Thermal Dynamics Drag-Gun Plasma Cutting
Contents
1. 1 1 01 Notes Cautions and Warnings 1 1 02 Important Safety Precautions 1 1 03 Publications 2 1 04 Note Attention et Avertissement 3 1 05 Precautions De Securite Importantes 3 1 06 Documents De Reference 5 1 07 Declaration of Conformity 7 1 08 Statement of Warranty 8 2 0 INTRODUCTION 9 2 1 Scope Of Manual 9 2 2 General Service Philosophy 9 2 3 Service Responsibilities 9 22. 27 5 1 Returns 27 5 2 Parts Replacement 27 5 3 Power Supply Replacement Parts 28 5 4 Options amp Accessories not shown 28 5 5 Torch Replacement Parts 30 APPENDIX I INTERCONNECTING DIAGRAM 31 APPENDIX II INTERCONNECTING DIAGRAM 32 Date November 15 2001 1 GENERAL INFORMATION SECTION 1 GENERAL INFORMATION 1 01 Notes Cautions and Warnings Throughout this manual notes cautions and warnings are used to highlight important information These 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 CAUTION A procedure which if not properly followed may cause damage to the equipment WARNING A procedure which if not properly followed may cause injury to the op
3. 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 INCENDIE 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 Ne coupez 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 Le gas 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 l
4. 17 4 4 Torch Switch Only Replacement 19 4 5 Air Compressor Replacement 19 4 6 Capacitor Replacement 20 4 7 Control PC Board Replacement 20 4 8 Power Relay Replacement 21 4 9 ON OFF Power Switch Replacement 21 4 10 Fan Replacement 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 amp Leads Replacement 24 4 15 Work Cable Replacement 25 4 16 Primary Input Power Cable Replacement 25 TABLE OF CONTENTS Continued 5 0 PARTS LIST
5. 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 All 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 All 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 Control 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 All Other Torches 180 Days 180 Days 180 Days 180 Days Repair Replacement Parts 90 Days 90 Days 90 Days None Warranty repairs or rep
6. 4 Norme ANSI Z87 1 PRATIQUES SURES POUR LA 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 Z41 1 NORMES POUR LES CHAUSSURES PROTECTRICES disponible aupr s de l American National Standards Institute 1430 Broadway New York NY 10018 6 Norme ANSI Z49 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 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 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 Protection Association Batterymarch Park Quincy MA 02269 GENERAL INFORMATION 6 Date November 15 2001 9 Norme 70 de la NFPA 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 PROC D S DE COUPE ET DE SOUDAGE disponible aupr s de la National Fire
7. QTY 2 2 2 4 2 2 NOTE Replacement hardware can be purchased locally F F E E B B D D D C C A A 11 12 To remove cover unfasten 4 side panel screws 2 handle screws 2 end panel screws 2 15 1 14 6 3 4 8 13 9 10 7 16 Figure 5 1 Exploded View of Power Supply PARTS LISTS 30 Manual 0 2683 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 To be replaced by Qualified Technician only A 02360 2 4 5 6 3 7 2 1 A 2 56 x 5 16 LG Phillips Pan Head B 6 Internal Star Washer C 6 32 x 3 16 Phillips Pan Head M S Zinc Plated 6 1 1 HARDWARE QTY A A A A A A B C 8 8 1 9 10 11 12 Figure 5 2 Exploded View of Torch Manual 0 2683 31 APPENDIX APPENDIX I INTERCONNECTING DIAGRAM A 02012 PIP Pin J2 J2 J2 J2 J
8. Silver Cadmium Manganese Vanadium Always read the Material Safety Data Sheets MSDS that should be supplied with the material you are using These MSDSs will give you the 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 fects and in some cases cancer California Health amp Safety Code Sec 25249 5 et seq ELECTRIC SHOCK Electric Shock can injure or kill The plasma arc process uses and produces high voltage electrical energy This electric energy can cause severe or fatal shock to the op erator or others in the workplace Never touch any parts that are electrically live or hot GENERAL INFORMATION 2 Date November 15 2001 Wear dry gloves and clothing Insulate yourself from the work piece or other parts of the welding
