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PLASMA

Art # A-09400

CUTSKILL

®

Service   Manual

C-35C

PLASMA CUTTING
SYSTEM

Rev. AB          Date: November 17, 2009          Manual 0-4745

Operating Features:

Содержание CUTSKILL C-35C

Страница 1: ...PLASMA Art A 09400 CUTSKILL Service Manual C 35C PLASMA CUTTING SYSTEM Rev AB Date November 17 2009 Manual 0 4745 Operating Features ...

Страница 2: ......

Страница 3: ...7 2008 2009 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 th...

Страница 4: ......

Страница 5: ...ON 3 0 INSTALLATION 3 1 3 01 Site Selection 3 1 3 02 Electrical Input Connections 3 1 3 03 Torch 3 1 SECTION 4 0 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 SECTION 6 TROUBLESHOOTING 6 1 6 01 Normal Setup and Operation 6 1 6 02 Basic Trouble Shooting Guide 6 2 6 03 Control PCB Indicators 6 3 6 04 Open Circuit...

Страница 6: ...erating Sequence Block Diagram A 1 Appendix 2 Torch Connection A 2 Appendix 3 Microchip Pin Out A 3 Appendix 4 System Schematic 230V CE A 4 Appendix 5 System Schematic 230V A 6 GLOBAL CUSTOMER SERVICE CONTACT INFORMATION Inside Rear Cover ...

Страница 7: ...rcury 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 workplac...

Страница 8: ...h Safety Code 25249 5 et seq 1 03 Publications Refer to the following standards or their latest revisions for more infor mation 1 OSHA SAFETY AND HEALTH STANDARDS 29CFR 1910 obtainable from the Superintendent of Documents U S Government Printing Office Washington D C 20402 2 ANSI Standard Z49 1 SAFETY IN WELDING AND CUTTING obtainable from the American Welding Society 550 N W LeJeune Rd Miami FL 3...

Страница 9: ...CTICE FOR RESPIRATORY PRO TECTION obtainable from American National Standards Institute 1430 Broadway New York NY 10018 Montez et maintenez le matériel conformément au Code électrique national des Etats Unis Voir la page 5 article 9 Débranchez l alimentation électrique avant tout travail d entretien ou de réparation Lisez et respectez toutes les consignes du Manuel de consignes ...

Страница 10: ...t 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 EN50192 EN50078 applicable to plasma cutting equipment and associated accessories For environments with increased hazard of electrical shock Power Supplies bearing the S mark conform to EN50192 when ...

Страница 11: ...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...

Страница 12: ...GENERAL INFORMATION 1 6 Manual 0 4745 ...

Страница 13: ...ity 5 8 15 mm Dimension W D H 10 5 x15 5 x11 267 mm x 394 mm x 279 mm Gross Weight 57 lbs 26 kg Duty cycle 104 F 40 C Ambient NOTE Refer to Local and National Codes or local au thority having jurisdiction for proper wiring re quirements 2 03 Features COMPACT and LIGHT Designed for easy trans portation ENERGY EFFICIENCY Advanced technology reduces power consumption HIGH SPEED GENUINE CUTTING The co...

Страница 14: ...ation with exposed tip the recommended standoff height is 1 8 3 8 3 9 mm Plasma Power Supply Used With 35C PCH 42 Torch Ratings 2 05 System Contents Description ITEMS Q ty Power source Model Drag Gun Plus 1 Torch Set PCH 42 with 20 6 1 m leads 1 Accessories Consumables Work Cable Manual Torch Electrodes Torch Tips 1 1 2 3 Input Power Cable U S CAN 3 Meter NEMA 10 AWG 4 8 mm2 with 6 50 P molded plu...

Страница 15: ... and any extension cords used must conform to local electrical code and the recommended circuit protection and wir ing requirements as specified in Section 2 3 03 Torch Make sure that the torch cable and torch switch terminals are connected to front panel Make sure the Work Cable is connected properly to front panel Before activating turn torch away from yourself and others DANGER Do not cut in hu...

Страница 16: ...Installation 3 2 Manual 0 4745 This Page Left Blank ...

Страница 17: ...t is possible to have enough air pressure to op erate the power supply but not enough air flow to operate the torch Torch 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 ...

Страница 18: ...ece or cutting table Work Cable And Clamp Art A 04389 D Torch Operation Wear gloves and protective goggles Do not place bare hand on work piece 1 For drag cutting keep the torch in contact with the workpiece 2 For standoff cutting hold the torch 1 8 3 8 in 3 9 mm from the workpiece as shown be low A 00024_AB Shield Cup Torch Standoff Distance 1 8 3 8 3 9mm 3 With the torch in starting position pre...

