DRAG-GUN™ PLUS Service Manual 35C
Contents
1. useeessssss 1 02 Important Safety Precautions sssssss 1 03 PublicatiOS iii tii 1 04 Declaration of Conformity ooconocccnnoncccnnnccnnonancninananincnnns 1 05 Statement of Warranty sse SECTION 2 INTRODUCTION 2 tie and teases a egt FO pote aad ies 2 01 INTRODUCTION e Eat rei ap teu pete fk eect 2 02 GENERAL SPECIFICATION eene 2 03 FOIS iecit rede beta lere La EE prex cane 2 04 Torch Specifications ssis nas 2 05 System Contents edi di 2 06 Transporting Methods seeeeeeeeees SECTION 3 NI em enne nennen nennen 3 01 Site Selection ooonocccinnncccnnnccccnnccccnnnnanccnnnacannnnrra narran 3 02 Electrical Input Connections sesseessss croci SECTION 4 OPERATION m 4 01 Front Control Panel sssseeeeennne 4 02 Preparations For Operating eeeseessss SECTION 5 MAINTENANCE viisisakarainen an 5 01 General Maintenance coooccccccnnncccncnnnoncnnnnnnnacancnonaninanos SECTION 6 TROUBLESHOOTING uii YY WYF eei cte cte dae 6 01 Normal Setup and Operation ssesssssss 6 02 Basic Trouble Shooting Guide sssssse 6 03 Control PCB Indicators ooococcnnnccccnnocccconaccnconannninnn nono 6 04 Open Circuit Voltage Check s es 6 05 Detailed Fault Finding Error Indicator2. Pilot Pilot i J Torch Head Torch Leads Art A 05557 2 Shorted Torch Check a Disconnect input power from power supply b Disconnect the pilot lead see previous diagram c Perform an Ohm check of the pilot lead to the negative lead This should show Open If it does not show Open check that the correct consumables were installed per the consumables label on the unit cover d Replace Torch as needed NOTE Every effort has been made to provide complete and accurate information in this manual However the publisher does not assume and hereby disclaims any liability to any party for any loss or damage caused by errors or omissions in this Manual whether such errors result from negligence accident or any other cause Manual 0 4751 6 9 TROUBLE SHOOTING This Page Left Blank TROUBLE SHOOTING 6 10 Manual 0 4751 SECTION 7 PARTS LIST General Information This parts list covers the Drag Gun Plus Model 35C Plasma Cutting Power Supply with Internal Air Compressor Do not use these instructions or parts on any other equipment Provide the power supply model number and serial number when ordering parts If a product must be returned for service contact your distributor Materials returned without proper authoriza tion will not be accepted Contact Information Thermal Dynamics Technical Service Dept Tel 1 800 752 7622 1 800 PLASMA2 Fax 1 800 221 4401 e mail address tdc techOthermadyne com Replac
3. Power source Model Drag Gun Plus PCH 42 with 20 6 1 m leads Work Cable Accessories amp Manual Consumables Torch Electrodes PCH 42 Torch Ratings Torch Tips Torch Configuration Input Power 3 Meter NEMA 10 AWG Toren Banale 4 8 mm with 6 50 P Torch Leads Length molded plug Ambient 104 F Temperature 40 C 3 Meter 3x2 5 sq mm 100 40 Amps rubber wire Duty Cycle 200 scfh Voltage Vacas 2 06 Transporting Methods Arc Striking Voltage 12kV Lift unit with handle on top of case Use handcart or similar device of adequate capacity for transporting 40 Amps DC MEIFOD Straight Polarity P in Pl Built in Switch aa in Torch Head Single Gas Ses Requirement Compressed Air Only 65 psi 4 5 bar 45MPa T f Cooli Ambient air and gas YPS eM stream through torch Input Gas Pressure 125 psi 8 6 bar 86MPa 200 SCFH 142 Ipm For operation with Minimum Gas Flow exposed tip the Direct Contact Hazard recommended standoff height is 1 8 3 8 3 9 mm Drag Gun Plus Plasma Power Supply Used With Introduction 2 2 A WARNING ELECTRIC SHOCK can kill DO NOT TOUCH live electrical parts Disconnect input power from supply before moving the power source FALLING EQUIPMENT can cause serious per sonal injury and equipment damage pm al Manual 0 4751 SECTION 3 INSTALLATION 3 01 Site
4. 8112 9 8102 4 2989 Manual 0 4751 Art A 07061 PARTS LIST T T Manual 0 4751 This Page Left Blank PARTS LIST 7 8 Manual 0 4751 Appendix 1 Operating Sequence Block Diagram Primary Input Power On or Plugged in Power Supply On Off Switch On Red Air Indicator Release Torch Switch Pilot Arc goes out Green Power Indicator On and Fan is Running More air flow is required for Torch to Pilot than to T run the power supply t E Compressor not functioning Alr SEL SWIIChEON properly need to be repaired by a Qualified Technician Compressor Starts and Air Flows at Torch Turn Air Set Switch Off i Check Torch parts Air Flow at Torch Stops amp alignment PIP switches need to be repaired by a Qualified Technician NEM Pilot Arc Ignition 3 5 seconds em Torch Switch On No Pilot Arc Torch Tip to Work within 3 5 seconds of Pilot Arc start YES Release Torch Switch Start Cutting Operation y Cutting Done NO Torch Switch Off Post Flow of Air Approximately 15 Seconds Then Stops Note The Torch will be very hot Do not set on or near flammable materials Art A 04694 Manual 0 4751 y Power Supply
5. On Off Switch Off Green Power Indicator Off and Fan Stops y Primary Input Power Switch Off or Unplugged A 1 APPENDIX Appendix 2 Torch Connection Disconnect power and air Lay unit Art A 04695 i on its side Remove two screws and access plate DETAIL Power Supply Adapter Connections r ir 1 To Power 2 J o Back o PIP Supply Adapter Orange 0 Switch b Green Torch DO White O Switch CET 9 Negative TIT Lead 9 SID pilot Pilot Ei e e l l Torch Leads Torch Head APPENDIX A 2 Manual 0 4751 Manual 0 4 751 Appendix 3 Microchip Pin Out 40 Pin Microchip P2 1 2 3 4 5 6 7 8j 9 10 11 12 CPU porre Socketon 5 24 22 20 18 16 14 12 10 8 6 al 2 Control Rpte 9 7 5 i pa 1 fTrirftri ii 55 I A 3 APPENDIX Appendix 4 System Schematic 230V CE A B C 230 VAC us a DIODE IGBT IGBT L Bk D 1 s 230 VAC iE 1 eur I 12 IB idi 182 N C