9. 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 on 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 REPLACEMENT PROCEDURES 20 Manual 0 2683 11 Position wire connector L4 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
10. 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 FIRE AND EXPLOSION Fire and explosion can be caused by hot slag sparks or the plasma arc Be sure there is no combustible or flammable 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 aluminum 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 Noise can cause permanent hearing loss Plasma arc pro 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 t
11. ou e 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 ou e Pour prot ger votre ou e 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 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 U S Government Printing Office Washington D C 20402 2 Norme ANSI Z49 1 LA S CURIT DES OP 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 L ARC ET AU GAZ disponible aupr s du Superin tendent of Documents U S Government Printing Office Washington D C 20402
12. 1 in 27 mm A 02385 180 70 Figure 2 2 Torch Dimensions Manual 0 2683 11 TROUBLE SHOOTING 3 0 TROUBLESHOOTING 3 1 Introduction This section provides service diagnostics for the DRAG GUN Plasma Cutter with PCH 10 Torch aiding the tech nician to isolate faulty subassemblies 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 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 Insufficient Penetration 1 Cutting speed too fast 2 Torch tilted too much 3 Metal too thick 4 Worn torch parts 5 Standoff too high 6 Line voltage too low 7 Extension
13. Before replacing cover make sure all wires are care fully positioned to avoid pinching when the cover and handle are secured 4 10 Fan Replacement 1 Remove cover handle from unit per subsection 4 2 2 Carefully slide the Air Compressor out of the Trans 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 3 For reference mark wires with correct connection designation then disconnect two wires to Fan 4 Remove two 2 rivets securing Fan to the front panel NOTE Some models may use screws instead of rivets 5 Install replacement Fan Refer to Figure 5 1 for proper Fan orientation or refer to the arrows marked on the Fan chassis NOTE Proper fan orientation is essential to ensure proper cooling of power supply parts 6 Install Compressor by reversing steps 1 3 keeping in mind the following a Position wire connector L4 so that it runs along side the Transformer NOT across the top of the Transformer or touching any metal parts b The Compressor is secured 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 Di
14. Power Cable 6 5 ft min 2 m DRAG GUN 100V 50Hz 110V 60Hz Power Cable 14 3 w molded plug 9 0052 DRAG GUN 120V 50Hz Power Cable CE 9 0044 DRAG GUN 120V 60Hz Power Cable 16 3 w molded plug 9 0014 DRAG GUN 220V 50Hz Power Cable CE 9 0044 DRAG GUN 208 230 60Hz Power Cable 16 3 w molded plug 9 0014 Plug to be supplied by customer 13 1 ON OFF Switch DRAG GUN Switch DPST 125V 15A w RED NEON non CSA 9 0015 DRAG GUN Switch DPST 22A 125VAC RED NEON CSA 9 0021 DRAG GUN Switch 16A 250VAC AMBER or Red NEON 9 0029 14 1 CD Transformer Ferrite Core Assembly 9 0018 15 2 Bridge Rectifier 7 3345 16 1 Handle 9 8115 5 4 Options amp Accessories not shown Qty Description Catalog 1 Circle Cutting Guide Kit 7 8910 1 Leads Wrap installed under Handle 9 7865 Manual 0 2683 29 PARTS LISTS BR2 BR1 For illustration purposes the Transformer Inductor Assembly is shown separated from the Chassis The Transformer Inductor Chassis is actually one assembly and should not be disassembled for any field repairs Rotation Direction Chassis A 02337 Torch amp Leads A Screw 6 32 x 3 3 4 Lg Phil Pan Hd Zinc B 6 32 Regular Nylon Lock Nut Zinc Plated C 5 16 18 x 1 3 4 Unc Cap Socket Head Bolt D 10 32 x 5 Pph Swageform Stl Zn Parker Kalon E Screw Black 6 32 x 1 2 Pph Swageform Steel F 10 32 Kepnut w Star Washer Mild Steel Air Flow Direction HARDWARE
