Thermal Dynamics Drag-Gun PLUS 35C
Contents
1. A B C 230 VAC Gs DIODE IGBT IGBT L BK EN 230 VAC me 1 wem I 12 181 a 182 N C M te LN T 3 Inrush Filter PCB r LE No 40276005 5 87 mE CN2 om o4 CO3G W 7 el E _B NY lal NI Hd IL To w w DC 2 W W Bk R 325 E B fae HE C3 230 VAC V R1 500 Ei W TAT 1141 we BK 6161 6262 _ 6368 6464 Capacitor TW TW TW TW 21 Hd DD 5 BWGR BWGR 64 G4E3G3 Go i Located on IGBT NOTE i HIT IH 0 NO CN6 CN8 attempt to adjust the LD1 PCB POTs SUL ES AC230 3 AAC Control Board No 40271005 BI ud Compressor Re A 3 R 25VDC i B RI G Br F li H E nn GEET LD3 NC R CO Br 12VDC I s gt gt gt 27 Sms CN2 I i A Or 1 MF 103K Sensor po bou dl 4000 CNI Panel Board Compressor No 40270601 U A e 2 GC A G BI nae MAIN POWER ERROR ERROR HOLD e Art A 06978 A B C APPENDIX A 4 Manual 0 4751 E F R3 C4 NNA E 220 Main Transformer 1 42. Current Sansor No H F RE LZ On Bk O C V 325 Pilot 130 GT 1 Cutting 80 100 Bk anoe See Sec 6 OCV in Service Manual NE e en rn W gt W GILOT MAR fat REACTOR Conduit Coil o j NE EE R7 C8 2 Sal 2 Twisted 3l i Y W PCR W C 12VDCHTL gt vci BR Mer e A i g LD2 12VDC42 9 VD 1 Red Dis E CN10 8 o 00 Ei H V Board _ L ae BS Y GM No 40273003 S GN_1 Gene ou E gt Se 5 gt GN1 G Es A H V Contactor m 1 Bk 1 only Pim TT S 3l It e Y Y AND to engage onst Pilot Relay Y 3 LD4 412VDC w Torch EH HW oe Filter lt m e IL W pH No 40276002 Do Not attempt to AA adjust the POB CHECK SCH PER Title 4 Air Plasma 35C 230V CE Size Number Rev A2 No 66001012 AA Date oct 19 2005 Drawn by Filename Sheet of D E F Art A 06978 Manual 0 4751 A 5 APPENDIX Appendix 5 System Schematic 230V A B C 230 VAC Red 6 e s DIODE 1681 IGBT Bk ri ER 1 gt T T i 230 VAC 230 VAC NE INPUT El E C2 O ZH Wh Wi Je T El Filter Board E lm No 40
3. Livret NWSA BIBLIOGRAPHIE SUR LA S CURIT DU SOUDAGE disponible aupr s de l Association Nationale de Fournitures de Soudage National Welding Supply Association 1900 Arch Street Philadelphia PA 19103 Norme AWSF4 1 de l Association Am ricaine de Soudage RECOMMANDATIONS DE PRATIQUES SURES POUR LA PR PARATION LA COUPE ET AU SOUDAGE DE CONTENEURS ET TUYAUX AYANT RENFERME DES PRODUITS DANGEREUX disponible aupr s de la American Welding Society 550 N W LeJeune Rd Miami FL 33126 Norme ANSI 288 2 PRATIQUES DE PROTECTION RESPIRATOIRE disponible aupr s de I American National Standards Institute 1430 Broadway New York NY 10018 Manual 0 4751 1 5 DRAG GUN PLUS 356 GENERAL INFORMATION DRAG GUN PLUS 356 1 06 Declaration Of Conformity C Manufacturer Thermadyne Corporation 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
4. i e Air Set Button W To check for proper air setting and to cool down heated torch MAIN CURRENT CONTROL KNOB To adjust cutting current Turning clockwise in creases the cutting current and counter clock wise decreases the cutting current au A Art A 04387 PRIMARY POWER SWITCH ON OFF The power switch is located on the front panel Placing the primary power switch to the ON position energizes the power source WARNING When the power source is overloaded the switch turns to the OFF position automatically DO NOT TURN ON BY FORCE Operation 4 02 Preparations For Operating At the start of each operating session A WARNING Disconnect primary power at the source before assembling or disassembling power supply torch parts or torch and leads assemblies A Torch Parts Selection Check the torch for proper assembly and appro priate 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 manufacturer s parts with this torch Electrode No 9 6542 Gas Distributor No 9 6507 Torch Head Assembly Tip No 9 6501 m Shield Cup No 9 6003 B Torch Connection Art A 04655 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 Cable And Clamp Art A 04389 O
5. e Eloignez toute fum e et gaz de votre zone de respiration Gardez votre t te hors de la plume de fum e provenant du chalumeau Utilisez un appareil respiratoire alimentation en air si Fa ration fournie ne permet pas d liminer la fum e et les gaz e Les sortes de gaz et de fum e provenant de l arc de plasma d pendent du genre de m tal utilis des rev tements se trouvant sur le m tal et des diff rents proc d s Vous devez prendre soin lorsque vous coupez ou soudez tout m tal pouvant contenir un ou plusieurs des l ments suivants antimoine cadmium mercure argent chrome nickel arsenic cobalt plomb baryum cuivre s l nium b ryllium mangan se vanadium e Lisez toujours les fiches de donn es sur la s curit des mati res sigle am ricain MSDS celles ci devraient tre fournies avec le mat riel que vous utilisez Les MSDS contiennent des renseignements quant la quantit et la nature de la fum e et des gaz pouvant poser des dangers de sant e Pour des informations sur la mani re de tester la fum e et les gaz de votre lieu de travail consultez l article 1 et les documents cit s la page 5 Utilisez un quipement sp cial tel que des tables de coupe d bit d eau ou courant descendant pour capter la fum e et les gaz e N tilisez pas le chalumeau au jet de plasma dans une zone o se trouvent des mati res ou des gaz combustibles ou explosifs e Lephosg ne un gaz toxique est g
6. 7 01 Parts List Power Supply Rem Number Quantity Description Catalog Number 6 1 Cecom 00296 8 1 Comm 97165 o 1 066 09000 ore m 1 PoBGont 9701 o a mwe f or 20 1 Brackat Upper 900 22 1 ome Toren Cor 9084 23 1 Pilot Relay Assembly 90304 PARTS LIST 7 2 Manual 0 4751 Art A 07771 N E Z Z lt 3 lt PARTS LIST 7 3 Manual 0 4751 PARTS LIST 7 4 Manual 0 4751 Qty Description Manual 0 4751 Replacement First Stage Cartridge Replacement Second Stage Cartridge Two Stage Air Line Filter Kit Includes Hose amp Mounting Screws Bracket Filter Mounting Not shown Dual Stage Air Filter Assembly 90 degree 1 4 NPT to 6mm fitting Not shown requires two Cycle Drain 7 5 First amp Second Stage Cartridges as marked Art A 08251 Catalog 9 0397 9 0396 9 0395 9 1021 9 1022 9 0398 PARTS LIST 7 02 Replacement Hand Torch Parts With Ergonomic Handle Item Qty 1 1 kA W W W W EH PE PE EH M M M M oe MH Description Assembly Basic Head 70 Head PIP Parts In Place Pins 6 32 x 3 16 Phillips Pan Head Screw 6 Internal Star Washer Ergonomic Handle Split with Trigger includes items 5 12 Trigger Lexan Orange Handle Spring 0 390 O D x 0 750 Torch Handle Socket Head Cap Screw Kit 5 pcs 6 32 x 1 2 Assembly Torch Switch Negative Plasma Lead Insulation Sleeving Pi
