ESAB DRAG-GUN™ Plasma Cutter with Built-In Air Manuel utilisateur

Marque: ESAB

Modèle: DRAG-GUN™ Plasma Cutter with Built-In Air

Catégorie: Système de soudage

Taper: Manuel utilisateur

Manual No. 0-2738

July 30, 1999

Service Manual

Includes:

• 12 Amp Power Supply

• PCH-10 Torch with Leads

• Work Cable with Clamp

• Input Cable with Plug

For Model: 220 VAC 50Hz

FOR AUSTRALIA

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 our

best judgement, Thermal Dynamics Corporation assumes no

liability for its use.

DRAG-GUN Plasma Cutter With Built-In Air For Australia

Service Manual Number 0-2738

Published by:

Thermal Dynamics Corporation

Industrial Park No. 2

West Lebanon, New Hampshire, USA 03784

(603) 298-5711

Thermal Dynamics Corporation

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 liabil-

ity to any party for any loss or damage caused by any error or

omission in the DRAG-GUN Plasma Cutter Service Manual,

whether such error results from negligence, accident, or any

other cause.

Printed in the United States of America

July 30, 1999

WARNING

TABLE OF CONTENTS

1: GENERAL INFORMATION ..............................................................................................................1

1.1 Notes, Cautions and Warnings ........................................................................................1

1.2 Important Safety Precautions ..........................................................................................1

1.3 Publications ....................................................................................................................2

1.4 Note, Attention et Avertissement......................................................................................3

1.5 Precautions De Securite Importantes...............................................................................3

1.6 Documents De Reference.................................................................................................5

1.7 Statement of Warranty ....................................................................................................7

2.0: INTRODUCTION ....................................................................................................................... 11

2.1 Scope Of Manual ...........................................................................................................11

2.2 General Service Philosophy............................................................................................11

2.3 Service Responsibilities ................................................................................................. 11

2.4 Technical Specifications ................................................................................................11

2.5 Dimensions ................................................................................................................... 12

3.0: SERVICE TROUBLESHOOTING ................................................................................................ 12

3.1 Introduction.................................................................................................................. 12

3.2 Periodic Inspection & Maintenance ................................................................................ 12

3.3 Common Cutting Faults ................................................................................................ 12

3.4 Common Operating Problems ........................................................................................13

3.5 Troubleshooting Guide .................................................................................................. 13

3.6 Torch & Leads Troubleshooting ..................................................................................... 16

4.0: REPAIRS & REPLACEMENT PROCEDURES .............................................................................. 17

4.1 General Information ...................................................................................................... 17

4.2 Removing Cover/Handle................................................................................................17

4.3 Torch Head Assembly Replacement ...............................................................................17

4.4 Torch Switch Only Replacement ....................................................................................18

4.5 Air Compressor Replacement......................................................................................... 19

4.6 Capacitor Replacement.................................................................................................. 20

4.7 Control PC Board Replacement...................................................................................... 20

4.8 Power Relay Replacement .............................................................................................. 20

4.9 ON/OFF Power Switch Replacement.............................................................................. 21

4.10 Fan Replacement.........................................................................................................21

4.11 Diode Bridge Rectifier Replacement ............................................................................. 22

4.12 Resistor Replacement ..................................................................................................22

4.13 Transformer/Ferrite Core Assembly Replacement ........................................................ 22

4.14 Torch & Leads Replacement ........................................................................................ 22

4.15 Work Cable Replacement .............................................................................................23

4.16 Primary Input Power Cable Replacement ..................................................................... 23

5.0 PARTS LIST ...............................................................................................................................25

5.1 Returns ........................................................................................................................ 25

5.2 Parts Replacement ........................................................................................................ 26

5.3 Power Supply Replacement Parts................................................................................... 26

5.4 Options & Accessories ...................................................................................................26

5.5 Torch Replacement Parts................................................................................................ 28

APPENDIX I: INTERCONNECTING DIAGRAM ................................................................................... 29

APPENDIX II: INTERCONNECTING DIAGRAM ..................................................................................30

6/22/99 (Special) 1 GENERAL INFORMATION

1: GENERAL

INFORMATION

1.1 Notes, Cautions and Warnings

Throughout this manual, notes, cautions, and warnings

are used to highlight important information. These high-

lights are categorized as follows:

NOTE

An operation, procedure, or background informa-

tion which requires additional emphasis or is help-

ful in efficient operation of the system.

CAUTION

A procedure which, if not properly followed, may

cause damage to the equipment.

WARNING

A procedure which, if not properly followed, may

cause injury to the operator or others in the oper-

ating area.

1.2 Important Safety Precautions

WARNING

OPERATION AND MAINTENANCE OF

PLASMA ARC EQUIPMENT CAN BE DAN-

GEROUS AND HAZARDOUS TO YOUR

HEALTH.

Plasma arc cutting produces intense electric and

magnetic emissions that may interfere with the

proper function of cardiac pacemakers, hearing

aids, or other electronic health equipment. Per-

sons who work near plasma arc cutting applica-

tions should consult their medical health profes-

sional and the manufacturer of the health

equipment to determine whether a hazard exists.

To prevent possible injury, read, understand and

follow all warnings, safety precautions and in-

structions before using the equipment. Call 1-603-

298-5711 or your local distributor if you have any

questions.

GASES AND FUMES

Gases and fumes produced during the plasma cutting

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

adequate to remove all fumes and gases.

• The kinds of fumes and gases from the plasma arc

depend on the kind of metal being used, coatings

on the metal, and the different processes. You must

be very careful when cutting or welding any met-

als which may contain one or more of the follow-

ing:

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 material you are

using. These MSDSs will give you the information

regarding 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 Subsection

1.3, Publications in this manual.

• Use special equipment, such as water or down draft

cutting tables, to capture fumes and gases.

• Do not use the plasma torch in an area where com-

bustible or explosive gases or materials are located.

• Phosgene, a toxic gas, is generated from the vapors

of chlorinated solvents and cleansers. Remove all

sources of these vapors.

ELECTRIC SHOCK

Electric Shock can injure or kill. The plasma arc process

uses and produces high voltage electrical energy. This

electric energy can cause severe or fatal shock to the op-

erator 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 welding cir-

cuit.

• Repair or replace all worn or damaged parts.

• Extra care must be taken when the workplace is

moist or damp.

GENERAL INFORMATION 2 6/22/99 (Special)

• Install and maintain equipment according to NEC

code, refer to item 9 in Subsection 1.3, Publications.