Страница 19: ...ighest setting and torch held at the indicated standoff height Unit Standoff Material Thickness ipm mm m ipm mm m 35C Drag 10 ga 0 135 3mm 94 7 2367 75 7 1893 35C Drag 7 ga 0 179 4 5mm 57 0 1425 45 6 1140 35C 1 8 3mm 1 4 6mm 36 3 908 29 1 727 35C 1 8 3mm 3 8 9 5mm 15 3 383 12 3 307 35C 1 8 3mm 1 2 12mm 9 7 242 7 7 193 Recommended Travel Speed Maximum Travel Speed NOTE Drag or Drag mode refers to t...

Страница 20: ...Operation 4 4 Manual 0 4745 This Page Left Blank ...

Страница 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 Months Replace all broken parts Visually check and Carefully clean the interior Maintain more often if used under severe conditions Art A 06884 ...

Страница 22: ...Maintenance 5 2 Manual 0 4745 This Page Left Blank ...

Страница 23: ...k surface within 3 5 seconds before the pilot arc turns off If arc was lost before transfer to work surface release the torch trigger and squeeze the trigger again to establish the pilot arc 7 When the torch trigger is released the compressor will continue to run for post flow approximately 15 seconds WARNING There are extremely dangerous voltage and power levels present inside this unit Do not at...

Страница 24: ...rch switch is activated 1 Airpressure too high ortoo low 2 Torch consumables missing 3 Worn orfaultytorch parts 4 Thermal Switch activated 1 Thereis no adjustment return to an authorized service centerforrepair 2 Turn off powersupply Removeshield cup Install missing parts 3 Inspect torch consumableparts Replaceif necessary 4 Allowthecooling fan to run for2 minutes orlongeruntil it will resumeopera...

Страница 25: ... the cooling fan comes on 2 Locate the Control PCB behind the front panel LD2 EN LED should be ON Illustration 6 1 Control PCB 3 Press the Air Set Button The the air compressor should come on causing air to flow through the torch and LD1 SOL LED should light Press the Air Set Button again and the air compressor stops and the LED goes out 4 Squeeze the torch trigger The pilot arc and compressor sta...

Страница 26: ...If not then the trigger will have to be releaed and then depressed again 6 Check for illumination of the SOL LED and that the EN Enable LED brightens on the Logic PCB 1 2 3 4 Art A 06991 5 6 Illustration 6 2 7 Measure output to Main Transformer Input between points 5 and 6 in Illustration 6 2 above It should be 220VAC 8 Measure Main Transformer secondary voltage between points 3 and 4 in Illustrat...

Страница 27: ...s needed 2 Change air related items as needed 3 If OCV is not OK follow OCV check procedures in section 6 04 4 If CN9 connection is OK replace the Control PCB Torch doesn t Pilot and the LD1 LED on the Control PCB is not on Check all air supply related issues before proceding If there are no air related issues replace the Control PCB CO LED on Control PCB comes on when not transferring Check Cable...

Страница 28: ... 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 direction and indicate between 0 3 to 0 9 volts 0 75 VR COM A Art...

Страница 29: ...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 ...

Страница 30: ...pen After Charging E1 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 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 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 Whi...

Страница 31: ...ort less than 1 Ohm Refer to diagram Torch Switch Negative Plasma Lead Torch Head White Black Orange Green PIP Switch Torch Leads To Power Supply Adapter Pilot Pilot 2 1 Continuity Check Art A 05557 2 Shorted Torch Check a Disconnect input power 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 Open If ...

Страница 32: ...TROUBLE SHOOTING 6 10 Manual 0 4745 This Page Left Blank ...

Страница 33: ...he power supply model number and serial number when ordering parts If a product must be returned for service contact your distributor Materials returned without proper authoriza tion 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 ...

Страница 34: ...PCB 9 7147 12 1 Relay 9 0319 13 1 Resistor 9 0300 14 1 Control Transformer 9 7144 15 1 Bracket Capacitor 9 0302 16 1 Electrolytic Capacitor Assembly 9 0303 17 1 Bracket Upper 9 0313 18 1 Compressor Part 9 0320 19 1 Current Sensor 9 7153 20 1 PCB Input Filter shown 9 7128 20 1 PCB Input Filter CE 9 7133 21 1 Heat Sink Assembly 9 0306 22 1 Case Torch Cover 9 0314 23 1 Connector 9 0305 24 1 Pilot Rel...

Страница 35: ...Manual 0 4745 7 3 PARTS LIST Art A 07768 1 2 3 4 5 6 7 8 Art A 07769 9 10 11 12 13 14 15 16 17 18 19 20 ...