7. Board L SR 4 gt u2 Y No 40273003 I S 5 gt GN 1 1 dp eT e s E S H V Contactor GN11 Bk 1 only ATT Lu I AH Y Y Y 12006 Y to engage GN12 E y 3 Pilot Relay eo Torch lt a LD4 12VDC gt W orc HN ona S Filter lt W d i W No 40276002 Do Not attempt to NE adjust the PCB CHECK SC ii Title 4 Air Plasma 35C 230V Size Number Rev A2 No 66001008 AB Date oct 19 2005 Drawn by Filename Sheet of D F Art A 07024 Manual 0 4751 A 7 APPENDIX This Page Left Blank APPENDIX A 8 Manual 0 4751 THERMAL DYNAMICS GLOBAL CUSTOMER SERVICE CONTACT INFORMATION Thermadyne USA 2800 Airport Road Denton Tx 76207 USA Telephone 940 566 2000 800 426 1888 Fax 800 535 0557 Thermadyne Canada 2070 Wyecroft Road Oakville Ontario Canada L6L5V6 Telephone 905 827 1111 Fax 905 827 3648 Thermadyne Europe Europe Building Chorley North Industrial Park Chorley Lancashire England PR6 7Bx Telephone 44 1257 261755 Fax 44 1257 224800 Thermadyne China RM 102A 685 Ding Xi Rd Chang Ning District 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 Tele
8. Manual 0 4751 SECTION 4 OPERATION 4 01 Front Control Panel Air Error Indicator Overheating Torch Switch Indicator m Catch Indicator On Off on Torch Switch Switch Latch Button AC Power GN Air Set Indicator SV Button SS Current Air Vents Control Knob Work Lead 9 Or Connection Connection v Kg Art A 04720 Roll bars not shown for clarity A INDICATOR LAMP Power Indicator Lights when primary power switch is turned on e TEMPERATURE Indicator JE Indicator is nor mally OFF Indicator is ON when internal tem perature exceeds normal limits Shut unit OFF let the unit cool before continuing operation e Air Error Indicator This indicator lights and is accompanied by an intermittent audible tone when there is not enough air pressure to operate the power supply NOTE It is possible to have enough air pressure to op erate the power supply but not enough air flow to operate the torch e Torch Switch Latch Indicator Vol This indicator lights when the Torch Switch Latch Button has been pressed for continuous cutting Manual 0 4751 C D 4 1 BUTTONS Torch Switch Latch Button Vol H For continuous cutting performance Depress this button turn On while cutting with the torch Release the torch trigger and the torch will con tinue to cut without depressing the torch trig ger
9. ee heus Han tenax EERSTEN ERT 1 1 1 01 Notes Cautions and Warnings cceececceeeceesneeeeeeeseeaeeeeeeeeeeeaeeeeeeeeseaeees 1 1 1 02 Important Safety Precautions nen 1 1 103 PUbliCatlOliS a e RAS ER Nes dat obtento 1 2 1 04 Note Attention et Avertissement 1 3 1 05 Precautions De Securite Importantes ssssseeeeeeee 1 3 1 06 Documents De Reference sesesessseseeee eene nennen nnns 14 1 06 Declaration Of Conformity ss 1 6 1 05 Statement of Warranty issue 1 7 SECTION 2 INTRODUCTION WEE 2 1 2 01 INTRODUCTION 1 zi i oi Gai vel EEE amine ere ree bie Eds 2 1 2 02 GENERAL SPECIFICATION signent taa dE toe ead HORE RE Ra c ee 2 1 2 03 UNI e 2 1 2 04 Torch Specifications us 2 2 2 05 System Contents etii eter inest idee ke Ere sites see b ene dados 2 2 2 06 Transporting Methods enne 2 2 SECTION 3 INSTALLATION EE 3 1 3 01 Site Selection renard dr eso reco ee fd Erna e Eee aea NENS 3 1 3 02 Electrical Input Connections zasysane ZA tenen ni ra eene 3 1 9 03 TOC ARE M EE T RN 3 1 SECTION 4 OP ERATION e 4 1 4 01 FrontControl Panel x Radia tunes annee teen db Mate alle EE 4 1 4 02 Preparations For Operating ss 4 2 SECTION 5 MAINTENANCE u eee eee aina eee aaa aaa amt anaana Fa aaa sehr sensn nnne NE een 5 1 5 01 General Maintenance eeeee eee aaa aa
10. galement les autres personnes se trouvant sur le lieu de travail e I faut mesurer les niveaux sonores afin d assurer que les d cibels le bruit ne d passent pas les niveaux s rs e Pour des renseignements sur la mani re de tester le bruit consultez l article 1 page 5 1 06 Documents De Reference Consultez les normes suivantes ou les r visions les plus r centes ayant t faites celles ci pour de plus amples renseignements 1 OSHA NORMES DE S CURIT DU TRAVAIL ET DE PROTECTION DE LA SANTE 29CFR 1910 disponible aupr s du Superintendent of Documents U S Government Printing Office Washington D C 20402 Norme ANSI 249 1 LA S CURIT DES OPERATIONS DE COUPE ET DE SOUDAGE disponible aupr s de la Soci t Am ricaine de Soudage American Welding Society 550 N W LeJeune Rd Mi ami FL 33126 NIOSH LA S CURIT ET LA SANT LORS DES OP RATIONS DE COUPE ET DE SOUDAGE L ARC ET AU GAZ disponible aupr s du Superintendent of Documents U S Government Printing Office Washington D C 20402 Norme ANSI Z87 1 PRATIQUES SURES POUR LA PROTECTION DES YEUX ET DU VISAGE AU TRAVAIL ET DANS LES ECOLES disponible de l Institut Am ricain des Normes Nationales Ameri can National Standards Institute 1430 Broadway New York NY 10018 Norme ANSI Z41 1 NORMES POUR LES CHAUSSURES PROTECTRICES disponible aupr s de l American National Stan dards Institute 1430 Broadway New York NY 10018 Norme ANSI 2
