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cutskill 35A

June 30, 2009                                                                     1-1                                                       GENERAL INFORMATION

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 operat-

ing area.

1.02  Important Safety Precautions

!

 WARNING

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 fol-

low all warnings, safety precautions and instructions 

before using the equipment.  Call 1-603-298-5711 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 chlo-

rinated 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.”
•  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 Manu-

al.

 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 work-

place.

•  Do not cut or weld on containers that may have held com-

bustibles.

•  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 aluminum 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. 

ARC WELDING SUPPLIES - 07 847 7870

Содержание cutskill 35A

Страница 1: ...35 AMP 1 PHASE DC Art A 09203 cutskill plasma cutting system 35A Operating Manual Rev AA Issue Date June 30 2009 Manual 0 5063 Operating Features A R C W E L D I N G S U P P L I E S 0 7 8 4 7 7 8 7 0 ...

Страница 2: ...e the time to read the entire manual especially the Safety Precautions They will help you to avoid po tential hazards that may exist when working with this product YOU ARE IN GOOD COMPANY The Brand of Choice for Contractors and Fabricators Worldwide Thermal Dynamics is a Global Brand of manual and automation Plasma Cutting Products for Thermadyne Industries Inc We distinguish ourselves from our co...

Страница 3: ...ether such error results from negli gence accident or any other cause Publication Date June 30 2009 Record the following information for Warranty purposes Where Purchased ____________________________________________ Purchase Date _______________________________________________ Power Supply Serial _________________________________________ Torch Serial _______________________________________________...

Страница 4: ... 01 Unpacking 3 1 3 02 Lifting Options 3 1 3 03 Primary Input Power Connections 3 1 3 04 Gas Connections 3 2 SECTION 4 SYSTEM OPERATION 4 1 4 01 Control Panel 4 1 4 02 Preparations For Operating 4 2 4 03 Sequence of Operation 4 4 4 04 Cut Quality 4 7 4 05 General Cutting Information 4 8 SECTION 5 SYSTEM SERVICE 5 1 5 01 General Maintenance 5 1 5 02 Basic Troubleshooting Guide 5 3 SECTION 5 TORCH S...

Страница 5: ... 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 co...

Страница 6: ...ggested 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 LEAD WARNING This product contains chemicals including lead or otherwise produces chemicals known to the State of California to cause cancer birth defects and other re...

Страница 7: ... 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 obtain able from the National Fire Protection Association Bat terymarch Park Quincy MA 02269 10 NFPA Standard 51B CUTTING AND WELDING PROCESSES obtainable from the National Fire Protection Association Batterymarch P...

Страница 8: ... 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 AS60974 1 Arc Welding Equipment Welding Power Sources For environments with increased hazard of electrical shock Power Supplies bearing the mark conform to EN50192 when u...

Страница 9: ...arter 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 Company 1 Repair of the defective product 2 Replacement of the defective product 3 Reimbursement of reasonable c...

Страница 10: ...A R C W E L D I N G S U P P L I E S 0 7 8 4 7 7 8 7 0 ...

Страница 11: ...an shown in this chart 2 Air supply must be free of oil moisture and other contaminants Excessive oil and moisture may cause double arcing rapid tip wear or even complete torch failure Contaminants may cause poor cutting perfor mance and rapid electrode wear Optional filters provide increased filtering capabilities NOTE IEC Rating is determined as specified by the International Electro Technical C...

Страница 12: ...wer Input Current Input Current Input Suggested Sizes See Note Voltage Freq kVA Max Amps Ieff Amps Fuse Amps Volts Hz 1 Ph 1 Ph 1 Ph 1 Ph 240 50 3 4 27 3 14 20 Line Voltages with Suggested Circuit Protection Motor start fuses or thermal circuit breakers are recommended for this application Check local requirements for your situation in this regard NOTE Refer to Local and National Codes or local au...

Страница 13: ...ure Regulator Filter Assembly Control Panel Torch Lead RUN SET CURRENT A 25 35 READY AIR OVERHEAT POWER 240V AC Power Source Work Cable and Clamp Art A 09175 Gas Pressure Regulator Filter Assembly Gas Pressure Gauge Art A 09176 A R C W E L D I N G S U P P L I E S 0 7 8 4 7 7 8 7 0 ...

Страница 14: ...This Page left blank intentionally A R C W E L D I N G S U P P L I E S 0 7 8 4 7 7 8 7 0 ...