Страница 36: ...PARTS LIST 7 4 Manual 0 4745 Art A 07770 21 22 23 24 25 26 27 28 29 ...

Страница 37: ...Manual 0 4745 7 5 PARTS LIST This Page Left Blank ...

Страница 38: ...Trigger includes items 5 12 9 8076 5 1 Trigger Lexan Orange 9 8059 6 1 Handle 9 8060 7 1 Spring 0 390 O D x 0 750 9 8061 8 1 Torch Handle Socket Head Cap Screw Kit 5 pcs 6 32 x 1 2 9 8062 9 1 Assembly Torch Switch 9 8063 10 1 Negative Plasma Lead Insulation Sleeving 9 8056 11 3 Pin Housing Used with item 12 9 8111 12 3 Pin 9 8101 13 3 Socket Housing Used with item 14 9 8112 14 3 Socket 9 8102 15 1...

Страница 39: ...Manual 0 4745 7 7 PARTS LIST Art A 07061 1 7 8 6 6 15 9 2 10 3 4 5 11 12 13 14 ...

Страница 40: ...PARTS LIST 7 8 Manual 0 4745 This Page Left Blank ...

Страница 41: ...tch On Compressor Starts and Air Flows at Torch 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 required for Torch to Pilot...

Страница 42: ... and air Lay unit on its side Remove two screws and access plate Pilot Power Supply Adapter Connections Negative Plasma Lead Art A 04695 DETAIL To Power Supply Adapter Pilot Negative Plasma Lead Black Orange Green White PIP Switch Torch Switch Pilot Torch Leads Torch Head ...

Страница 43: ...45 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 ...

Страница 44: ...H R1 Control Board Panel Board Compressor Bk Wh DIODE 230 VAC W W N C Red Bk DC 325 NOTE Do Not attempt to adjust the PCB POTs E4 G3 G2 G4 E3 E1 E2 G1 TW TW TW TW B W G R B W G R 230 VAC Lt Bl W Br 580 Ω 672Ω W W Bk Bk R W W Bk 50 Ω R Bl Bl Bl Or Or N C W W Located on IGBT Heatsink 2 1 N C N C Bl Bl R R Bk LD1 SOL LD3 CO CN5 12VDC 25VDC 2 2 12VDC 1 1 1 3 3 3 3 1 1 1 230 VAC 230 VAC W 2 Bk 2 C2 R2 ...

Страница 45: ...oard Air Plasma 35C 230V CE No 66001012 CN10 5 12VDC 12VDC 1 2 3 4 BR Red O Y G W Twisted CN12 1 2 12VDC to engage Pilot Relay Torch Filter CN3 W W 12VDC 2 1 LD2 Enable Bk 220 VAC 190VAC O C V 325 Pilot 130 Cutting 80 100 See Sec 6 OCV in Service Manual Br R Y G O Bk 2 1 No H F On 80 Ω W W Y Y PCR Y Y Bk 1 only NOTE Do Not attempt to adjust the PCB POTs LD4 H V 3 1 36VAC 10k Ω CN1 Spark Gap PCB no...

Страница 46: ...PH R1 Control Board Panel Board Compressor Bk Wh DIODE 230 VAC W W N C Red Bk DC 325 NOTE Do Not attempt to adjust the PCB POTs E4 G3 G2 G4 E3 E1 E2 G1 TW TW TW TW B W G R B W G R 230 VAC Lt Bl W Br 580 Ω 672Ω W W Bk Bk R W W Bk 50 Ω R Bl Bl Bl Or Or N C W W Located on IGBT Heatsink 2 1 N C N C Bl Bl R R Bk LD1 SOL LD3 CO CN5 12VDC 25VDC 2 2 12VDC 1 1 1 3 3 3 3 1 1 1 230 VAC 230 VAC W 2 Bk 2 C2 R2...

Страница 47: ... Board Air Plasma 35C 230V No 66001008 CN10 5 12VDC 12VDC 1 2 3 4 BR Red O Y G W Twisted CN12 1 2 12VDC to engage Pilot Relay Torch Filter CN3 W W 12VDC 2 1 LD2 Enable Bk 220 VAC 190VAC O C V 325 Pilot 130 Cutting 80 100 See Sec 6 OCV in Service Manual Br R Y G O Bk 2 1 No H F On 80 Ω W W Y Y PCR Y Y Bk 1 only NOTE Do Not attempt to adjust the PCB POTs LD4 H V 3 1 36VAC 10k Ω CN1 Spark Gap PCB not...

Страница 48: ...APPENDIX A 8 Manual 0 4745 This Page Left Blank ...

Страница 49: ...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...

Страница 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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