15. cord with inadequate rating B Main Arc Extinguishes 1 Cutting speed too slow 2 Torch standoff too high from workpiece 3 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 D Short Torch Parts Life 1 Exceeding system capability material too thick 2 Excessive pilot arc time 3 Improperly assembled torch 4 Inadequate air supply check filter on Compressor 5 Faulty Air Compressor 6 Ground or work lead not connected 3 4 Common Operating Problems Getting used to the way the system sounds and feels while it is operating properly will help to determine the nature of problems if they arise 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 Let the unit warm up to room temperature ap proximately 50 F 10 C 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 blow air through it then reinstall it TROUBLE SHOOTING 12 Manual 0 2683 B Power Source Related If the service available is saggy pilot and cut performance will be degraded In so
16. il importe d insister davantage ou qui contribue l efficacit de fonctionnement du syst me ATTENTION 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 la zone de travail en cas de non respect de la proc dure en question 1 05 Precautions De Securite Importantes AVERTISSEMENTS L OP RATION ET LA MAINTENANCE DU MAT RIEL DE SOUDAGE L ARC AU JET DE PLASMA PEUVENT PR SENTER DES RISQUES ET DES DANGERS DE SANT 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 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 d
17. 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 GENERAL INFORMATION 8 Date November 15 2001 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 instructions 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
18. on the 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 02652 Black Brown Wire Black Wire 5 Black Wire 6 White Blue Wire 11 12 24 25 A Black Brown Wire Black Wire 21 Black Wire 22 White Blue Wire 11 12 24 25 B C 1 4 2 5 D Black Wire 5 1 4 2 5 Black Wire 21 Black Wire 6 Black Wire 22 Black Brown Wire White Blue Wire White Blue Wire Black Brown Wire A 03649 White or Blue Wire Brown or Black Wire 4B 1A 5B 2A 6B 3A Not Used Wire No 5 or 21 Wire No 6 or 22 E Not Used Figure 4 6 Input Power Cable Connections REPLACEMENT PROCEDURES 26 Manual 0 2683 Strain Relief Primary Input Power Cable A 02653 Green Wire from Primary Input Power Cable Green Wire with Tracer Connect to Compressor Frame Ground Stud ON OFF Input Power Switch Figure 4 7 Ground Connections 7 Connect 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 Manual 0 2683 27 PARTS LISTS 5 0 PARTS LIST Order replacement parts by catalog number and complete description of the part or assembly Also include the model and s
19. or power supply A To Remove PC Board 1 Remove cover handle from unit per subsection 4 2 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 Remove the two 2 metal C clips located on the top two standoffs that secure the PC Board to the unit b Gently pry PC Board off the standoffs then re move the second set of metal C clips 2 NOTE In some cases the PCB may be mounted on stand offs and secured with RTV over the ends Remove the RTV and then remove the PCB from the unit PC Board with key slotted mounting holes a Remove two 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 21 REPLACEMENT PROCEDURES B To Install Replacement PC Board 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 a Make sure J2 is not offset by one or more pins b Install new tie wr
20. 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 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 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 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 followi
21. 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 WARNINGS Disconnect primary power to the system before disassembling the torch leads or power supply 4 2 Removing Cover Handle 1 Remove 2 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 4 3 Torch Head Assembly Replacement 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 To Remove Torch Head Assembly NOTE Refer to Figure 4 1 for parts identification 1 Remove consumable parts from front end of torch 2 Remove six screws from torch handle assembly A 3 Remove both torch handle halves from the torch and leads assembly then complete the following a Disconnect positive pilot lead connection at torch head by removing pilot lead screw B b Cut tie wrap from torch hose C c Using X acto knife or other small cutting tool cut torch lead 1 2 54 cm from the
