Thermal Dynamics Drag-gun Service Manual

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Plasma Cutting Power Supply Drag-gun TM A-03642 Service Manual November 11, 2003 Manual No. 0-2683 ...

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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 M...

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TABLE OF CONTENTS SECTION 1: GENERAL INFORMATION ................................................................................................... 1 1.01 Notes, Cautions and Warnings ....................................................................

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TABLE OF CONTENTS (Continued) 5.0 PARTS LIST .........................................................................................................................27 5.1 Returns ......................................................................

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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 ...

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GENERAL INFORMATION 2 Date: November 15, 2001 • Wear dry gloves and clothing. Insulate yourself from the work piece or other parts of the welding circuit. • Repair or replace all worn or damaged parts. • Extra care must be taken when the work...

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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, WELD...

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GENERAL INFORMATION 4 Date: November 15, 2001 • Eloignez toute fumée et gaz de votre zone de respira- tion. Gardez votre tête hors de la plume de fumée provenant du chalumeau. • Utilisez un appareil respiratoire à alimentation en air si l�...

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Date: November 15, 2001 5 GENERAL INFORMATION ultra-violets très forts. Ces rayons d’arc nuiront à vos yeux et brûleront votre peau si vous ne vous protégez pas correctement. • Pour protéger vos yeux, portez toujours un casque ou un écran...

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GENERAL INFORMATION 6 Date: November 15, 2001 9. Norme 70 de la NFPA, CODE ELECTRIQUE NA- TIONAL, disponible auprès de la National Fire Pro- tection Association, Batterymarch Park, Quincy, MA 02269 10.Norme 51B de la NFPA, LES PROCÉDÉS DE COUPE E...

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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 applicabl...

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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 failu...

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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 layo...

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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 *5022129530 120V 60 20 12 70 30 220V *5013128530 208/230V 60 10 12 78 30...

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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...

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TROUBLE-SHOOTING 12 Manual 0-2683 B. Power Source Related If the service available is saggy, pilot and cut performance will be degraded. In some cases, the service circuit breaker may open during use. Some things that will help: • Use a service fu...

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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...

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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...

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Manual 0-2683 15 TROUBLE-SHOOTING 3.6 Torch & 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 t...

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TROUBLE-SHOOTING 16 Manual 0-2683 ...

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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 f...

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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 F...

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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...

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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: ...

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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 keyh...

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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 en...

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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. Wi...

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REPLACEMENT PROCEDURES 24 Manual 0-2683 4.14 Torch & 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 �...

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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 ...

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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 Conn...

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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 serial number of the torch. Address all inquiries to your authorized distributor or ...

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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 220...

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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 repai...

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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 Elect...

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Manual 0-2683 31 APPENDIX APPENDIX I - INTERCONNECTING DIAGRAM A-02012 PIP Pin + - + - J2 J2 J2 J2 J2 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 330µƒ 450v 3...

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APPENDIX 32 Manual 0-2683 A-02277 APPENDIX II - INTERCONNECTING DIAGRAM ...

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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. ...

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