Thermal Dynamics Cutskill 35A User manual

AMP

PHASE

Art # A-09203

CUTSKILL™

PLASMA CUTTING SYSTEM

35A

Operating Manual

Rev. AA Issue Date: June 30, 2009 Manual # 0-5063

Operating Features:

ARCWELDINGSUPPLIES-078477870

WE APPRECIATE YOUR BUSINESS!

Congratulations on your new Thermal Dynamics product. We are

proud to have you as our customer and will strive to provide you

with the best service and reliability in the industry. This product is

backed by our extensive warranty and world-wide service network.

To locate your nearest distributor or service provider visit us on

the web at www.cigweld.com.au (Asia Paciﬁc) www.thermal-

dynamics.com (Americas and Europe).

This Operating Manual has been designed to instruct you on the

correct use and operation of your Thermal Dynamics product. Your

satisfaction with this product and its safe operation is our ultimate

concern. Therefore please take 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 competition through market-

leading, dependable products that have stood the test of time.

We pride ourselves on technical innovation, competitive prices,

excellent delivery, superior customer service and technical support,

together with excellence in sales and marketing expertise.

Above all, we are committed to developing technologically advanced

products to achieve a safer working environment within the welding

industry.

ARCWELDINGSUPPLIES-078477870

Plasma Cutting Power Supply

CutSkill™ 35A

SL60 1Torch™

Operating Manual Number 0-5063

Published by:

Thermal Dynamics Corporation

82 Benning Street

West Lebanon, New Hampshire, USA 03784

(603) 298-5711

www.thermal-dynamics.com

Thermadyne Corporation

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 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 #:___________________________________ ___________

WARNINGS

Read and understand this entire Manual and your employer’s safety practices before installing,

operating, or servicing the equipment.

While the information contained in this Manual represents the Manufacturer's best judgement, the

Manufacturer assumes no liability for its use.

ARCWELDINGSUPPLIES-078477870

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.............................................................................................................. 1-3

1.04 Declaration of Conformity ........................................................................................ 1-4

1.05 Statement of Warranty ............................................................................................. 1-5

SECTION 2 SYSTEM: INTRODUCTION ..................................................................................................... 2-1

2.01 Working Principle..................................................................................................... 2-1

2.02 Power Supply Speciﬁcations .................................................................................... 2-1

2.03 Input Wiring Speciﬁcations ...................................................................................... 2-2

2.04 Power Supply Features............................................................................................. 2-3

SECTION 2 TORCH: INTRODUCTION ..................................................................................................... 2T-1

2T.01 Scope of Manual..................................................................................................... 2T-1

2T.02 Speciﬁcations ........................................................................................................ 2T-1

2T.03 Introduction to Plasma........................................................................................... 2T-2

SECTION 3: INSTALLATION ..................................................................................................................... 3-1

3.01 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: SERVICE.................................................................................................................. 5T-1

5T.01 General Maintenance.............................................................................................. 5T-1

5T.02 Inspection and Replacement of Consumable Torch Parts....................................... 5T-1

SECTION 6: PARTS LISTS ......................................................................................................................... 6-1

6.01 Introduction.............................................................................................................. 6-1

6.02 Ordering Information................................................................................................ 6-1

APPENDIX 1: CIRCUIT DIAGRAM ............................................................................................................ A-1

GLOBAL CUSTOMER SERVICE CONTACT INFORMATION...................................................Inside Rear Cover

ARCWELDINGSUPPLIES-078477870

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.

ARCWELDINGSUPPLIES-078477870

cutskill 35A

GENERAL INFORMATON 1-2 June 30, 2009

NOISE

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 work-

place.

• 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 Sub-

section 1.03, Publications, in 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 infrared

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 protec-

tive 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.

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 reproductive harm. Wash hands after

handling. (California Health & Safety Code § 25249.5 et seq.)

Eye protection ﬁlter shade selector for welding or cutting

(goggles or helmet), from AWS A6.2-73.