11. 160 E me E 60 20 89 0 TG NOTE Drag or Drag mode refers to the torch tip being in contact with the work piece at all times Manual 0 4751 4 3 Operation This Page Left Blank Operation 4 4 Manual 0 4751 SECTION 5 MAINTENANCE 5 01 General Maintenance Maintain more often Warning if used under severe Disconnect input power before maintaining conditions Each Use Visual check of torch tip and electrode Ih Weekly Visually inspect the cables and leads Visually inspect the torch body Replace as needed tip electrode and shield cup 3 Months Replace all broken parts exterior of power supply 6 Months Visually check and Carefully clean the interior Art A 06884 Manual 0 4751 5 1 Maintenance This Page Left Blank Maintenance 5 2 Manual 0 4751 SECTION 6 TROUBLESHOOTING 6 01 Normal Setup and Operation 1 Connect the unit to power 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 lights and the cooling fan comes on 4 Select the correct current setting for the material being cut 5 Squeeze the torch trigger The pilot arc and compressor start 6 Transfer arc to work surface within 3 5 seconds before the pilot arc turns off If arc was lost before transfer to work surface release the torch trig
12. 276003 s e i 87 CN2 on ou CN3 i W Bk THIS DIS ma 13 DC wi Iw d w w SN ak IR 325 2 See 230 VAC Pe R1 a el d C W2 Bk2 G1E1 6262 G3 E3 G4 E4 Capacitor d TW TW TW TW KI VAN ill pb cc BWGR BWGR 64 6463 G3 2 G2 E1 G1 NOTE Loa on 6 MI TI 00 Not Heatsink CN6 CNB attempt to adjust the LD1 PCB POTs Se A AC230 290 VAG Control Board T No 40271005 BI M Compressor Relay 9720 3 EC aa 25VDC ee 3 T REN LD3 we R 1 t I 60 1 d i 2 z P CN2 I pm JW MERTDSK B M NIC BI 630V s il om Panel Board Compressor No 40270601 H D ES gt gt 4 OE F P5 TEMP AIR s MAIN POWER ERROR ERROR HOLD Art A 07024 APPENDIX A 6 Manual 0 4751 E F 220 Main Transformer Curen Sensor No H F a ZA l On Y Bk A O C V 325 Pilot 130 C T1 eee Cutting 80 100 Bk EE See Sec 6 OCV AAN in Service Manual R5 C6 3 4 1 __ iH R6 C7 ANN E 8 REACTOR Conduit Coil Lol IH o R7 c8 Twisted 31 IE He Y w PCR W 009 412VDC IT 5 vc BR NE RPA E LD2 12VDC 42 gt VD Red He cNiol3 gt oUi 0 CO H V
13. 49 2 PREVENTION DES INCENDIES LORS DE L EMPLOI DE PROC D S DE COUPE ET DE SOUDAGE disponible aupr s de l American National Standards Institute 1430 Broadway New York NY 10018 Norme A6 0 de l Association Am ricaine du Soudage AWS LE SOUDAGE ET LA COUPE DE CONTENEURS AYANT RENFERM DES PRODUITS COMBUSTIBLES disponible aupr s de la Ameri can Welding Society 550 N W LeJeune Rd Miami FL 33126 Norme 51 de l Association Am ricaine pour la Protection contre les Incendies NFPA LES SYSTEMES GAZ AVEC ALIMENTATION EN OXYGENE POUR LE SOUDAGE LA COUPE ET LES PROC D S ASSOCIES disponible aupr s de la National Fire Protection Asso ciation Batterymarch Park Quincy MA 02269 Norme 70 de la NFPA CODE ELECTRIQUE NATIONAL disponible aupr s de la National Fire Protection Association Batterymarch Park Quincy MA 02269 Manual 0 4751 Norme 51B de la NFPA LES PROC D S DE COUPE ET DE SOUDAGE disponible aupr s de la National Fire Protection Asso ciation Batterymarch Park Quincy MA 02269 Brochure GCA P 1 LA MANIPULATION SANS RISQUE DES GAZ COMPRIMES EN CYLINDRES disponible aupr s de FAssociation des Gaz Comprim s Compressed Gas Association 1235 Jefferson Davis Highway Suite 501 Arlington VA 22202 Norme CSA W117 2 CODE DE S CURIT POUR LE SOUDAGE ET LA COUPE disponible aupr s de l Association des Normes Canadiennes Standards Sales 178 Rexdale Boulevard Rexdale Ontario Canada M9W 1R3
14. CUTTING obtainable from the American Welding Society 550 N W LeJeune Rd Miami FL 33126 NIOSH SAFETY AND HEALTH IN ARC WELDING AND GAS WELDING AND CUTTING obtainable from the Superinten dent of Documents U S Government Printing Office Wash ington D C 20402 ANSI Standard Z87 1 SAFE PRACTICES FOR OCCUPATION AND EDUCATIONAL EYE AND FACE PROTECTION obtain able from American National Standards Institute 1430 Broad way New York NY 10018 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 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 AWS Standard A6 0 WELDING AND CUTTING CONTAINERS WHICH HAVE HELD COMBUSTIBLES obtainable from Ameri can Welding Society 550 N W LeJeune Rd Miami FL 33126 NFPAStandard 51 OXYGEN FUEL GAS SYSTEMS FOR WELD ING CUTTING AND ALLIED PROCESSES obtainable from the National Fire Protection Association Batterymarch Park Quincy MA 02269 NFPA Standard 70 NATIONAL ELECTRICAL CODE obtain able from the National Fire Protection Association Batterymarch Park Quincy MA 02269 NFPA Standard 51B CUTTING AND WELDING PROCESSES obtainable from the National Fire Protection Association Batterymarch Park Quincy MA 02269 CGA Pamph
15. IHERMAL DYNAMICS JUL DRAG GUN PLUS PLASMA CUTTING SYSTEM DRAG GUN Le SDR w acl AE gm O of Service Manual Rev AB Issue Date October 18 2007 Manual 0 4751 Operating Features SAME A WARNING 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 Plasma Gutting Power Supply Drag Gun Plus 350 PCH 42 Torch Service Manual Number 0 4751 Covered under U S Patents Published by Thermadyne Corporation 82 Benning Street West Lebanon New Hampshire USA 03784 603 298 5711 www thermal dynamics com Copyright 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 the United States of America Publication Date October 18 2007 Record the following information for Warranty purposes Where Purchased Purchase Date Power Supply Serial Torch Serial SECTION 1 TABLE OF CONTENTS GENERAL INFORMATION og naastes
16. Temperatures exceeding that may diminish cutting capacity or quality The cutting machine must be placed on an even firm surface so that it stands firmly A WARNING This equipment must be electrically connected by a qualified electrician 3 02 Electrical Input Connections e Input voltage is 230V 10 50 60 Hz single phase A CAUTION Check your power source for correct voltage be fore plugging in or connecting the unit The primary power source fuse 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 Manual 0 4751 3 03 Torch 3 1 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 A GER Do not cut in humid or wet surroundings Before you maintain or replace torch parts wait for the post flow air cycle approximately 15 sec onds to stop then turn the machine off Always use original manufacturers parts The use of aftermarket parts could result in lower parts life and in unsatisfactory cutting results Any war ranty claims would be waived Recycle worn parts according to local require ments NOTE Repairs must be done by skilled and qualified personnel only Installation This Page Left Blank Installation 3 2
