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Manual 0-4751

7-1

PARTS LIST

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: [email protected]

Replacement parts are shown on the following pages. Catalog numbers are shown below each part.

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Summary of Contents for 35C

Page 1: ...PLASMA DRAG GUN PLUS Service Manual 35C PLASMA CUTTING SYSTEM Rev AA 01 Issue Date March 26 2007 Manual 0 4751 Operating Features...

Page 2: ......

Page 3: ...ht 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 a...

Page 4: ......

Page 5: ...ON 3 INSTALLATION 3 1 3 01 Site Selection 3 1 3 02 Electrical Input Connections 3 1 3 03 Torch 3 1 SECTION 4 OPERATION 4 1 4 01 Front Control Panel 4 1 4 02 Preparations For Operating 4 2 SECTION 5 MA...

Page 6: ...rating Sequence Block Diagram A 1 Appendix 2 Torch Connection A 2 Appendix 3 Microchip Pin Out A 3 Appendix 4 System Schematic 230V CE A 4 Appendix 5 System Schematic 230V A 6 GLOBAL CUSTOMER SERVICE...

Page 7: ...l 1 603 298 5711 or your local distributor if you have any questions GASES AND FUMES Gases and fumes produced during the plasma cut ting process can be dangerous and hazardous to your health Keep all...

Page 8: ...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 cu...

Page 9: ...tandards Institute 1430 Broadway New York NY 10018 7 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...

Page 10: ...ent 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...

Page 11: ...trodes 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...

Page 12: ...GENERAL INFORMATION 1 6 Manual 0 4751 This Page Left Blank...

Page 13: ...Maximum Cutting Capacity 1 2 12mm Dimension W D H 10 5 x15 5 x11 267 mm x 394 mm x 279 mm Duty cycle 104 F 40 C Ambient NOTE Refer to Local and National Codes or local au thority having jurisdiction f...

Page 14: ...with exposed tip the recommended standoff height is 1 8 3 8 3 9 mm Plasma Power Supply Used With Drag Gun Plus PCH 42 Torch Ratings 2 05 System Contents Description ITEMS Q ty Power source Model Drag...

Page 15: ...d any extension cords used must conform to local electrical code and the recommended circuit protection and wir ing requirements as specified in Section 2 3 03 Torch Make sure that the torch cable and...

Page 16: ...Installation 3 2 Manual 0 4751 This Page Left Blank...

Page 17: ...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 This indicator lights when the Torch Swit...

Page 18: ...piece or cutting table Work Cable And Clamp Art A 04389 D Torch Operation Wear gloves and protective goggles Do not place bare hand on work piece 1 For drag cutting keep the torch in contact with the...

Page 19: ...tandoff height Unit Standoff Material Thickness ipm mm m ipm mm m Drag Gun Plus Drag 10 ga 0 135 3mm 95 0 2375 76 0 1900 Drag Gun Plus Drag 7 ga 0 179 4 5mm 57 0 1425 46 0 1150 Drag Gun Plus 1 8 3mm 1...

Page 20: ...Operation 4 4 Manual 0 4751 This Page Left Blank...

Page 21: ...check of torch tip and electrode Weekly Visually inspect the torch body tip electrode and shield cup Visually inspect the cables and leads Replace as needed 3 Months Clean exterior of power supply 6 M...

Page 22: ...Maintenance 5 2 Manual 0 4751 This Page Left Blank...

Page 23: ...surface within 3 5 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 When the...

Page 24: ...witch is activated 1 Air pressure too high or too low 2 Torch consumables missing 3 Worn or faulty torch parts 4 Thermal Switch activated 1 There is no adjustment return to an authorized service cente...

Page 25: ...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 3 Press the Air Set Button The the air compressor should come on causing a...

Page 26: ...f 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 1 2 3 4 Art A 06991 5 6 Illustrati...

Page 27: ...needed 2 Change air related items as needed 3 If OCV is not OK follow OCV check procedures in section 6 04 4 If CN9 connection is OK replace the Control PCB Torch doesn t Pilot and the LD1 LED on the...

Page 28: ...diode module to be tested 3 Remove P5 from IGBT module 4 Set digital volt ohmmeter to diode test scale 5 Connect the volt ohmmeter positive lead to the anode of the diode and the negative lead to the...

Page 29: ...ck in the reverse bias direction and depending on the meter function will indicate an open or OL OL VR COM A Art A 00306 Anode Cathode Reverse Bias Diode Not Conducting _ Testing Diode Reverse Bias 7...

Page 30: ...en After Charging E1 Black Open After Charging Black E1 DD 1 270 E1 G1 DD 770 G1 E1 DD 770 E2 G2 DD 770 G2 E2 DD 770 E3 White DD 1 270 White E3 Open After Charging E3 Black DD 770 Black E3 DD 770 G3 E...