22. 10 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 2 1020 PCH 10 180 w 20 ft 6m Leads 2 1021 PARTS LISTS 28 Manual 0 2683 5 3 Power Supply Replacement Parts Item Qty Description Ref Catalog 1 1 Transformer Inductor Incl Chassis T1 L1 DRAG GUN 100V 50Hz 110V 60Hz 9 0023 DRAG GUN 120V 50Hz 9 0024 DRAG GUN 120V 60Hz 9 0001 DRAG GUN 220V 50Hz 9 0037 DRAG GUN 208 230 60Hz 9 0036 2 1 Cover incl Labels 9 0002 3 1 Control PCB Assembly 9 0003 4 1 Capacitor C13 DRAG GUN 100V 50Hz 110V 60Hz Capacitor AC 120UF 180V 9 0004 DRAG GUN 120V 50Hz Capacitor AC 120UF 180V 9 0004 DRAG GUN 120V 60Hz Capacitor AC 120UF 180V 9 0004 DRAG GUN 220V 50Hz Capacitor AC 60MFD 370V 9 3924 DRAG GUN 208 230 60Hz Capacitor AC 60 MFD 370V 9 3924 5 1 Wire Harness Not Shown 9 0005 6 1 Relay DPST NO 25A 250V K1 9 7508 7 1 Fan DRAG GUN 100V 50Hz 110V 60Hz Fan 115V 8 3209 DRAG GUN 120V 50Hz Fan 115V 8 3209 DRAG GUN 120V 60Hz Fan 115V 8 3209 DRAG GUN 220V 50Hz Fan 220V 9 7687 DRAG GUN 208 230 60Hz Fan 220V 9 7687 8 1 Compressor Air 12VDC 0 5 CFM 9 0010 1 Compressor Disc Filter 9 7912 9 1 Resistor 0 5ohm 55 watt 10 3 16 Faston 9 0011 10 1 Resistor 1Kohm 55 watt 5 3 16 Faston 9 0012 11 1 Work Cable 15 ft 4 57 m w Red Handles 9 0013 12 1 Input
23. 2 J2 J2 J2 J2 J2 J2 J2 K1 12v TEMP FAN AIR COMPRESSOR 12 VDC SW1 K1 C K1 B C13 BR1 BRIDGE 35A 1200V BR 2 BRIDGE 35A 1200V T1 L1 CD XFMR 330 450v 330 450v RED BLK CD PRIMARY CD PWR CIRCUIT E6 E5 E1 E2 SPK1 350V Spark Gap LOGIC CIRCUIT 0 5 55 watt 1K 55 watt 22 3 watt W O R K T O R C H PILOT RED Sleeved 1 4 7 10 11 12 13 16 17 14 15 18 PIP Pin TORCH SWITCH CD PCB Shield Cup 1 4 7 10 11 12 13 16 17 14 15 18 21 22 5 6 20 19 20 19 11 29 8 7 7A 3 4 1 10 26 24 150 450v 50 5 watt 2 L1 27 43 L4 1A 1 23 C13 T1 21 22 5 6 8 7 7A 3 4 FAN 20 19 208 230 NOTES Model 220vac 120vac 100vac C13 60 120 120 370vac 180vac 180vac FAN 220vac 120vac 120vac T1 PR1 Single voltage marked 6 Dual voltage marked 208v tap amp 230v NOTE Use this diagram for all rev C units or earlier Check the data tag on the unit for rev level APPENDIX 32 Manual 0 2683 A 02277 APPENDIX II INTERCONNECTING DIAGRAM Manual 0 2683 33 APPENDIX A 02277 8063 12 01 98 1 1 NOTE Use this diagram for all rev D or later units Check the data tag on the unit for rev level
24. 4 Technical Specifications 9 2 5 Dimensions 10 3 0 TROUBLESHOOTING 11 3 1 Introduction 11 3 2 Periodic Inspection amp Maintenance 11 3 3 Common Cutting Faults 11 3 4 Common Operating Problems 11 3 5 Troubleshooting Guide 12 3 6 Torch amp Leads Troubleshooting 15 4 0 REPLACEMENT PROCEDURES 17 4 1 General Information 17 4 2 Removing Cover Handle 17 4 3 Torch Head Assembly Replacement
25. Plasma Cutting Power Supply Drag gunTM A 03642 Service Manual November 11 2003 Manual No 0 2683 WARNINGS 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
26. Protection Association Batterymarch Park Quincy MA 02269 11 Brochure GCA P 1 LA MANIPULATION SANS RISQUE DES GAZ COMPRIM S 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 S CURIT POUR LE SOUDAGE ET LA COUPE disponible aupr s de l Association des Normes Canadiennes Stan dards Sales 178 Rexdale Boulevard Rexdale Ontario Canada M9W 1R3 13 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 14 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 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 Standards Institute 1430 Broadway New York NY 10018 Date November 15 2001 7 GENERAL INFORMATION 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 regula
27. 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 products 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
28. ace cover by reversing step 1 Torch Leads Assembly Strain Relief Nut Strain Relief 1 Clearance Strain Relief Torch Lead Faston Connector Red Connect to Bottom Resistor 2 Pin Connectors Torch Lead Faston Connector to CD Coil 90 White Nylon Fitting Brass Torch Lead Fitting A 02009 Nylon Nut Front Panel Hole Location Note Do not remove strain relief from torch lead Figure 4 4 Torch amp Leads Replacement Manual 0 2683 25 REPLACEMENT PROCEDURES 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 Work Cable Strain Relief Install 5 1 2 from Faston A 02011 Work Cable Faston Connect to mounting tab at bottom of Rectifier Bridge Rectifier Figure 4 5 Work Cable Replacement 4 16 Primary Input Power Cable Replacement 1 Remove cover handle from unit per subsection 4 2 2 Disconnect Input Power Cable wiring to the ON OFF Switch and Ground 3 Loosen Input Power Cable Strain Relief and re move Input Cable from unit 4 Install Strain Relief on replacement Input Power Cable 5 Install the Input Power Cable through rear panel 6 Check the wire numbers
