Thermal Dynamics Drag-Gun Plasma Cutting
Contents
1. 21020 Ss 8 god Ee T Lon gt S 1 ME Os V SE St er x Zr FEES vL PE Zt 21 Sr orf or bo 91897 d 1 del agog eng S amp eb EL did 4 dno 9 ejBuiS LL piel zi Ku 57 OBADZL Se 5 froze 109 10 nas zr orf v CA 5 Le note SILON EI 0021 t AuvwiHd gt 99 1 rE OWO 2 19 deo eds 6L ve HEM GG 1 1 1 n el I T cg q ewe 1 1 I I v1 lu we 1 0021 VSE APPENDIX 31 Manual 0 2683 APPENDIX Il INTERCONNECTING DIAGRAM NOTES 2 FAN 3 TI PRI 4 sw2. 200 230 VAC 120 120 VAC 200 230 VAC 100 120 VAC 21 6 5 BRI BRIDGE 35A I200V 15 51 K1 B 8 18 7 5 7 EN NOTE 1 3i 6 161 NOTE 31 141 BR2 BRIDGE 35A 1200V 14 AIR COMPRESSOR I2VDC KI C BLK 21 und 197 2 TORCH SWITCH E SHIELD K PIP PIN CUP K PIP PIN 03 2 CI3 88u 370 VAC CI3 I20uf 188 VAC FAN 22 FAN 120 VAC SINGLE VOLTAGE MARKED 6 DUAL VOLTAGE MARKED 208V FOR ASSEMBLY PURPOSES SOME WIRES WHICH ARE ELECTRICALLY COMMON ARE MARKED WITH A COMMON NUMBER BUT DIFFERENT LETTER SUFFIXES WHICH DO NOT APPEAR ON THE SCHEMATIC FOR EXAMPLE WIRES 1 AND REPRESENTED ON THE SCHEMATIC 1 1A amp TAP amp 238V ARE ALL COMMON A 02277 APPENDIX 32 Manual 0 2683 NOTE Use this diagram for rev D or later units Check the data tag on the unit for rev level L1 2 2 CD PILOT RED SLEEVED 25 OHM ug
3. 2 Faulty open Voltage Divider Resistor a The voltage divider is the top Resistor Discon nect the push on connectors and measure the Resistor with an ohmmeter It should read 1K ohms If measurement is not 1K ohms replace Resistor 3 Shorted Bridge Rectifier BR1 a Probable if a loud hum or buzz is heard from the main transformer after the Relay actuates If hum or buzzing noise exists replace Bridge Rectifier Replace lower Bridge Rectifier clos est to Chassis Power OK fan runs compressor runs no pilot or cutting arc with the torch switch pressed 1 Worn contaminated or incorrect torch parts a Check that all torch parts are in good condition and designed for use in the PCH 10 torch Re place worn parts as necessary 2 Parts not assembled correctly a Reassemble torch parts Damaged torch or leads a Check per subsection 3 6 Torch and Leads Troubleshooting 4 Faulty Control PCB a Listen fora faint sharp clicking noise at about 3 4 clicks second from the Ferrite Core Assem bly If nothing is heard the PCB should be re placed 5 Faulty open Pilot Resistor a The Pilot Resistor is mounted closest to the chas sis Disconnect the push on connectors and measure the resistor with an ohmmeter It should read 0 5 ohms essentially a short 6 AC input too low a Ifthe AC line is below about 105vac the torch may not always start Try an outlet on a differ ent branc
4. 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 Le bruit peut provoquer une perte permanente de l ouie Les proc d s de soudage 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 Pour prot ger votre contre les bruits forts portez des tampons protecteurs et ou des protections auriculaires Prot gez galement les autres personnes se trouvant sur le lieu de travail Il faut mesurer les niveaux sonores afin d assurer que les d cibels le bruit ne d passent pas les niveaux s rs Pour des renseignements sur la mani re de tester le bruit consultez l article 1 page 5 Date November 15 2001 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 SANT 29CFR 1910 disponible aupr s du Superintendent of Documents 0 5 Government Printing Office Washington 20402 2 Norme ANSI 749 1 LA S CURIT DES OP
5. ing techniques B How To Use This Guide The following information is a guide to help determine the most likely causes for various symptoms The guide is set up in the following manner Symptom Bold type Cause Italic type Remedy Test type Locate your symptom check causes easiest is usually first sometimes the order is important if noted then remedies Repair as needed being sure to verify that the unit is fully operational after any repairs C No Power AC switch on red amber for 220V indicator dark no fan 1 No power from wall unit a Testelectrical outlet with voltmeter or some other known good load trouble light hand drill etc If AC line voltage is present go to next step If AC line voltage is not present replace fuse or reset circuit breaker 12 Manual 0 2683 2 Damaged power cord a Confirm with voltmeter if AC line voltage is present at input to power switch If AC voltage is present proceed to next step If ac line voltage is not present replace Power Cord 3 Power Switch faulty a Confirm with voltmeter if AC line voltage is present at main Capacitor C13 terminals when power switch is on If AC line voltage is not present replace Power Switch D Power OK service circuit breaker or fuse opens after the power switch is switched on NOTE Proceed with troubleshooting for these components in order 1 Faulty Fan a Disconnect the Fan and ins
6. 1 1 02 Important Safety Precautions 1 1 03 Publications ties 2 1 04 Note Attention et Avertissement 3 1 05 Precautions De Securite Importantes 3 1 06 Documents De Reference ss 5 1 07 Declaration of Conformity ss 7 1 08 Statement of Warranty iii 8 2 0 INTRODUC TON a SN MR SO er nn ne 9 2 1 Scope Of Manual Ie le ee Re Re HER e ne 9 2 2 General Service Philosophy ss 9 2 3 Service Responsibilities 9 2 4 Technical Specifications 9 2 5 Dirriensloris lt 3 eta eise Ra Hom 10 3 07 TROUBLESHOOTING ha iter e a eee tr cet herus diio 11 SEU Introduction iet Rr ce eed icit tnu bem 11 3 2 Periodic Inspection amp Maintenance 11 3 3 Common Cutting 11 3 4 Common Operating Problems sse 11 3 5 Troubleshooting Guide ss 12 3 6 Torch amp Leads Troubleshooting sem 15 4 0 REPLACEMENT 17 41 G neral information etn 17 4 2 Removing 17 4 3 Torch Head Assem
7. 1 55W I Ci R2 150 400 50 es y 191 pzy SPARK 350V 21 ES CD N PWR RCUIT SIREUE CD PRIMARY 4 2 T7330 45av 45av V 2 2 4 1 LOGIC CIRCUIT EMP 17 TD 17 14 12V LEE 27 15 1K 1 55W 18 18 22 3W 27 R31 v 1 OHM CD PCB E 5X 55W REV REVISIONS DpATE REV REVISIONS BY THERMAL DYNAMICS woustaiaL PARK 2 PCB NO ASSY NO 09723 WEST LEBANON NH 23784 7854 gg CORPORATION 298 571 SCALE SUPERSEDES B 8063 Hag 12 01 INFORMATION PROPRIETARY TO THERMAL DYNAMICS DATE SUPERSEDED 98 CORPORATION NOT FOR RELEASE OR DISTRIBUTION n 2197 8Y NOTE DRAWN REFERENCE UNLESS OTHERWISE SPECIFIED RESISTORS ARE D DEMERS OHMS 1 4W 5 CAPACITORS ARE MICROF ARADSIUF 1 oF 1 TITLE UNIT SCHEMATIC DRAG GUN 42x1202 Manual 0 2683 33 APPENDIX
8. For environments with increased hazard of electrical shock Power Supplies bearing the mark conform to EN50192 when used in conjunction with hand torches with properly installed standoff guides Extensive product design verification is conducted at the manufacturing facility as part of the routine design and manufac turing 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 Thermal Dynamics has been manufacturing products for more than 30 years and will continue to achieve excellence in our area of manufacture Manufacturers responsible representative Giorgio Bassi Managing Director Thermal Dynamics Europe Via rio Fabbiani 8A 40067 Rastignano BO Italy Date November 15 2001 7 GENERAL INFORMATION 1 08 Statement of Warranty LIMITED WARRANTY Thermal Dynamics Corporation hereinafter Thermal warrants that its products will be free of defects in workmanship or material Should any failure to conform to this warranty appear within the time period applicable to the Thermal products as stated below Thermal shall upon notification thereof and substantiation that the product has been stored installed operated and maintained in accordance with Thermal s specifications instru