Welding or Cutting

Operation

Electrode Size

Metal Thickness

Filter

Shade

Welding or Cutting

Operation

Electrode Size

Metal Thickness

Filter

Shade

Torch soldering 2 Gas metal-arc

welding (MIG)

Torch brazing 3 or 4 Non-ferrous base metal All 11

Oxygen Cutting Non-ferrous base metal All 12

Light Under 1 in., 25 mm 3 or 4 Gas tungsten arc welding All 12

Medium 1 to 6 in., 25-150 mm 4 or 5 (TIG) All 12

Heavy Over 6 in., 150 mm 5 or 6 Atomic hydrogen welding All 12

Gas welding Carbon arc welding All 12

Light Under 1/8 in., 3 mm 4 or 5 Plasma arc welding

Medium 1/8 to 1/2 in., 3-12 mm 5 or 6 Carbon arc air gouging

Heavy Over 1/2 in., 12 mm 6 or 8 Light 12

Shielded metal-arc

welding

(stick) electrodes

Under 5/32 in., 4 mm 10 Heavy 14

5/32 to 1/4 in.,

4 to 6.4 mm 12 Plasma arc cutting

Over 1/4 in., 6.4 mm 14 Light Under 300 Amp 9

Medium 300 to 400 Amp 12

Heavy Over 400 Amp 14

Table 1-1

ARCWELDINGSUPPLIES-078477870

cutskill 35A

June 30, 2009 1-3 GENERAL INFORMATION

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

2. ANSI Standard Z49.1, SAFETY IN WELDING AND CUTTING,

obtainable from the American Welding Society, 550 N.W.

LeJeune Rd, Miami, FL 33126

3. NIOSH, SAFETY AND HEALTH IN ARC WELDING AND GAS

WELDING AND CUTTING, obtainable from the Superin-

tendent 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, obtain-

able 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 Stan-

dards Institute, 1430 Broadway, New York, NY 10018

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 CONTAIN-

ERS 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, 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 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 obtain-

able from the National Welding Supply Association, 1900

Arch Street, Philadelphia, PA 19103

14. American Welding Society Standard AWSF4.1, RECOM-

MENDED 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 PRO-

TECTION, obtainable from American National Standards

Institute, 1430 Broadway, New York, NY 10018

16. Safety in Welding and Allied Processes Part 2: Electrical,

AS1674.2-2007 from SAI Global Limited, www.saiglobal.

com

ARCWELDINGSUPPLIES-078477870

cutskill 35A

GENERAL INFORMATON 1-4 June 30, 2009

1.04 Declaration of Conformity

Manufacturer: Thermadyne Company

Address: 82 Benning Street

West Lebanon, New Hampshire 03784

USA

The equipment described in this manual conforms to all applicable aspects and regulations of the ‘Low Voltage Directive’ (European Council

Directive 73/23/EEC as amended by Council Directive 93/68/EEC) and to the National legislation for the enforcement of this Directive.

The equipment described in this manual conforms to all applicable aspects and regulations of the "EMC Directive" (European Council Directive

89/336/EEC) and to the National legislation for the enforcement of this Directive.

Serial numbers are unique with each individual piece of equipment and details description, parts used to manufacture a unit and date of

manufacture.

National Standard and Technical Speciﬁcations

The product is designed and manufactured to a number of standards and technical requirements. Among them are:

* CSA (Canadian Standards Association) standard C22.2 number 60 for Arc welding equipment.

* 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.

* 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 used in

conjunction with hand torches with exposed cutting tips, if equipped with properly installed standoff guides.

* Extensive product design veriﬁcation is conducted at the manufacturing facility as part of the routine design and manufacturing process.

This is to ensure the product is safe, when used according to instructions in this manual and related industry standards, and performs

as speciﬁed. Rigorous testing is incorporated into the manufacturing process to ensure the manufactured product meets or exceeds all

design speciﬁcations.

Thermadyne has been manufacturing products for more than 30 years, and will continue to achieve excellence in our area of manufacture.

Manufacturers responsible representative in Europe: Steve Ward

Operations Director

Thermadyne Europe

Europa Building

Chorley N Industrial Park

Chorley, Lancashire,

England PR6 7BX

ARCWELDINGSUPPLIES-078477870

cutskill 35A

June 30, 2009 1-5 GENERAL INFORMATION

1.05 Statement of Warranty

LIMITED WARRANTY: Subject to the terms and conditions established below, Thermadyne Company warrants to the original retail purchaser

that new Thermal Dynamics CUTSKILL™ 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 Company shall, upon

notiﬁcation thereof and substantiation that the product has been stored operated and maintained in accordance with Thermadyne’s 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 Company must be notiﬁed within 30 days of any failure, at which time Thermadyne Company will

provide instructions on the warranty procedures to be implemented.

Thermadyne Company 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 or 1 year after sale to an authorized Thermadyne Distributor.

LIMITED WARRANTY PERIOD

Product Power Supply Components

(Parts and Labor)

Torch and Leads

(Parts and Labor)

CUTSKILL 35A 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 Company:

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 Company 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 Thermal Dynamics product is sold by non - authorized persons.

Effective June 30, 2009

ARCWELDINGSUPPLIES-078477870

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