Page 31: ...rt less than 1 Ohm Refer to diagram Torch Switch Negative Plasma Lead Torch Head White Black Orange Green PIP Switch Torch Leads To Power Supply Adapter Pilot Pilot 2 1 Continuity Check Art A 05557 2...

Page 32: ...TROUBLE SHOOTING 6 10 Manual 0 4751 This Page Left Blank...

Page 33: ...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 acce...

Page 34: ...V PCB 9 7147 13 1 Relay 9 0319 14 1 PCB Input Filter shown 9 7128 14 1 PCB Input Filter CE 9 7133 15 1 Resistor 9 0300 16 1 Control Transformer 9 7144 17 1 Bracket Capacitor 9 0302 18 1 Electrolytic C...

Page 35: ...Manual 0 4751 7 3 PARTS LIST Art A 07771 1 2 3 4 5 6 7 8 9 Art A 07772 10 11 12 13 14 15 16 17 18 19 20 21...

Page 36: ...PARTS LIST 7 4 Manual 0 4751 Art A 07773 22 23 24 25 26 27 28 29 30...

Page 37: ...Manual 0 4751 7 5 PARTS LIST This Page Left Blank...

Page 38: ...rigger includes items 5 12 9 8076 5 1 Trigger Lexan Orange 9 8059 6 1 Handle 9 8060 7 1 Spring 0 390 O D x 0 750 9 8061 8 1 Torch Handle Socket Head Cap Screw Kit 5 pcs 6 32 x 1 2 9 8062 9 1 Assembly...

Page 39: ...Manual 0 4751 7 7 PARTS LIST Art A 07061 1 7 8 6 6 15 9 2 10 3 4 5 11 12 13 14...

Page 40: ...PARTS LIST 7 8 Manual 0 4751 This Page Left Blank...

Page 41: ...ch On Compressor Starts and Air Flows at Torch Turn Air Set Switch Off Red Air Indicator Pilot Arc goes out Release Torch Switch Primary Input Power Switch Off or Unplugged Green Power Indicator Off a...

Page 42: ...and air Lay unit on its side Remove two screws and access plate Pilot Power Supply Adapter Connections Negative Plasma Lead Art A 04695 DETAIL To Power Supply Adapter Pilot Negative Plasma Lead Black...

Page 43: ...1 A 3 APPENDIX Appendix 3 Microchip Pin Out P2 1 2 3 4 5 6 7 8 9 10 11 12 24 22 20 18 16 14 12 10 8 6 4 2 23 21 19 17 15 13 11 9 7 5 3 1 P3 1 2 3 4 5 6 7 8 9 10 11 12 CPU Socket on Control PCB 40 Pin...

Page 44: ...PH R1 Control Board Panel Board Compressor Bk Wh DIODE 230 VAC W W N C Red Bk DC 325 NOTE Do Not attempt to adjust the PCB POTs E4 G3 G2 G4 E3 E1 E2 G1 TW TW TW TW B W G R B W G R 230 VAC Lt Bl W Br...

Page 45: ...Board Air Plasma 35C 230V CE No 66001012 CN10 5 12VDC 12VDC 1 2 3 4 BR Red O Y G W Twisted CN12 1 2 12VDC to engage Pilot Relay Torch Filter CN3 W W 12VDC 2 1 LD2 Enable Bk 220 VAC 190VAC O C V 325 Pi...

Page 46: ...1 PH R1 Control Board Panel Board Compressor Bk Wh DIODE 230 VAC W W N C Red Bk DC 325 NOTE Do Not attempt to adjust the PCB POTs E4 G3 G2 G4 E3 E1 E2 G1 TW TW TW TW B W G R B W G R 230 VAC Lt Bl W Br...

Page 47: ...V Board Air Plasma 35C 230V No 66001008 CN10 5 12VDC 12VDC 1 2 3 4 BR Red O Y G W Twisted CN12 1 2 12VDC to engage Pilot Relay Torch Filter CN3 W W 12VDC 2 1 LD2 Enable Bk 220 VAC 190VAC O C V 325 Pil...

Page 48: ...APPENDIX A 8 Manual 0 4751 This Page Left Blank...

Page 49: ...i PR 200052 Telephone 86 21 69171135 Fax 86 21 69171139 Thermadyne Asia Sdn Bhd Lot 151 Jalan Industri 3 5A Rawang Integrated Industrial Park Jln Batu Arang 48000 Rawang Selangor Darul Ehsan West Mala...

Page 50: ...Corporate Headquarters 16052 Swingley Ridge Road Suite 300 St Louis MO 63017 Telephone 636 728 3000 Email TDCSales Thermadyne com www thermadyne com...

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