29. aps 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 WARNING 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 instructions 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 L4 so that it runs along side the Transformer NOT across the top of the Transformer 4 9 ON OFF Power Switch Replacement NOTE When ordering a replacement ON OFF Switch order the same as found in your unit ON OFF Switches are as follows Model Switch Type Size Neon Color Voltage Catalog Number A 5 prong 1 x 2 Red 115 9 0015 B 4 prong 1 x 1 1 4 Red 115 9 0021 4 prong 6 prong C Amber or Red 220 9 0029 1 x 1 1 4 WARNING Disconnect primary power
30. ed 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 I 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 15 TROUBLE SHOOTING 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 normal opera tion Always wear light cutting gloves when chang ing torch parts just after operating the Drag Gun system A Checking the Center Insulator The Center Insula
31. end of black sleeve D to reveal butt splice 4 Pull torch head away from torch lead to expose 1 2 3 4 of cable 5 Clamp down with vise grips on black sleeve of lead so that cable cannot spring back into lead E 6 Cut cable at end of butt splice and remove torch head assembly F 7 Remove orange insulating sleeving from torch head gas input G Note Sleeving is optional Some torch assemblies may not have sleeving 8 Remove torch O ring from torch split holder H 9 Remove the two screws from the torch head split holder and separate the halves I 10 Remove the torch head from the holder Do not disturb PIP connections REPLACEMENT PROCEDURES 18 Manual 0 2683 1 000 O Ring Remove Screws Orange Torch Sleeving Optional Cut Cable Here Place Vise Grips Here Remove Pilot Lead Screw Cut Black Hose Cut Tie Wrap Remove Six Screws Switch A B C D E F G H I A 02295 Washer Figure 4 1 Removing Torch HeadAssembly To Install Replacement Torch Head Assembly NOTE Refer to Figure 4 2 for parts identification 1 Place replacement 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 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 in
32. er 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 F 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 14 Manual 0 2683 G Power OK 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 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
33. er votre peau Le proc d l arc de plasma produit une lumi re infra rouge et des rayons Date November 15 2001 5 GENERAL INFORMATION 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 ASC Z49 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 BRUIT Le bruit peut provoquer une perte permanente de l
34. erator or others in the oper ating area 1 02 Important Safety Precautions WARNINGS 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 GASES AND FUMES Gases and fumes produced during the plasma cutting process can be dangerous and hazardous to your health Keep all fumes and gases from the breathing area Keep your head out of the welding fume plume Use an air supplied respirator if ventilation is not adequate to remove all fumes and gases The kinds of fumes and gases from the plasma arc depend on the kind of metal being used coatings on the metal and the different processes You must be very careful when cutting or welding any met als which may contain one or more of the follow ing Antimony Chromium Mercury Arsenic Cobalt Nickel Barium Copper Selenium Beryllium Lead
35. erial 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 Catalog A Complete Systems 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 1 1111 3 DRAG GUN 120V 50Hz PCH 10 CE 1 1811 6 DRAG GUN 120V 60Hz PCH 10 1 1111 1 DRAG GUN 220V 50Hz PCH 10 CE 1 1811 5 DRAG GUN 208 230 60Hz PCH 10 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 1 1111 3 180 DRAG GUN 120V 50Hz PCH 10 CE 1 1811 6 180 DRAG GUN 120V 60Hz PCH 10 1 1111 1 180 DRAG GUN 220V 50Hz PCH 10 CE 1 1811 5 180 DRAG GUN 208 230 60Hz PCH 10 1 1111 2 180 B Power Supply Only Includes Power Supply Input Power Cord and Work Cable DRAG GUN 100V 50Hz 110V 60Hz 3 1112 DRAG GUN 120V 50Hz CE 3 1113 DRAG GUN 120V 60Hz 3 1111 DRAG GUN 220V 50Hz CE 3 1114 DRAG GUN 208 230 60Hz 3 11
