Tweco FP-70A User Manual

Plasma Cutting System

Model FP-70A

Art # A-04487

Operating Manual

January 23, 2006 Manual 0-4682

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

Appendix 4: 230 Volt 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:

g

g

INTRODUCTION

70A

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 Description FP-70A

Maximum Output 70 Amps

Input Voltage & Phase

Frequency 50/60 Hz
Input Power 1 Phase
Input Power 3 Phase
Input Power Fuse, 1 Phase
Input Power Fuse, 3 Phase
No Load Volta
Load Volta
Output Current 25-70 Amps
Post-Flow Time 10 Seconds
Operating Air Pressure .5MPa (5 bar)
Maximum Input Air Pressure .86MPa (8.6 bar)

Air flow

System Duty Cy cle Rat ing*
at Ambient Air Temperatures
of 40° C / 104° F.
System Duty Cy cle Rat ing*
at Ambient Air Temperatures
of 40° C / 104° F.
System Duty Cy cle Rat ing*
at Ambient Air Temperatures
of 40° C / 104° F.

Genuine Cutting Capac ity 3/4" (19 mm)

Maximum Cutting Capacity 1" (25.4 mm)

Dimensions (W x D x H)

Net Weight 66 lbs. (30 kg)

e250V

e108V

230V, Single and
Three Phase

67 Amps (15.4 kVA )
37 Amps ( 8.5 kVA )
80 Amp
40 Amp

400 scfh, 6.6 scfm
(188.7 lpm)

35% @ 70Amps

60% @ 60Amps

100% @ 50Amps

9.7" x 21.7" x 16.5"
(245 mm x 550 mm x
420 mm )

CUT

60A

CUT

50A

35% (3.5 min)

60% (6 min)

OFF

100% (10 min)

NOTE:

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

2.03 Features

• RELIABLE AND POWERFUL - This inverter
based power supply operates on standard 230V
single or three phase power.

• POWERFUL CUTTING PERFORMANCE ­Genuine cutting capacity is 3/4” (19 mm) and
1” (25.4 mm) 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 SL100™
1Torch™ provides state of the art technology and
performance of more expensive torches.

6

Art # A-0450

Manual 0-4682 2-1 Introduction

2.04 Torch Specifications

g

p

g

y

If you have questions or concerns regarding your sys­tem, please contact:

Thermal Dynamics Technical Service Dept.

SL100™ 1Torch™ Ratings for FP-70A

Torch Configuration

Torch Leads Len
Ambient
Temperature

Torch Duty Cycle

Maximum Current

Voltage (V
Arc Striking Voltage 7kV

Type of Cooling

Parts-in-Place:

Gas Requirement:

Input
Gas Pressure

Minimum Gas Flow

Plasma Power
Supply Used With:

)500V

eak

Torch Head at 75° to
Torch Handle

th 20 feet (6.1 m)

104° F
40° C
100% @ 100 Amps
@ 400 scfh
100 Amps, DC,
Straight Polarity

Ambient air and gas
st ream t hrou
Built-in Switch
in Torch Head
Single Gas,
Compressed Air Only
.5MPa (5 bar) ­.86MPa (8.6 bar)
400 scfh 6.6 scfm
(188.7 lpm)

FP-70A

h torch

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

Fax: [phone]

e-mail address: [e-mail]

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.

2.05 System Contents

ITEMS Description Q't

Power Source Model FP-70A 1
Torch Set SL100™, 20' (6.1m) 1

Air Regulator

Added
Features

Input Power
Cable

Work Cable
Manual
Torch Electrodes
Torch Tips

2 Meter 6 AWG SOW with
6 - 50 P molded plug

1
1
1
2
3

1

Introduction 2-2 Manual 0-4682

SECTION 3:

3.03 Compressed Air Connection

INSTALLATION

3.01 Site Selection

• Place in a clean and dry area.

• Provide adequate ventilation and fresh air sup­ply.

• Ideal ambient temperature should not exceed
40°C / 104°F. Temperatures exceeding that may
diminish cutting capacity or quality.

• The cutting machine must be placed on an even,
firm surface so that it stands firmly.

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 or three phase.

CAUTION

• An air compressor is required and should be con­nected to rear panel of power source by air hose.

• Air pressure should be .5MPa (5 bar) and air
should be dry and clean.

• Air flow should be 400 scfh / 6.6 scfm (188.7 lpm)
minimum.

