Thermal Dynamics C-20A Cutskill Service Manual Download

Page: 39 / 42

Manual 0-4697

A-5

APPENDIX

HOLD

CN9

OU_1

VD_1

OU_2

S/W

TORCH

WORK

AIR
ERROR

AIR
CHECK

REACTOR

GN_1

VC_1

PILOT

CN3

GN_1

VD_1

VC_1

Current Sensor

CN10

OU_1

VC_2

Pilot
Relay

C/T 1

2005 / 01 / 12

POWWEL ELECTRONIC IND.CO., LTD.

Air Plasma 20A

Main Transformer

Art # A-05555

LD2
Enable

14VDC

O.C.V.

Jumper

Pilot

To Current
Sensor

PCR

10.3 MF
630V

239VAC at 115VAC input
210VAC at 220VAC input

207VAC at 115VAC input
182VAC at 220VAC input

335VAC at 115VAC input
291VAC at 220VAC input

Pilot 90
Cutting 110

(Power Supply)

NOTE:
Do Not attempt to
adjust the POTs!

CN12

1
2

+20VDC
to engage
Pilot Relay

-12VDC

+12VDC

R
O

2
3
4
5

Summary of Contents for C-20A Cutskill

Page 1: ...PLASMA CUTSKILL Service Manual C 20A PLASMA CUTTING SYSTEM Rev AA 01 Issue Date March 26 2007 Manual 0 4697 Operating Features ...

Page 2: ......

Page 3: ...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...

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Page 5: ... 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 MAINTENANCE 5 1 5 01 General Maintenance 5 1 5 02 Maintenance Torch O Rings 5 2 SECTION 6 TROUBLESHOOTING 6 1 6 01 Setup and Operation 6 1 6 02 Basic Trouble Shooting Guide 6 2 6 03 Control PCB Indicators 6 3 6 04 Open Circuit Voltage Check 6 4 6 05 Detailed Fault Findi...

Page 6: ......

Page 7: ... 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 met als which may contain one or more of the follow ...

Page 8: ...03 Publications in this manual PLASMAARC 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 hel met or shield Also always wear safety glasses with side shields goggles or other pro...

Page 9: ...ire Protection Association Batterymarch Park Quincy MA 02269 11 CGA Pamphlet P 1 SAFE HANDLING OF COM PRESSED GASES IN CYLINDERS obtainable from the Compressed Gas Association 1235 Jefferson Davis Highway Suite 501 Arlington VA 22202 12 CSAStandard W117 2 CODE FOR SAFETY IN WELD ING AND CUTTING obtainable from the Canadian Standards Association Standards Sales 178 Rexdale Boulevard Rexdale Ontario...

Page 10: ...ble 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 Replacem...

Page 11: ...ratures of 40 C 104 F 100 10Amps Cutting Capacity 115V 20 Amps 1 4 6mm Cutting Capacity 230V 25 Amps 3 8 10mm Dimensions W x D x H 8 3 x 20 x 14 8 210 mm x 510 mm x 350 mm Net Weight 44 lbs 20 kg 10A 15A 25A 30 3 min 60 6 min 100 10 min OFF OFF CUT CUT CUT Art A 04504 NOTE Duty Cycle is the percentage of time the sys tem can be operated without overheating Duty cycle is reduced if primary input vo...

Page 12: ...r C 20A 2 05 System Contents Items Description Q ty Power Source Model C 20A 1 Torch Set SL 60 with 20 6 1m leads 1 Accessories Consumables Air Regulator Work Cable Manual Torch Electrodes Torch Tips 1 1 1 2 3 Input Power Cable 12 3 AWG SOW with molded 5 20 plug 1 If you have questions or concerns regarding your sys tem please contact Thermal Dynamics Technical Service Dept Tel 1 800 752 7622 1 80...

Page 13: ...ip back the outer cord cover as needed to con nect the inner conductors to the replacement plug 3 Connect conductors to the plug contacts according to the plug manufacturer s instructions All three conductors must be connected to the plug Connect the input power cord as follows 1 Check the power source for correct voltage before plugging in the unit 2 Connect the input power cable or close the mai...

Page 14: ...Installation 3 2 Manual 0 4697 This Page Left Blank ...

Page 15: ...h Switch Latch Indicator This indicator lights when the Torch Switch Latch Button has been pressed for continuous cutting B Buttons Torch Switch Latch Button 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 adjust air pressure and to cool do...