36. es questions FUM E 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 4 Date November 15 2001 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 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 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 co
37. 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 ANSI Standard 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 3 GENERAL INFORMATION 6 ANSI Standard Z49 2 FIRE PREVENTION IN THE USE OF CUTTING AND WELDING PROCESSES obtain able from American National Standards Institute 1430 Broadway New York NY 10018 7 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 8 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 9 NFPA Standard 70 NATIONAL ELECTRICAL CODE obtainable from the National Fire Protection Associa
38. he workplace Noise levels should be measured to be sure the deci bels sound do not exceed safe levels For information on how to test for noise see item 1 in Subsection 1 03 Publications in this manual PLASMA ARC RAYS Plasma Arc Rays can injure your eyes and burn your skin The plasma arc process produces very bright ultra violet and 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 the following per ANSI ASC Z49 1 Minimum Protective Suggested Arc Current Shade No Shade No Less Than 300 8 9 300 400 9 12 400 800 10 14 These values apply where the actual arc is clearly seen Experience has shown that lighter filters may be used when the arc is hidden by the 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
39. 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 as a unit No replacement 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 Introduction 10 Manual 0 2683 B Input Output Specifications Model Hz Input Amps RMS Output Amps DC Output Voltage DC Duty Cycle 100 110V 50 60 25 24 12 85 30 120V 50 22 12 95 30 120V 60 20 12 70 30 220V 50 13 12 85 30 208 230V 60 10 12 78 30 CE approved 2 5 Dimensions 16 0 in 406 mm 9 0 in 229 mm 10 0 in 254 mm A 02004 Figure 2 1 Power Supply Dimensions 8 in 203 mm 1 1 in 27 mm 2 9 in 75 mm 8 9 in 226 mm 1
40. lacement 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 Manual 0 2683 9 Introduction 2 3 Service Responsibilities The Service 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 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 System Specifications Input Power 100 VAC 50Hz 110 VAC 60Hz Single Phase 100 110 VAC 50 60Hz Single Phase 120VAC 10 50Hz Single Phase 120VAC 10 60Hz Single Phase 220VAC 10 50Hz Single Phase 208 230VAC 10 60Hz Single Phase Output Power See subsection 2 3B Duty Cycle See subsection 2 3B Maximum OCV 280 VDC Pilot Circuitry Capacitive Discharge CD Co
41. me cases the service circuit breaker may open during use Some things that will help Use a service fused or circuit breaker for the 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 Use as 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 the leads 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 the torch tip will wear fairly rapidly if you pilot for an extended time or cut with too great a standoff essen 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
42. ng 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 Test electrical 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 Manual 0 2683 13 TROUBLE SHOOTING 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 insulate 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 nex
43. nstant DC Weight with Leads 55 lbs 24 9 kg Power Supply L 16 in 406 mm Dimensions W 9 in 229 mm H 10 in 254 mm Work Cable 15 ft 4 6 m Input Power Cable 6 6 ft 2 m minimum PCH 10 70 PCH 10 180 L See subsection 2 4 W See subsection 2 4 Cutting Rating 12 Amps Max Straight Polarity Cut Capacity Most metals up to 1 8 in 3 2 mm max Severance Most metals up to 3 16 in 4 8 mm Pierce Rating 1 16 in 1 6 mm Transfer Distance Approx 1 8 in 3 2 mm Gas Requirements Compressed Air Built in Leads Length 20 ft 6 1 m Torch Style Torch Dimensions 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 essential 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