9. sembly and remove torch and leads assembly 3 Using soldering iron carefully remove solder where orange wire connects to switch terminal NOTE Be careful not to overheat the torch switch while removing soldering from terminals 4 Apply Flux to orange wire and to switch post In sert orange wire in switch post hole and solder keeping solder at a minimum required for good joint 5 Repeat steps 3 and 4 this time for the white wire Torch Switch l O O PIP Pin To Control Cable Wiring Cup 00784 PIP Pin Butt Splice Figure 4 3 Torch Switch Schematic 6 Place the torch head in the torch handle bottom Carefully return the torch switch and button w springs to their proper position Replace cover on the handle assembly and screw together with six screws NOTE Make sure torch switch wires are seated in their guides so that the wires are not pinched when the handle is secured 7 Install consumables parts in front end of torch Manual 0 2683 4 5 Air Compressor Replacement NOTES Refer to subsection 4 1 General Information for information about wire harnesses Refer to Appendix II for parts location and orienta tion 1 Remove cover handle from unit per subsection 4 2 2 Locate the nylon nut on the 90 nylon fitting on side of Air Compressor Loose the nylon nut and slide the brass torch lead fitting faston connector out 3 Complete one of the following as
10. tially switching from a transferred cutting arc back to the constant DC pilot arc The best way to prevent this is to pilot for no more than 5 seconds at a time or start with the torch in contact with the material and drag cut that is hold the tip in direct contact with the material to be cut For some materials holding a slight standoff 1 16 may provide a better cut NOTE Piloting is harder on parts life than actual cutting because the pilot arc is directed from the electrode to the tip rather than to a workpiece Whenever pos sible avoid excessive pilot arc time to improve parts life TROUBLE SHOOTING 2 Torch Standoff Improper standoff the distance between the torch tip and workpiece can adversely affect tip life as well as shield cup life Reducing standoff will generally re sult in a more square cut NOTE Although the DRAG GUN will cut using standoff this unit is primarily a drag cutting machine 3 5 Troubleshooting Guide A General The troubleshooting covered in this Service Manual re quires power supply disassembly and live measurements Troubleshooting and repairing this unit is a process which should be undertaken only by those familiar with high voltage high power electronic equipment 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 troubleshoot
11. Push plastic clips down on top end of Switch and slide Switch out through front panel 3 For reference mark wires with correct connection 4 Check the numbering sequence of the connectors designation then disconnect two wires to Fan on the ON OFF Switch and install the switch as 4 Remove two 2 rivets securing Fan to the front follows panel a 1 2 4 5 Install switch with connectors posi NOTE tioned towards the bottom of unit Some models may use screws instead of rivets b 11 12 24 25 Install switch with connectors positioned towards the top of the unit 5 Install replacement Fan Refer to Figure 5 1 for proper Fan orientation or refer to the arrows marked on the Fan chassis NOTE 1A 2A 4B 5B Install switch with these con nectors positioned towards the top of the unit 5 Toconnecttheinput wiring to the ON OFF Switch refer to subsection 4 17 step 6 Proper fan orientation is essential to ensure proper cooling of power supply parts 6 Install cover handle by reversing step 1 keeping 8 of p pp y mind the following 6 Install Compressor by reversing steps 1 3 keeping in mind the following NOTE a Position wire connector 50 that it runs along side the Transformer NOT across the top of the Transformer or touching any metal parts Before replacing cover make sure all wires are care fully positioned to avoid pinching when the cover and handle are secured b The Compressor is s
12. 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 m 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 Date November 15 2001 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 Portez toujours des lunettes de s curit munies de parois lat rales ou des lunettes de protection ou une autre sorte de protection 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 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 Utilisez la nuance de lentille qui est sugg r e dans le recommendation qui suivent ANSI 749 1 Nuance Minimum Nuance Sugger e
13. 1 GENERAL INFORMATION 1 01 Notes Cautions and Warnings Throughout this manual notes cautions and warnings are used to highlight important information These high lights are categorized as follows NOTE An operation procedure or background informa tion which requires additional emphasis or is help ful in efficient operation of the system me CAUTION A procedure which if not properly followed may cause damage to the equipment G A procedure which if not properly followed may cause injury to the operator or others in the oper ating area 1 02 Important Safety Precautions GS OPERATION AND MAINTENANCE OF PLASMA ARC EQUIPMENT CAN BE DAN GEROUS 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 Per sons who work near plasma arc cutting applica tions 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 in structions before using the equipment Call 1 603 298 5711 or your local distributor if you have any questions EE Date November 15 2001 AND FUMES Gases and fumes produced during the plasma cutting process can be dangerous a
14. 10 DRAG GUN 220V 50Hz PCH 10 CE DRAG GUN 208 230 60Hz PCH 10 B Power Supply Only Includes Power Supply Input Power Cord and Work Cable DRAG GUN 100V 50Hz 110V 60Hz DRAG GUN 120V 50Hz CE DRAG GUN 120V 60Hz DRAG GUN 220V 50Hz DRAG GUN 208 230 60Hz C Torch amp Leads Only Includes Torch amp Leads 90 Nylon Air Compressor Fitting Torch Leads alone are not replaceable PCH 10 70 w 20 ft 6 m Leads PCH 10 180 w 20 ft Leads Manual 0 2683 27 1 1111 3 180 1 1811 6 180 1 1111 1 180 1 1811 5 180 1 1111 2 180 3 1112 3 1113 3 1111 3 1114 3 1110 2 1020 2 1021 PARTS LISTS 5 3 Power Supply Replacement Parts Item 1 13 14 15 16 1 N Description Ref Transformer Inductor Incl Chassis T1 L1 DRAG GUN 100V 50Hz 110V 60Hz DRAG GUN 120V 50Hz DRAG GUN 120V 60Hz DRAG GUN 220V 50Hz DRAG GUN 208 230 60Hz Cover incl Labels Control PCB Assembly Capacitor C13 DRAG GUN 100V 50Hz 110V 60Hz Capacitor 120UF 180 DRAG GUN 120V 50Hz Capacitor AC 120UF 180V DRAG GUN 120V 60Hz Capacitor AC 120UF 180V DRAG GUN 220V 50Hz Capacitor AC 60MFD 370V DRAG GUN 208 230 60Hz Capacitor AC 60 MFD 370V Wire Harness Not Shown Relay DPST 25A 250V K1 Fan DRAG GUN 100V 50Hz 110V 60Hz Fan 115V DRAG GUN 120V 50Hz Fan 115V DRAG GUN 120V 60Hz Fan 115V DRAG GUN 220V 50Hz Fan 220V DRAG GUN 208 230
15. 3 4 Unc Cap Socket Head Bolt 2 Transformer Inductor Assembly D 10 32 x 5 Pph Swageform Stl Zn Parker Kalon 4 is shown separated from the E Screw Black 6 32 x 1 2 Pph Swageform Steel 2 Chassis The Transformer Inductor F 10 32 Kepnut w Star Washer Mild Steel 2 Chassis is actually one assembly NOTE Replacement hardware can be purchased locally and should not be disassembled for any field repairs To remove cover unfasten 4 side panel screws 2 handle screws 2 end panel screws A 02337 Figure 5 1 Exploded View of Power Supply Manual 0 2683 29 PARTS LISTS 5 5 Torch Replacement Parts Item Qty Description Catalog 1 1 PCH 10 70 Torch Head Assembly 9 0016 PCH 10 180 Torch Head Assembly 9 0017 2 1 Torch Handle Only 9 0019 3 1 Torch Switch 9 1058 4 1 Standard Electrode 9 6006 5 1 PCH 10 Tip 9 6099 6 1 Gas Distributor 9 6007 7 1 Shield Cup 9 6003 8 1 Torch Head Split Holders PCH 10 70 9 6259 PCH 10 180 9 6261 9 1 PIP Parts In Place Wire Assembly 9 6290 10 1 O Ring 8 0533 11 1 Torch Switch Button 8 4256 12 2 Torch Switch Button Springs 9 6292 be replaced by Qualified Technician only 02360 QTY A 2 56 x 5 16 LG Phillips Pan Head 6 B 6 Internal Star Washer 1 6 32 x 3 16 Phillips Pan Head 5 1 Zinc Plated Figure 5 2 Exploded View of Torch PARTS LISTS 30 Manual 0 2683 APPENDIX INTERCONNECTING DIAGRAM
