Thermal Dynamics DRAG-GUN 38 Скачать руководство пользователя страница 8

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 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 the 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 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

Содержание DRAG-GUN 38

Страница 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...

Страница 2: ......

Страница 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...

Страница 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...

Страница 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...

Страница 6: ......

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

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

Страница 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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