirator if ventilation is not
adequate to remove all fumes and gases.

• The kinds of fumes and gases from the plasma arc
depend on the kind of metal being used, coatings
on the metal, and the different processes. You must
be very careful when cutting or welding any met­als which may contain one or more of the follow­ing:

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.

January 23, 2006 1-1 GENERAL INFORMATION

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

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

• Repair or replace all worn or damaged parts.

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

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

• Disconnect power source before performing any ser­vice or repairs.

• Read and follow all the instructions in the Operat­ing Manual.

FIRE AND EXPLOSION

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

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

• Ventilate all flammable or explosive vapors from
the workplace.

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

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

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

PLASMA ARC RAYS

Plasma Arc Rays can injure your eyes and burn your skin.
The plasma arc process produces very bright ultra violet
and infra red light. These arc rays will damage your eyes
and burn your skin if you are not properly protected.

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

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

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

• Protect others in the work area from the arc rays.
Use protective booths, screens or shields.

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

Minimum Protective Suggested

Arc Current Shade No. Shade No.

Less Than 300* 8 9

300 - 400* 9 12

400 - 800* 10 14

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

1.03 Publications

Refer to the following standards or their latest revisions
for more information:

1. OSHA, SAFETY AND HEALTH STANDARDS, 29CFR
1910, obtainable from the Superintendent of Documents,
U.S. Government Printing Office, Washington, D.C.
20402

NOISE

2. ANSI Standard Z49.1, SAFETY IN WELDING AND
CUTTING, obtainable from the American Welding So­ciety, 550 N.W. LeJeune Rd, Miami, FL 33126

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.

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 January 23, 2006

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

January 23, 2006 1-3 GENERAL INFORMATION

1.04 Statement of Warranty

LIMITED WARRANTY: Subject to the terms and conditions established below, Thermadyne® Corporation warrants to the original retail
purchaser that new Thermadyne CutSkill Series plasma cutting systems sold after the effective date of this warranty are free of defects in
material and workmanship. Should any failure to conform to this warranty appear within the applicable period stated below, Thermadyne
Corporation shall, upon notification thereof and substantiation that the product has been stored operated and maintained in accordance
with Thermadynes’ 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 /Purchaser.

LIMITED WARRANTY PERIOD

Product

Power Supply Components

(Parts and Labor)

Torch and Leads

(Parts and Labor)
FP-20A 1 Year 1 Year
FP-35A 1 Year 1 Year
FP-70A 1 Year 1 Year

FP-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

GENERAL INFORMATION 1-4 January 23, 2006

SECTION 2:

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INTRODUCTION

35A

CUT

OFF

2.01 Overview

Plasma is a gas which has been heated to an extremely
high temperature and ionized so that it becomes elec­trically conductive. The plasma arc cutting process uses
this plasma to transfer an electrical arc to the work­piece. The metal to be cut is melted by the heat of the
arc and then blown away.

2.02 General Specifications

System Des criptions FP-35A

Maximum Output 35 Amps

Input Voltage & Phase

Frequenc
Input Power 7.4 kVA
Current Input Fus e 20 Amps
No Load Volta
Load Volta
Output Current 15-35 Amps
Post Flow Time 10 Seconds

Operating Air Pressure

Maximum Air Pressure

Air Flow

System *Duty Cycle ratings
at Ambient Air Temperatures
of 40° C / 104° F.
System *Duty Cycle ratings
at Ambient Air Temperatures
of 40° C / 104° F.
System *Duty Cycle ratings
at Ambient Air Temperatures
of 40° C / 104° F.
Genuine Cutting Capacity
@ 35A
Maximum Cutting Capacity
@ 35A

Dimens ion (W x D x H)

Net Weight

e220V

e94V

230V,

le Phase

Sin
50/60Hz

75 psi (5.2
bar)(.52 MPa)
125 psi (8.6
bar)(.86 Mpa)

400 scfh

6.6 scfm
(188.7 lpm)

35% @ 35Amps

60% @ 27Amps

100% @ 20Amps

3/8" (10mm)

1/2" (12mm)

8.3"x20"x14.8"
(210 mm x 510
mm x 350 mm )
44 lbs.

)

(20k

CUT

27A

CUT

20A

35% (3.5 min)

60% (6 min)

OFF

100% (10 min)

NOTE:

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

2.03 Features

• PORTABLE - Weighing just 44 lbs., (20 kg) it is
easily moved from location to location.

• POWERFUL CUTTING PERFORMANCE ­Genuine cutting capacity is 3/8” (10mm) and
1/2” (12mm) for maximum cut.

• CUTS MOST METALS - Useful for most metals
such as stainless steel, aluminum, mild steel, cop­per and alloys.

• NO HIGH FREQUENCY - Starts without high­frequency so it won’t interfere with controls or
computers.

• MORE TORCH, LESS MONEY - The SL60™
1Torch™ provides state of the art technology and
performance of more expensive torches.

5

Art # A-0450

Manual 0-4681 2-1 Introduction