16. 4 9 ON OFF Power Switch 1 Install replacement key slotted PC Board by plac ing PC Board over standoffs and sliding Board down into position 2 Push a white fastener plastic push on into each keyhole just above standoffs to secure the PC Board into position 3 Reverse steps 1 4 keeping in mind the following Make sure J2 is not offset by one or more pins b Install new tie wraps on wires connected to the PC Board as necessary 4 8 Power Relay Replacement NOTES The Control PC Board must be moved out of the way before the Power Relay can be replaced It may be easier to move the Control PC Board if the Ca pacitor is removed first Refer to subsection 4 1 General Information for information about wire harnesses Replacement NOTE When ordering a replacement ON OFF Switch order the same as found in your unit ON OFF Switches are as follows Switch Neon Type Color Voltage Sprong xz Red 115 90015 x Red 115 90021 c Prong gyar Amber 200 9 0029 ane A WARNING Disconnect primary power to the system before dis assembling the torch leads or power supply A Models A amp WARNING Remove cover handle from unit per subsection 4 2 Disconnect primary power to the system before dis assembling the torch leads or power supply 1 Remove cover handle from unit per subsection 4 2 2 Remove Capacitor optional step per instructi
17. 60Hz Fan 220V Compressor Air 12VDC 0 5 Compressor Disc Filter Resistor 0 5ohm 55 watt 10 3 16 Faston Resistor 1Kohm 55 watt 5 3 16 Faston Work Cable 15 ft 4 57 m w Red Handles Input Power Cable 6 5 ft min 2 m Catalog 9 0023 9 0024 9 0001 9 0037 9 0036 9 0002 9 0003 9 0004 9 0004 9 0004 9 3924 9 3924 9 0005 9 7508 8 3209 8 3209 8 3209 9 7687 9 7687 9 0010 9 7912 9 0011 9 0012 9 0013 DRAG GUN 100V 50 2 110V 60Hz Power Cable 14 3 w molded plug 9 0052 DRAG GUN 120V 50Hz Power Cable CE DRAG GUN 120V 60Hz Power Cable 16 3 w molded plug DRAG GUN 220V 50Hz Power Cable CE DRAG GUN 208 230 60Hz Power Cable 16 3 w molded plug Plug to be supplied by customer ON OFF Switch DRAG GUN Switch DPST 125V 15A w RED NEON CSA DRAG GUN Switch DPST 22A 125VAC RED NEON CSA DRAG GUN Switch 16A 250VAC AMBER or Red NEON CD Transformer Ferrite Core Assembly Bridge Rectifier Handle 5 4 Options amp Accessories not shown Qty 1 1 PARTS LISTS Description Circle Cutting Guide Kit Leads Wrap installed under Handle 28 9 0044 9 0014 9 0044 9 0014 9 0015 9 0021 9 0029 9 0018 7 3345 9 8115 Catalog 7 8910 9 7865 Manual 0 2683 HARDWARE QTY A Screw 6 32 x 3 3 4 Lg Phil Pan Hd Zinc 2 B 6 32 Regular Nylon Lock Nut Zinc Plated 2 For illustration purposes the C 5 16 18 x 1
18. FORMATION 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 R parez ou remplacez toute pi ce us e ou endommag e Prenez des soins particuliers lorsque la zone de tra vail est humide ou moite Montez et maintenez le mat riel conform ment au Code lectrique national des Etats Unis Voir la page 5 article 9 D branchez l alimentation lectrique avant tout tra vail d entretien ou de r paration Lisez et respectez toutes les consignes du Manuel de consignes Ao ET EXPLOSION Les incendies et les explosions peuvent r sulter des scories 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 com bustibles ou provoquer l explosion de fum es inflammables Soyez certain qu aucune mati re combustible ou in flammable 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 Procurez une bonne a ration de toutes les fum es inflammables ou explosives Necoupez pas et ne soudez pas les conteneurs ayant pu renfermer des mati res combustibles Pr voyez une veille d incendie lors de tout travail dans une zone pr sentant des dangers d incendie Legas hydrog ne peut se former
19. IHERMAL DYNAMICS THERMADYNE Company Plasma Cutting Power Supply Drag gun Service Manual November 11 2003 Manual No 0 2683 GS Read and understand this entire Manual and your employer s safety practices before installing oper ating 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 Cutting Power Supply with Built in Air Drag Gun Service Manual Number 0 2683 Published by Thermal Dynamics Corporation 82 Benning Street West Lebanon New Hampshire USA 03784 603 298 5711 www thermal dynamics com Copyright 1999 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 November 11 2003 Record the following information for Warranty purposes Where Purchased Purchase Date Power Supply Serial Torch Serial TABLE OF CONTENTS SECTION 1 GENERAL INFORMATION 1 1 01 Notes Cautions and Warnings
20. LACEMENT PROCEDURES 11 Position wire connector 14 so that it runs along side the Transformer NOT across the top of the Transformer 12 Install cover handle by reversing steps in subsec tion 4 2 keeping in mind the following a The Air Compressor is secured in position by one of the handle screws on the top side of the power supply b Make sure that no wires obstruct the cover when it is installed 4 6 Capacitor Replacement A WARNING Disconnect primary power to the system before dis assembling the torch leads or power supply NOTE Refer to subsection 4 1 General Information for information about wire harnesses 1 Remove cover handle from unit per subsection 4 2 2 Make note of all wire connections and locations to Capacitor 3 Remove all wire connections to Capacitor 4 The Capacitor is held in place by a tab located on the Transformer frame Using a screw driver or similar tool pry the tab back slightly to allow the Capacitor to slide out of the bracket 5 Install replacement Capacitor by reversing steps 1 4 keeping in mind the following Make sure the Capacitor is securely positioned behind tab Tab may need to be bent b Position wire connector 14 so that it runs along side the Transformer avoiding contact with metal parts REPLACEMENT PROCEDURES 20 4 7 Control PC Board Replacement The DRAG GUN Plasma Cutter has been manufactured using one of two styles of PC Boar
21. RACTICE FOR RESPIRATORY PROTECTION obtainable from American National Standards Institute 1430 Broadway New York NY 10018 1 04 Note Attention et Dans ce manuel les mots note Avertissement attention et avertissement sont utilis s pour mettre en relief des informations a caract re important Ces mises en relief sont classifi es comme suit 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 Date November 15 2001 wmm ATTENTION Toute proc dure pouvant r sulter l endommagement du mat riel en cas de non respect de la proc dure en question SSEMENT Toute proc dure pouvant provoquer des blessures de l op rateur ou des autres personnes se trouvant dans la zone de travail en cas de non respect de la proc dure en question 1 05 Precautions De Securite Importantes SSEMENTS L OP RATION 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 m
22. RATIONS DE COUPE ET DE SOUDAGE disponible aupr s de la Soci t Am ricaine de Soudage American Welding Society 550 N W LeJeune Rd Miami FL 33126 3 NIOSH LA S CURIT ET LA SANT LORS DES OP RATIONS DE COUPE ET DE SOUDAGE AU GAZ disponible aupr s du Superin tendent of Documents U S Government Printing Office Washington D C 20402 4 Norme ANSI Z87 1 PRATIQUES SURES POUR PROTECTION DES YEUX ET DU VISAGE AU TRA VAIL ET DANS LES ECOLES disponible de l Institut Am ricain des Normes Nationales American Na tional Standards Institute 1430 Broadway New York NY 10018 5 Norme ANSI 7411 NORMES POUR LES CHAUSSURES PROTECTRICES disponible aupr s de l American National Standards Institute 1430 Broadway New York NY 10018 6 Norme ANSI 749 2 PR VENTION DES INCENDIES LORS DE L EMPLOI DE PROC D S DE COUPE ET DE SOUDAGE disponible aupr s de l American Na tional Standards Institute 1430 Broadway New York NY 10018 7 Norme A6 0 del Association Am ricaine du Soudage AWS LE SOUDAGE ET LA COUPE DE CONTENEURS AYANT RENFERM DES PRODUITS COMBUSTIBLES disponible aupr s de la American Welding Society 550 N W LeJeune Rd Miami FL 33126 8 Norme 51 de l Association Am ricaine pour la Pro tection contre les Incendies NFPA LES SYSTEMES GAZ AVEC ALIMENTATION EN OXYGENE POUR LE SOUDAGE LA COUPE ET LES PROC D S ASSOCI S disponible aupr s de la Na tional Fire Protec