44. 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 H 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 3 Damaged torch or leads a Check per subsection 3 6 Torch and Leads Troubleshooting 4 Faulty Control PCB a Listen for a 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 If the AC line is below about 105vac the torch may not always start Try an outlet on a differ ent branch circuit 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 limit
45. ontinuity 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 TROUBLE SHOOTING 16 Manual 0 2683 Manual 0 2683 17 REPLACEMENT PROCEDURES 4 0 REPLACEMENT PROCEDURES 4 1 General Information 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 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 can be purchased lo cally One of two harnesses has been used in this unit For units which are rev C or earlier refer to the sche matic in Appendix II For units
46. r keeping solder at a minimum required for good joint 5 Repeat steps 3 and 4 this time for the white wire Torch Switch PIP Pin PIP Pin Shield Cup To Control Cable Wiring Butt Splice A 00784 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 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 it pertains to your unit Rev C 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
47. sconnect 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 Manual 0 2683 23 REPLACEMENT PROCEDURES 4 12 Transformer Ferrite Core Assembly Replacement WARNINGS Disconnect primary power at source before assem bling or disassembling t he power supply 1 Remove cover handle from unit per subsection 4 2 2 Wire connections are as follows Connector Location L1 E6 on PCB L2 E1 on PCB L3 E2 on PCB L4 Brass Torch Lead Fitting 3 Disconnect wire connections Pull L4 connector through loose tie wrap if available 4 Remove two Ferrite Core Assembly screws which hold the Transformer Ferrite Core Assembly in position Remove Transformer Ferrite Core As sembly from unit 5 Install replacement Transformer Ferrite Core As sembly by reversing steps 1 4 keeping in mind the following a Pull L4 through loose tie wrap if available b Position wire connector L4 so that it runs along side the Transformer NOT across the top of the Transformer or near any metal parts 4 13 Input Voltage Changeover For 208 230 VAC Service Only All 208 230 VAC units are factory set for 230 VAC To switch to 208VAC input power operation complete the following WARNINGS Do not touch live electrical parts Disconnect primary power at source before assem bling or disas
48. sembling the power supply torch parts or torch and leads assemblies 1 Remove cover handle from unit per subsection 4 2 2 Locate the wiring on the end of the Capacitor 3 Remove tie wrap and orange sleeving from wire 208VAC 4 Remove wire 230VAC from Capacitor and replace with wire 208VAC 5 Slide orange sleeving over wire 230VAC fold over and secure with a tie wrap WARNING Do not leave other input wire unprotected inside unit 6 Reinstall cover REPLACEMENT PROCEDURES 24 Manual 0 2683 4 14 Torch amp Leads Replacement 1 Remove cover handle from unit per subsection 4 2 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 3 Loosen the Strain Relief Nut from the Strain Relief and remove Torch Lead Assembly from unit 4 Install Strain Relief on replacement torch 5 Insert Torch leads through front hole on unit 6 Slide Strain Relief Nut over the end of the torch lead 7 Allow one inch clearance between the end of the torch lead sheath and the hole in the front panel then tighten the Strain Relief Nut This allows al low enough length in the torch lead to make all the connections inside the unit 8 Reconnect all connections by reversing step 2 9 Repl
49. t 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 a Leave power on so fan can cool unit test again after 10 minutes 3 Shorted torch parts a Replace torch consumables 4 Torch switch may have broken or shorted wires a Refer to subsection 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 has cooled down replace the compressor 6 Shorted Bridge Rectifier BR2 a If the Rectifier upper is hot and the Transformer is buzzing or heating up the rectifier is shorted Replace Rectifi