6. PCBison before proceding 2 Change air related items as 3 Check LD2 EN LED it should get needed brighter with the torch trigger 3 If OCV is not OK follow OCV depressed check procedures in section 6 04 4 Check OCV Voltage If OCV Voltage 4 If CN9 connection is OK replace is OK check C T 1 connection the Control PCB Torch doesn t Pilot and Check all air supply related issues If there are no air related issues the LD1 LED on the before proceding replace the Control PCB Control PCB is not on CO LED on Control Check Cable Connection on PCB If connection and Current Sensor PCB comes on when CN10 and Current Sensor are OK replace the Control PCB not transferring A Diode Testing Basics A G There are extremely dangerous voltage and power levels present inside this unit Do not attempt to diagnose or repair unless you have had training in power electronics measurement and troubleshooting techniques Disconnect primary power at the source before disassembling the power supply torch or torch leads Discharge power at the H V spark gap using a metal tipped screw driver as shown Art A 07116 Manual 0 4751 6 5 TROUBLE SHOOTING Testing of diode modules requires a digital volt ohmmeter that has a diode test scale Remember that even if the diode module checks good it may still be bad Ifin doubt replace the diode module 1 Remove AC power Refer to Appendix 3 Wiring diagram Locate the IGBT diode module to
7. Work Cable Make a clean work cable connection to the work piece or cutting table Work Cable And Clamp Art A 04389 Operation 4 2 D Torch Operation e Wear gloves and protective goggles Do not place bare hand on work piece 1 For drag cutting keep the torch in contact with the workpiece For standoff cutting hold the torch 1 8 3 8 in 3 9 mm from the workpiece as shown be low Torch Standoff Distance 1 8 3 8 Y AE A 00024 Shield Cup With the torch in starting position press and hold the Torch Trigger After an initial two sec ond pre flow the pilot arc will come on and re main on until the cutting arc starts Once on the cutting arc remains on as long as the Torch Trigger is held down unless the torch is withdrawn from the work or torch motion is too slow To shut off the torch simply release the Torch Trigger When the trigger is released a gas post flow will occur If the Torch Trigger is pushed during the post flow the cutting arc will restart immediately when the torch is brought within range of the workpiece Manual 0 4751 E Typical Cutting Speeds Cutting speeds vary according to torch output the type of material being cut and operator skill Speeds shown are typical for this cutting system using air plasma to cut mild steel with output current at the highest setting and torch held at the indicated standoff height Unit Standoff Malena EE Maximum Tra
8. arc cutting produces intense elec tric and magnetic emissions that may inter fere with the proper function of cardiac pacemakers hearing aids or other elec tronic health equipment Persons who work near plasma arc cutting applications should consult their medical health professional and the manufacturer of the health equipment to determine whether a hazard exists Manual 0 4751 1 1 To prevent possible injury read understand and follow all warnings safety precautions and instructions before using the equip ment Call 1 603 298 5711 or your local distributor if you have any questions yN AND FUMES Gases and fumes produced during the plasma cut ting 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 adeguate to remove all fumes and gases The kinds of fumes and gases from the plasma arc depend on the kind of metal being used coat ings on the metal and the different processes You must be very careful when cutting or weld ing any metals which may contain one or more of the following Antimony Chromium Mercury Arsenic Cobalt Nickel Barium Copper Selenium Beryllium Lead Silver Cadmium Manganese Vanadium Always read the Material Safety Data Sheets MSDS that should be supplied with the mate rial you are using These MSDSs will give you the information r
9. before performing any service or repairs Read and follow all the instructions in the Oper ating Manual Ar AND EXPLOSION Fire and explosion can be caused by hot slag sparks or the plasma arc e Be sure there is no combustible or flammable material in the workplace Any material that can not 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 un der aluminum workpieces when they are cut un derwater or while using a water table DO NOT GENERAL INFORMATION 1 2 cut aluminum alloys underwater or on a water table unless the hydrogen gas can be eliminated or dissipated Trapped hydrogen gas that is ig nited will cause an explosion Ojos Noise can cause permanent hearing loss Plasma arc processes can cause noise levels to exceed safe lim its You must protect your ears from loud noise to prevent permanent loss of hearing To protect your hearing from loud noise wear protective ear plugs and or ear muffs Protect others in the workplace e Noise levels should be measured to be sure the decibels sound do not exceed safe levels e For information on how to test for noise see item 1 in Subsection 1 03 Publications in this manual m Sis ARC RAYS Plasma Arc Rays can injure
