Thermal Dynamics 35C User manual

PLASMA

DRAG-GUN™PLUS

Service Manual

35C

PLASMA CUTTING

SYSTEM

Rev. AA.01 Issue Date: March 26, 2007 Manual 0-4751

Operating Features:

WARNING

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 the Manufacturer's best judgement,

the Manufacturer assumes no liability for its use.

Plasma Cutting Power Supply

Drag-Gun Plus

PCH 42 Torch

Service Manual Number 0-4751

Covered under U.S. Patents.

Published by:

Thermadyne Corporation

82 Benning Street

West Lebanon, New Hampshire, USA 03784

(603) 298-5711

www.thermal-dynamics.com

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 liability to any party for any loss or damage

caused by any error or omission in this Manual, whether such error results from negligence, accident, or

any other cause.

Printed in the United States of America

Publication Date: March 26, 2007

Record the following information for Warranty purposes:

Where Purchased:____________________________________

Purchase Date:_______________________________________

Power Supply Serial #:________________________________

Torch Serial #:________________________________________

TABLE OF CONTENTS

SECTION 1:

GENERAL INFORMATION ................................................................................................ 1-1

1.01 Notes, Cautions and Warnings ...................................................................... 1-1

1.02 Important Safety Precautions ....................................................................... 1-1

1.03 Publications .................................................................................................. 1-3

1.04 Declaration of Conformity ............................................................................. 1-4

1.05 Statement of Warranty .................................................................................. 1-5

SECTION 2:

INTRODUCTION ............................................................................................................... 2-1

2.01 INTRODUCTION .......................................................................................... 2-1

2.02 GENERAL SPECIFICATION ......................................................................... 2-1

2.03 Features ....................................................................................................... 2-1

2.04 Torch Specifications ..................................................................................... 2-2

2.05 System Contents .......................................................................................... 2-2

2.06 Transporting Methods ................................................................................... 2-2

SECTION 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: MAINTENANCE .................................................................................................... 5-1

5.01 General Maintenance .................................................................................... 5-1

SECTION 6:

TROUBLESHOOTING ....................................................................................................... 6-1

6.01 Normal Setup and Operation ........................................................................ 6-1

6.02 Basic Trouble Shooting Guide ....................................................................... 6-2

6.03 Control PCB Indicators ................................................................................. 6-3

6.04 Open Circuit Voltage Check .......................................................................... 6-4

6.05 Detailed Fault Finding / Error Indicators ........................................................ 6-5

6.06 Torch Tests ................................................................................................... 6-9

SECTION 7:

PARTS LIST ...................................................................................................................... 7-1

7.01 Parts List Power Supply................................................................................ 7-2

7.02 Replacement Hand Torch Parts With Ergonomic Handle ................................ 7-6

TABLE OF CONTENTS (Con't)

Appendix 1: Operating 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 CONTACT INFORMATION .............................. Inside Rear Cover

Manual 0-4751 1-1 GENERAL INFORMATION

SECTION 1:

GENERAL INFORMATION

1.01 Notes, Cautions and Warnings

Throughout this manual, notes, cautions, and warn-

ings are used to highlight important information. These

highlights are categorized as follows:

NOTE

An operation, procedure, or background in-

formation which requires additional empha-

sis or is helpful 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 operating area.

1.02 Important Safety Precautions

WARNING

OPERATION AND MAINTENANCE OF PLASMA

ARC EQUIPMENT CAN BE DANGEROUS AND

HAZARDOUS TO YOUR HEALTH.

Plasma arc cutting produces intense elec-

tric and magnetic emissions that may inter-

fere with the proper function of cardiac

pacemakers, hearing aids, or other elec-

tronic health equipment. Persons who work

near plasma arc cutting applications should

consult their medical health professional 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 instructions before using the equip-

ment. Call 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 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, coat-

ings on the metal, and the different processes.

You must be very careful when cutting or weld-

ing any metals which may contain one or more

of the following:

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 mate-

rial 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 Sub-

section 1.03, 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

combustible or explosive gases or materials are

located.

• Phosgene, a toxic gas, is generated from the va-

pors of chlorinated solvents and cleansers. Re-

move all sources of these vapors.

GENERAL INFORMATION 1-2 Manual0-4751

• This product, when used for welding or cutting,

produces fumes or gases which contain chemi-

cals known to the State of California to cause birth

defects and, in some cases, cancer. (California

Health & Safety Code Sec. 25249.5 et seq.)

ELECTRIC SHOCK

Electric Shock can injure or kill. The plasma arc pro-

cess uses and produces high voltage electrical en-

ergy. This electric energy can cause severe or fatal

shock to the operator 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 weld-

ing 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, Publi-

cations.

• Disconnect power source before performing any

service or repairs.

• Read and follow all the instructions in the Oper-

ating 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

material in the workplace. Any material that can-

not 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 un-

der aluminum workpieces when they are cut un-

derwater 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 dissipated. Trapped hydrogen gas that is ig-

nited will cause an explosion.