23. adway New York NY 10018 AWS Standard A6 0 WELDING AND CUTTING CON TAINERS WHICH HAVE HELD COMBUSTIBLES ob tainable from American Welding Society 550 N W LeJeune Rd Miami FL 33126 NFPA Standard 51 OXYGEN FUEL GAS SYSTEMS FOR WELDING CUTTING AND ALLIED PRO CESSES obtainable from the National Fire Protection Association Batterymarch Park Quincy MA 02269 NFPA Standard 70 NATIONAL ELECTRICAL CODE obtainable from the National Fire Protection Associa tion Batterymarch Park Quincy MA 02269 NFPA Standard 51B CUTTING AND WELDING PRO CESSES obtainable from the National Fire Protection Association Batterymarch Park Quincy MA 02269 CGA Pamphlet P 1 SAFE HANDLING OF COM PRESSED GASES IN CYLINDERS obtainable from the Compressed Gas Association 1235 Jefferson Davis Highway Suite 501 Arlington VA 22202 CSA Standard W117 2 CODE FOR SAFETY IN WELD ING AND CUTTING obtainable from the Canadian Standards Association Standards Sales 178 Rexdale Boulevard Rexdale Ontario Canada M9W 1R3 NWSA booklet WELDING SAFETY BIBLIOGRAPHY obtainable from the National Welding Supply Associa tion 1900 Arch Street Philadelphia PA 19103 American Welding Society Standard AWSF4 1 RECOM MENDED SAFE PRACTICES FOR THE PREPARA TION FOR WELDING AND CUTTING OF CONTAIN ERS 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 P
24. al to properly support the application and operation of this equipment A Application The equipment should satisfy the customer s requirements as supplied and as described in Section 3 of this manual Be sure to confirm that the equipment is capable of the application desired B Modifications No physical or electrical modifications other than selec tion of standard options and accessories are to be made to this equipment C Customer Operator Responsibilities It is the customer operator s responsibility to maintain the equipment and peripheral accessories provided by Thermal Dynamics in good operating order in accordance with the procedures outlined in the Operating Manual and to protect the equipment from accidental or malicious damage D Repair Restrictions The electronics consists of a Printed Circuit Board Assem bly which must be carefully handled and must be replaced asaunit Noreplacement of printed circuit solder mounted components is allowed except as noted in this manual If PC Board is to be returned the replaced Printed Circuit Board Assembly must be properly packaged in protective material and returned intact per normal procedures Manual 0 2683 2 3 Service Responsibilities TheService Technician should be familiar with the equip ment and its capabilities and should be prepared to rec ommend arrangements of components which will provide the most efficient layout utilizing the equipment to its best
25. blow air through it then reinstall it 11 TROUBLE SHOOTING Power Source Related If the service available is saggy pilot and cut performance will be degraded In some cases the service circuit breaker may open during use Some things that will help Use a service fused or circuit breaker for speci fied amps Refer to Operator s Manual 0 2682 sub section 4 0 D for service amperage Use heavy gauge extension cords Refer to Operator s Manual 0 2682 subsection 4 0 D for sizes Useas short an extension cord as possible Try different outlets on different branch circuits Use the one that gives the strongest pilot C Power Supply Torch Related In some instances when the torch switch is pressed there is no pilot You may need to try several times before the torch fires If the torch does not fire no pilot arc soon after the torch switch is activated try releasing the torch switch and let ting theleads bleed down before trying again This should help because the torch fires best at a lower voltage with lower air pressure at the torch D Cutting Related 1 Piloting One of the features of this plasma cutter is the con stant DC pilot This means the plasma arc is always on either as a pilot arc or a cutting arc resulting in a very smooth forgiving system This also means that thetorch tip will wear fairly rapidly if you pilot for an extended time or cut with too great a standoff essen
26. bly Replacement 17 4 4 Torch Switch Only Replacement 19 4 5 Air Compressor Replacement 19 4 6 Capacitor Replacement 20 4 7 Control PC Board 20 4 8 Power Relay Replacement 21 4 9 ON OFF Power Switch Replacement 21 4 10 Fan Replacement ses 22 4 11 Diode Bridge Rectifier Replacement 22 4 12 Transformer Ferrite Core Assembly Replacement 23 4 13 Input Voltage Changeover For 208 230 VAC Service Only 23 4 14 Torch Leads Replacement 24 4 15 Work Cable Replacement ss 25 4 16 Primary Input Power Cable Replacement 25 TABLE OF CONTENTS Continued 5 0 PARTS EIS To tint eti EIE a aan TET 27 5 1 e Mee cee ie d LS 27 5 2 Parts Replacement iii 27 5 3 Power Supply Replacement Parts sse 28 5 4 Options amp Accessories not shown 28 5 5 Torch Replacement Parts 30 APPENDIX I INTERCONNECTING DIAGRAM iii 31 APPENDIX II INTERCONNECTING DIAGRAM
27. can be purchased 10 cally One of two harnesses has been used in this unit For units which are rev or earlier refer to sche matic in Appendix II For units which are rev D or later refer to the schematic in Appendix III Check the data tag on your unit for the rev level of your unit and follow instructions in this section where appli cable as they pertain to your unit A WARNINGS Disconnect primary power to the system before disassembling the torch leads or power supply 4 2 Removing Cover Handle 1 Remove2 screws in handle 2 screws in end pan els and four screws near base to remove cover and handle from unit NOTE When replacing cover make sure all wires are care fully positioned so that the wires are not pinched when the cover and handle are secured Manual 0 2683 4 3 Torch Head Assembly Replacement A WARNINGS Disconnect primary power to the system before dis assembling the torch or power supply Torch parts may get quite hot during normal opera tion Always wear light cutting gloves when chang ing torch parts just after operating the Drag Gun system Remove Torch Head Assembly 17 NOTE Refer to Figure 4 1 for parts identification T 2 10 Remove consumable parts from front end of torch Remove six screws from torch handle assembly A Remove both torch handle halves from the torch and leads assembly then compl
28. ctions recommendations and recognized standard industry practice and not subject to misuse repair neglect alteration or accident correct such defects by suitable repair or replacement at Thermal s sole option of any components or parts of the product determined by Thermal to be defective THIS WARRANTY IS EXCLUSIVE AND IS IN LIEU OF ANY WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE LIMITATION OF LIABILITY Thermal 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 customers of distributor hereinafter Purchaser for service interruption The remedies of the Purchaser set forth herein are exclusive and the liability of Thermal 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 any goods covered by or furnished by Thermal 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 such liability is based THIS WARRANTY BECOMES INVALID IF REPLACEMENT PARTS OR ACCESSORIES ARE USED WHICH MAY IMPAIR THE SAFETY OR PERFORMANCE OF ANY THERMAL PRODUCT THIS WARRANTY IS INVALID IF THE PRODUCT IS SOLD BY NON AUTHORIZED PERSONS The limited warranty periods for Thermal pr
29. d Assemblies The Board will either have round mounting holes in the cor ners or key slotted mounting holes in the corners Follow procedures as they apply to your unit NOTES It may be easier to remove the PC Board if the Ca pacitor is removed first All replacement PC Boards have key slotted holes A WARNING Disconnect primary power to the system before dis assembling the torch leads or power supply A To Remove PC Board 1 Removecover handle from unit per subsection 42 2 Remove Capacitor optional per subsection 4 6 3 Note all wiring connections and locations to the PC Board 4 Disconnect all wire connections to the PC Board removing any tie wraps where necessary 5 Remove PC Board from unit by completing the fol lowing as it applies to your unit PC Board with round mounting holes a Removethe two 2 metal clips located on the top two standoffs that secure the PC Board to theunit b Gently pry PC Board off the standoffs then re move the second set of metal clips 2 NOTE In some cases the PCB may be mounted on stand offs and secured with RTV over the ends Remove the and then remove the PCB from the unit PC Board with key slotted mounting holes a Removetwo 2 fastener plastic push ons from key slotted holes in corners of PC Board b Slide PC Board up or down to disengage then remove from unit Manual 0 2683 To Install Replacement PC Board