10. ere adjust the PCB CHECK F ii Title 4 Air Plasma 35C 230V Size Number Rev A2 No 66001008 AB Date oct 19 2005 Drawn by Filename Sheet of D F Art A 07024 Manual 0 4751 A 7 APPENDIX This Page Left Blank APPENDIX A 8 Manual 0 4751 IHERMAL DYNAMICS GLOBAL CUSTOMER SERVICE CONTACT INFORMATION Thermadyne USA 2800 Airport Road Denton Tx 76207 USA Telephone 940 566 2000 800 426 1888 Fax 800 535 0557 Thermadyne Canada 2070 Wyecroft Road Oakville Ontario Canada L6L5V6 Telephone 905 827 1111 Fax 905 827 3648 Thermadyne Europe Europe Building Chorley North Industrial Park Chorley Lancashire England PR6 7Bx Telephone 44 1257 261755 Fax 44 1257 224800 Thermadyne China RM 102A 685 Ding Xi Rd Chang Ning District Shanghai PR 200052 Telephone 86 21 69171135 Fax 86 21 69171139 Thermadyne Asia Sdn Bhd Lot 151 Jalan Industri 3 5A Rawang Integrated Industrial Park JIn Batu Arang 48000 Rawang Selangor Darul Ehsan West Malaysia Telephone 603 6092 2988 Fax 603 6092 1085 Cigweld Australia T1 Gower Street Preston Victoria Australia 3072 Telephone 61 3 9474 7400 Fax 61 3 9474 7510 Thermadyne Italy OCIM S r L Via Benaco 3 20098 S Giuliano Milan Italy TTel 39 02 36546801 Fax 39 02 36546840 Thermadyne International 2070 Wyecroft Road Oakville Ontario Canada L6L5V6 Telephone 905 827 9777 Fax 905 827 9797 16082 Swingley Ridge Road I
11. seconds before the pilot arc turns off If arc was lost before transfer to work surface release the torch trigger and squeeze the trigger again to establish the pilot arc 7 Whenthetorch trigger is released the compressor will continue to run for post flow approximately 15 seconds A G There are extremely dangerous voltage and power levels present inside this unit Do not attempt to diagnose or repair unless you have had training in power electronics measurement and troubleshooting techniques Disconnect primary power at the source before disassembling the power supply torch or torch leads NOTE All procedures are done with the cover removed Manual 0 4751 6 1 TROUBLE SHOOTING 6 02 Basic Trouble Shooting Guide Problem Symptom Possible Cause Recommended Action Power Switch is on 1 Improper electrical connection 1 Check input power source and fuse Check input cable and but the A C Indicator 2 System was overloaded connections does not light 3 Switch may be faulty 2 Turn Primary Power Switch Off and then On again 3 Return to authorized service center for repair or replacement Primary power 1 No power or incorrect powerto 1 Check electrical connections to fan switch is on but the fan 2 Return to authorized service center for repair or replacement cooling fan does not 2 Faulty fan work No air flow attorch 1 Internal connection is loose or 1 Check all air line connections and fittings wh
12. to Eb Eb te EN T 3 Inrush Filter PCB UF Je i No 40276005 o 87 mE CN2 oi o4 aa Wl 7 E B NY 11 fla RISO OTel PA r w w DC a Hn Ww Ww Bk R 325 E B fae o po o Ln C3 230 VAC V R1 500 AN 2 O WU HUI W2 Bk GIE1G2E2 G3E3G4E4 Capacitor TW TW TW TW 2 EE FR AP Jo 0C o BWGR BWGR E4 G4E3 G3 E2 G2E Gl a Located on IGBT NOTE imi HIT 1111 0 NO CN6 CN8 attempt to adjust the LD1 PCB POTS oe ES AC230 o AU Control Board No 40271005 Bl M Compressor Re y f 3 D R 25VDC i B CN4 Br F li Bl E 1 LD3 N C R CO Br 12VDC A cnr l CE CN2 l i A Or 1 l MF 103K Sensor e UE Ei CN Panel Board Compressor No 40270601 M A A D 4 Q H Bl nae MAIN POWER ERROR ERROR HOLD d Art A 06978 A B C APPENDIX A 4 Manual 0 4751 D E F R3 4 AMA 220 Main Transformer 1 4 Current Sansor No H F KU LZ On Bk A 0 C V 325 Pilot 130 C T 1 Cutting 80 100 Bk anoe See Sec 6 OCV in Service Manual E RS E lt E v W PLOT wk Ta REACTOR Conduit Coil y o j C o lt rt BEEN R7 08 gt 2 Twisted 3116 i Y w PCR Y C 2VDC TT gt vc 1 BR AAN EF A i
13. HERMAL DYNAMICS SLE MO 63017 By THERMAUYNES ORK Telephone 636 728 3000 Email TDCSales Thermadyne com www thermadyne com
14. IHERMAL DYNAMICS 9900 DRAG GUN PLUS PLASMA GUTTING SYSTEM Art A 04718 te Mar Rev AA 01 Issue Da ch 26 2007 Manual 0 4751 Operating Features A WARNING Read and understand this entire Manual and your employer s safety practices before installing operating or servicing the equipment While the information contained in this Manual represents the Manufacturer s best judgement the Manufacturer assumes no liability for its use Plasma Cutting Power Supply Drag Gun Plus PCH 42 Torch Service Manual Number 0 4751 Covered under U S Patents Published by Thermadyne Corporation 82 Benning Street West Lebanon New Hampshire USA 03784 603 298 5711 www thermal dynamics com Copyright 2006 2007 by Thermal Dynamics Corporation All rights reserved Reproduction of this work in whole or in part without written permission of the publisher is prohibited The publisher does not assume and hereby disclaims any liability to any party for any loss or damage caused by any error or omission in this Manual whether such error results from negligence accident or any other cause Printed in the United States of America Publication Date March 26 2007 Record the following information for Warranty purposes Where Purchased Purchase Date Power Supply Serial Torch Serial TABLE OF CONTENTS SECTION 1 GENERALINFORMATION 1 rtt tdt tentiae 1 01 Notes Cautions and Warnings