17. a zone de travail en cas de non respect de la proc dure en question 1 05 Precautions De Securite Importantes 4 VERTISSEMENTS L OPERATION ET LA MAINTENANCE DU MATERIEL DE SOUDAGE A L ARC AU JET DE PLASMA PEUVENT PRESENTER DES RISQUES ET DES DANGERS DE SANTE Coupant l arc au jet de plasma produit de l nergie lectrique haute tension et des missions magn tique qui peuvent interf rer la fonction propre d un pacemaker cardiaque les appareils auditif ou autre mat riel de sant electronique Ceux qui travail pr s d une application l arc au jet de plasma devrait consulter leur membre professionel de m dication et le manufacturier de mat riel de sant pour d terminer s il existe des risques de sant ll faut communiquer aux op rateurs et au personnel TOUS les dangers possibles Afin d viter les blessures possibles lisez comprenez et suivez tous les avertissements toutes les pr cautions de s curit et toutes les consignes avant d utiliser le mat riel Composez le 603 298 5711 ou votre distributeur local si vous avez des questions et GAZ La fum e et les gaz produits par le proc d de jet de plasma peuvent pr senter des risques et des dangers de sant Manual 0 4751 attention et avertissement sont utilis s pour mettre en relief des informations caract re important Ces mises en relief sont classifi es comme suit DRAG GUN PLUS 356
18. a aaa aaa aaa aaa aaa aaaaaaacia 5 1 SECTION 6 ueU Bzc eec 6 1 6 01 Normal Setup and Operation is 6 1 6 02 Basic Trouble Shooting Guide AA 6 2 6 03 Control PCB Indicators wa uc ici en texte itr tee tete red 6 3 6 04 Open Circuit Voltage Check A 6 4 6 05 Detailed Fault Finding Error Indicators sseeeeee 6 5 6 06 TENTS rena EE 6 9 SECTION 7 PARTS LIST pe SPI 7 1 7 01 Parts List Power Supply 2 LAWA aa AAAA AAA 72 7 02 Replacement Hand Torch Parts With Ergonomic Handle 7 6 TABLE OF CONTENTS Con t Appendix 1 Operating Sequence Block Diagram RE A 1 Appendix 2 Torch COmMeCtion E A 2 Appendix 3 Microchip Pin Out issues A 3 Appendix 4 System Schematic 230V CE iii A 4 Appendix 5 System Schematic 230V ii A 6 GLOBAL CUSTOMER SERVICE CONTACT INFORMATION 1 01 Throughout this manual notes cautions and warnings are used to highlight important information These highlights are categorized as SECTION 1 GENERAL INFORMATION Notes Cautions and Warnings follows 1 02 NOTE An operation procedure or background information which requires additional emphasis or is helpful in efficient op eration of the system 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 operating area Imp
19. 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 No 60 for Arc Welding Equipment CENELEC EN50199 EMC Product Standard for Arc Welding Equipment IEC EN 60974 1 EN50192 EN50078 Arc Welding Equipment Part 1 Welding Power Supplies IEC EN 60974 5 Arc Welding Equipment Part 5 Wire Feeders IEC EN 60974 7 Arc Welding Equipment Part 7 Torches IEC EN 60974 10 Arc Welding Equipment Part 10 Electromagnetic Compatibility EMC Requirements For environments with increased hazard of electrical shock Power Supplies bearing the S 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 Thermadyne has been manufacturing products for more than 30 years and will continue to achieve excellence in our area of manufacture Manufacturers responsible representative Steve Ward Operations Director Thermadyne Europe Europa Building Cho
20. brighter with the torch trigger 3 If OCV is not OK follow OCV depressed check procedures in section 6 04 4 Check OCV Voltage If OCV Voltage 4 If CN9 connection is OK replace is OK check C T 1 connection the Control PCB Torch doesn t Pilot and Check all air supply related issues If there are no air related issues the LD1 LED onthe before proceding replace the Control PCB Control PCB is not on CO LED on Control Check Cable Connection on PCB If connection and Current Sensor PCB comes on when CN10 and Current Sensor are OK replace the Control PCB not transferring A Diode Testing Basics A G There are extremely dangerous voltage and power levels present inside this unit Do not attempt to diagnose or repair unless you have had training in power electronics measurement and troubleshooting techniques Disconnect primary power at the source before disassembling the power supply torch or torch leads Discharge power at the H V spark gap using a metal tipped screw driver as shown Manual 0 4751 6 5 TROUBLE SHOOTING Testing of diode modules requires a digital volt ohmmeter that has a diode test scale Remember that even if the diode module checks good it may still be bad If in doubt replace the diode module 1 Remove AC power Refer to Appendix 3 Wiring diagram Locate the IGBT diode module to be tested Remove P5 from IGBT module Set digital volt ohmmeter to diode test scale m gt bh Connect the volt o
21. chaudes des tincelles ou de l arc de plasma Le proc d l arc de plasma produit du m tal des tincelles des scories chaudes pouvant mettre le feu aux mati res combustibles ou provoquer l explosion de fum es inflammables e Soyez certain qu aucune mati re combustible ou inflammable ne se trouve sur le lieu de travail Prot gez toute telle mati re qu il est impossible de retirer de la zone de travail e Procurez une bonne a ration de toutes les fum es inflammables ou explosives e Ne coupez pas et ne soudez pas les conteneurs ayant pu renfermer des mati res combustibles e Pr voyez une veille d incendie lors de tout travail dans une zone pr sentant des dangers d incendie e Legas hydrog ne peut se former ou s accumuler sous les pi ces de travail en aluminium lorsqu elles sont coup es sous l eau ou sur une table d eau NE PAS couper les alliages en aluminium sous l eau ou sur une table d eau moins que le gas hydrog ne peut s chapper ou se dissiper Le gas hydrog ne accumul explosera si enflamm RAYONS D ARC DE PLASMA Les rayons provenant de l arc de plasma peuvent blesser vos yeux et br ler votre peau Le proc d l arc de plasma produit une lumi re infra rouge et des rayons ultra violets tr s forts Ces rayons d arc nuiront vos yeux et br leront votre peau si vous ne vous prot gez pas correctement Pour prot ger vos yeux portez toujours un casque ou un cran de soudeur Por