30. e following per ANSI 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 work piece 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 Docu ments U S Government Printing Office Washington D C 20402 2 ANSI Standard Z49 1 SAFETY IN WELDING AND CUTTING obtainable from the American Welding So ciety 550 N W LeJeune Rd Miami FL 33126 3 NIOSH SAFETY AND HEALTH IN ARC WELDING AND GAS WELDING AND CUTTING obtainable from the Superintendent of Documents U S Govern ment Printing Office Washington D C 20402 4 ANSIStandard Z87 1 SAFE PRACTICES FOR OCCU PATION AND EDUCATIONAL EYE AND FACE PRO TECTION obtainable from American National Stan dards Institute 1430 Broadway New York NY 10018 5 ANSI Standard Z41 1 STANDARD FOR MEN S SAFETY TOE FOOTWEAR obtainable from the Ameri can National Standards Institute 1430 Broadway New York NY 10018 Date November 15 2001 10 1 12 13 14 15 ANSI Standard 749 2 FIRE PREVENTION IN THE USE OF CUTTING AND WELDING PROCESSES obtain able from American National Standards Institute 1430 Bro
31. ecured in position by one of the handle screws 4 11 Diode Bridge Rectifier Replacement NOTE Refer to subsection 4 1 General Information for information about wire harnesses 1 Remove cover handle from unit per subsection 4 2 2 Note all wire connections and locations to the Di ode Bridge Rectifier 3 Disconnect wires to the Diode s and remove Di ode from unit 4 Install replacement Diode by reversing steps 1 3 above noting the following a Diode should be oriented with plus sign down and to the right REPLACEMENT PROCEDURES 22 Manual 0 2683 4 12 Transformer Ferrite Core 4 13 Input Voltage Changeover For Assembly Replacement 208 230 VAC Service Only All 208 230 VAC units are factory set for 230 VAC To WARNINGS switch to 208VAC input power operation complete the following FEEE Disconnect primary power at source before assem bling or disassembling t he power supply WARNINGS 1 Remove cover handle from unit per subsection 4 2 Do not touch live electrical parts 2 Wire connections are as follows Disconnect primary power at source before assem bling or disassembling the power supply torch parts Connector Location or torch and leads assemblies ES on PCB E1 on PCB 1 Remove cover handle from unit per subsection 4 2 2 Locate the wiring on the end of the Capacitor Lead Fitting 3 Remove tie wrap and orange sleeving from wire 208VAC 3 Disconnect w
32. embre professionel de m dication et le manufacturier de mat riel de sant pour d terminer s il existe des risques de sant Il faut communiquer aux op rateurs et au person nel 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 n HEGBAs g 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 GENERAL INFORMATION Eloignez toute fum e et gaz de votre zone de respira tion Gardez votre t te hors de la plume de fum e provenant du chalumeau Utilisez un appareil respiratoire alimentation en air si l a ration fournie ne permet pas d liminer la fum e et les gaz 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 Lisez toujours les fiches de donn es sur la s curi
33. eplaced without replacing the torch assembly as well If no continuity is found check the resistance between the negative plasma lead fitting and the electrode seat in torch head If no continuity is found replace the torch and leads assembly C Checking Pilot and Switch Control Wires Check the pilot and switch control wires for continuity from one end of the torch lead to the other If no continuity exists replace torch and lead assembly D Reassembling Torch and Leads Replace parts as required then recheck the torch head and lead connections to confirm proper measurements If each component is okay reassemble torch and leads 15 TROUBLE SHOOTING TROUBLE SHOOTING 16 Manual 0 2683 4 0 PROCEDURES 4 1 General Information e Failures identified on the Transformer Inductor Chassis Assembly cannot be repaired the entire power supply must be replaced Refer to the Parts List for the catalog number for a replacement power supply e The torch head torch switch and torch amp leads as sembly are replaceable parts The torch leads alone are not serviceable problems encountered in the leads will require the torch amp leads assembly to be replaced For instructions on replacing the torch amp leads work cable amp clamp and input power cable refer to Oper ating Manual 0 2682 Refer to Appendix I in this manual for leads connection diagram Most replacement hardware
34. ete the following a Disconnect positive pilot lead connection at torch head by removing pilot lead screw B b Cuttie wrap from torch hose C c Using X acto knife or other small cutting tool cut torch lead 1 2 54 cm from the end of black sleeve D to reveal butt splice Pull torch head away from torch lead to expose 1 2 3 4 of cable Clamp down with vise grips on black sleeve of lead so that cable cannot spring back into lead E Cut cable at end of butt splice and remove torch head assembly F Remove orange insulating sleeving from torch head gas input G Note Sleeving is optional Some torch assemblies may not have sleeving Remove torch O ring from torch split holder Remove the two screws from the torch head split holder and separate the halves I Remove the torch head from the holder Do not disturb PIP connections REPLACEMENT PROCEDURES Remove Six Screws d Switch Cut Black Hose 1 000 Remove Pilot Lead Screw Place Vise Grips Here Remove Screws O Ring Orange Torch Cut Cable Here Sleeving Optional G A 02295 Figure 4 1 Removing Torch HeadAssembly To Install Replacement Torch Head Assembly NOTE Refer to Figure 4 2 for parts identification 1 Place replaceme
35. h circuit TROUBLE SHOOTING 14 7 Faulty Ferrite Transformer Assembly a The Ferrite Transformer Assembly is used to generate a high voltage pulse to establish the pilot arc Troubleshooting is limited to visual inspection The two primary connections and two secondary connections should be checked for general integrity and snug fit onto the push on connectors The Transformer Assembly it self should be free of large ferrite chips and cracks along the core Torch pilots but does not cut well 1 AC input power too low a Use shortest service from AC outlet to breaker panel as possible or larger gauge extension cord 2 Work cable not attached a Check work cable connection 3 Restricted air flow a Check lead for kinks or pinching restricting air flow 4 Loose shield cup a Tighten shield cup 5 One or more gas distributor holes blocked a Replace Gas Distributor 6 Excessive parts wear a Inspect torch consumables and replace as nec essary 7 Damaged torch insulator a Check insulator between anode and cathode for charring per subsection 3 6 Torch and Leads Troubleshooting Manual 0 2683 3 6 Torch amp Leads Troubleshooting WARNINGS Disconnect primary power to the system before dis assembling the torch leads or power supply DO NOT touch any internal torch parts while the AC indicator light on the front panel of the power supply is on Torch parts may get quite hot during nor