15. ND GAS WELDING AND CUTTING obtainable from the Superinten dent of Documents U S Government Printing Office Wash ington D C 20402 ANSI Standard Z87 1 SAFE PRACTICES FOR OCCUPATION AND EDUCATIONAL EYE AND FACE PROTECTION obtain able from American National Standards Institute 1430 Broadway New York NY 10018 ANSI Standard 741 1 STANDARD FOR MEN S SAFETY TOE FOOTWEAR obtainable from the American National Stan dards Institute 1430 Broadway New York NY 10018 ANSI Standard 749 2 FIRE PREVENTION IN THE USE OF CUTTING AND WELDING PROCESSES obtainable from American National Standards Institute 1430 Broadway New York NY 10018 AWS Standard A6 0 WELDING AND CUTTING CONTAIN ERS WHICH HAVE HELD COMBUSTIBLES obtainable from American Welding Society 550 N W LeJeune Rd Miami FL 33126 NFPA Standard 51 OXYGEN FUEL GAS SYSTEMS FOR WELDING CUTTING AND ALLIED PROCESSES obtainable from the National Fire Protection Association Batterymarch Park Quincy MA 02269 NFPA Standard 70 NATIONAL ELECTRICAL CODE obtain able from the National Fire Protection Association Batterymarch Park Quincy MA 02269 Manual 0 4751 o po co A a NFPA Standard 51B CUTTING AND WELDING PROCESSES obtainable from the National Fire Protection Association Batterymarch Park Quincy MA 02269 CGA Pamphlet P 1 SAFE HANDLING OF COMPRESSED GASES IN CYLINDERS obtainable from the Compressed Gas Association 1235 J
16. Selection Place in a clean and dry area Provide adequate ventilation and fresh air sup ply Ideal ambient temperature should not exceed 40 C 104 F Temperatures exceeding that may diminish cutting capacity or quality The cutting machine must be placed on an even firm surface so that it stands firmly A WARNING This equipment must be electrically connected by a qualified electrician 3 02 Electrical Input Connections Input voltage is 230V 10 50 60 Hz single phase A CAUTION Check your power source for correct voltage be fore plugging in or connecting the unit The primary power source fuse and any extension cords used must conform to local electrical code and the recommended circuit protection and wir ing requirements as specified in Section 2 Manual 0 4751 3 03 Torch 3 1 Make sure that the torch cable and torch switch terminals are connected to front panel Make sure the Work Cable is connected properly to front panel Before activating turn torch away from yourself and others A GER Do not cut in humid or wet surroundings Before you maintain or replace torch parts wait for the post flow air cycle approximately 15 sec onds to stop then turn the machine off Always use original manufacturers parts The use of aftermarket parts could result in lower parts life and in unsatisfactory cutting results Any war ranty claims would be waived Recycle worn parts accord
17. be tested Remove P5 from IGBT module Set digital volt ohmmeter to diode test scale or gt m Connect the volt ohmmeter positive lead to the anode of the diode and the negative lead to the cathode of the diode for forward bias testing refer to following figure A properly functioning diode will conduct in the forward bias direction and indicate between 0 3 to 0 9 volts Art A 00307 0 75 Forward Bias Diode Conducting Me Diode Test Symbol VR COM A Anode e O Cathode Testing Diode Forward Bias TROUBLE SHOOTING 6 6 Manual 0 4751 6 Reverse the meter leads across the diode for reverse bias testing refer to following figure A properly function ing diode will block in the reverse bias direction and depending on the meter function will indicate an open or OL Art A 00306 NES Reverse Bias Diode Not Conducting VR COM A O Cathode Anode Testing Diode Reverse Bias 7 Using the Figures for each test check each diode in the module Each diode must be checked in forward bias plus to negative and reverse bias negative to plus direction Manual 0 4751 6 7 TROUBLE SHOOTING B Component Tests Li Disconnect primary power at the source before taking any resistance checks 1 Input Diode Module Board Circuit Test a CheckInput Diode for sho
18. center for repair or button doesn t work replacement properly TROUBLE SHOOTING 6 2 Manual 0 4751 6 03 Control PCB Indicators A G There are extremely dangerous voltage and power levels present inside this unit Do not attempt to diagnose or repair unless you have had training in power electronics measurement and troubleshooting techniques NOTE All procedures are done with the cover removed 1 Turn the switch located on the front panel to the On position The Q C indicator on the front panel lights and the cooling fan comes on 2 Locate the Control PCB behind the front panel LD2 EN LED should be ON Illustration 6 1 Control PCB l 3 Press the Air Set Button V The the air compressor should come on causing air to flow through the torch and LD1 SOL LED should light Press the Air Set Button again and the air compressor stops and the LED goes out 4 Squeeze the torch trigger The pilot arc and compressor start LD2 EN should brighten and LD1 SOL LED and LD4 H V should be on 5 Transfer the arc to the work surface within 3 5 seconds LD4 goes off and LD3 comes on so that three LEDs are on NOTE If no transfer of arc occurs check the work lead connection Manual 0 4751 6 3 TROUBLE SHOOTING 6 04 Open Circuit Voltage Check Unplug the CN1 connector on the H V spark gap PCB Turn unit power on Measure terminal TB2 Pins 1 and 3 It should be 230VAC Measure output voltage