Page 16: ...must correspond with the type of operation and with the amperage output of this Power Supply 25 amps maximum Use only genuine manufactured parts with this torch Electrode 9 8215 Start Cartridge 9 8213 Tip 9 8206 Shield Cup 9 8218 Art A 04429 B Torch Connection Check that the torch is properly connected C Connect Work Cable Make a clean work cable connection to the work piece or cutting table Work ...

Page 17: ...the highest setting and the torch used in the Drag mode only Inches per minute Milimeters per minute Inches per minute Milimeters per minute C 20A Drag Only 10GA 0 135 3mm 42 7 1067 34 1 853 C 20A Drag Only 7GA 0 179 4 5mm 26 2 655 21 0 524 C 20A Drag Only 1 4 6mm 16 0 401 12 8 321 Recommended Travel Speed Unit Standoff Material Thickness Maximum Travel Speed NOTE Drag or Drag mode refers to the t...

Page 18: ...Operation 4 4 Manual 0 4697 This Page Left Blank ...

Page 19: ...sure Visual check of torch tip and electrode Weekly Visually inspect the torch body tip electrode and shield cup Visually inspect the cables and leads Replace as needed 3 Months Clean exterior of power supply 6 Months Replace all broken parts Visually check and Carefully clean the interior Maintain more often if used under severe conditions Gas and air lines Art A 04929 ...

Page 20: ...o 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 co...

Page 21: ...r 2 Connect the work lead clamp to cleaned area of work surface 3 Turn the switch located on the front panel to the On position The A C indicator on the front panel should light 4 Set the air pressure Press the Air Set Button and set the regulator pressure to 65 psi 4 5 bar 45 MPa Air should be flowing continuously Press the Air Set Button again to stop the air flow NOTE If the Air Error Indicator...

Page 22: ...ge is stuck 4 Worn or faulty torch parts 5 Thermal Switch activated 1 Adjust gas pressure per pressure setting label on power supply 2 Turn off power supply Remove shield cup Install missing parts 3 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 4 Inspect torch ...

Page 23: ...t panel LD2 EN LED should be ON Control PCB 3 Press the Air Set Button The LD1 SOL LED should light Press the Air Set Button again and it should go out 4 Squeeze the torch trigger slight delay pilot arc starts LD2 EN should brighten and LD1 SOL LED should be on 5 Transfer the arc to the work surface and LD3 should come on so that all three LEDs are on NOTE If no transfer of arc occurs check the wo...

Page 24: ...6 05 Detailed Fault Finding Error Indicators Problem Check Test Recommended Action Air Indicator is on and or audible intermitant tone If the air supply and regulator setting are OK check the Pressure Switch 1 Replace Pressure Switch if needed 2 If the Pressure Switch is OK then replace the Control PCB Torch doesn t Pilot and the LD1 LED light on the Control PCB is on 1 Check torch consumables 2 C...

Page 25: ...moveAC power Refer toAppendix 3 Wiring diagram 2 Locate the IGBT diode module to be tested 3 Remove P5 from IGBT module 4 Set digital volt ohmmeter to diode test scale 5 Connect the volt ohmmeter positive lead to the anode of the diode and the negative lead to the cathode of the diode for forward bias testing refer to following figure A properly functioning diode will conduct in the forward bias d...

Page 26: ...ock in the reverse bias direction and depending on the meter function will indicate an open or OL OL VR COM A Art A 00306 Anode Cathode Reverse Bias Diode Not Conducting _ Testing Diode Reverse Bias 7 Using the Figures for each test check each diode in the module Each diode must be checked in forward bias plus to negative and reverse bias negative to plus direction ...

Page 27: ...Open After Charging 1 Black Open After Charging Black E1 DD 1 270 E1 G1 DD 770 G1 E1 DD 770 E2 G2 DD 770 G2 E2 DD 770 E3 Red DD 1 270 Red E3 Open After Charging E3 Black DD 770 Black E3 DD 770 G3 E3 DD 770 E3 G3 DD 770 G4 E4 DD 770 E4 G4 DD 770 Gate PCB J5 IGBT Check Diode Test P5 Gate Connector 1 G1 Black 1 Black 2 E1 White 2 White 3 G2 Green 3 Green 4 E2 Red 4 Red 5 G3 Black 1 Black 6 E3 White 2...