• Disconnect power source before performing any ser-

vice 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 mate-

rial 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 1.3, 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.

1.3 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

Documents, U.S. Government Printing Office, Wash-

ington, D.C. 20402

2. ANSI Standard Z49.1, SAFETY IN WELDING AND

CUTTING, obtainable from the American Welding

Society, 550 N.W. LeJeune Rd, Miami, FL 33126

3. NIOSH, SAFETY AND HEALTH IN ARC WELD-

ING AND GAS WELDING AND CUTTING, obtain-

able from the Superintendent of Documents, U.S.

Government Printing Office, Washington, D.C. 20402

4. ANSI Standard Z87.1, SAFE PRACTICES FOR OC-

CUPATION AND EDUCATIONAL EYE AND FACE

PROTECTION, obtainable from American National

Standards Institute, 1430 Broadway, New York, NY

10018

5. ANSI Standard Z41.1, STANDARD FOR MEN’S

SAFETY-TOE FOOTWEAR, obtainable from the

American National Standards Institute, 1430 Broad-

way, New York, NY 10018

6. ANSI Standard Z49.2, FIRE PREVENTION IN THE

USE OF CUTTING AND WELDING PROCESSES,

obtainable from American National Standards Insti-

tute, 1430 Broadway, New York, NY 10018

7. AWS Standard A6.0, WELDING AND CUTTING

CONTAINERS WHICH HAVE HELD COMBUS-

TIBLES, obtainable from American Welding Society,

550 N.W. LeJeune Rd, Miami, FL 33126

6/22/99 (Special) 3 GENERAL INFORMATION

8. NFPA Standard 51, OXYGEN-FUEL GAS SYSTEMS

FOR WELDING, CUTTING AND ALLIED PRO-

CESSES, obtainable from the National Fire Protection

Association, Batterymarch Park, Quincy, MA 02269

9. NFPA Standard 70, NATIONAL ELECTRICAL CODE,

obtainable from the National Fire Protection Asso-

ciation, Batterymarch Park, Quincy, MA 02269

10. NFPA Standard 51B, CUTTING AND WELDING

PROCESSES, obtainable from the National Fire Pro-

tection Association, Batterymarch Park, Quincy, MA

02269

11. CGA Pamphlet P-1, SAFE HANDLING OF COM-

PRESSED GASES IN CYLINDERS, obtainable from

the Compressed Gas Association, 1235 Jefferson

Davis Highway, Suite 501, Arlington, VA 22202

12. CSA Standard W117.2, CODE FOR SAFETY IN

WELDING AND CUTTING, obtainable from the Ca-

nadian Standards Association, Standards Sales, 178

Rexdale Boulevard, Rexdale, Ontario, Canada M9W

1R3

13. NWSA booklet, WELDING SAFETY BIBLIOGRA-

PHY obtainable from the National Welding Supply

Association, 1900 Arch Street, Philadelphia, PA 19103

14. American Welding Society Standard AWSF4.1, REC-

OMMENDED SAFE PRACTICES FOR THE PREPA-

RATION FOR WELDING AND CUTTING OF CON-

TAINERS AND PIPING THAT HAVE HELD

HAZARDOUS SUBSTANCES, obtainable from the

American Welding Society, 550 N.W. LeJeune Rd,

Miami, FL 33126

15. ANSI Standard Z88.2, PRACTICE FOR RESPIRA-

TORY PROTECTION, obtainable from American

National Standards Institute, 1430 Broadway, New

York, NY 10018

1.4 Note, Attention et Avertissement

Dans ce manuel, les mots “note,” “attention,” et

“avertissement” sont utilisés pour mettre en relief des

informations à caractère important. Ces mises en relief

sont classifiées comme suit :

NOTE

Toute opération, procédure ou renseignement

général sur lequel il importe d’insister davantage

ou qui contribue à l’efficacité de fonctionnement

du système.

ATTENTION

Toute procédure pouvant résulter

l’endommagement du matériel en cas de non-

respect de la procédure en question.

AVERTISSEMENT

Toute procédure pouvant provoquer des blessures

de l’opérateur ou des autres personnes se trouvant

dans la zone de travail en cas de non-respect de la

procédure en question.

1.5 Precautions De Securite

Importantes

AVERTISSEMENT

L’OPÉRATION ET LA MAINTENANCE DU

MATÉRIEL DE SOUDAGE À L’ARC AU JET

DE PLASMA PEUVENT PRÉSENTER DES

RISQUES ET DES DANGERS DE SANTÉ.

Coupant à l’arc au jet de plasma produit de l’énergie

électrique haute tension et des émissions

magnétique qui peuvent interférer la fonction

propre d’un “pacemaker” cardiaque, les appareils

auditif, ou autre matériel de santé electronique.

Ceux qui travail près d’une application à l’arc au

jet de plasma devrait consulter leur membre

professionel de médication et le manufacturier de

matériel de santé pour déterminer s’il existe des

risques de santé.

Il faut communiquer aux opérateurs et au person-

nel TOUS les dangers possibles. Afin d’éviter les

blessures possibles, lisez, comprenez et suivez tous

les avertissements, toutes les précautions de sécurité

et toutes les consignes avant d’utiliser le matériel.

Composez le + 603-298-5711 ou votre distributeur

local si vous avez des questions.

FUMÉE et GAZ

La fumée et les gaz produits par le procédé de jet de

plasma peuvent présenter des risques et des dangers de

santé.

• Eloignez toute fumée et gaz de votre zone de respi-

ration. Gardez votre tête hors de la plume de fumée

provenant du chalumeau.

• Utilisez un appareil respiratoire à alimentation en

air si l’aération fournie ne permet pas d’éliminer la

fumée et les gaz.

GENERAL INFORMATION 4 6/22/99 (Special)

• Les sortes de gaz et de fumée provenant de l’arc de

plasma dépendent du genre de métal utilisé, des

revêtements se trouvant sur le métal et des différents

procédés. Vous devez prendre soin lorsque vous

coupez ou soudez tout métal pouvant contenir un

ou plusieurs des éléments suivants:

antimoine cadmium mercure

argent chrome nickel

arsenic cobalt plomb

baryum cuivre sélénium

béryllium manganèse vanadium

• Lisez toujours les fiches de données sur la sécurité

des matières (sigle américain “MSDS”); celles-ci

devraient être fournies avec le matériel que vous

utilisez. Les MSDS contiennent des renseignements

quant à la quantité et la nature de la fumée et des

gaz pouvant poser des dangers de santé.

