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Thermal Dynamics DRAG-GUN 38, Instruction Manual

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Thermal Dynamics DRAG-GUN 38 Instruction Manual Download Page 35

Manual 0-2729

29

SECTION 5: SERVICE

Is Control

Shaft Okay?

Yes

No

CURRENT Control Knob Turns Completely

Around And Doesn't Stop At Minimum Or

Maximum Positions

Troubleshooting Chart #6:  Faulty Current Control

Check Shaft Of CURRENT

Control Is Not Loose Or

Broken From PC Board

Secure or Replace 

CURRENT Control

Knob per Section 5.11C

Replace Power Supply

Summary of Contents for DRAG-GUN 38

Page 1: ...ere d or ove rsiz ed orif ice Ele ctr od e 9 6 50 6 Ga s Dis trib uto r 9 6 50 7 Tip 9 6 50 1 Sh iel d Cu p 9 6 00 3 Pa rt De sc rip tio n Ca tal og No RE PL AC EM EN T TO RC H PA RT S Ch eck the ele...

Page 2: ......

Page 3: ...e Manufacturer assumes no liability for its use Plasma Cutting Power Supply Drag Gun 38 Instruction Manual Number 0 2729 Published by Thermal Dynamics Corporation 82 Benning Street West Lebanon New Ha...

Page 4: ...llation 11 SECTION 4 OPERATION 13 4 01 Introduction 13 4 02 Functional Overview 13 4 03 Operating Controls Connections 13 4 04 Getting Started 13 4 05 Torch Consumable Parts Selection 14 4 06 Cut Qual...

Page 5: ...dering Information 45 6 03 Power Supply Replacement Parts 46 6 04 Complete Assembly Replacement 48 6 05 Torch Replacement Parts 49 6 06 Options and Accessories 50 APPENDIX I SEQUENCE OF OPERATION BLOC...

Page 6: ......

Page 7: ...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...

Page 8: ...s in this manual PLASMAARC RAYS PlasmaArc 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...

Page 9: ...ble 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...

Page 10: ...r 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 per...

Page 11: ...e 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 suivan...

Page 12: ...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...

Page 13: ...ion standard C22 2 number 60 forArc welding equipment UL Underwriters Laboratory rating 94VO flammability testing for all printed circuit boards used ISO IEC 60974 1 BS 638 PT10 EN 60 974 1 EN50192 EN...

Page 14: ...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...

Page 15: ...pplies to the DRAG GUN 38 Power Sup ply only 1 Controls AC POWER ON OFF Switch CURRENT Output Control 2 Panel LED Indicators AC GAS DC OverTEMP 3 Input Power 208 230 Volts 10 Single Phase 50 60 Hz 4 O...

Page 16: ...ransfer Distance 1 8 inch 3 2 mm 8 Torch Parts Gas Distributor Electrode Tip Shield Cup 9 Gas Requirements Included compressed air 10 Weight without leads 1 0 lb 45 kg 11 Torch Dimensions 7 98 in 203...

Page 17: ...and packing mate rial to prevent damage during shipping A System Components Included with each system is the following 1 Power Supply with the following installed PCH 25 38 Torch and Leads 1 each Work...

Page 18: ...SECTION 3 INSTALLATION PROCEDURES 12 Manual 0 2729...

Page 19: ...s overheating unit must be allowed to cool The indicator will also flash momentarily if the torch is shorted 5 CURRENT Control Adjusts output current from 12 to 29 amps 6 TORCH Lead Connection Input f...

Page 20: ...ence of Operation 4 05 Torch Consumable Parts Selection A Torch Parts The same torch parts are used for drag or standoff cutting Refer to Figure 4 3 for the various torch parts Standard Shield Cup Cat...

Page 21: ...ts can be left on the surface of the cut when nitrogen is present in the plasma gas stream These buildups may create difficulties if the material is to be welded after the cutting process C Bevel Angl...

Page 22: ...ON OFF switch on rear panel to the ON position AC POWER indicator light comes on Fan turns on Compressor runs 3 5 seconds Main power relay closes 2 Wear protective clothing refer to Section 1 of Manu...

Page 23: ...ol switch After an initial gas purge the pilot arc will come on and remain on until the cut ting arc starts 5 Once on the main arc remains on as long as the control switch is held down unless the torc...