19. ed to damage or loss of purchased or replacement goods or claims of customer of distributors hereinafter Purchaser for service interruption The remedies of the Purchaser set forth herein are exclusive and the liability of Thermadyne with respect to any contract or anything done in connection therewith such as the performance or breach thereof or from the manufacture sale delivery resale or use of the goods covered by or furnished by Thermadyne whether arising out of contract negligence strict tort or under any warranty or otherwise shall not except as expressly provided herein exceed the price of the goods upon which liability is based This warranty becomes invalid if replacement parts or accessories are used which may impair the safety or performance of any Thermadyne product This warranty is invalid if the Thermadyne product is sold by non authorized persons Effective January 3 2006 Manual 0 4751 1 5 GENERAL INFORMATION This Page Left Blank GENERAL INFORMATION 1 6 Manual 0 4751 SECTION 2 INTRODUCTION 2 01 INTRODUCTION Plasma is a gas which has been heated to an extremely high temperature and ionized so that it becomes elec trically conductive The plasma arc cutting process uses this plasma to transfer an electrical arc to the work piece The metal to be cut is melted by the heat of the arc and then blown away 2 02 GENERAL SPECIFICATION 10 5 x15 5 x11 Dimension W D H 267 mm x 394 mm x 279
20. efferson Davis Highway Suite 501 Arlington VA 22202 CSA Standard W117 2 CODE FOR SAFETY IN WELDING AND CUTTING obtainable from the Canadian Standards Association Standards Sales 178 Rexdale Boulevard Rexdale Ontario Canada M9W 1R3 NWSA booklet WELDING SAFETY BIBLIOGRAPHY obtain able from the National Welding Supply Association 1900 Arch Street Philadelphia PA 19103 American Welding Society Standard AWSF4 1 RECOM MENDED SAFE PRACTICES FOR THE PREPARATION FOR WELDING AND CUTTING OF CONTAINERS AND PIPING THAT HAVE HELD HAZARDOUS SUBSTANCES obtainable from the American Welding Society 550 N W LeJeune Rd Mi ami FL 33126 ANSI Standard 288 2 PRACTICE FOR RESPIRATORY PRO TECTION obtainable from American National Standards In stitute 1430 Broadway New York NY 10018 GENERAL INFORMATION 1 04 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 EEC as amended by Council Directive 93 68 EEC and to the Na tional legislation for the enforcement of this Directive The equipment described in this manual conforms to all applicable aspects and regulations of the EMC Direc tive European Council Directive 89 336 EEC and to the National legislation for the enforcem
21. egarding 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 Sub section 1 03 Publications in this manual Use special eguipment such as water or down draft cutting tables to capture fumes and gases Do not use the plasma torch in an area where combustible or explosive gases or materials are located Phosgene a toxic gas is generated from the va pors of chlorinated solvents and cleansers Re move all sources of these vapors GENERAL INFORMATION This product when used for welding or cutting produces fumes or gases which contain chemi cals known to the State of California to cause birth defects and in some cases cancer California Health amp Safety Code Sec 25249 5 et seq A CE SHOCK Electric Shock can injure or kill The plasma arc pro cess uses and produces high voltage electrical en ergy This electric energy can cause severe or fatal shock to the operator or others in the workplace Never touch any parts that are electrically live or hot Wear dry gloves and clothing Insulate yourself from the work piece or other parts of the weld ing 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 Publi cations Disconnect power source
22. ement parts are shown on the following pages Catalog numbers are shown below each part Manual 0 4751 7 1 PARTS LIST 7 01 Parts List Power Supply Rem Number Guantity Description Catalog Number 6 cable Ground Paz 9026 8 1 Poma 97163 9 1 ome RadlBa O 97218 29 1 Brack Upper 90813 2 1 Case Toreh Cor 9054 28 1 Piot Relay Assembly 90304 PARTS LIST 7 2 Manual 0 4751 Art A 07771 N N F lt SE tz lt PARTS LIST 7 3 Manual 0 4751 PARTS LIST 7 4 Manual 0 4751 This Page Left Blank Manual 0 4751 7 5 PARTS LIST 7 02 Replacement Hand Torch Parts With Ergonomic Handle Item Qty 1 1 m U Q Q QOL Lm Lm RP RP PP PP onm MH Description Assembly Basic Head 70 Head PIP Parts In Place Pins 6 32 x 3 16 Phillips Pan Head Screw 6 Internal Star Washer Ergonomic Handle Split with Trigger includes items 5 12 Trigger Lexan Orange Handle Spring 0 390 O D x 0 750 Torch Handle Socket Head Cap Screw Kit 5 pcs 6 32 x 1 2 Assembly Torch Switch Negative Plasma Lead Insulation Sleeving Pin Housing Used with item 12 Pin Socket Housing Used with item 14 Socket Lead Assembly including items No 6 8 and 9 20 ft 7 6 m Length NOTE Item can be purchased locally PARTS LIST Catalog 9 8442 9 5723 See Note See Note 9 8076 9 8059 9 8060 9 8061 9 8062 9 8063 9 8056 9 8111 9 8101 9
23. en air check disconnected 2 Return to an authorized service center for repair switch is turned on 2 Internal air supply compressor 3 Return to an authorized service center for repair not working 3 Control PCB faulty Torch will not pilot 1 Air pressure too high ortoo 1 There is no adjustment return to an authorized service when torch switch is low center for repair activated 2 Torch consumables missing 2 Turn off power supply Remove shield cup Install missing 3 Worn or faulty torch parts parts 4 Thermal Switch activated 3 Inspect torch consumable parts Replace if necessary 4 Allow the cooling fan to run for 2 minutes or longer until it will resume operation Pilot transferarc 1 Torch removed from work piece 1 Release torch trigger and re establish the pilot arc See goes out and or moved away from metal being block diagram Appendix 1 doesn t reactivate cut Cut performance is 1 Worn torch parts 1 Check current setting Check the Electrode and Tip for diminished 2 Poor Work Lead connection excess Wear 3 Current sensor or PWM PCB 2 Checkthe connection of the Work Lead to the work piece faulty 3 Return to an authorized service center for repair or replacement Air flows 1 Torch Switch Latch button on 1 Return to an authorized service center for repair or continuously and front panel faulty replacement torch switch latch 2 Control PCB faulty 2 Return to an authorized service