Connect Air
Here

Input Power
Cable

Check your power source for correct voltage be­fore plugging in or connecting the unit. The
primary power source, fuse, and any extension
cords used must conform to local electrical code
and the recommended circuit protection and wir­ing requirements as specified in Section 2.0.

Art # A-04486

DANGER

Do not cut in humid or wet surroundings.

• Before you maintain or replace torch parts, wait
for the post flow air cycle (approximately 10 sec­onds), to stop, then turn the machine off.

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

• Worn parts should be recycled according to local
requirements.

NOTE

Repairs must be done by skilled and qualified
personnel only.

Manual 0-4682 3-1 Installation

Installation 3-2 Manual 0-4682

SECTION 4:

OPERATION

B. Buttons

• Torch Switch Latch Button

4.01 Front Control Panel

AC Power
Indicator

"On / Off"
Switch

Torch Switch
Latch Button

Air Set
Button

Work Lead
Connection

A. Indicator Lamp

• Power Indicator

Lights when primary power switch is turned
on.

• TEMPERATURE Indicator

Indicator is normally OFF. Indicator is ON
when internal temperature exceeds normal
limits.

Overheating
Indicator

I

O

Art # A-04430

Air Error Indicator

70A

50

0
4

60

0
3

70

20

A

Torch Switch
Latch Indicator

Current Control
Knob

Air Vents

Torch
Connection

For continuous cutting performance. Depress
this button ( turn “On” ) while cutting with the
torch. Release the torch trigger and the torch
will continue to cut without depressing the torch
trigger.

• Air Set Button

To check for proper air setting and to cool down
heated torch.

Art # A-04503

Air will flow from gap
next to shield cup.

C. Main Current Control Knob

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

40

50

60

70

• Air Error Indicator

This indicator lights when there is not enough

30

20

air pressure to operate the power supply. In­dicator is normally off.

Art # A-04431

A

NOTE

It is possible to have enough air pressure to op­erate the power supply but not enough air flow
to operate the torch.

D. Primary Power Switch, ON / OFF

The power switch is located on the front panel.
Placing the primary power switch to the “ON”
position energizes the power source and acti­vates the Power Indicator.

• Torch Switch Latch Indicator

This indicator lights when the Torch Switch

WARNING

Latch Button has been pressed for continuous
cutting.

When the power source is overloaded, the switch
turns to the OFF position automatically. DO
NOT TURN ON BY FORCE.

Manual 0-4682 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 (70 amps maximum).
Use only genuine manufactured parts with this
torch.

• Refer to Section 1 for necessary safety precau­tions.

Trigger

1

2

Trigger Release

3

4

Art # A-03383

Electrode
9-8215

Start Cartridge
9-8213

Tip
9-8231

Art # A-04432

Shield Cup
9-8218

B. Torch Connection

Check that the torch is properly connected.

C. Connect Work Cable

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

Work Cable
And Clamp

Art # A-04389

Operation 4-2 Manual 0-4682

E. Typical Cutting Speeds

Cutting speeds vary according to torch output, the type of material being cut, and operator skill. Speeds
shown are typical for this cutting system using air plasma to cut mild steel, with output current at the
highest setting and the torch set at the indicated standoff height.

Unit Standoff

FP-70A 3/16" (5mm) 1/4" (6mm) 129.7 3242 103.7 2593
FP-70A 3/16" (5mm) 3/8" (10mm) 63.3 1583 50.7 1267
FP-70A 3/16" (5mm) 1/2" (12mm) 38.0 951 30.4 761
FP-70A 3/16" (5mm) 3/4" (19mm) 19.9 498 15.9 399
FP-70A 3/16" (5mm) 1" (25mm) 14.4 361 11.5 289

Material

Thi cknes s

Maximum Travel Speed

(ipm , mm/m)

Recommended Travel Speed

(imp , mm/m)

Manual 0-4682 4-3 Operation

Operation 4-4 Manual 0-4682

SECTION 5:

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 input power that its 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.

B. Primary power switch is on, but the cooling fan

does not work.

1. No power / incorrect power to fan or failed fan.

Upper Groove
with Vent Holes
Must Remain Open

Upper O-Ring
in Correct Groove
Cat. #8-3487

Threads
Lower O-Ring

Cat. #8-3486

5.02 Basic Troubleshooting Guide

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.

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 compressor manufacturer's manual

for trouble shooting and follow 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 0-4682 5-1 SERVICE

D. Torch will not pilot when torch switch is activated.

E. Cut performance is diminished.

1. Gas pressure too high or too low.

a. Adjust gas pressure per pressure setting label

on 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.