• Pour des informations sur la manière de tester la

fumée et les gaz de votre lieu de travail, consultez

l’article 1 et les documents cités à la page 4.

• Utilisez un équipement spécial tel que des tables de

coupe à débit d’eau ou à courant descendant pour

capter la fumée et les gaz.

• N’utilisez pas le chalumeau au jet de plasma dans

une zone où se trouvent des matières ou des gaz

combustibles ou explosifs.

• Le phosgène, un gaz toxique, est généré par la fumée

provenant des solvants et des produits de nettoyage

chlorés. Eliminez toute source de telle fumée.

CHOC ELECTRIQUE

Les chocs électriques peuvent blesser ou même tuer. Le

procédé au jet de plasma requiert et produit de l’énergie

électrique haute tension. Cette énergie électrique peut

produire des chocs graves, voire mortels, pour l’opérateur

et les autres personnes sur le lieu de travail.

• Ne touchez jamais une pièce “sous tension” ou

“vive”; portez des gants et des vêtements secs.

Isolez-vous de la pièce de travail ou des autres par-

ties du circuit de soudage.

• Réparez ou remplacez toute pièce usée ou

endommagée.

• Prenez des soins particuliers lorsque la zone de tra-

vail est humide ou moite.

• Montez et maintenez le matériel conformément au

Code électrique national des Etats-Unis. (Voir la

page 4, article 9.)

• Débranchez l’alimentation électrique avant tout tra-

vail d’entretien ou de réparation.

• Lisez et respectez toutes les consignes du Manuel

de consignes.

INCENDIE ET EXPLOSION

Les incendies et les explosions peuvent résulter des scories

chaudes, des étincelles ou de l’arc de plasma. Le procédé

à l’arc de plasma produit du métal, des étincelles, des

scories chaudes pouvant mettre le feu aux matières com-

bustibles ou provoquer l’explosion de fumées

inflammables.

• Soyez certain qu’aucune matière combustible ou in-

flammable ne se trouve sur le lieu de travail.

Protégez toute telle matière qu’il est impossible de

retirer de la zone de travail.

• Procurez une bonne aération de toutes les fumées

inflammables ou explosives.

• Ne coupez pas et ne soudez pas les conteneurs ayant

pu renfermer des matières combustibles.

• Prévoyez une veille d’incendie lors de tout travail

dans une zone présentant des dangers d’incendie.

• Le gas hydrogène peut se former ou s’accumuler

sous les pièces de travail en aluminium lorsqu’elles

sont coupées sous l’eau ou sur une table d’eau. NE

PAS couper les alliages en aluminium sous l’eau ou

sur une table d’eau à moins que le gas hydrogène

peut s’échapper ou se dissiper. Le gas hydrogène

accumulé explosera si enflammé.

RAYONS D’ARC DE PLASMA

Les rayons provenant de l’arc de plasma peuvent blesser

vos yeux et brûler votre peau. Le procédé à l’arc de plasma

produit une lumière infra-rouge et des rayons ultra-vio-

lets 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 de soudeur. Portez toujours des lunettes

de sécurité munies de parois latérales ou des lu-

nettes de protection ou une autre sorte de protec-

tion oculaire.

• Portez des gants de soudeur et un vêtement

protecteur approprié pour protéger votre peau

contre les étincelles et les rayons de l’arc.

• Maintenez votre casque et vos lunettes de protec-

tion en bon état. Remplacez toute lentille sale ou

comportant fissure ou rognure.

• Protégez les autres personnes se trouvant sur la zone

de travail contre les rayons de l’arc en fournissant

des cabines ou des écrans de protection.

6/22/99 (Special) 5 GENERAL INFORMATION

• Use the shade of lens as suggested in the following

chart per ANSI/ASC Z49.1:

• Utilisez la nuance de lentille qui est suggèrée dans

le recommendation qui suivent ANSI/ASC Z49.1:

Nuance Minimum Nuance Suggerée

Courant Arc Protective Numéro Numéro

Moins de 300* 8 9

300 - 400* 9 12

400 - 800* 10 14

* Ces valeurs s’appliquent ou l’arc actuel est observé

clairement. L’experience a démontrer que les filtres

moins foncés peuvent être utilisés quand l’arc est

caché par moiceau de travail.

BRUIT

Le bruit peut provoquer une perte permanente de l’ouïe.

Les procédés de soudage à l’arc de plasma peuvent

provoquer des niveaux sonores supérieurs aux limites

normalement acceptables. Vous dú4ez vous protéger les

oreilles contre les bruits forts afin d’éviter une perte

permanente de l’ouïe.

• Pour protéger votre ouïe contre les bruits forts, portez

des tampons protecteurs et/ou des protections

auriculaires. Protégez également les autres

personnes se trouvant sur le lieu de travail.

• Il faut mesurer les niveaux sonores afin d’assurer

que les décibels (le bruit) ne dépassent pas les

niveaux sûrs.

• Pour des renseignements sur la manière de tester le

bruit, consultez l’article 1, page 5.

1.6 Documents De Reference

Consultez les normes suivantes ou les révisions les plus

récentes ayant été faites à celles-ci pour de plus amples

renseignements :

1. OSHA, NORMES DE SÉCURITÉ DU TRAVAIL ET

DE PROTECTION DE LA SANTÉ, 29CFR 1910,

disponible auprès du Superintendent of Docu-

ments, U.S. Government Printing Office, Washing-

ton, D.C. 20402

2. Norme ANSI Z49.1, LA SÉCURITÉ DES

OPÉRATIONS DE COUPE ET DE SOUDAGE,

disponible auprès de la Société Américaine de

Soudage (American Welding Society), 550 N.W.