24. ent of this Direc tive Serial numbers are unique with each individual piece of equipment and details description parts used to manu facture 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 equip ment and associated accessories For environments with increased hazard of electrical shock Power Supplies bearing the mark conform to EN50192 when used in conjunction with hand torches with exposed cutting tips if equipped with properly installed standoff guides Extensive product design verification is conducted at the manufacturing facility as part of the routine design and manufacturing process This is to ensure the product is safe when used according to instructions in this manual and related industry standards and performs as specified Rigorous testing is incorporated into the manufacturing process to ensure the manufactured product meets or exceeds all design specifications Thermal Dynamics has been manufacturing products for more than 30 yea
25. g LD2 12VDC42 9 VD 1 Red prp E CN10 3 0U 1 Ei HA Board E ae 7992 Y oN No 40273003 3 GN 1 i oa S gt E 5l gt GN1 G E a H V Contactor E ont a Bk 1 only HT TT S 3l It tl 1 b Y Y 2woc Y to engage cata HH Pilot Relay Y 3 LD4 VDC w Torch 9j ES HN on J Filter Cw gt IL W pH No 40276002 Do Not attempt to AR adjust the PCB CHECK S3 iu Title 4 Air Plasma 35C 230V CE Size Number Rev A2 No 66001012 AA Date oct 19 2005 Drawn by Filename Sheet of D E F Art A 06978 Manual 0 4751 A 5 APPENDIX Appendix 5 System Schematic 230V A B C 230 VAC Red e Ye a DIODE IGBT IGBT Bk 7 EN w 1 gt T T gt i 230 VAC 230 vac a INPUT dal E C2 E A Wh ces 9 TR T El Filter Board El i lm No 40276003 T3 67 CN2 CN CN4 CN3 i W NE Bk 1118 MBL RITS I3 DC w Jw d w w ann ak IR 325 2 E 230 VAC PR Ri 3 A al C W2 Bk2 G1E1 G2E2 G3 E3 G4 E4 Capacitor d TW TW TW TW 21 E Ute ill pb cc BWGR BWGR E4 G4E3 G3 2 G2 E1 G1 NOTE Loa on 6 UTT 11 Do Not Heatsink CN6 CN8 attempt to adjust t
26. g with the torch Release the torch trigger and the torch will con tinue to cut without depressing the torch trig ger I e Air Set Button W To check for proper air setting and to cool down heated torch MAIN CURRENT CONTROL KNOB To adjust cutting current Turning clockwise in creases the cutting current and counter clock wise decreases the cutting current au A Art A 04387 PRIMARY POWER SWITCH ON OFF The power switch is located on the front panel Placing the primary power switch to the ON position energizes the power source A WARNING When the power source is overloaded the switch turns to the OFF position automatically DO NOT TURN ON BY FORCE Operation 4 02 Preparations For Operating At the start of each operating session A WARNING Disconnect primary power at the source before assembling or disassembling power supply torch parts or torch and leads assemblies A Torch Parts Selection Check the torch for proper assembly and appro priate torch parts The torch parts must correspond with the type of operation and with the amperage output of this Power Supply 35 amps maximum Use only genuine manufacturer s parts with this torch Electrode No 9 6542 Gas Distributor No 9 6507 Torch Head Assembly Tip No 9 6501 Shield Cup No 9 6003 o B Torch Connection Art A 04655 Check that the torch is properly connected C Connect
27. he LD1 PCB POTS Pus A AC230 290 VAG Control Board T No 40271005 BI M Compressor Relay 9720 3 pa Fn 25VDC J AE T REN LD3 we R 1 co b d i aR 2 z P i 2v e CN2 l dni jw MERTDSK B TIT NIC BI 630V v il cM Panel Board Compressor No 40270601 ELL xo D ES gt gt 4 OTE F P5 TEMP AIR o BT MAIN POWER ERROR ERROR HOLD Art A 07024 APPENDIX A 6 Manual 0 4751 D E F 220 Main Transformer Curen Sensor No H F E ZZ l On Y Bk A 0 C V 325 Pilot 130 C T1 eee Cutting 80 100 Bk A9 See Sec 6 OCV MH in Service Manual R5 C6 E mt 1 __ iH R6 C7 nan 8 REACTOR Conduit Coil o o IH o I R7 3 C8 Twisted 3116 He Y w PCR W C 412VDC IT 5 vc 1 BR NE ped 3 LD2 12VDC 42 WD_1 Red dr cNMol3F 001 O B H V Board enang 4 gt le Y 7 No 40273003 2 gt 5 gt GN 1 1 E Cc E vr s barrens E 3 HN Contactor CN11 Bk 1 only HTA o Lu I E AH pp Y Y Y axo Y to engage CN12 E y z Pilot Relay eo Torch lt a LD4 12VDC 5 W orc HN ona ay Filter Sw d dle i W No 40276002 t Do Not attempt to
28. ing to local require ments NOTE Repairs must be done by skilled and qualified personnel only Installation This Page Left Blank Installation 3 2 Manual 0 4751 SECTION 4 i OPERATION 4 01 Front Control Panel Air Error Indicator Overheating Torch Switch Indicator Latch Indicator 7 E On Of Torch Switch Switch Ce Button AC Power_ A Air Set ES Indicator des C Current Control Knob Work Lead Figli Connection Connection v v Air ves E E Art A 04720 Roll bars not shown for clarity A INDICATOR LAMP Power Indicator o Lights when primary power switch is turned on e TEMPERATURE Indicator JE Indicator is nor mally OFF Indicator is ON when internal tem D perature exceeds normal limits Shut unit OFF let the unit cool before continuing operation Air Error Indicator This indicator lights and is accompanied by an intermittent audible tone when there is not enough air pressure to operate the power supply NOTE It is possible to have enough air pressure to op erate the power supply but not enough air flow to operate the torch Torch Switch Latch Indicator Wl amp This indicator lights when the Torch Switch Latch Button has been pressed for continuous cutting Manual 0 4751 4 1 BUTTONS e Torch Switch Latch Button W a For continuous cutting performance Depress this button turn On while cuttin