Page 24: ...SECTION 4 OPERATION 18 Manual 0 2729...

Page 25: ...OTE The actual frequency of maintenance may need to be adjusted according to usage and the environment R ecom m ended R outine M aintenance Schedule D aily O perational C hecks or Every 6 C utting H o...

Page 26: ...and what is the possible cause 1 Insufficient Penetration a Cutting speed too fast b Torch tilted too much c Metal too thick d Worn torch parts e Cutting current too low f Non genuine manufacturer s t...

Page 27: ...re 5 4 Electrode Wear 6 Install the electrode gas distributor tip and shield cup 7 Hand tighten the shield cup until it is seated on the torch head If resistance is felt when installing the cup check...

Page 28: ...ec tion 5 04 or shorted torch head per Section 5 10 4 Input voltage too high a Check voltage at wall outlet must not exceed 253 VAC 230 10 C AC Indicator blinks for 4 seconds when power is turned on b...

Page 29: ...st Procedures Specific test procedures have been grouped together and are referenced by the flowcharts B How to Use This Guide The following information is a guide to help the Service Technician deter...

Page 30: ...cator Replace Power Supply Check Main Power Disconnect Main Power Disconnect ON No Yes Main Power Line FuseOkay No Yes Place Main Power Disconnect to ON Check Main Disconnect Power Line Fuse Main Powe...

Page 31: ...upply per Section 5 11F AC Indicator Comes ON Yes No Replace Starting Relay K3 per Section 5 11H Check Capacitor PC Board Assembly on Heatsink PC Board Assembly Per Section 5 09C Capacitor PC Board As...

Page 32: ...hecks Replace Power Supply Assembly Duty Cycle Exceeded No Yes Allow Power Supply To Cool Temperature Indicator ON Yes No Use Proper Operating Procedures Temperature Indicator Still ON Yes No Fan Oper...

Page 33: ...re ON DC Indicator Blinks or Momentary ON When Torch Switch is pressed Troubleshooting Chart 4 Resistor R3 Checks Check Resistor R3 Assembly per Section 5 09 E Replace Power Supply Resistor R3 Check O...

Page 34: ...oting Chart 5 Faulty Torch Check Torch And Leads per Section 5 10 A B Replace Power Supply Torch Check Correct Yes No Replace Torch AC Indicator ON No GAS Flow When Torch Switch is Depressed Compresso...

Page 35: ...trol Knob Turns Completely Around And Doesn t Stop At Minimum Or Maximum Positions Troubleshooting Chart 6 Faulty Current Control Check Shaft Of CURRENT Control Is Not Loose Or Broken From PC Board Se...

Page 36: ...tive to plus direction 5 Input Rectifier should be isolated for further testing Label and disconnect wires attached to Input Rec tifier 6 Connect the volt ohm meter positive lead to the anodeofthediod...

Page 37: ...ET Assemblies 1 Remove the top Panel Cover of the Power Supply per subsection 5 11 E 2 Using an ohmmeter set on the Rx1 scale make the following checks A 02122 Capacitor PC Board Wire 3 Terminal Termi...

Page 38: ...pacitor dis charges and charges If meter shows short open or does not change replace Capacitor PC Board D Checking Pilot Return 1 Remove the right SidePanel of the Power Supply per subsection 5 11 D 2...

Page 39: ...apacitance A short may be detected with an ohmeter Remove leads from one of the Capacitor s terminals then measure across the terminals If it reads a low resistance less than a few thousand ohms then...

Page 40: ...nd replace the torch leads If no continuity is found the torch leads are okay and the problem was in the way the components were assembled Proceed to Step 7 7 Carefully reassemble the components and r...

Page 41: ...c Bell Filter Dryer Element Figure 5 14 Filter Dryer Assembly C Current Control Knob Replacement 1 Using a small blade screwdriver loosen the screw securing the knob to the CURRENT Control adjust ment...

Page 42: ...l or damage the current control shaft 9 Disconnect ground wire connection from top panel cover 10 Rest cover beside Power Supply NOTE To replace top panel reverse steps F Fuse Replacement NOTE Removal...