22. d 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 chlori nated solvents and cleansers Remove all sources of these va pors This product when used for welding or cutting produces fumes or gases which contain chemicals known to the State of Califor nia to cause birth defects and in some cases cancer California Health amp Safety Code Sec 25249 5 et seq SHOCK Electric Shock can injure or kill The plasma arc process uses and pro duces high voltage electrical energy This electric energy can cause se vere 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 maintai
23. el Description Maximum output 230V Input Voltage amp Phase Single Phase Frequenc Input power U S Canada 40 Amps Gurtent Input fuse Ai others 20A Slow Blow Fuse No Load Voltage Load Voltage Output Current Post flow time 35 35A 94vdc Duty cycle 104 F 60 27A 40 C Ambient 91vdc 100 20A 88 vdc Genuine Cutting 3 8 Capacity 9 mm Maximum Cutting 1 2 Capacity 12mm 2 03 Features 2 1 COMPACT and LIGHT Designed for easy trans portation ENERGY EFFICIENCY Advanced technology reduces power consumption HIGH SPEED GENUINE CUTTING The con stricted plasma arc provides high speed cutting as well as a good quality genuine narrow cut LOW COST WITH COMPRESSED AIR The Drag Gun Plus operates on compressed air ALL KINDS OF METALS Useful for most met als such as stainless steel aluminum mild steel copper and their alloys PILOT ARC IGNITION FROM TORCH The Pi lot Arc ignites the cutting arc POWERFUL CUTTING PERFORMANCE Genuine cutting capacity is 3 8 9 mm ABLE TO CUT PAINTED MATERIALS Pilot Arc ignition allows the Drag Gun Plus to cut painted materials EXTENDED PARTS LIFE Consumable parts life is longer Manual 0 4751 2 04 Torch Specifications 2 05 System Contents pee ea nm Description mes ay Model Drag Gun Plus 10 5 in 266 7 mm E PCH 42 with 20 m Torch Set 6 1 m leads 1 Work Cable 1 Accessories amp Manual 1 Consumables T
24. ernal air supply compressor 3 Return to an authorized service center for repair not working 3 Control PCB faulty Torch will not pilot 1 Air pressure too high ortoo 1 There is no adjustment return to an authorized service when torch switch is low center for repair activated 2 Torch consumables missing 2 Turn off power supply Remove shield cup Install missing 3 Worn or faulty torch parts parts 4 Thermal Switch activated 3 Inspect torch consumable parts Replace if necessary 4 Allow the cooling fan to run for 2 minutes or longer until it will resume operation Pilot transfer arc 1 Torch removed from work piece 1 Release torch trigger and re establish the pilot arc See goes out and or moved away from metal being block diagram Appendix 1 doesn t reactivate cut Cut performance is 1 Worn torch parts 1 Check current setting Check the Electrode and Tip for diminished 2 Poor Work Lead connection excess wear 3 Current sensor or PWM PCB 2 Check the connection of the Work Lead to the work piece faulty 3 Return to an authorized service center for repair or replacement Air flows 1 Torch Switch Latch button on 1 Return to an authorized service center for repair or continuously and front panel faulty replacement torch switch latch 2 Control PCB faulty 2 Return to an authorized service center for repair or button doesn t work replacement properly TROUBLE SHOOTING 6 2 Manual 0 4751 6 03 Co
25. from the IGBT and make the following IGBT checks Gate PCB J5 IGBT Check R OWH ee White Et Black Et G1 E2 G2 E3 White E3 Black G3 E3 G4 E4 DD 770 Diode Test 1 Je CE Wie Rei Red LT 64 Green 6 feared Pin out diagram EC FE De Dr Am Cm L3 i EN b If reading is not as shown replace both IGBT modules and Gate PCB c Reconnect P5 connector TROUBLE SHOOTING 6 8 Manual 0 4751 6 06 Torch Tests A G Disconnect primary power at the source before disassembling the power supply torch or torch leads 1 PIP and Torch Switch Adapter Check a Disconnect input power from power supply b Confirm that the torch parts are in place and that they match the parts consumables label on the power supply cover c Refer to Appendix 2 for torch connection and access With the power supply on it s side and the panel removed disconnect the Power Supply Adapter from the power supply d While the torch trigger is depressed complete an Ohm check on the two pins in the Power Supply Adapter The reading should show a short less than 1 Ohm Refer to diagram m D Negative 7 Plasma Lead Q PIP O Black To Power Switch 100 nuc ER PX e B Torch O Green S Switch White Continuity Se Check Pilot Pilot i 4 Torch Head Torch Leads Art A 05557 2 Shorted Torch Check a Disconnect input power fr
26. ger 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 A G There are extremely dangerous voltage and power levels present inside this unit Do not attempt to diagnose or repair unless you have had training in power electronics measurement and troubleshooting techniques Disconnect primary power at the source before disassembling the power supply torch or torch leads NOTE All procedures are done with the cover removed Manual 0 4751 6 1 TROUBLE SHOOTING 6 02 Basic Trouble Shooting Guide Problem Symptom Possible Cause Recommended Action Power Switch is on 1 Improper electrical connection 1 Check input power source and fuse Check input cable and but the A C Indicator 2 System was overloaded connections does not light 3 Switch may be faulty 2 Turn Primary Power Switch Off and then On again 3 Return to authorized service center for repair or replacement Primary power 1 No power or incorrect power to 1 Check electrical connections to fan switch is on but the fan 2 Return to authorized service center for repair or replacement cooling fan does not 2 Faulty fan Work No air flow attorch 1 Internal connection is loose or 1 Check all air line connections and fittings when air check disconnected 2 Return to an authorized service center for repair switch is turned on 2 Int