Page 28: ... a Disconnect input power and air from power supply b Disconnect the pilot lead see previous diagram c Perform an Ohm check of the pilot lead to the negative lead This should show a short of less than 1 Ohm If it does not show a short check the function of the start cartridge The inner piece is spring loaded and should move freely Also check other consumables for proper wear and fit d Connect the ...

Page 29: ...y model number and serial number when ordering parts If a product must be returned for service contact your distributor Materials returned without proper authorization will not be accepted Contact Information Thermal Dynamics Technical Service Dept Tel 1 800 752 7622 1 800 PLASMA2 Fax 1 800 221 4401 e mail address tdc tech thermadyne com Replacement parts are shown on the following pages Catalog n...

Page 30: ...21 9 0296 9 1 Air Assembly 9 0297 10 1 Cooling Fan 9 7163 11 1 Connector 9 0305 12 1 Main Trans and Reactor Assy 9 0325 13 1 Heat Sink Assembly 9 0306 14 1 Case Bottom 9 0298 15 1 Case Terminal Plate 9 0327 16 1 PCB Torch Filter 9 7121 17 1 Case Top 9 0299 18 1 PCB Control 9 7115 19 1 PCB Input Filter 9 7126 20 1 Control Transformer 9 7150 21 1 Pilot Relay Assembly 9 0304 22 1 Current Sensor 9 715...

Page 31: ...Manual 0 4697 7 3 Parts List Art A 07744 11 12 13 14 15 16 Art A 07745 17 18 19 20 21 22 23 24 ...

Page 32: ...ssembly 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 SL60 30 Amp 20 foot Leads Assembly with O2B connectors 7 5240 8 1 Switch Kit 9 7031 ...

Page 33: ...Manual 0 4697 7 5 Parts List 5 6 3 4 2 7 7 A 07060 1 8 ...

Page 34: ...Parts List 7 6 Maual 0 4697 This Page Left Blank ...

Page 35: ...s Cutting Done Torch Switch On Air Flows at Torch Set Air Pressure Then Turn Air Set Switch Off Red Air Indicator Pilot Arc goes out Release Torch Switch Primary Input Power Switch Off or Unplugged Green Power Indicator Off and Fan Stops Air Flow at Torch Stops Power Supply On Off Switch Off Check Torch parts alignment PIP switches need to be repaired by a Qualified Technician More air flow is req...

Page 36: ...itch Negative Plasma Lead Torch Head White Black Orange Green PIP Switch Torch Leads To Power Supply Adapter Disconnect power and air Lay unit on its side Remove access plate Pilot Power Supply Adapter Negative Plasma Lead Art A 04445 Work Cable Pilot Pilot DETAIL ...

Page 37: ...97 A 3 APPENDIX Appendix 3 Microchip Pin Out P2 1 2 3 4 5 6 7 8 9 10 11 12 24 22 20 18 16 14 12 10 8 6 4 2 23 21 19 17 15 13 11 9 7 5 3 1 P3 1 2 3 4 5 6 7 8 9 10 11 12 CPU Socket on Control PCB 40 Pin Microchip P1 ...

Page 38: ...enoid V V No 40271002 INPUT AC115 230V 1 PH TB2 Control Board Panel Board Filter Board Art A 05555 1 7 230VAC 67Ω 1 1 2 2 12VDC 19VDC 115VAC 220VAC NC LD1 SOL LD3 CO 337VDC at 115VAC input 298VDC at 220VAC input AC AC INPUT DIODE Gas Solenoid Transfer Input Capcitor NOTE Do Not attempt to adjust the POTs PS Closes At 30 PSI 12VDC 2 1 W B W B W W W W B B G G R R TW TW TW TW 1 1 2 2 3 3 4 4 R O BL O...

Page 39: ...NIC IND CO LTD Air Plasma 20A Main Transformer Art A 05555 LD2 Enable 14VDC 1 2 O C V Ω Jumper Pilot To Current Sensor 77 Y Y PCR 10 3 MF 630V 239VAC at 115VAC input 210VAC at 220VAC input 207VAC at 115VAC input 182VAC at 220VAC input 335VAC at 115VAC input 291VAC at 220VAC input Pilot 90 Cutting 110 Power Supply NOTE Do Not attempt to adjust the POTs CN12 1 2 20VDC to engage Pilot Relay 12VDC 12V...

Page 40: ...APPENDIX A 6 Manual 0 4697 This Page Left Blank ...

Page 41: ...strict Shanghai PR 200052 Telephone 86 21 69171135 Fax 86 21 69171139 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 V...

Page 42: ...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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