LeJeune Rd., Miami, FL 33126

3. NIOSH, LA SÉCURITÉ ET LA SANTÉ LORS DES

OPÉRATIONS DE COUPE ET DE SOUDAGE À

L’ARC ET AU GAZ, disponible auprès du Superin-

tendent of Documents, U.S. Government Printing

Office, Washington, D.C. 20402

4. Norme ANSI Z87.1, PRATIQUES SURES POUR LA

PROTECTION DES YEUX ET DU VISAGE AU

TRAVAIL ET DANS LES ECOLES, disponible de

l’Institut Américain des Normes Nationales (Ameri-

can National Standards Institute), 1430 Broadway,

New York, NY 10018

5. Norme ANSI Z41.1, NORMES POUR LES

CHAUSSURES PROTECTRICES, disponible auprès

de l’American National Standards Institute, 1430

Broadway, New York, NY 10018

6. Norme ANSI Z49.2, PRÉVENTION DES

INCENDIES LORS DE L’EMPLOI DE PROCÉDÉS

DE COUPE ET DE SOUDAGE, disponible auprès

de l’American National Standards Institute, 1430

Broadway, New York, NY 10018

7. Norme A6.0 de l’Association Américaine du

Soudage (AWS), LE SOUDAGE ET LA COUPE DE

CONTENEURS AYANT RENFERMÉ DES

PRODUITS COMBUSTIBLES, disponible auprès de

la American Welding Society, 550 N.W. LeJeune Rd.,

Miami, FL 33126

8. Norme 51 de l’Association Américaine pour la Pro-

tection contre les Incendies (NFPA), LES SYSTEMES

À GAZ AVEC ALIMENTATION EN OXYGENE

POUR LE SOUDAGE, LA COUPE ET LES

PROCÉDÉS ASSOCIÉS, disponible auprès de la Na-

tional Fire Protection Association, Batterymarch

Park, Quincy, MA 02269

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 ET DE SOUDAGE, disponible auprès de

la National Fire Protection Association,

Batterymarch Park, Quincy, MA 02269

11. Brochure GCA P-1, LA MANIPULATION SANS

RISQUE DES GAZ COMPRIMÉS EN CYLINDRES,

disponible auprès de l’Association des Gaz

Comprimés (Compressed Gas Association), 1235

Jefferson Davis Highway, Suite 501, Arlington, VA

22202

12. Norme CSA W117.2, CODE DE SÉCURITÉ POUR

LE SOUDAGE ET LA COUPE, disponible auprès

de l’Association des Normes Canadiennes, Stan-

dards Sales, 178 Rexdale Boulevard, Rexdale,

Ontario, Canada, M9W 1R3

13. ivret NWSA, BIBLIOGRAPHIE SUR LA SÉCURITÉ

DU SOUDAGE, disponible auprès de l’Association

Nationale de Fournitures de Soudage (National

Welding Supply Association), 1900 Arch Street,

Philadelphia, PA 19103

GENERAL INFORMATION 6 6/22/99 (Special)

14. Norme AWSF4.1 de l’Association Américaine de

Soudage, RECOMMANDATIONS DE PRATIQUES

SURES POUR LA PRÉPARATION À LA COUPE ET

AU SOUDAGE DE CONTENEURS ET TUYAUX

AYANT RENFERMÉ DES PRODUITS

DANGEREUX , disponible auprès de la American

Welding Society, 550 N.W. LeJeune Rd., Miami, FL

33126

15. Norme ANSI Z88.2, PRATIQUES DE PROTEC-

TION RESPIRATOIRE, disponible auprès de

l’American National Standards Institute, 1430

Broadway, New York, NY 10018

6/22/99 (Special) 7 GENERAL INFORMATION

1.7 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 failure to conform to this warranty appear within the time period applicable to the Thermal

products as stated below, Thermal shall, upon notification thereof and substantiation that the product has been stored, installed, operated,

and maintained in accordance with Thermal’s specifications, instructions, recommendations and recognized standard industry practice,

and not subject to misuse, repair, neglect, alteration, or accident, correct such defects by suitable repair or replacement, at Thermal’s sole

option, of any components or parts of the product determined by Thermal to be defective.

THIS WARRANTY IS EXCLUSIVE AND IS IN LIEU OF ANY WARRANTY OF MERCHANTABILITY OR FITNESS FOR A

PARTICULAR PURPOSE.

LIMITATION OF LIABILITY: Thermal shall not under any circumstances be liable for special or consequential damages, such as, but

not limited to, damage or loss of purchased or replacement goods, or claims of customers of distributor (hereinafter “Purchaser”) for

service interruption. The remedies of the Purchaser set forth herein are exclusive and the liability of Thermal 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 any goods covered by or furnished by Thermal 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 such liability is based.

THIS WARRANTY BECOMES INVALID IF REPLACEMENT PARTS OR ACCESSORIES ARE USED WHICH MAY IMPAIR THE

SAFETY OR PERFORMANCE OF ANY THERMAL PRODUCT.

THIS WARRANTY IS INVALID IF THE PRODUCT IS SOLD BY NON-AUTHORIZED PERSONS.

The limited warranty periods for Thermal products shall be as follows (with the exception of XL Plus Series, CutMaster 80XL , 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 sale by such distributor to the Purchaser, and with the further limitations on such two (2) year period (see chart below).

The limited warranty period for XL Plus Series and CutMaster 80XL shall be as follows: A maximum of four (4) years from date

of sale to an authorized distributor and a maximum of three (3) years from date of sale by such distributor to the Purchaser, and

with the further limitations on such three (3) year period (see chart below).

The limited warranty period for Cougar and DRAG-GUN shall be as follows: A maximum of two (2) years from date of sale to an

authorized distributor and a maximum of one (1) year from date of sale by such distributor to the Purchaser, and with the further

limitations on such two (2) year period (see chart below).

Parts

XL Plus Series & Parts Parts

PAK Units, Power Supplies CutMaster 80XL Cougar/Drag-Gun All Others Labor

Main Power Magnetics 3 Years 1 Year 2 Years 1 Year

Original Main Power Rectifier 3 Years 1 Year 2 Years 1 Year

Control PC Board 3 Years 1 Year 2 Years 1 Year

All Other Circuits And Components Including, 1 Year 1 Year 1 Year 1 Year

But Not Limited To, Starting Circuit,

Contactors, Relays, Solenoids, Pumps,

Power Switching Semi-Conductors

Consoles, Control Equipment, Heat 1 Year 1 Year 1 Year

Exchanges, And Accessory Equipment

Torch And Leads

Maximizer 300 Torch 1 Year 1 Year

All Other Torches 180 Days 180 Days 180 Days 180 Days

Repair/Replacement Parts 90 Days 90 Days 90 Days None

Warranty repairs or replacement claims under this limited warranty must be submitted by an authorized Thermal Dynamics® repair

facility within thirty (30) days of the repair. No transportation costs of any kind will be paid under this warranty. Transportation

charges to send products to an authorized warranty repair facility shall be the responsibility of the customer. All returned goods shall

be at the customer’s risk and expense. This warranty supersedes all previous Thermal warranties.