NOISE

Noise can cause permanent hearing loss. Plasma arc

processes can cause noise levels to exceed safe lim-

its. You must protect your ears from loud noise to

prevent permanent loss of hearing.

• To protect your hearing from loud noise, wear

protective ear plugs and/or ear muffs. Protect

others in the workplace.

• Noise levels should be measured to be sure the

decibels (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 dam-

age your eyes and burn your skin if you are not prop-

erly 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 condi-

tion. Replace lenses when cracked, chipped or

dirty.

• Protect others in the work area from the arc rays.

Use protective booths, screens or shields.

Manual0-4751 1-3 GENERAL INFORMATION

• Use the shade of lens as suggested in the fol-

lowing 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 workpiece.

1.03 Publications

Refer to the following standards or their latest revi-

sions for more information:

1. OSHA, SAFETY AND HEALTH STANDARDS, 29CFR 1910,

obtainable from the Superintendent of Documents, U.S.

Government Printing Office, Washington, 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 WELDING AND GAS

WELDING AND CUTTING, obtainable from the Superinten-

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

ington, D.C. 20402

4. ANSI Standard Z87.1, SAFE PRACTICES FOR OCCUPATION

AND EDUCATIONAL EYE AND FACE PROTECTION, obtain-

able 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 Stan-

dards Institute, 1430 Broadway, New York, NY 10018

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

CUTTING AND WELDING PROCESSES, obtainable from

American National Standards 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 33126

8. NFPA Standard 51, OXYGEN-FUEL GAS SYSTEMS FOR

WELDING, CUTTING AND ALLIED PROCESSES, obtainable

from the National Fire Protection Association, Batterymarch

Park, Quincy, MA 02269

9. NFPA Standard 70, NATIONAL ELECTRICAL CODE, obtain-

able from the National Fire Protection Association,

Batterymarch Park, Quincy, MA 02269

10. NFPA Standard 51B, CUTTING AND WELDING PROCESSES,

obtainable from the National Fire Protection Association,

Batterymarch Park, Quincy, MA 02269

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

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 Canadian Standards

Association, Standards Sales, 178 Rexdale Boulevard,

Rexdale, Ontario, Canada M9W 1R3

13. NWSA booklet, WELDING SAFETY BIBLIOGRAPHY obtain-

able from the National Welding Supply Association, 1900

Arch Street, Philadelphia, PA 19103

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

MENDED SAFE PRACTICES FOR THE PREPARATION FOR

WELDING AND CUTTING OF CONTAINERS AND PIPING THAT

HAVE HELD HAZARDOUS SUBSTANCES, obtainable from

the American Welding Society, 550 N.W. LeJeune Rd, Mi-

ami, FL 33126

15. ANSI Standard Z88.2, PRACTICE FOR RESPIRATORY PRO-

TECTION, obtainable from American National Standards In-

stitute, 1430 Broadway, New York, NY 10018

GENERAL INFORMATION 1-4 Manual0-4751

1.04 Declaration of Conformity

Manufacturer: Thermal Dynamics Corporation

Address: 82 Benning Street

West Lebanon, New Hampshire 03784

USA

The equipment described in this manual conforms to all applicable aspects and regulations of the ‘Low Voltage

Directive’ (European Council Directive 73/23/EEC as amended by Council Directive 93/68/EEC) and to the Na-

tional legislation for the enforcement of this Directive.

The equipment described in this manual conforms to all applicable aspects and regulations of the "EMC Direc-

tive" (European Council Directive 89/336/EEC) and to the National legislation for the enforcement of this Direc-

tive.

Serial numbers are unique with each individual piece of equipment and details description, parts used to manu-

facture a unit and date of manufacture.

National Standard and Technical Specifications

The product is designed and manufactured to a number of standards and technical requirements. Among

them are:

* CSA (Canadian Standards Association) standard C22.2 number 60 for Arc welding equipment.

* 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 60 974-1) (EN50192) (EN50078) applicable to plasma cutting equip-

ment and associated accessories.

* For environments with increased hazard of electrical shock, Power Supplies bearing the

mark conform to

EN50192 when used in conjunction with hand torches with exposed cutting tips, if equipped with properly

installed standoff guides.

* Extensive product design verification is conducted at the manufacturing facility as part of the routine design

and manufacturing process. This is to ensure the product is safe, when used according to instructions in this

manual and related industry standards, and performs as specified. Rigorous testing is incorporated into the

manufacturing process to ensure the manufactured product meets or exceeds all design specifications.

Thermal Dynamics has been manufacturing products for more than 30 years, and will continue to achieve

excellence in our area of manufacture.

Manufacturers responsible representative: Steve Ward

Operations Director

Thermadyne Europe

Europa Building

Chorley N Industrial Park

Chorley, Lancashire,

England PR6 7BX

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