29. mm NOTE Refer to Local and National Codes or local au thority having jurisdiction for proper wiring re quirements Introduction Model Description Maximum output Input Voltage amp Phase CR ae Frequenc Input power U S Canada 40 Amps Current Input fuse All others 20A Slow Blow Fuse No Load Voltage Load Voltage Output Current Post flow time 35 p 35A O 94vdc Duty cycle 104 F 60 O 27A O 40 C Ambient 91vdc 100 O 20A O 88 vdc Genuine Cutting 3 8 Capacity 9 mm Maximum Cutting 1 2 Capacity 12mm 2 03 Features 2 1 COMPACT and LIGHT Designed for easy trans portation ENERGY EFFICIENCY Advanced technology reduces power consumption HIGH SPEED GENUINE CUTTING The con stricted plasma arc provides high speed cutting as well as a good quality genuine narrow cut LOW COST WITH COMPRESSED AIR The Drag Gun Plus operates on compressed air ALL KINDS OF METALS Useful for most met als such as stainless steel aluminum mild steel copper and their alloys PILOT ARC IGNITION FROM TORCH The Pi lot Arc ignites the cutting arc POWERFUL CUTTING PERFORMANCE Genuine cutting capacity is 3 8 9 mm ABLE TO CUT PAINTED MATERIALS Pilot Arc ignition allows the Drag Gun Plus to cut painted materials EXTENDED PARTS LIFE Consumable parts life is longer Manual 0 4751 2 04 Torch Specifications 2 05 System Contents 3 in 76 2 mm Description ITEMS
30. on Input diode and It should be 325VDC Sh ow m e Depress and hold the torch trigger for each of the following checks steps numbers 6 9 Each check has to be done within the 3 5 second pilot arc time If not then the trigger will have to be releaed and then depressed again 6 Check for illumination of the SOL LED and that the EN Enable LED brightens on the Logic PCB Art A 06991 Illustration 6 2 7 Measure output to Main Transformer Input between points 5 and 6 in Illustration 6 2 above It should be 220VAC 8 Measure Main Transformer secondary voltage between points 3 and 4 in Illustration 6 2 above It should be 190VAC 9 Measureoutput OCV between points 1 and 2in Illustration 6 2 above It should be 325VDC 10 Turn off the unit power and plug the connector back in to CN1 removed in step 1 above TROUBLE SHOOTING 6 4 Manual 0 4751 6 05 Detailed Fault Finding Error Indicators Problem Check Test Recommended Action ze Air Indicator is on 1 Check air and electrical connections 1 If connections are good return and or audible to the internal air compressor to an authorized service center for intermitant tone 2 Control PCB faulty repair 3 Check the compressor relay 2 Replace the Control PCB 3 Replace the relay if bad Torch doesn t Pilot and 1 Check torch consumables 1 Replace torch consumables as the LD1 LED light on 2 Check all air supply related issues needed the Control
31. rs and will continue to achieve excellence in our area of manufacture Manufacturers responsible representative Steve Ward Operations Director Thermadyne Europe Europa Building Chorley N Industrial Park Chorley Lancashire England PR6 7BX CE GENERAL INFORMATION 1 4 Manual 0 4751 1 05 Statement of Warranty LIMITED WARRANTY Subject to the terms and conditions established below Thermadyne Corporation warrants to the original retail purchaser that new Thermadyne CutSkill Series plasma cutting systems sold after the effective date of this warranty are free of defects in material and workmanship Should any failure to conform to this warranty appear within the applicable period stated below Thermadyne Corporation shall upon notification thereof and substantiation that the product has been stored operated and maintained in accordance with Thermadyne s specifications instructions recommendations and recognized industry practice correct such defects by suitable repair or replacement This warranty is exclusive and in lieu of any warranty of merchantability or fitness for a particular purpose Thermadyne will repair or replace at its discretion any warranted parts or components that fail due to defects in material or workmanship within the time periods set out below Thermadyne Corporation must be notified within 30 days of any failure at which time Thermadyne Corporation will provide instructions on the warranty procedures to be implemen
32. rt per schematic located in Appendix 4 2 IGBT Module Test a With an ohmmeter set on the diode range remove P5 from the IGBT and make the following IGBT checks Gate PCB J5 IGBT Check ONERE EN POR El White El Black El G1 E2 G2 E3 White E3 Black G3 E3 G4 E4 DD 770 Diode Test CT Bad L2 Wie Rei Red LT 64 Green DELI Pin out diagram EN H fer I MEER ENG EN b If reading is not as shown replace both IGBT modules and Gate PCB c Reconnect P5 connector TROUBLE SHOOTING 6 8 Manual 0 4751 6 06 Torch Tests A G Disconnect primary power at the source before disassembling the power supply torch or torch leads 1 PIP and Torch Switch Adapter Check a Disconnect input power from power supply b Confirm that the torch parts are in place and that they match the parts consumables label on the power supply cover c Refer to Appendix 2 for torch connection and access With the power supply on it s side and the panel removed disconnect the Power Supply Adapter from the power supply d Whilethe torch trigger is depressed complete an Ohm check on the two pins in the Power Supply Adapter The reading should show a short less than 1 Ohm Refer to diagram aU 0 Negative 7 Plasma Lead 9 PIP O Black To Power Switch lo nuc Te PE 00 B Torch O Green s Switch Om White Continuity a 2e Check