Страница 15: ...s 10 ft 3 m C Torch Parts Starter Cartridge Electrode Tip Shield Cup D Parts In Place PIP Torch Head has built in switch 12 vdc circuit rating E Type Cooling Combination of ambient air and gas stream through torch F Torch Ratings SL60 Torch Ratings Ambient Temperature 104 F 40 C Duty Cycle 100 60 Amps 400 scfh Maximum Current 60 Amps Voltage Vpeak 500V Arc Striking Voltage 7kV G Current Ratings SL...

Страница 16: ...concentration of heat to a small area The stiff constricted plasma arc is shown in Zone C Direct current DC straight polarity is used for plasma cutting as shown in the illustration Zone A channels a secondary gas that cools the torch This gas also assists the high velocity plasma gas in blowing the molten metal out of the cut allowing for a fast slag free cut A 00002 Workpiece Power Supply _ C B ...

Страница 17: ...ndle for hand lifting only Be sure unit is lifted and transported safely and securely WARNING Do not touch live electrical parts Disconnect input power cord before moving unit FALLING EQUIPMENT can cause serious personal injury and can damage equipment HANDLE is not for mechanical lifting Only persons of adequate physical strength should lift the unit Lift unit by the handle using two hands Do not...

Страница 18: ...fe work voltage range it will shorten the power source life span 3 04 Air Supply Connections A Connecting Air Supply to Unit The connection is the same for compressed air or industrial compressed air in gas cylinders 1 Connect the gas line to the compressed air input inlet port at the appropriate pressure The illustration shows typical fittings as an example NOTE For a secure seal apply thread sea...

Страница 19: ...of oil grease or any foreign material Briefly open each cylinder valve to blow out any dust which may be present 3 The cylinder must be equipped with an adjustable high pressure regulator capable of outlet pressures up to 100 psi 6 9 bar maximum and flows of at least 300 scfh 141 5 lpm 4 Connect gas supply hose to the cylinder NOTE Pressure should be set at 100 psi 6 9 bar at the high pressure gas...

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Страница 21: ...setting gas pressure and purging lines 3 A Output Current Control Sets the desired output current If the overload protection fuse or circuit breaker on the input power circuit opens frequently either reduce cutting output reduce the cutting time or connect the unit to more adequate input power Refer to Section 2 for input power requirements 4 Power ON Indicator AC Indicator Steady light indicates ...

Страница 22: ...ies 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 35 amps maximum Use only genuine Thermal Dynamics parts with this torch Art A 03409_AB Large O Ring Cat No 8 3487 Small O Ring Cat No 8 3486 Electrode Cat No 9 8215 Start Cartridge Cat No 9 8213 Shie...

Страница 23: ...le to the workpiece or cutting table The area must be free from oil paint and rust Con nect only to the main part of the workpiece do not connect to the part to be cut off Art A 03387 F Power On Place the power supply ON OFF switch to the ON I position Power indicator turns on Art A 09181 RUN SET CURRENT A 15 25 35 READY AIR OVERHEAT POWER Front Panel With Power ON OFF Indicator G Set Operating Pr...

Страница 24: ...sequence of operation for this power supply Refer to Appendix 1 for block diagram 1 Plug the input power cord into an active circuit a AC power is available at the power supply 2 Place the ON OFF switch on the power supply to ON up position a AC indicator turns on fan turns on NOTE Gas will automatically flow from torch for 4 seconds this is a safety circuit that makes sure the torch tip is proper...

Страница 25: ...orch head for maximum control or near the back end for maximum heat protection Choose the hold ing technique that feels most comfortable and allows good control and movement NOTE The tip should never come in contact with the workpiece except during drag cutting operations B Depending on the cutting operation do one of the following a For edge starts hold the torch perpendicular to the workpiece wi...

Страница 26: ...he output current B The torch can be comfortably held in one hand or steadied with two hands Position the hand to press the Trigger on the torch handle With the hand torch the hand may be positioned close to the torch head for maximum control or near the back end for maximum heat protection Choose the hold ing technique that feels most comfortable and allows good control and movement C Keep the to...

Страница 27: ... Build Up Top Spatter A 00007 Cut Quality Characteristics Cut Surface The desired or specified condition smooth or rough of the face of the cut Nitride Build Up Nitride deposits can be left on the surface of the cut when nitrogen is present in the plasma gas stream These buildups may create difficulties if the material is to be welded after the cutting process Bevel Angle The angle between the sur...