36. has cooled down replace the compressor 6 Shorted Bridge Rectifier BR2 a Ifthe Rectifier upper is hot and the Transformer is buzzing or heating up the rectifier is shorted Replace Rectifier 7 Faulty Control PCB or Relay CAUTION Be sure torch is directed away from people or haz ards A pilot arc may start a Push the test button on the side of the Relay If the Compressor starts and the torch operates the PCB or Relay has most likely failed The PCB can be isolated by removing the push on connectors from the Relay coil and measur ing the relay coil with an ohmmeter If the coil measures between 50 100ohms the Relay is good and the PCB should be replaced If the Compressor runs intermittently and arc ing can be seen in the Relay case while the torch switch is held on the Relay contacts are worn and the Relay should be replaced Power OK fan runs compressor runs intermit tently Relay Case shows arcing when the torch switch is held on 1 Faulty Relay a If the Compressor runs intermittently and arc ing can be seen in the Relay Case while the torch switch is held on the relay contacts are worn and the Relay should be replaced TROUBLE SHOOTING Power fan runs compressor starts then shuts down as soon as the torch switch is pressed 1 Shorted damaged or incorrect torch parts a Check that all torch parts are in good condition and designed for use in the PCH 10 torch
37. icient Penetration Cutting speed too fast Torch tilted too much Metal too thick Worn torch parts Standoff too high Line voltage too low OY OO ee Ne Extension cord with inadequate rating Manual 0 2683 B Main Arc Extinguishes Cutting speed too slow Torch standoff too high from workpiece So eho rs Work cable disconnected 4 Worn torch parts C Excessive Dross Formation 1 Cutting speed too slow 2 Torch standoff too high from workpiece 3 Worn torch parts Short Torch Parts Life Exceeding system capability material too thick Excessive pilot arc time Improperly assembled torch Inadequate air supply check filter on Compressor Faulty Air Compressor LOT E Ground or work lead not connected 3 4 Getting used to the way the system sounds and feels while itis operating properly will help to determine the nature of problems if they arise Common Operating Problems A Compressor Related If the unit is cold the Air Compressor may not start up or may run sluggishly Most likely when the torch switch is depressed the unit will click once and nothing more will happen unit warm up to room temperature ap proximately 50 10 and try again If the air filter on the compressor becomes clogged the compressor may sound more labored cut speed and qual ity will be reduced and the arc may have a more green color The air filter element can be cleaned remove it
38. ire connections Pull L4 connector through loose tie wrap if available 4 Remove wire 230VAC from Capacitor and replace with wire 208VAC 4 Remove two Ferrite Core Assembly screws which hold the Transformer Ferrite Core Assembly in 5 Slide orange sleeving over wire 230VAC fold over position Remove Transformer Ferrite Core As and secure with a tie wrap sembly from unit 5 Install replacement Transformer Ferrite Core As A WARNING sembly by reversing steps 1 4 keeping in mind the following Do not leave other input wire unprotected inside a Pull L4 through loose tie wrap if available b Position wire connector 14 that it runs along side the Transformer NOT across the top of the 6 Reinstall cover Transformer or near any metal parts Manual 0 2683 23 REPLACEMENT PROCEDURES 4 14 Torch 8 Leads Replacement Remove cover handle from unit per subsection 4 2 Disconnect the following refer to Figure 4 4 Faston Connector to CD Coil from the Brass Torch Lead Fitting Brass Torch Lead Fitting from the 90 degree White Nylon Fitting 2 pin Connectors Torch Lead Faston Connector red from bot tom Resistor Loosen the Strain Relief Nut from the Strain Relief and remove Torch Lead Assembly from unit Install Strain Relief on replacement torch Brass Torch Lead Fitting Nylon Nut 90 White Nylon Fitting Torch Lead Relief Torch Lead Fast
39. it pertains to your unit Rev units or earlier Disconnect black wire from Compressor to faston splice amp wire 21 Disconnect red wire from Compressor to up per diode piggy back terminal Rev D units or later Disconnect black wire from Compressor to faston splice amp wire 29 Disconnect red wire from Compressor to up per diode piggy back terminal 4 Slide Compressor out of bracket 5 Note position and angle of 90 nylon nut connected to the Air Compressor Remove fitting 6 Clean old teflon thread sealant from nylon fitting apply new thread sealant and install nylon fitting replacement Air Compressor Make sure fitting is in proper position 7 Remove feet from Compressor and install on re placement Compressor 8 Insert replacement Air Compressor into bracket insuring feet have dropped into slots in bracket 9 Apply a small amount of O Ring lubricant to brass torch fitting and insert into 90 nylon fitting Tighten nylon nut NOTE Be careful not to remove the nylon nut completely as there are small parts inside that could fall out 10 Connect the following as it pertains to your unit Connect black wire from Compressor to faston splice amp wire 21 Connect red wire from Com pressor to upper diode piggyback terminal Connect black wire from Compressor to faston splice amp wire 29 Connect red wire from Com pressor to upper diode piggyback terminal 19 REP
40. le from unit per subsection 4 2 Disconnect Input Power Cable wiring to the ON OFF Switch and Ground Loosen Input Power Cable Strain Relief and re move Input Cable from unit Install Strain Relief on replacement Input Power Cable Install the Input Power Cable through rear panel Check the wire numbers on Input Power Cable and the prong numbers on the ON OFF Switch Match that information to one of the configura tions in Figure 4 6 and connect the wires accord ingly A B White Blue Black Brown White Blue Black Brown Wire Wire Wire Wire LI EL Black Wire Black Wire Black Wire Black Wire 5 6 21 22 C D Black Wire Black Wire Black Wire Black Wire 5 6 21 22 1L IL CI Li 1 Ly White Blue Black White Blue Black Brown Wire Wire Wire Wire 02652 White or Blue Wire Black Wire 4B 1A Wire No 5 4 6 or 21 5 or 22 Not Used Not Used cmm 6B 3A A 03649 Figure 4 6 Input Power Cable Connections REPLACEMENT PROCEDURES Power Switch Green Wire with Tracer Connect to Compressor Frame Primary Relief Input Power Cable Green Wire from Primary Ground Stud 02653 Input Power Cable Figure 4 7 Ground Connections 7 Connec
41. mal opera tion Always wear light cutting gloves when chang ing torch parts just after operating the Drag Gun system A Checking Center Insulator The Center Insulator separates the negative and positive charged sections of the torch If the center insulator does not provide adequate resistance current which is intended for the pilot arc may be dissipated into the torch head resulting in torch failure 1 Removethe shield cup tip gas distributor and electrode from the torch Electrode Gas Distributor Standard Shield Cup Torch Head Assembly A 02007 Figure 3 1 PCH 10 Torch Head Parts Removal 2 Disconnect the torch lead from the power supply to isolate the torch from power supply circuits Refer to Appendix I for Leads connections 3 Using an ohmmeter set to 10K or higher check for continuity between the electrode seat negative and the brass threads of the torchassembly Infinite resistance no continuity should be found If there is continuity between the two remove the torch head from the lead and check the torch head separately Manual 0 2683 B Checking Torch Lead If the torch head assembly is okay check the torch lead by measuring the resistance between the positive pilot lead connector and the negative lead fitting If continuity is found the insulation between the torch leads is breaking down and the torch and leads assembly should be replaced NOTE The lead cannot be r
42. nd 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 met als which may contain one or more of the follow ing 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 in formation 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 com bustible or explosive gases or materials are located Phosgene a toxic gas is generated from the vapors of chlorinated 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 de fect