Effective May 6, 1999

GENERAL INFORMATION 8 6/22/99 (Special)

Service Manual 0-2738 9 DRAG-GUN Plasma Cutter (Australia)

2.3 Service Responsibilities2.3 Service Responsibilities

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 pro-

vide the most efficient layout, utilizing the equipment to

its best possible advantage.

Maintenance work should be accomplished in a timely

manner. If problems are encountered, or the equipment

does not function as specified, contact Technical Services

Department in West Lebanon for assistance.

2.4 T2.4 T

2.4 T

echnical Specificationsechnical Specifications

echnical Specifications

A. System SpecificationsA. System Specifications

A. System Specifications

System Specifications

Input Power 220VAC ±10%,50Hz, Single Phase, 13

Output Power 12 Amps @ 85 vdc Output Volts

Duty Cycle 30%

Maximum OCV 280 VDC

Pilot Circuitry Capacitive Discharge (CD), Constant DC

Weight with Leads 55 lbs (24.9 kg)

Power Supply L 16 in. (406 mm)

Dimensions W 9 in. (229 mm)

H 10 in. (254 mm)

Work Cable 15 ft. (4.6 m)

Input Power Cable 6.6 ft. (2 m) minimum

Torch Style PCH-10 70°

PCH-10 180°

Torch Dimensions L 7.98 in. (203 mm)

W 2.95 in. (75 mm)

Cutting Rating 12 Amps Max. Straight Polarity

Cut Capacity Most metals up to 1/8 in. (3.2 mm) max.

Severance Most metals up to 3/16 in. (4.8 mm)

Pierce Rating 1/16 in. (1.6 mm)

Transfer Distance Approx. 1/8 in. (3.2 mm)

Gas Requirements Compressed Air (Built-in)

Leads Length 20 ft. (6.1m)

2.0: INTRODUCTION2.0: INTRODUCTION

2.0: INTRODUCTION

2.1 Scope Of Manual2.1 Scope Of Manual

2.1 Scope Of Manual

This manual provides service instructions for the Ther-

mal Dynamics® DRAG-GUN Plasma Cutter (for Austra-

lia).

Information in this edition is particularly applicable to

the Troubleshooting and Repair of the equipment, and is

intended for use by properly trained Service Technicians

familiar with this equipment.

Read this manual and the DRAG-GUN Operating

Manual, 0-2737, thoroughly. A complete understanding

of the capabilities and functions of the equipment will

assure obtaining the performance for which it was de-

signed.

2.2 General Service Philosophy2.2 General Service Philosophy

2.2 General Service Philosophy

Several key points are essential to properly support the

application and operation of this equipment.

A. ApplicationA. Application

A. Application

The equipment should satisfy the customer’s require-

ments as supplied and as described in Section 3 of this

manual. Be sure to confirm that the equipment is capable

of the application desired.

B. ModificationsB. Modifications

B. Modifications

No physical or electrical modifications other than selec-

tion of standard options and accessories are to be made

to this equipment.

C. Customer/Operator ResponsibilitiesC. Customer/Operator Responsibilities

C. Customer/Operator Responsibilities

It is the customer/operator's responsibility to maintain

the equipment and peripheral accessories provided by

Thermal Dynamics in good operating order in accordance

with the procedures outlined in the Operating Manual,

and to protect the equipment from accidental or mali-

cious damage.

D. Repair RestrictionsD. Repair Restrictions

D. Repair Restrictions

The electronics consists of a Printed Circuit Board Assem-

bly which must be carefully handled, and must be re-

placed as a unit. No replacement of printed circuit sol-

der-mounted components is allowed except as noted in

this manual. If PC Board is to be returned, the replaced

Printed Circuit Board Assembly must be properly pack-

aged in protective material and returned intact per nor-

mal procedures.

DRAG-GUN Plasma Cutter (Australia) 10 Service Manual 0-2738

2.5 Dimensions2.5 Dimensions

2.5 Dimensions

16.0 in

(406 mm)

9.0 in

(229 mm)

10.0 in.

(254 mm)

A-02004

Figure 2-1 Power Supply Dimensions

8 in (203 mm)

1.1 in (27 mm)

2.9 in

(75 mm)

8.9 in (226 mm)

1.1 in

(27 mm)

A-02385

180˚

70˚

Figure 2-4 Torch Dimensions

3.0: SER3.0: SER

3.0: SER

VICEVICE

VICE

TROUBLESHOOTINGTROUBLESHOOTING

TROUBLESHOOTING

3.1 Intr3.1 Intr

3.1 Intr

oductionoduction

oduction

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 field repairs to be attempted

on Printed Circuit Boards or other subassemblies of this

unit. Evidence of unauthorized repairs will void the fac-

tory warranty.

WARNING

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 troubleshoot-

ing techniques.

3.2 Periodic Inspection &3.2 Periodic Inspection &

3.2 Periodic Inspection &

MaintenanceMaintenance

Maintenance

The DRAG-GUN Operating Manual 0-2737(for Austra-

lia), describes the inspection and maintenance procedures

which should be performed at periodic intervals. Rou-

tine Maintenance ensures optimum performance of

equipment and can prevent the user from encountering

problems with this equipment. Refer to that manual for

instructions on power supply and torch maintenance.

3.3 Common Cutting Faults3.3 Common Cutting Faults

3.3 Common Cutting Faults

Poor or lackluster performance can often be improved

by slight modifications to technique or equipment. For

example:

A. InsufA. Insuf

A. Insuf

ficient Penetrationficient Penetration

ficient Penetration

1. Cutting speed too fast

2. Torch tilted too much

3. Metal too thick

4. Worn torch parts

5. Standoff too high

6. Line voltage too low

7. Extension cord with inadequate rating

B. Main ArB. Main Ar

B. Main Ar

c Extinguishesc Extinguishes

c Extinguishes

1. Cutting speed too slow

2. Torch standoff too high from workpiece

3. Work cable disconnected

4. Worn torch parts

C. Excessive DrC. Excessive Dr

C. Excessive Dr

oss Foross For

oss For

mationmation

mation

1. Cutting speed too slow

2. Torch standoff too high from workpiece

3. Worn torch parts

Service Manual 0-2738 11 DRAG-GUN Plasma Cutter (Australia)

D. Short TD. Short T

D. Short T

oror

ch Parts Lifech Parts Life

ch Parts Life

1. Exceeding system capability (material too thick)

2. Excessive pilot arc time

3. Improperly assembled torch

4. Inadequate air supply (check filter on Compressor)

5. Faulty Air Compressor

6. Ground or work lead not connected

3.4 Common Operating3.4 Common Operating

3.4 Common Operating

PrPr

oblemsoblems

oblems

Getting used to the way the system sounds and feels while

it is operating properly will help to determine the nature

of problems if they arise.