Page 43: ...3 making sure the two prong side of Relay faces the Capacitor Connect wires as shown below Capacitor Blue 12 Red 23 Blue 3 Blue 11 Red 3 A 02608 Figure 5 17 Relay Wiring Connections I Input Power Cabl...

Page 44: ...d s to top Panel Cover 3 Install replacement Guard s by reversing steps 1 3 WARNING Be careful of ground wire when removing and in stalling cover l Work Cable and Clamp Replacement 1 Remove right side...

Page 45: ...Resistor R1 Damping Resistor A 02143 Figure 5 21 Pilot Resistor R1 Replacement 3 Using a phillips screwdriver remove the two screws securing the Pilot and Damping Resistors to the internal frame 4 Pu...

Page 46: ...ow Plain Wire Striped Wire A 02575 Compressor Side Figure 5 23 Starting Capacitor Wiring 5 12 Torch and Leads Replacement Procedure 1 Remove right panel of Power Supply per paragraph D above 2 Locate...

Page 47: ...NING NEVER touch any internal torch parts while the AC indicator light on the top panel is lighted A Removing Torch Head 1 Remove the six screws from the torch handle assem bly Pull the cover off the...

Page 48: ...t holder Damage to holder and or PIP pin recep tacles may occur 3 Install replacement PIP pin assemblies by position ing the square solder post of the PIP pin receptacle in the retention slot in the s...

Page 49: ...not to damage the wires 2 Carefully solder the wire s to the terminals on the replacement torch switch Torch Switch PIP Pin PIP Pin Shield Cup To Control Cable Wiring Butt Splice A 00784 Figure 5 32...

Page 50: ...SECTION 5 SERVICE 44 Manual 0 2729...

Page 51: ...Parts Section 6 06 Options And Accessories Section 6 07 Torch Spare Parts Kit NOTE Partslistedwithoutitemnumbersarenotillustrated but may be ordered by the catalog numbers shown B Returns If a product...

Page 52: ...12 1 ON OFF Switch 8 4248 13 1 Capacitor PC Board Assembly 9 4607 14 1 Pilot Resistor R1 15 ohms 55W 9 6323 15 1 Work Cable 20 ft 6 m with Clamp 9 6596 16 1 Input Power Cable 9 5ft 2 9 m 9 7951 17 1...

Page 53: ...Manual 0 2729 47 SECTION 6 PARTS LISTS 1 2 3 4 5 6 7 9 10 11 14 12 13 17 18 19 21 8 22 23 24 25 28 26 27 20 A 02302 R1 R1 R3 R3...

Page 54: ...h Leads Spare Parts Kit Input and Ground Cables 70 Torch with 25 ft 7 6 m Leads 1 8800 90 Torch with 25 ft 7 6 m Leads 1 8801 180 Torch with 25 ft 7 6 m Leads 1 8802 Power Supply Australia Only 3 8801...

Page 55: ...PCH25 38 90 9 5808 1 Assembly Basic Head PCH25 38 180 9 5809 5 1 Distributor Gas 9 6507 6 1 Tip Air 0 031 Orifice Drag Cutting 9 6501 7 1 Electrode Air 9 6506 8 1 ShieldCup 9 6003 9 1 Handle Split PCH...

Page 56: ...log 1 Circle Guide 7 3291 1 Cutting Guide Kit 7 8910 6 07 Torch Spare Parts Kit Qty Description Catalog 1 Spare Parts Kit PCH 25 38 includes 5 3800 5 Tip Air 0 031 Orifice Drag Cutting 9 6501 3 Electr...

Page 57: ...Power Cord RESULT No power to system ACTION Plug in Power Cord RESULT Power to system ACTION Torch moved away from work while still activated RESULT Main arc stops Pilot arc auto matically restarts P...

Page 58: ...APPENDICES 52 Manual 0 2699 APPENDIX II SYSYTEM SCHEMATIC A 02576...

Page 59: ...Manual 0 2699 53 APPENDICES A 02576...

Page 60: ...16 85 140 208 drag 1 8 1 8 25 55 85 drag 1 8 3 16 15 30 55 drag 1 16 1 4 8 16 27 drag 1 16 3 8 na 10 14 drag 1 16 Stainless Steel 24 Gauge 150 310 385 drag 1 8 1 16 40 80 115 drag 1 8 1 8 25 44 70 dr...

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