43. nt torch head in torch head split holder halves and secure with 2 screws removed in step 9 above K Do not disturb PIP connec tions REPLACEMENT PROCEDURES 2 Install O ring removed in step 8 above L 3 Optional Install orange sleeving on replacement torch head gas input 4 Place torch head in correct orientation then insert lead cable into torch butt slice and crimp M 5 Remove vise grips 6 Lubricate torch head glands lightly with silicone and push hose back onto barbs up to the point where the teflon tubing and brass fitting meet N 7 Install tie wrap onto hose in correct position C removing any excess 8 Connect pilot lead to pilot lead terminal by plac ing washer between terminal and connector and installing screw O 9 Push pilot lead under cable jacket until there is no excess New Torch Head Insert Cable Into Butt Splice amp Crimp Washer Install Pilot Butt Splice Lead Screw Teflon Tubing A 02296 4 2 Installing Torch Head Assembly Manual 0 2683 4 4 Torch Switch Only Replacement NOTE This procedure requires the following tools or equivalent screwdriver soldering iron Flux A WARNING Disconnect primary power to the system before dis assembling the torch leads or power supply 1 Remove consumable parts from front end of torch 2 Remove the six screws from the torch handle as
44. oducts shall be as follows with the exception of XL Plus Series CutMaster Series Cougar and DRAG GUN A maximum of three 3 years from date of sale to an authorized distributor and a maximum of two 2 years from date of sale by such distributor to the Purchaser and with the further limitations on such two 2 year period see chart below The limited warranty period for XL Plus Series and CutMaster Series shall be as follows A maximum of four 4 years from date of sale to an authorized distributor and a maximum of three 3 years from date of sale by such distributor to the Purchaser and with the further limitations on such three 3 year period see chart below The limited warranty period for Cougar and DRAG GUN shall be as follows A maximum of two 2 years from date of sale to an authorized distributor and a maximum of one 1 year from date of sale by such distributor to the Purchaser and with the further limitations on such two 2 year period see chart below Parts XL Plus amp Parts Parts PAK Units Power Supplies CutMaster Series Cougar Drag Gun Others Labor Main Power Magnetics 3 Years 1 Year 2 Years 1 Year Original Main Power Rectifier 3 Years 1 Year 2 Years 1 Year Control PC Board 3 Years 1 Year 2 Years 1 Year Other Circuits And Components Including 1 Year 1 Year 1 Year 1 Year But Not Limited To Starting Circuit Contactors Relays Solenoids Pumps Power Switching Semi Conductors Consoles Cont
45. on Connector Red 2592009 Connect to Bottom Resistor 5 Insert Torch leads through front hole on unit Slide Strain Relief Nut over the end of the torch lead Allow one inch clearance between the end of the torch lead sheath and the hole in the front panel then tighten theStrain Relief Nut This allows al low enough length in the torch lead to make all the connections inside the unit Reconnect all connections by reversing step 2 Replace cover by reversing step 1 Faston Connector to CD Coil Front Panel Strain Relief Nut Hole Location Strain Relief 1 Clearance Torch Leads Assembly Note Do not remove strain relief from torch lead 2 Pin Connectors Figure 4 4 Torch amp Leads Replacement REPLACEMENT PROCEDURES 24 Manual 0 2683 4 15 Work Cable Replacement 1 Remove cover handle from unit per subsection 4 2 2 Disconnect the Work Cable Faston from mounting tab on bottom of Rectifier 3 Loosen Strain Relief and remove Work Cable from unit 4 Install Strain Relief on replacement Work Cable 5 1 2 inches from Faston 5 Install replacement Work Cable by reversing steps 1 3 Bridge A 02011 cen Rectifier Work Cable Work Cable Faston Connect to mounting tab at bottom of Rectifier Strain Relief Install 5 1 2 from Faston Figure 4 5 Work Cable Replacement Manual 0 2683 4 16 Primary Input Power Cable Replacement Removecover hand
46. ons in 4 6 3 Remove PCB from standoffs per subsection 4 7 B 4 Slide PC Board away from Relay 5 Note all wiring connections and locations to the Relay 6 Remove wirings connected to Relay 7 Slide Relay out from bracket towards the center of the unit 8 Install replacement Relay by reversing the above steps keeping in mind the following a Position wire connector so that it runs along side the Transformer NOT across the top of the Transformer Manual 0 2683 21 Note all wiring connections and locations to On Off Switch 3 Disconnect wires to ON OFF Switch 4 Push plastic clips down on top side of Switch and slide Switch out by pulling it through front panel Install replacement ON OFF Switch by reversing the above steps keeping in mind the following a Position wire connector so that it runs along side the Transformer NOT across the top of the Transformer REPLACEMENT PROCEDURES Model 4 10 Fan Replacement Bere 1 Remove cover handle from unit per subsection Type C switch with 6 prongs replaces Type C switch 4 2 KUET PONES 2 Carefully slide the Air Compressor out of the Trans 1 Remove cover handle from unit per subsection 4 2 former bracket and out of the way of the Fan Be careful not to strain wire connections If neces sary remove Compressor completely following procedures described in subsection 4 5 2 Disconnect wires to ON OFF Switch 3
47. possible advantage Maintenance work should be accomplished in a timely manner If problems are encountered or the equipment does not function as specified contact Technical Services Department in West Lebanon for assistance 2 4 Technical Specifications A System Specifications IX VAC 9 220VAC 10 50Hz Single Phase 1208 230 10 60Hz Single Phase Duy Seesusedon238 1 psovoc PiotCircuty Decharge CD Constant Weightwih Leads 5049 Power Supply Dimensions 0 in 254 mm Work Cable 10 70 10 180 ee subsection 2 4 See subsection 2 4 Ratng 12 Amps Max StraightPolarity ICutCapaciy Mostmetals up to 1 8 in 3 2 mm max Severance Nostnews up b 3167 8 Perce Rang Wien Trans r Distance Approx U6 n 32 1 Gas Requirements Compressed Air Built in Leads Length 20 ft 6 1 ft 6 ft 2 m minimum Torch Style L Torch Dimensions Wi 15 46 m InputPowerCable 6 6 f 9 Introduction Input Output Specifications Input Output Amps Voltage RMS DC 001107 20 20 0872307 60 CE approved 2 5 Dimensions 10 0 in 254 mm 16 0 406 mm an 229 mm Figure 2 1 Power Suppl
48. rol Equipment Heat 1 Year 1 Year 1 Year Exchanges And Accessory Equipment Torch And Leads Maximizer 300 Torch 1 Year 1 Year SureLok Torches 1 Year 1 Year 1 Year Other Torches 180 Days 180 Days 180 Days 180 Days Repair Replacement Parts 90 Days 90 Days 90 Days None Warranty repairs or replacement claims under this limited warranty must be submitted by an authorized Thermal Dynamics repair facility within thirty 30 days of the repair No transportation costs of any kind will be paid under this warranty Transportation charges to send products to an authorized warranty repair facility shall be the responsibility of the customer All returned goods shall be at the customer s risk and expense This warranty supersedes all previous Thermal warranties Effective November 15 2001 GENERAL INFORMATION 8 Date November 15 2001 2 0 INTRODUCTION 2 1 Scope Of Manual This manual provides service instructions for the Ther mal Dynamics DRAG GUN Plasma Cutter Information in this edition is particularly applicable to the Troubleshooting and Repair of the equipment and is intended for use by properly trained Service Technicians familiar with this equipment Read this manual and the DRAG GUN Operating Manual 0 2682 thoroughly A complete understanding of the ca pabilities and functions of the equipment will assure ob taining the performance for which it was designed 2 2 General Service Philosophy Several key points are essenti