A. ComprA. Compr

A. Compr

essor Relatedessor Related

essor Related

If the unit is cold, the Air Compressor may not start up or

may run sluggishly. Most likely, when the torch switch is

depressed, the unit will click once and nothing more will

happen. Let the unit warm up to room temperature ap-

proximately over 50° F(10° C ) and try again.

If the air filter on the compressor becomes clogged, the

compressor may sound more labored, cut speed and qual-

ity will be reduced, and the arc may have a more green

color. The air filter element can be cleaned - remove it,

blow air through it, then reinstall it.

B. Power SourB. Power Sour

B. Power Sour

ce Relatedce Related

ce Related

If the 220V service available is saggy, pilot and cut per-

formance will be degraded. In some cases, the service cir-

cuit breaker may open during use. Some things that will

help:

• Use a service fused or circuit breaker for 20 amps.

• Use heavy gauge extension cords (Refer to Operat-

ing Manual 0-2737, subsection 4.0-D for extension

cord sizes).

• Use as short an extension cord as possible.

• Try different outlets on different branch circuits. Use

the one that gives the strongest pilot.

C. Power Supply/TC. Power Supply/T

C. Power Supply/T

oror

ch Relatedch Related

ch Related

In some instances when the torch switch is pressed there

is no pilot. You may need to try several times before the

torch fires.

If the torch does not fire (no pilot arc) soon after the torch

switch is activated, try releasing the torch switch and let-

ting the leads bleed down before trying again. This should

help because the torch fires best at a lower voltage with

lower air pressure at the torch.

D. Cutting RelatedD. Cutting Related

D. Cutting Related

1. Piloting

One of the features of this plasma cutter is the con-

stant DC pilot. This means the plasma arc is always

“on”- either as a pilot arc, or a cutting arc, resulting in

a very smooth, forgiving system. This also means that

the torch tip will wear fairly rapidly if you pilot for

an extended time or cut with too great a standoff (es-

sentially switching from a transferred cutting arc back

to the constant DC pilot arc).

The best way to prevent this is to pilot for no more

than 5 seconds at a time (or start with the torch in

contact with the material) and “drag cut”, that is, hold

the tip in direct contact with the material to be cut.

For some materials, holding a slight standoff (1/

16")(1.6 mm) may provide a better cut.

NOTE

Piloting is harder on parts life than actual cutting

because the pilot arc is directed from the electrode

to the tip rather than to a workpiece. Whenever

possible, avoid excessive pilot arc time to improve

parts life.

2. Torch Standoff

Improper standoff (the distance between the torch tip

and workpiece) can adversely affect tip life as well as

shield cup life. Reducing standoff will generally re-

sult in a more square cut.

NOTE

Although the DRAG-GUN will cut using stand-

off, this unit is primarily a drag-cutting machine.

3.5 T3.5 T

3.5 T

oubleshooting Guideoubleshooting Guide

oubleshooting Guide

A. GeneralA. General

A. General

The troubleshooting covered in this Service Manual re-

quires power supply disassembly and live measurements.

Troubleshooting and repairing this unit is a process which

should be undertaken only by those familiar with high

voltage high power electronic equipment.

WARNING

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 troubleshoot-

ing techniques.

DRAG-GUN Plasma Cutter (Australia) 12 Service Manual 0-2738

B. How TB. How T

B. How T

o Use This Guideo Use This Guide

o Use This Guide

The following information is a guide to help determine

the most likely causes for various symptoms. The guide

is set up in the following manner:

X. Symptom (Bold Type)

1. Cause (Italic Type)

a. Check/Remedy (Test Type)

Locate your symptom, check causes (easiest is usually

first; sometimes the order is important, if noted), then

remedies. Repair as needed being sure to verify that the

unit is fully operational after any repairs.

C. No PowerC. No Power

C. No Power

, AC switch on, amber, AC switch on, amber

, AC switch on, amber

indicator dark, no fan.indicator dark, no fan.

indicator dark, no fan.

1. No power from wall unit.

a. Test electrical outlet with voltmeter or some

other known good load (trouble light, hand

drill, etc).

If AC line voltage is present, go to the next step.

If AC line voltage is not present, replace fuse

or reset circuit breaker.

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 subsection

C3.

If AC line voltage is not present, replace power

cord.

3. Power switch faulty.

a. Confirm with voltmeter if AC line voltage is

present at main capacitor terminals when

power switch is on.

If AC line voltage is not present, replace power

switch.

D. Power OK, service cirD. Power OK, service cir

D. Power OK, service cir

cuit brcuit br

cuit br

eaker oreaker or

eaker or

fuse opens after the power switch isfuse opens after the power switch is

fuse opens after the power switch is

switched on.switched on.

switched on.

NOTE

Proceed with troubleshooting for these components

in order:

1. Faulty Fan.

a. Disconnect the Fan and insulate the two wires

going to the Fan with tape (separately), then

reapply power.

If the circuit breaker or fuse opens after the

power switch is switched on, go to next step.

If the circuit breaker or fuse is okay, replace

Fan.

2. Faulty Transformer Assembly or Capacitor.

a. With the Fan still disconnected, disconnect two

leads from the transformer that are connected

to the Capacitor (C13) , then apply power.

If the circuit breaker or fuse opens after power

is applied, the Capacitor is shorted. Replace

Capacitor (C13).

If the circuit breaker or fuse is okay, replace

Transformer.

E. Power OK, fan runs, no comprE. Power OK, fan runs, no compr

E. Power OK, fan runs, no compr

essoressor

essor

operation or pilot when toroperation or pilot when tor

operation or pilot when tor

ch switchch switch

ch switch

prpr

essed.essed.

essed.

1. Shield cup loose, PIP not making contact.

a. Reseat the torch parts, tighten shield cup.

2. Unit overtemp.

a. Leave power on so fan can cool unit, test again

after 10 min.

3. Shorted torch parts.

a. Replace torch consumables.

4. Torch switch may have broken or shorted wires.

a. Refer to subsection 3.6, Torch and Leads Trouble-

shooting.

5. Overheated or faulty Compressor.

a. Press the torch switch. If a clicking can be heard

and/or the Relay is actuating (test button on

side pulls in), the Compressor motor may have

failed or overheated. If the Case of the Com-

pressor motor feels very warm, allow it to cool

and try again. The Compressor has its own

overtemp cutout switch.

