Thermal Dynamics C-70A CUTSKILL Service Manual Download | Manualshive

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Manual 0-4699

A-7

APPENDIX

P3

P8

S/W

S/W

P9

P10

P6

P4

OU_2

OU_1

VD_1

OU_1

VD_1

OU_2

VD_2

TORCH

WORK

P3

VC_2
VD_2

GN_2

GN_1

VC_1

REACTOR

C16

R1

C11

GN_1

VC_1

Pilot
Relay

VC_2

GN_2

PILOT

AB

HOLD

AIR
CHECK

Current Sensor

Main Transformer

oct. 18. 2005

No.40276002

R8

R5

C10

C/T 1

Air Plasma 70A (400V CE)

No. 66001010

Torch
S/W

Art # A-06949

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Summary of Contents for C-70A CUTSKILL

Page 1: ...PLASMA 70 400 v CUTSKILL Service Manual C 70A PLASMA CUTTING SYSTEM Rev AA 01 Issue Date March 26 2007 Manual 0 4699 Operating Features...

Page 2: ......

Page 3: ...05 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 a...

Page 4: ......

Page 5: ...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 MAINTENANCE 5 1 5 01 General Maintenance 5 1 5 02...

Page 6: ......

Page 7: ...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 m...

Page 8: ...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 a...

Page 9: ...re 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 High...

Page 10: ...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 E...

Page 11: ...le 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 opera...

Page 12: ...GENERAL INFORMATION 1 6 Manual 0 4699 This Page Left Blank...

Page 13: ...6 6 scfm 188 7 lpm System Duty Cycle Ratings at Ambient Air Temperatures of 40 C 104 F 35 70Amps System Duty Cycle Ratings at Ambient Air Temperatures of 40 C 104 F 60 60Amps System Duty Cycle Rating...

Page 14: ...scription Q ty Power Source Model C 70A 1 Torch Set SL100 20 6 1m 1 Added Features Air Regulator Work Cable Manual Torch Electrodes Torch Tips 1 1 1 2 3 Input Power Cable For Systems 1 1670 1 2 Meter...

Page 15: ...local electrical code and the recommended circuit protection and wir ing requirements as specified in Section 2 0 3 03 Compressed Air Connection An air compressor is required and should be con nected...

Page 16: ...Installation 3 2 Manual 0 4699 This Page Left Blank...

Page 17: ...h 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...

Page 18: ...ust 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 Electrode 9 8215 Start Cartridge 9 8213...

Page 19: ...cut mild steel with output current at the highest setting and the torch set at the indicated standoff height Unit Standoff Material Thickness C 70A 3 16 5mm 1 4 6mm 129 7 3242 103 7 2593 C 70A 3 16 5m...

Page 20: ...Operation 4 4 Manual 0 4699 This Page Left Blank...

Page 21: ...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 M...

Page 22: ...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 T...

Page 23: ...nect 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 and the cooling fan should be...

Page 24: ...e 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 Tu...

Page 25: ...n 1 8 Spring Loaded Cylinder at Rest Full Extension Start Cartridge Worn Electrode New Electrode Art A 03284 Electrode Example Good Tip Worn Tip A 03406 Tip Example Make a clean work cable connection...

Page 26: ...e running 2 Locate the Control PCB behind the front panel and the PWM PCB behind that LD2 LED s on both PCB s should be ON Control PCB PWM PCB 3 Squeeze the torch trigger slight delay pilot arc starts...

Page 27: ...easure Output voltage of the Input Diode Terminals 1 Black and 2 White It should be 320 VAC 6 Depress the torch trigger Air should flow 7 Check for illumination of the LD2 on both the Control Board an...

Page 28: ...module 1 RemoveAC 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 o...

Page 29: ...ck 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...

Page 30: ...checks 1 Input Diode Module Board Circuit Test a Check Input Diode for short per schematic located in Appendix 4 b Use the following photo with call outs for test points O C V Measured between these p...

Page 31: ...770 E3 White DD 1 270 White 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 4 G1 Black 1...

Page 32: ...ridge Check 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 o...

Page 33: ...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 Info...

Page 34: ...y 9 0296 13 1 Fan 9 7164 14 1 Connector 9 0305 15 1 Case Torch Cover 9 0337 16 1 Case Bottom 9 0336 17 1 Capacitor Assembly 9 0350 18 1 Heat Sink Assembly 9 0349 19 1 Reactor 9 7110 20 1 Main Transfor...

Page 35: ...Manual 0 4699 7 3 Parts List Art A 07757 1 2 3 Art A 07758 4 5 6 7 8 9...

Page 36: ...Parts List 7 4 Manual 0 4699 Art A 07759 10 11 13 6 Art A 07760 14 15 16 17 18 19 20 21...

Page 37: ...Manual 0 4699 7 5 Parts List Art A 07761 MAGNET ASSEMBLY 22 23 24 25 26 27 28 33 MAGNET DISASSEMBLE 29 30 31 32...

Page 38: ...sembly 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...

Page 39: ...Manual 0 4699 7 7 Parts List 5 6 3 4 2 7 7 A 07060 1 8...

Page 40: ...Parts List 7 8 Manual 0 4699 This Page Left Blank...

Page 41: ...nds Then Stops 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...

Page 42: ...tch 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...

Page 43: ...Manual 0 4699 A 3 APPENDIX This Page Left Blank...

Page 44: ...104MF 103 3KV NFB FILTER W Bk INPUT AC230V 1 3 PH Input Power Connection R W Bk Bk Bk Bk W W W Bk W R4 R3 R7 C7 C8 C12 C13 DIODE C4 C5 C3 FUSE CONTROL 3A IGBT IGBT Solenoid V V AC230 AC160 AC230 AC12...

Page 45: ...1 OU_1 GN_1 VC_2 VD_2 OU_2 GN_2 Current Sensor WORK PILOT TORCH S W S W P6 P3 P4 VC_1 VD_1 OU_1 GN_1 VC_2 VD_2 OU_2 GN_2 CN1 N C N C HOLD AIR ERROR 220VAC 2 2 W W W W Bk Jumper Pilot DC Output 50 12VD...

Page 46: ...3 G2 E1 P8 E3 FAN T AC160 AC230 AC15 AC12 AC15 CN2 NFB MAGNET P7 P9 P5 C14 P1 P1 G3 E4 G4 IGBT MAIN POWER P11 R3 C12 R9 R7 C7 TEMP ERROR HOLD C13 No 40279016 DELAY PCB PW 1 0300 P 02 Pressure Sensor S...

Page 47: ..._1 OU_1 VD_1 OU_2 VD_2 TORCH WORK P3 VC_2 VD_2 GN_2 GN_1 VC_1 REACTOR C16 R1 C11 GN_1 VC_1 Pilot Relay VC_2 GN_2 PILOT AB HOLD AIR CHECK Current Sensor Main Transformer oct 18 2005 No 40276002 R8 R5 C...

Page 48: ...APPENDIX A 8 Manual 0 4699 This Page Left Blank...

Page 49: ...trict 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 Eh...

Page 50: ...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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