27. hmmeter 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 Art A 00307 0 75 Forward Bias Diode Conducting Me Diode Test Symbol VR COM A Anode e gt Cathode Testing Diode Forward Bias TROUBLE SHOOTING 6 6 Manual 0 4751 6 Reverse the meter leads across the diode for reverse bias testing refer to following figure A properly function ing diode will block in the reverse bias direction and depending on the meter function will indicate an open or OL Art A 00306 NES Reverse Bias Diode Not Conducting VR COM A Cathode Anode 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 Manual 0 4751 6 7 TROUBLE SHOOTING 6 Component Tests A Disconnect primary power at the source before taking any resistance checks 1 Input Diode Module Board Circuit Test a Check Input Diode for short per schematic located in Appendix 4 2 IGBT Module Test a With an ohmmeter set on the diode range remove P5
28. item 1 in Subsection 1 08 Publications in this manual m 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 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 e 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 protective booths screens or shields e Use the shade of lens as suggested in the following per ANSI ASC 749 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 1 03 Publications Refer to the following standards or their latest revisions for more infor mation 1 OSHA SAFETY AND HEALTH STANDARDS 29CFR 1910 ob tainable from the Superintendent of Documents U S Gov ernment Printing Office Washington D C 20402 GENERAL INFORMATION N W o ANSI Standard 249 1 SAFETY IN WELDING AND
29. let P 1 SAFE HANDLING OF COMPRESSED GASES IN CYLINDERS obtainable from the Compressed Gas Association 1235 Jefferson Davis Highway Suite 501 Ar lington VA 22202 CSA Standard W117 2 CODE FOR SAFETY IN WELDING AND CUTTING obtainable from the Canadian Standards Asso ciation Standards Sales 178 Rexdale Boulevard Rexdale Ontario Canada M9W 1R3 NWSA booklet WELDING SAFETY BIBLIOGRAPHY obtain able from the National Welding Supply Association 1900 Arch Street Philadelphia PA 19103 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 ANSI Standard 788 2 PRACTICE FOR RESPIRATORY PRO TECTION obtainable from American National Standards In stitute 1430 Broadway New York NY 10018 Manual 0 4751 Dans ce manuel les mots note 1 04 Note Attention et Avertissement amp NOTE Toute op ration proc dure ou renseignement g n ral sur lequel il importe d insister davantage ou qui contribue l efficacit de fonctionnement du syst me TION Toute proc dure pouvant r sulter l endommagement du mat riel en cas de non respect de la proc dure en question AVERTISSEMENT Toute proc dure pouvant provoquer des blessures de l op rateur ou des autres personnes se trouvant dans l
30. n r par la fum e provenant des solvants et des produits de nettoyage chlor s Eliminez toute source de telle fum e e Ce produit dans le proc der de soudage et de coupe produit de la fum e ou des gaz pouvant contenir des l ments reconnu dans L tat de la Californie qui peuvent causer des d fauts de naissance et le cancer La s curit de sant en Californie et la code s curit Sec 25249 5 et seq Ly ELECTRIQUE Les chocs lectriques peuvent blesser ou m me tuer Le proc d au jet de plasma requiert et produit de l nergie lectrique haute tension Cette nergie lectrique peut produire des chocs graves voire mortels pour l op rateur et les autres personnes sur le lieu de travail e Ne touchez jamais une pi ce sous tension ou vive portez des gants et des v tements secs Isolez vous de la pi ce de travail ou des autres parties du circuit de soudage e R parez ou remplacez toute pi ce us e ou endommag e e Prenez des soins particuliers lorsque la zone de travail est humide ou moite e Montez et maintenez le mat riel conform ment au Code lectrique national des Etats Unis Voir la page 5 article 9 e D branchez l alimentation lectrique avant tout travail d entretien ou de r paration Lisez et respectez toutes les consignes du Manuel de consignes 1 3 GENERAL INFORMATION DRAG GUN PLUS 356 A s ET EXPLOSION Les incendies et les explosions peuvent r sulter des scories
31. n Housing Used with item 12 Pin Socket Housing Used with item 14 Socket Lead Assembly including items No 6 8 and 9 20 ft 7 6 m Length NOTE Item can be purchased locally PARTS LIST Catalog 9 8442 9 5723 See Note See Note 9 8076 9 8059 9 8060 9 8061 9 8062 9 8063 9 8056 9 8111 9 8101 9 8112 9 8102 4 2989 Manual 0 4751 Art A 07061 PARTS LIST 7 7 Manual 0 4751 This Page Left Blank PARTS LIST 7 8 Manual 0 4751 Appendix 1 Operating Sequence Block Diagram Primary Input Power 00 or Plugged in Power Supply On Off Switch On Green Power Indicator On and Fan is Running More air flow is required for Torch to Pilot than to d run the power supply RAS Compressor not functioning Red Air Indicator lt Air Set Switch On properly need to be repaired by a Qualified Technician Compressor Starts and Air Flows at Torch Turn Air Set Switch Off i Check Torch parts Air Flow at Torch Stops lt alignment PIP switches need to be repaired by a Qualified Technician Release Torch Switch EE Pilot Arc Ignition 3 5 seconds lt Torch Switch On gt No Pilot Arc Pilot Arc goes out Torch Tip to Work within 3 5 seconds of Pilot Arc start Release Torch Switch Star