Service Manual 0-2738 13 DRAG-GUN Plasma Cutter (Australia)

If the unit fails to operate once it has cooled

down, replace the compressor.

6. Shorted Bridge Rectifier (BR2)

a. If the Rectifier (upper) is hot and the Trans-

former is buzzing or heating up, the rectifier is

shorted. Replace Rectifier.

7 . Faulty Control PCB or Relay

CAUTION

Be sure torch is directed away from people or haz-

ards. A pilot arc may start!

a. Push the test button on the side of the Relay. If

the Compressor starts and the torch operates,

the PCB or Relay has most likely failed.

The PCB can be isolated by removing the push

on connectors from the Relay coil and measur-

ing the relay coil with an ohmmeter. If the coil

measures between 50 - 100ohms, the Relay is

good and the PCB should be replaced.

If the Compressor runs intermittently and arc-

ing can be seen in the Relay case while the torch

switch is held on, the relay contacts are worn

and the Relay should be replaced.

. Power OK, fan runs, compr. Power OK, fan runs, compr

. Power OK, fan runs, compr

essor runsessor runs

essor runs

interinter

inter

mittently, Relay Case showsmittently, Relay Case shows

mittently, Relay Case shows

arar

cing when the torcing when the tor

cing when the tor

ch switch is heldch switch is held

ch switch is held

on.on.

on.

1. Faulty Relay.

a. If the Compressor runs intermittently and arc-

ing can be seen in the Relay Case while the torch

switch is held on, the relay contacts are worn

and the Relay should be replaced.

G. Power OK, fan runs, ComprG. Power OK, fan runs, Compr

G. Power OK, fan runs, Compr

essor startsessor starts

essor starts

then shuts down as soon as the torthen shuts down as soon as the tor

then shuts down as soon as the tor

chch

switch is prswitch is pr

switch is pr

essed.essed.

essed.

1. Shorted, damaged, or incorrect torch parts.

a. Check that all torch parts are in good condition

and designed for use in the PCH-10 torch.

2. Faulty (open) Voltage Divider Resistor.

a. The voltage divider is the top Resistor. Discon-

nect the push-on connectors and measure the

Resistor with an ohmmeter. It should read 1K

ohms. If measurement is not 1K ohms, replace

Resistor.

3. Shorted Bridge Rectifier (BR1).

a. Probable if a loud hum or buzz is heard from

the main transformer after the Relay actuates.

If hum or buzzing noise exists, replace Bridge

Rectifier. (replace lower Bridge Rectifier, clos-

est to Chassis).

H. Power OK, Fan runs, ComprH. Power OK, Fan runs, Compr

H. Power OK, Fan runs, Compr

essor runs,essor runs,

essor runs,

no pilot or cutting arno pilot or cutting ar

no pilot or cutting ar

c with the torc with the tor

c with the tor

chch

switch prswitch pr

switch pr

essed.essed.

essed.

1. Worn, contaminated, or incorrect torch parts.

a. Check that all torch parts are in good condition

and designed for use in the PCH-10 torch. Re-

place worn parts as necessary.

2. Parts not assembled correctly.

a. Reassemble torch parts.

3. Damaged torch or leads.

a. Check per subsection 3.6, Torch and Leads

Troubleshooting.

4. Faulty Control PCB.

a. Listen for a faint, sharp clicking noise, at about

3-4 clicks/second from the Ferrite Core Assem-

bly. If nothing is heard, the PCB should be re-

placed.

5. Faulty (open) Pilot Resistor.

a. The Pilot Resistor is mounted closest to the chas-

sis. Disconnect the the push on connectors and

measure the resistor with an ohmmeter. It

should read 0.5 ohms (essentially a short).

6. AC input too low.

a. If the AC line is below about 105vac, the torch

may not always start. Try an outlet on a differ-

ent branch circuit.

7. Faulty Ferrite/Transformer Assembly.

a. The Ferrite Transformer Assembly is used to

generate a high voltage pulse to establish the

pilot arc. Troubleshooting is limited to visual

inspection. The two primary connections and

two secondary connections should be checked

for general integrity and snug fit onto the push

on connectors. The Transformer Assembly it-

self should be free of large ferrite chips and

cracks along the core.

DRAG-GUN Plasma Cutter (Australia) 14 Service Manual 0-2738

I. TI. T

I. T

oror

ch pilots but does not cut well.ch pilots but does not cut well.

ch pilots but does not cut well.

1. AC input power too low.

a. Use shortest service from AC outlet to breaker

panel as possible or larger gauge extension cord.

2. Work cable not attached.

a. Check work cable connection.

3. Restricted air flow.

a. Check lead for kinks or pinching restricting air

flow.

4. Loose shield cup.

a. Tighten shield cup.

5. One or more gas distributor holes blocked.

a. Replace Gas Distributor.

6. Excessive parts wear.

a. Inspect torch consumables and replace as nec-

essary.

7. Damaged torch insulator

a. Check insulator between anode and cathode for

charring per subsection 3.6, Torch and Leads

Troubleshooting.

3.6 T3.6 T

3.6 T

oror

ch & Leadsch & Leads

ch & Leads

oubleshootingoubleshooting

oubleshooting

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 the front panel of the power

supply is on.

Torch parts may get quite hot during normal op-

eration. Always wear light cutting gloves when

changing torch parts just after operating the Drag-

Gun system.

A. Checking the Center InsulatorA. Checking the Center Insulator

A. Checking the Center Insulator

The Center Insulator separates the negative and positive

charged sections of the torch. If the center insulator does

not provide adequate resistance, current which is in-

tended for the pilot arc may be dissipated into the torch

head, resulting in torch failure.

1. Remove the shield cup, tip, gas distributor, and elec-

trode from the torch.

Torch Head Assembly

Electrode

Tip

Standard

Shield Cup

Gas

Distributor

PCH-10

A-02007

Figure 3-1 PCH-10 Torch Head Parts Removal

2. Disconnect the torch lead from the power supply to

isolate the torch from power supply circuits. Refer to

Appendix I for Leads connections.

3. Using an ohmmeter (set to 10K or higher), check for

continuity between the electrode seat (negative) and

the brass threads of the torch assembly. Infinite resis-

tance (no continuity) should be found. If there is con-

tinuity between the two, remove the torch head from

the lead and check the torch head separately.