50. that no wires obstruct the cover when it is installed 4 6 Capacitor Replacement 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 a Make sure the Capacitor is securely positioned behind tab Tab may need to be bent b Position wire connector L4 so that it runs along side the Transformer avoiding contact with metal parts 4 7 Control PC Board Replacement The DRAG GUN Plasma Cutter has been manufactured using one of two styles of PC Board 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 WARNING Disconnect primary power to the system before dis assembling the torch leads
51. tion Batterymarch Park Quincy MA 02269 10 NFPA Standard 51B CUTTING AND WELDING PRO CESSES obtainable from the National Fire Protection Association Batterymarch Park Quincy MA 02269 11 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 12 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 13 NWSA booklet WELDING SAFETY BIBLIOGRAPHY obtainable from the National Welding Supply Associa tion 1900 Arch Street Philadelphia PA 19103 14 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 15 ANSI Standard Z88 2 PRACTICE FOR RESPIRATORY PROTECTION obtainable from American National Standards Institute 1430 Broadway New York NY 10018 1 04 Note Attention et Avertissement Dans ce manuel les mots note attention et avertissement sont utilis s pour mettre en relief des informations 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
52. tions 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 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 ISO IEC 60974 1 BS 638 PT10 EN 60 974 1 EN50192 EN50078 applicable to plasma cutting equipment and associ ated accessories 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 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
53. to the system before dis assembling the torch leads or power supply A Models A amp B 1 Remove cover handle from unit per subsection 4 2 2 Note all wiring connections and locations to the 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 5 Install replacement ON OFF Switch by reversing the above steps keeping in mind the following a Position wire connector L4 so that it runs along side the Transformer NOT across the top of the Transformer REPLACEMENT PROCEDURES 22 Manual 0 2683 B Model C NOTE Type C switch with 6 prongs replaces Type C switch with 4 prongs 1 Remove cover handle from unit per subsection 4 2 2 Disconnect wires to ON OFF Switch 3 Push plastic clips down on top end of Switch and slide Switch out through front panel 4 Check the numbering sequence of the connectors on the ON OFF Switch and install the switch as follows a 1 2 4 5 Install switch with connectors posi tioned towards the bottom of unit b 11 12 24 25 Install switch with connectors positioned towards the top of the unit c 1A 2A 4B 5B Install switch with these con nectors positioned towards the top of the unit 5 To connect the input wiring to the ON OFF Switch refer to subsection 4 17 step 6 6 Install cover handle by reversing step 1 keeping in mind the following NOTE
54. to 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 Install Pilot Lead Screw Butt Splice Insert Cable Into Butt Splice amp Crimp Install O Ring Install Screws New Torch Head J K M N Teflon Tubing A 02296 L O Washer 4 2 Installing Torch Head Assembly Manual 0 2683 19 REPLACEMENT PROCEDURES 4 4 Torch Switch Only Replacement NOTE This procedure requires the following tools or equivalent screwdriver soldering iron Flux 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 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 solde
55. tor 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 Remove the shield cup tip gas distributor and electrode from the torch Torch Head Assembly Electrode Tip Standard Shield Cup Gas Distributor PCH 10 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 torch assembly 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 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 replaced 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 c
56. upe 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 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 CHOC 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 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
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