32. n equipment according to NEC code refer to item 9 in Subsection 1 03 Publications Disconnect power source before performing any service or re pairs Read and follow all the instructions in the Operating Manual AND EXPLOSION Fire and explosion can be caused by hot slag sparks or the plasma arc 1 1 Be sure there is no combustible or flammable material in the workplace Any material that cannot be removed must be pro tected Ventilate all flammable or explosive vapors from the workplace Do not cut or weld on containers that may have held combus tibles GENERAL INFORMATION DRAG GUN PLUS 356 e 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 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 workplace e Noise levels should be measured to be sure the decibels sound do not exceed safe levels e For information on how to test for noise see
33. ntrol PCB Indicators A G There are extremely dangerous voltage and power levels present inside this unit Do not attempt to diagnose or repair unless you have had training in power electronics measurement and troubleshooting techniques NOTE All procedures are done with the cover removed 1 Turn the switch located on the front panel to the On position The C indicator on the front panel lights and 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 I 3 Pressthe AirSet Button V 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 start LD2 EN should brighten and LD1 SOL LED and LD4 H V should be on 5 Transfer the arc to the work surface within 3 5 seconds LD4 goes off and LD3 comes on so that three LEDs are on NOTE If no transfer of arc occurs check the work lead connection Manual 0 4751 6 3 TROUBLE SHOOTING 6 04 Open Circuit Voltage Check Unplug the CN1 connector on the H V spark gap PCB Turn unit power on Measure terminal TB2 Pins 1 and 3 It should be 230VAC Measure output voltage on Input diode and It should be 325VDC Sr Ze Je SS Depress and hold the torch trigger for each
34. o the original retail customer or 1 year after sale to an authorized Thermadyne Distributor LIMITED WARRANTY PERIOD Product Power Supply Componants Torch and Leads Parts and Labor Parts and Labor Drag Gun Plus 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 Corporation 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 Corporation 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 Purcha
35. of the following checks steps numbers 6 9 Each check has to be done within the 3 5 second pilot arc time 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 Art A 06991 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 Illustration 6 2 above It should be 190VAC 9 Measure output OCV between points 1 and 2 in Illustration 6 2 above It should be 325VDC 10 Turn off the unit power and plug the connector back in to CN1 removed in step 1 above TROUBLE SHOOTING 6 4 Manual 0 4751 6 05 Detailed Fault Finding Error Indicators Problem Check Test Recommended Action ze Air Indicator is on 1 Check air and electrical connections 1 If connections are good return and or audible to the internal air compressor to an authorized service center for intermitant tone 2 Control PCB faulty repair 3 Check the compressor relay 2 Replace the Control PCB 3 Replace the relay if bad Torch doesn t Pilot and 1 Check torch consumables 1 Replace torch consumables as the LD1 LED light on 2 Check all air supply related issues needed the Control PCBis on before proceding 2 Change air related items as 3 Check LD2 EN LED it should get needed
36. om 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 it does not show Open check that the correct consumables were installed per the consumables label on the unit cover d Replace Torch as needed NOTE Every effort has been made to provide complete and accurate information in this manual However the publisher does not assume and hereby disclaims any liability to any party for any loss or damage caused by errors or omissions in this Manual whether such errors result from negligence accident or any other cause Manual 0 4751 6 9 TROUBLE SHOOTING This Page Left Blank TROUBLE SHOOTING 6 10 Manual 0 4751 SECTION 7 PARTS LIST General Information This parts list covers the Drag Gun Plus Model 35C Plasma Cutting Power Supply with Internal Air Compressor Do not use these instructions or parts on any other equipment Provide the 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 pages Catalog numbers are shown below each part Manual 0 4751 7 1 PARTS LIST
37. orch Electrodes 2 PCH 42 Torch Ratings Torch Tips 3 Torch Configuration TEE te Input Power 3 Meter NEMA 10 AWG Torch Handle a Cable U S 4 8 mmf with 6 50 P Torch Leads Length 20 feet 6 1 m CAN molded pi Ambient 104 F p ug 1 Temperature 40 C His A 8 Meter 3x2 5 sq mm Duty Cycle 100 40 Amps able Outside bber wire y Ly 200 scfh of U S CAN Maximum Current ee Voltage Vasan 500V 2 06 Transporting Methods Arc Striking Voltage 1216 Lift unit with handle on top of case Use handcart or T f Cooli Ambienta and ges similar device of adequate capacity for transportin Ype or E stream through torch q FAY P e Ge Built in Switch ae ne ee in Torch Head A WARNING S Single Gas ubica ed Compressed Air Only 65 psi 4 5 bar ELECTRIC SHOCK can kill DO NOT Input A5MPa TOUCH live electrical parts Disconnect input Gas presets 125 psi 8 6 bar power from supply before moving the power 86MPa source Minimum Gas Flow 200 SCFH 142 Ipm FALLING EQUIPMENT can cause serious per For operation with sonal injury and equipment damage exposed tip the er Direct Contact Hazard recommended standoff height is 1 8 3 8 3 9 mm Plasma Power Supply Used With Drag Gun Plus Introduction 2 2 Manual 0 4751 SECTION 3 INSTALLATION 3 01 Site Selection Place in a clean and dry area Provide adequate ventilation and fresh air sup ply Ideal ambient temperature should not exceed 40 C 104 F
38. ortant 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 profes sional and the manufacturer of the health equipment to determine whether a hazard exists To prevent possible injury read understand and follow all warnings safety precautions and instructions before us ing the equipment Call 1 603 298 5711 or your local distributor if you have any questions Ay 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 Manual 0 4751 DRAG GUN PLUS 35C 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 rea