Страница 28: ...ickly as possible Direction of Cut In the torches the plasma gas stream swirls as it leaves the torch to maintain a smooth column of gas This swirl effect results in one side of a cut being more square than the other Viewed along the direction of travel the right side of the cut is more square than the left Right Side Cut Angle Left Side Cut Angle A 00512 Side Characteristics Of Cut To make a squa...

Страница 29: ... Source must be returned to an Accredited CIGWELD Service Provider for repair Each Use Visual check of torch tip and electrode Weekly Visually inspect the torch body tip electrode start cartridge and shield cup Visually inspect the cables and leads Replace as needed 3 Months 6 Months Replace all broken parts Visually check and Carefully clean the interior Maintain more often if used under severe c...

Страница 30: ... 1 Common Faults symptom A Gas regulator leakage 1 Gas regulator on a Reset the regulator to 0 PSI and re adjust it to 65 PSI 4 5 bar B AC indicator OFF 1 Main input power cord does not connect to power distribution net a Connect the power cord 2 Power ON OFF switch in OFF down position a Turn switch to ON up position 3 Actual input voltage does not correspond to voltage of unit a Verify that the ...

Страница 31: ...orking cable not connected to work piece or connection is poor a Make sure that work cable has a proper connection to a clean dry area of the work piece 3 Faulty components in unit a Return for repair or have qualified technician repair per service manual 4 Faulty torch a Return for repair or have qualified technician repair G Torch cuts but not adequately 1 Incorrect setting of output current con...

Страница 32: ...ted TEMP indicator ON a Let unit cool down for at least 5 minutes Make sure the unit has not been operated beyond duty cycle limit 2 Fan blades blocked TEMP indicator ON a Check and clear blades 3 Air flow blocked a Check for blocked air flow around the unit and correct condition 4 Gas pressure is too low Air indicator ON when torch trigger is activated a Check gas source It should be set to at le...

Страница 33: ...spection and Replacement of Consumable Torch Parts WARNING Disconnect primary power to the system before disassembling the torch or torch leads DO NOT touch any internal torch parts while the AC indicator light of the Power Supply is ON Remove the consumable torch parts as follows NOTE The shield cup holds the tip and starter cartridge shield cup in place Position the torch with the shield cup fac...

Страница 34: ...cessive wear Refer to the following figure Worn Electrode New Electrode Art A 03284 Electrode Wear 6 Reinstall the electrode by pushing it straight into the torch head until it clicks 7 Reinstall the desired starter cartridge and tip into the torch head 8 Hand tighten the shield cup until it is seated on the torch head If resistance is felt when install ing the cup check the threads before proceed...

Страница 35: ...sure Switch 9 0136 7 1 Current Transformer 9 0138 1 3 4 2 5 Art A 09192_AB 6 7 B Returns If a product must be returned for service contact your distributor Materials returned without proper authorization will not be accepted 6 02 Ordering Information Order replacement parts by catalog number and complete description of the part or assembly as listed in the parts list for each type item Also includ...

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Страница 37: ...e in Microfarads UF TITLE SCHEMATIC 35A 240V SINGLE PHASE 50 60 Hz Date By Rev Revision PILOT WORK T O R C H WV OUTPUT BLACK RED FAN DC24V AC240V INPUT 50 60 Hz AC240V D T WV OUTPUT FEEDBACK SIGNAL N A DRIVE POWER OT AIR READY CURRENT CONTROL SET RUN DRIVE SIGNAL N A SOURCE TIP SIGNAL HF QF GAS SOLENOID TEST TORCH SW PRESSURE SW OVER TEMPERATURE 1 2 3 1 2 3 1 2 1 2 3 4 1 2 3 4 1 2 3 4 5 1 2 3 4 5 ...

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Страница 39: ...ababeka VI Blok P No 3 Cikarang Bekasi 17550 Indonesia Telephone 62 21 8936071 Fax 62 21 8936067 6068 http www thermadyne com 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 Thermadyne Australia 71 Gower Street Preston Victoria Australia 3072 Telephone 61 3...

Страница 40: ...acific Regional Headquarters 71 Gower Street Preston Victoria Australia 3072 Telephone 61 3 9474 7400 Fax 61 3 9474 7488 Email cigweldsales cigweld com au A R C W E L D I N G S U P P L I E S 0 7 8 4 7 7 8 7 0 ...

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