33. s 6 06 Torch Tests i d ere tanen beer e Cane nae SECTION 7 PARTS STi GN Wn dd de dude 7 01 Parts List Power Supply sseseeene 7 02 Replacement Hand Torch Parts With Ergonomic Handle TABLE OF CONTENTS Con t Appendix 1 Operating Sequence Block Diagram iio A 1 Appendix 2 Torch Connectiorn usn aiu nn la A 2 Appendix 3 Microchip PINO Utkina aieeaa i canaria LL LLE RH nnn cnn A 3 Appendix 4 System Schematic 230V CE oooocccccocccconanacanonnncnnnnnccnnannnnanann cnn nan nn cnn nnne entren A 4 Appendix 5 System Schematic 230V coccccnncccconocccconancnononanononnncnnnnno cnn nono LLARY aiae iiaa eiea A 6 GLOBAL CUSTOMER SERVICE CONTACT INFORMATION SECTION 1 GENERAL INFORMATION 1 01 Notes Cautions and Warnings Throughout this manual notes cautions and warn ings are used to highlight important information These highlights are categorized as follows NOTE An operation procedure or background in formation which requires additional empha sis or is helpful in efficient operation of the system ddyo A procedure which if not properly followed may cause damage to the eguipment A WARNING A procedure which if not properly followed may cause injury to the operator or others in the operating area 1 02 Important Safety Precautions A WARNING OPERATION AND MAINTENANCE OF PLASMA ARC EQUIPMENT CAN BE DANGEROUS AND HAZARDOUS TO YOUR HEALTH Plasma
34. ted Thermadyne Corporation will honor warranty claims submitted within the warranty periods listed below All warranty periods begin on the date of sale of the product to the original retail customer or 1 year after sale to an authorized Thermadyne Distributor LIMITED WARRANTY PERIOD Product Power Supply Componants Torch and Leads Parts and Labor Parts and Labor Drag Gun Plus This warranty does not apply to 1 Consumable Parts such as tips electrodes shield cups o rings starter cartridges gas distributors fuses filters 2 Equipment that has been modified by an unauthorized party improperly installed improperly operated or misused based upon industry standards In the event of a claim under this warranty the remedies shall be at the discretion of Thermadyne Corporation il Repair of the defective product 2 Replacement of the defective product 3 Reimbursement of reasonable costs of repair when authorized in advance by Thermadyne 4 Payment of credit up to the purchase price less reasonable depreciation based on actual use These remedies may be authorized by Thermadyne and are FOB West Lebanon NH or an authorized Thermadyne service station Product returned for service is at the owner s expense and no reimbursement of travel or transportation is authorized LIMITATION OF LIABILITY Thermadyne Corporation shall not under any circumstances be liable for special or consequential damages such as but not limit
35. vel rom ae omens Travel Speed im mm panas Gun mM ga 0 135 3mm 95 0 2375 1900 a 0 178 Gsm 70 ws 0 19m Emm TE om 1 2 a NOTE Drag or Drag mode refers to the torch tip being in contact with the work piece at all times Manual 0 4751 4 3 Operation This Page Left Blank Operation 4 4 Manual 0 4751 SECTION 5 MAINTENANCE 5 01 General Maintenance Maintain more often Warning if used under severe Disconnect input power before maintaining conditions Each Use Visual check of torch tip and electrode ln Weekly Visually inspect the cables and leads Visually inspect the torch body Replace as needed tip electrode and shield cup 3 Months Replace all broken parts Gaani exterior of power supply 6 Months Visually check and Carefully clean the interior Art A 06884 Manual 0 4751 5 1 Maintenance This Page Left Blank Maintenance 5 2 Manual 0 4751 SECTION 6 TROUBLESHOOTING 6 01 Normal Setup and Operation 1 Connect the unit to power 2 Connect the work lead clamp to cleaned area of work surface 3 Turn the switch located on the front panel to the On position The o A C indicator on the front panel lights and the cooling fan comes on 4 Selectthe correct current setting for the material being cut 5 Squeeze the torch trigger The pilot arc and compressor start 6 Transfer arc to work surface within 3 5
36. your eyes and burn your skin The plasma arc process produces very bright ultra violet and infra red light These arc rays will dam age your eyes and burn your skin if you are not prop erly 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 condi tion Replace lenses when cracked chipped or dirty Protect others in the work area from the arc rays Use protective booths screens or shields Manual 0 4751 Use the shade of lens as suggested in the fol lowing per ANSI ASC 249 1 Minimum Protective Suggested Arc Current Shade No Shade No Less Than 300 8 9 300 400 9 12 400 800 10 14 These values apply where the actual arc is clearly seen Experience has shown that lighter filters may be used when the arc is hidden by the workpiece 1 03 Publications Refer to the following standards or their latest revi sions for more information 1 OSHA SAFETY AND HEALTH STANDARDS 29CFR 1910 obtainable from the Superintendent of Documents U S Government Printing Office Washington D C 20402 ANSI Standard 249 1 SAFETY IN WELDING AND CUTTING obtainable from the American Welding Society 550 N W LeJeune Rd Miami FL 33126 NIOSH SAFETY AND HEALTH IN ARC WELDING A
Download Pdf Manuals
Related Search