2. Torch 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.

Start Cartridge

Lower End Fitting

1. Worn torch parts.

a. Check current setting. Check the Electrode and

Tip for excess wear.

New Electrode

Art # 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.

Art # A-03621

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.

NOTE

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.

Art # A-04503

Start Cartridge

Lower End Fitting

Art # A-03621

Air will flow from gap
next to shield cup.

SERVICE 5-2 Manual 0-4682

2. Poor Work Lead connection.

a. Check the connection of the Work Lead to the

work piece.

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

Work Cable
And Clamp

Art # A-04389

3. Current sensor or PWM PCB faulty.

a. Return to an authorized service center for re-

pair.

F. Air flows continuously and torch switch latch

button doesn't work properly.

1. Torch Switch Latch button 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.

5.03 Contact information

Thermal Dynamics Technical Service Dept.

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

Fax: [phone]

e-mail address: [e-mail]

Manual 0-4682 5-3 SERVICE

SERVICE 5-4 Manual 0-4682

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 0-4682 A-1 APPENDIX

Appendix 2: Torch Connection

Art # A-04445

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

DETAIL

Negative / Plasma Lead

Power Supply
Adapter

PIP

Switch

Torch

Switch

Torch Head

Negative / Plasma Lead

Black
Orange

Green

White

Pilot

Torch Leads

Pilot

Work Cable

To Power
Supply Adapter

Pilot

APPENDIX A-2 Manual 0-4682

This Page Intentionally Blank

Manual 0-4682 A-3 APPENDIX

Appendix 3: Replacement Hand Torch Parts List

Item # Qty Description 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 / 70Amp, 20 - foot Leads Assembly with O2B connectors 7-5242

8 1 Switch Kit 9-7031

APPENDIX A-4 Manual 0-4682

7

1

2

4

5

6

3

8

7

A-07060

Manual 0-4682 A-5 APPENDIX

Appendix 4: 230 Volt System Schematic

1PH - R&Bk
3PH - R,W&Bk

R

W

Bk

G

INPUT
AC230V
1/3 PH

TB1

Input Power
Connection

Solenoid V/V

1.7k

FILTER

R

W

Bk

Ω

103 3KV

C1 C6

C2

C3

W

W

FAN

AC230

AC160
AC230

230VAC

NFB

FUSE

CONTROL 3A

T1

Pressure
Sensor

103 3KV

C4

C5

AC12

AC15

AC15

Bk

R

W

W,2

DIODE

320VDC

C7

630V 104MF

R7

C8

+

(-)

Capacitor

TH

W

C8

Bk

Bk,2

R3

Bk

C7

R7

W

C12

P5

G1 E1 G2 E2

E4 G4 E3 G3

P8

5

P

12 VDC

IGBT

Bk

P5

G3 E3 G4 E4

E2 G2 E1 G1

P7

PWM DRIVE

IGBT

W

Bk

R4

W

C13

BOARD

40272004

P1

N/C

P4 P11

CONTROL BOARD

No. 40270702

P1

P1

PANEL BOARD

12 VDC

P2

P2

P3

1

R

1

G

G

Y

Bk

Y

W

W

5

P9

1

3

P7

1

P5

2

1

Art # A-06948

MAIN

HOLD

AIR
CHECK

POWER

TEMP
ERROR

APPENDIX A-6 Manual 0-4682

220VAC

C/T 1

Main Transformer

(2)

(2)

Current Sensor

W

W

W

C11

R5

C16

R8

Bk

R1

C10

VC_1
VD_1
OU_1
GN_1

VC_2
VD_2
OU_2
GN_2

Pilot
Relay

WW

O.C.V. 290 VDC
Pilot 160 VDC
Cutting 130 VDC

WORK

PILOT

N/C

CN1

P6

15 VDC

REACTOR

W

TORCH

S/W

Output Diode

Jumper

R5

C11

R1

S/W

12VDC

Pilot

C10

C16

R8

VC_1

N/C

N/C

VD_1
OU_1
GN_1

VC_2
VD_2
OU_2
GN_2

3

1

50

Ω

DC Output

Torch

S/W

W

Bk

W

W

P3

P4

2

1

P8

15 VDC

P10

0 = Start

P6

P3

Air Plasma 70A (230V)

AIR
ERROR

HOLD

2005 / 01 / 12

A

Art # A-06948

Manual 0-4682 A-7 APPENDIX