49. s and insome cases cancer California Health amp Safety Code Sec 25249 5 et seq A 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 op erator or others in the workplace Never touch any parts that are electrically live or hot GENERAL INFORMATION 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 Publica tions Disconnect power source before performing any service or repairs Read and follow all the instructions in the Operat ing Manual Ay AND EXPLOSION Fire and explosion can be caused by hot slag sparks or the plasma arc sure there is no combustible or flammable ma terial in the workplace Any material that cannot be removed must be protected Ventilate all flammable or explosive vapors from the workplace Do not cut or weld on containers that may have held combustibles 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 under water or while using a water table DO NOT cut al
50. t 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 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 N utilisez pas le chalumeau au jet de plasma dans une zone o se trouvent des mati res ou des gaz combus tibles ou explosifs Le phosg ne un gaz toxique est g n r par la fum e provenant des solvants et des produits de nettoyage chlor s Eliminez toute source de telle fum e Ceproduit 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 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 GENERAL IN
51. t the Ground Wires as shown 8 Tighten Strain Relief 9 Replace cover handle by reversing step 1 NOTE When replacing cover make sure all wires are care fully positioned so that no wires are pinched REPLACEMENT PROCEDURES 26 Manual 0 2683 5 0 PARTS LIST Order replacement parts by catalog number and complete description of the part or assembly Also include the model and serial number of the torch Address all inquiries to your authorized distributor or call toll free 1 888 832 4250 NOTE Standard hardware has been used in this unit Replacement hardware can be purchased locally 5 1 Returns If a product must be returned for service contact your authorized distributor Items return to the manufacturer without proper authorization will not be accepted 5 2 Parts Replacement NOTE Refer to Power Supply data tag to identify model of your unit Description A Complete Systems Catalog Includes Power Supply PCH 10 70 Torch with Leads Spare Consumable Parts Input Power Cord and Work Cable DRAG GUN 100V 50Hz 110V 60Hz PCH 10 DRAG GUN 120V 50Hz PCH 10 DRAG GUN 120V 60Hz PCH 10 DRAG GUN 220V 50Hz PCH 10 CE DRAG GUN 208 230 60Hz PCH 10 1 1111 3 1 1811 6 1 1111 1 1 1811 5 1 1111 2 Includes Power Supply PCH 10 180 Torch with Leads Spare Consumable Parts Input Power Cord and Work Cable DRAG GUN 100V 50Hz 110V 60Hz PCH 10 DRAG GUN 120V 50Hz PCH 10 CE DRAG GUN 120V 60Hz PCH
52. tandards Institute 1430 Broadway New York NY 10018 GENERAL INFORMATION 6 Date November 15 2001 1 07 Declaration of Conformity Manufacturer Thermal Dynamics 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 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 Euro pean 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 150 60974 1 BS 638 10 EN 60 974 1 EN50192 EN50078 applicable to plasma cutting equipment and associ ated accessories
53. tion Association Batterymarch Park Quincy MA 02269 GENERAL INFORMATION 9 Norme 70 la CODE ELECTRIQUE NA TIONAL disponible aupr s de la National Fire Pro tection Association Batterymarch Park Quincy MA 02269 10 Norme 51B de la NFPA LES PROCEDES DE COUPE ET DE SOUDAGE disponible aupr s de la National Fire Protection Association Batterymarch Park Quincy MA 02269 11 Brochure GCA P 1 LA MANIPULATION SANS RISQUE DES GAZ COMPRIMES EN CYLINDRES disponible aupr s de l Association des Gaz Comprim s Compressed Gas Association 1235 Jefferson Davis Highway Suite 501 Arlington VA 22202 12 Norme CSA W117 2 CODE DE SECURITE POUR LE SOUDAGE ET LA COUPE disponible aupr s de l Association des Normes Canadiennes Stan dards Sales 178 Rexdale Boulevard Rexdale Ontario Canada 9 1R3 13 Livret NWSA BIBLIOGRAPHIE SUR 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 14 Norme AWSFA 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 RENFERM DES PRODUITS DANGEREUX disponible aupr s de la American Welding Society 550 N W LeJeune Rd Miami FL 33126 15 Norme ANSI Z88 2 PRATIQUES DE PROTECTION RESPIRATOIRE disponible aupr s de l American National S
54. ulate the two wires going to the Fan with tape separately then reapply power If the circuit breaker or fuse opens after the power switch is switched on go to next step If the circuit breaker or fuse is okay replace Fan 2 Faulty Transformer Assembly or Capacitor a With the Fan still disconnected disconnect two leads from the transformer that are connected to the Capacitor C13 then apply power If the circuit breaker or fuse opens after power is applied the Capacitor is shorted Replace Capacitor C13 If the circuit breaker or fuse is okay replace Transformer E Power OK fan runs no compressor operation or pilot when torch switch pressed 1 Shield cup loose PIP not making contact a Reseat the torch parts tighten shield cup 2 Unit overheated 3 a Leave power on so fan can cool unit test again after 10 minutes Shorted torch parts a Replace torch consumables Manual 0 2683 13 4 Torch switch may have broken or shorted wires a Refertosubsection 3 6 Torch and Leads Trouble shooting 5 Overheated or faulty Compressor a Press the torch switch If a clicking can be heard and or the Relay is actuating test button on side pulls in the Compressor motor may have failed or overheated If the Case of the Com pressor motor feels very warm allow it to cool and try again The Compressor has its own overtemp cutout switch If the unit fails to operate once it
55. uminum alloys underwater or on a water table unless the hydrogen gas can be eliminated or dis sipated Trapped hydrogen gas that is ignited will cause an explosion Noise can cause permanent hearing loss Plasma arc cesses can cause noise levels to exceed safe limits You must protect your ears from loud noise to prevent per manent loss of hearing To protect your hearing from loud noise wear pro tective ear plugs and or ear muffs Protect others in the workplace Noise levels should be measured to be sure the deci bels sound do not exceed safe levels e For information on how to test for noise see item 1 in Subsection 1 03 Publications in this manual GENERAL INFORMATION 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 hel met or shield Also always wear safety glasses with side shields goggles or other protective eye wear Wear welding gloves and suitable clothing to pro tect 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 Use the shade of lens as suggested in th
56. y Dimensions 2 9 in 2 75 mm 1 1 in 27 mm 8 in 203 mm 70 8 9 226 mm 180 y 1 1 in 27 02385 Figure 2 2 Torch Dimensions Introduction 10 Manual 0 2683 3 0 TROUBLESHOOTING 3 1 This section provides service diagnostics for the DRAG GUN Plasma Cutter with PCH 10 Torch aiding the tech nician to isolate faulty subassemblies Introduction Under no circumstances are field repairs to be attempted on Printed Circuit Boards or other subassemblies of this unit Evidence of unauthorized repairs will void the fac tory warranty A WARNING 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 troubleshoot ing techniques 3 2 Periodic Inspection amp Maintenance The DRAG GUN Operating Manual 0 2682 describes the inspection and maintenance procedures which should be performed at periodic intervals Routine Maintenance ensures optimum performance of equipment and can pre vent the user from encountering problems with this equip ment Refer to that manual for instructions on power sup ply and torch maintenance 3 3 Common Cutting Faults Poor or lackluster performance can often be improved by slight modifications to technique or equipment For ex ample A Insuff
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