B. Checking TB. Checking T

B. Checking T

oror

ch Leadch Lead

ch Lead

If the torch head assembly is okay, check the torch lead

by measuring the resistance between the positive pilot

lead connector and the negative lead fitting. If continu-

ity is found, the insulation between the torch leads is

breaking down and the torch and leads assembly should

be replaced.

NOTE

The lead cannot be replaced without replacing the

torch assembly as well.

If no continuity is found, check the resistance between

the negative plasma lead fitting and the electrode seat in

torch head. If no continuity is found, replace the torch

and leads assembly.

C. Checking Pilot and Switch ContrC. Checking Pilot and Switch Contr

C. Checking Pilot and Switch Contr

olol

irir

eses

Check the pilot and switch control wires for continuity

from one end of the torch lead to the other. If no continu-

ity exists, replace torch and lead assembly.

Service Manual 0-2738 15 DRAG-GUN Plasma Cutter (Australia)

D. Reassembling TD. Reassembling T

D. Reassembling T

oror

ch and Leadsch and Leads

ch and Leads

Replace parts as required, then recheck the torch head,

and lead connections to confirm proper measurements.

If each component is okay, reassemble torch and leads.

4.0: REP4.0: REP

4.0: REP

AIRS &AIRS &

AIRS &

REPLACEMENTREPLACEMENT

REPLACEMENT

PROCEDURESPROCEDURES

PROCEDURES

4.1 General Infor4.1 General Infor

4.1 General Infor

mationmation

mation

• Failures identified on the Transformer/Inductor/

Chassis Assembly cannot be repaired - the entire

power supply must be replaced. Refer to the Parts

List for the catalog number for a replacement power

supply.

• The torch head, torch switch, and torch & leads as-

sembly are replaceable parts. The torch leads alone

are not serviceable; problems encountered in the leads

will require the torch & leads assembly to be replaced.

• For instructions on replacing the torch & leads, work

cable & clamp, and input power cable, refer to Oper-

ating Manual 0-2737. (Refer to Appendix I, in this

manual, for leads connection diagram.)

• Most replacement hardware can be purchased locally.

• One of two harnesses has been used in this unit. For

units which are rev "C" or earlier, refer to the sche-

matic in Appendix II. For units which are rev "D" or

later, refer to the schematic in Appendix III. Check

the data tag on your unit for the rev level of your unit

and follow instructions in this section where appli-

cable, as they pertain to your unit.

WARNING

Disconnect primary power to the system before dis-

assembling the torch, leads, or power supply.

4.2 Removing Cover/Handle4.2 Removing Cover/Handle

4.2 Removing Cover/Handle

1. Remove 2 screws in handle, 2 screws in end pan-

els, and four screws near base to remove cover and

handle from unit.

NOTE

When replacing cover, make sure all wires are care-

fully positioned so that the wires are not pinched

when the cover and handle are secured.

4.3 T4.3 T

4.3 T

oror

ch Head Assemblych Head Assembly

ch Head Assembly

ReplacementReplacement

Replacement

WARNINGS

Disconnect primary power to the system before dis-

assembling the torch or power supply.

Torch parts may get quite hot during normal op-

eration. Always wear light cutting gloves when

changing torch parts just after operating the Drag-

Gun system.

To Remove Torch Head Assembly:

NOTE

Refer to Figure 4-1 for parts identification.

1. Remove consumable parts from front end of torch.

2. Remove six screws from torch handle assembly (A).

3. Remove both torch handle halves from the torch

and leads assembly , then complete the following:

a. Disconnect positive pilot lead connection at

torch head by removing pilot lead screw (B).

b. Cut tie wrap from torch hose (C).

c. Using X-acto knife or other small cutting tool,

cut torch lead 1" (25.4 mm) from the end of

black sleeve (D) to reveal butt splice.

4. Pull torch head away from torch lead to expose 1/

2"-3/4" (12.7mm -19 mm) of cable.

5. Clamp down with vise grips on black sleeve of

lead so that cable cannot spring back into lead (E).

6. Cut cable at end of butt splice and remove torch

head assembly (F).

7. Remove orange insulating sleeving from torch head

gas input (G). Note: Sleeving is optional. Some

torch assemblies may not have sleeving.

8. Remove torch O-ring from torch split holder (H).

9. Remove the two screws from the torch head split

holder and separate the halves (I).

10. Remove the torch head from the holder. Do not

disturb PIP connections.

DRAG-GUN Plasma Cutter (Australia) 16 Service Manual 0-2738

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-02295

Washer

Figure 4-1 Removing Torch HeadAssembly

To Install Replacement Torch Head Assembly:

NOTE

Refer to Figure 4-2 for parts identification.

1. Place replacement torch head in torch head split

holder halves and secure with 2 screws removed

in step 9 above (K). Do not disturb PIP connec-

tions.

2. Install O-ring removed in step 8 above (L).

3. Optional: Install orange sleeving on replacement

torch head gas input.

4. Place torch head in correct orientation, then insert

lead cable into torch butt slice and crimp (M).

5. Remove vise grips.

6. Lubricate torch head glands lightly with silicone

and push hose back onto barbs up to the point

where the teflon tubing and brass fitting meet (N).

7. Install tie wrap onto hose in correct position (C),

removing any excess.

8. Connect pilot lead to pilot lead terminal by placing

washer between terminal and connector and in-

stalling screw (O).

9. Push pilot lead under cable jacket until there is no

excess.

Install Pilot

Lead Screw

Butt Splice

Insert Cable Into

Butt Splice & Crimp

Install

O-Ring

Install Screws

New Torch Head

Teflon Tubing

A-02296

Washer

4-2 Installing Torch Head Assembly

4.4 T4.4 T

4.4 T

oror

ch Switch Onlych Switch Only

ch Switch Only

ReplacementReplacement

Replacement

NOTE

This procedure requires the following tools (or

equivalent): screwdriver, soldering iron, Nokorde

Flux.

WARNING

Disconnect primary power to the system before dis-

assembling the torch, leads, or power supply.

1. Remove consumable parts from front end of torch.

2. Remove the six screws from the torch handle as-

sembly and remove torch and leads assembly.

3. Using soldering iron, carefully remove solder where

orange wire connects to switch terminal.

NOTE

Be careful not to overheat the torch switch while

removing soldering from terminals.

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ESAB DRAG-GUN™ Plasma Cutter with Built-In Air Manuel utilisateur

Marque: ESAB

Modèle: DRAG-GUN™ Plasma Cutter with Built-In Air

Catégorie: Système de soudage

Taper: Manuel utilisateur

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