39. peration 4 2 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 For standoff cutting hold the torch 1 8 3 8 in 3 9 mm from the workpiece as shown be low Torch Standoff Distance 1 8 3 8 Y JL A 00024 Shield Cup With the torch in starting position press and hold the Torch Trigger After an initial two sec ond pre flow the pilot arc will come on and re main on until the cutting arc starts Once on the cutting arc remains on as long as the Torch Trigger is held down unless the torch is withdrawn from the work or torch motion is too slow To shut off the torch simply release the Torch Trigger When the trigger is released a gas post flow will occur If the Torch Trigger is pushed during the post flow the cutting arc will restart immediately when the torch is brought within range of the workpiece Manual 0 4751 E Typical Cutting Speeds Cutting speeds vary according to torch output the type of material being cut and operator skill Speeds shown are typical for this cutting system using air plasma to cut mild steel with output current at the highest setting and torch held at the indicated standoff height Unit Standoff Matana R Maximum Travel SEE Recommended Travel Speed ipm mmm NE HEN CUN ats KA ga 0 135 3mm 95 0 2375 1900 ToS Gsm 500 was o 1
40. phone 61 3 9474 7400 Fax 61 3 9474 7510 Thermadyne Italy OCIM S r L Via Benaco 3 20098 S Giuliano Milan Italy Tel 39 02 98 80320 Fax 39 02 98 281773 Thermadyne International 2070 Wyecroft Road Oakville Ontario Canada L6L5V6 Telephone 905 827 9777 Fax 905 827 9797 Suite 300 St Louis MO 63017 By THERMADYNE Telephone 636 728 3000 Email TDCSales Thermadyne com www thermadyne com 16052 Swing Ridge Roa IHERMAL DYNAMICS
41. rley N Industrial Park Chorley Lancashire England PR6 7BX GENERAL INFORMATION 1 6 Manual 0 4751 DRAG GUN PLUS 356 1 05 Statement of Warranty LIMITED WARRANTY Subject to the terms and conditions established below Thermadyne Corporation warrants to the original retail purchaser that new Thermadyne CutSkill Series 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 Corporation shall upon notification thereof and substantiation that the product has been stored operated and maintained in accordance with Thermadynes 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 Corporation must be notified within 30 days of any failure at which time Thermadyne Corporation will provide instructions on the warranty procedures to be implemented Thermadyne Corporation will honor warranty claims submitted within the warranty periods listed below All warranty periods begin on the date of sale of the product t
42. ser 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 Thermadyne product is sold by non authorized persons Effective August 28 2005 Manual 0 4751 1 7 GENERAL INFORMATION DRAG GUN PLUS 356 This Page Left Blank GENERAL INFORMATION 1 8 Manual 0 4751 SECTION 2 INTRODUCTION 2 01 INTRODUCTION Plasma is a gas which has been heated to an extremely high temperature and ionized so that it becomes elec trically conductive The plasma arc cutting process uses this plasma to transfer an electrical arc to the work piece The metal to be cut is melted by the heat of the arc and then blown away 2 02 GENERAL SPECIFICATION 10 5 x15 5 x11 Dimension W D H 267 mm x 394 mm x 279 mm NOTE Refer to Local and National Codes or local au thority having jurisdiction for proper wiring re quirements Introduction Mod
43. t Cutting Operation v YES Cutting Done NO Torch Switch Off Post Flow of Air Approximately 15 Seconds Then Stops Note The Torch will be very hot Do not set on or near flammable materials Y Power Supply On Off Switch Off Green Power Indicator Off and Fan Stops Y Primary Input Power Switch Off or Unplugged Art A 04694 Manual 0 4751 A 1 APPENDIX Appendix 2 Torch Connection Disconnect power and air Lay unit ATEI A046939 on its side Remove two screws and access plate DETAIL r E 1 To Power Ww o Back o PIP Supply Adapter Orange o Switch Green 0 Torch CI gt White Switch CET 9 Negative RES Lead d SQ Put Pilot E Un Torch Leads Torch Head APPENDIX A 2 Manual 0 4751 Manual 0 4751 Appendix 3 Microchip Pin Out 40 Pin Microchip P2 2 3 41 5 8j 9 10 11 12 CPU porre Socketon 5 24 22 20 18 16 14 12 10 8 4 Control 129121119117115119111 5 3 1 08 m 11112 A 3 APPENDIX Appendix 4 System Schematic 230V CE
44. tez toujours des lunettes de s curit munies de parois lat rales ou des lunettes de protection ou une autre sorte de protec tion oculaire Portez des gants de soudeur et un v tement protecteur appropri pour prot ger votre peau contre les tincelles et les rayons de l arc e Maintenez votre casque et vos lunettes de protection en bon tat Remplacez toute lentille sale ou comportant fissure ou rognure Prot gez les autres personnes se trouvant sur la zone de travail contre les rayons de l arc en fournissant des cabines ou des crans de protection e Utilisez la nuance de lentille qui est sugg r e dans le recommenda tion qui suivent ANSI ASC 749 1 Nuance Minimum Nuance Sugger e Courant Arc Protective Num ro Num ro Moins de 300 8 9 300 400 9 12 400 800 10 14 Ces valeurs s appliquent ou l arc actuel est observ clairement L experience a d montrer que les filtres moins fonc s peuvent tre utilis s quand l arc est cach par moiceau de travail GENERAL INFORMATION Le bruit peut provoquer une perte permanente de l ouie Les proc d s de soudage l arc de plasma peuvent provoquer des niveaux sonores sup rieurs aux limites normalement acceptables Vous d 4ez vous prot ger les oreilles contre les bruits forts afin d viter une perte permanente de l ouie e Pour prot ger votre ou e contre les bruits forts portez des tampons protecteurs et ou des protections auriculaires Prot gez
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