Plasma Cutting Power
Supply
Drag-gun
TM
A-03642
November 11, 2003 Manual No. 0-2683
Service Manual
WARNINGS
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 with Built-in Air
Drag-Gun
Service Manual Number 0-2683
Published by:
Thermal Dynamics Corporation
82 Benning Street
West Lebanon, New Hampshire, USA 03784
(603) 298-5711
www.thermal-dynamics.com
Copyright 1999 by
Thermal Dynamics Corporation
All rights reserved.
Reproduction of this work, in whole or in part, without written permission of the
publisher is prohibited.
The publisher does not assume 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: November 11, 2003
Record the following information for Warranty purposes:
Where Purchased:____________________________________
Purchase Date:_______________________________________
Power Supply Serial #:________________________________
Torch Serial #:________________________________________
TABLE OF CONTENTS
SECTION 1:
GENERAL INFORMA TION ................................................................................................... 1
1.01 Notes, Cautions and W arnings ......................................................................... 1
1.0 2 Important Safety Precautions .......................................................................... 1
1.03 Publications..................................................................................................... 2
1.0 4 Note, Attention et Avertissement..................................................................... 3
1.0 5 Precautions De Securite Importantes .............................................................. 3
1.06 Documents De Reference................................................................................ 5
1.07 Declaration of Conformity ................................................................................ 7
1.08 Statement of W arranty ..................................................................................... 8
2.0 INTRODUCTION .................................................................................................................... 9
2.1 Scope Of Manual.............................................................................................. 9
2.2 General Service Philosophy.............................................................................. 9
2.3 Service Responsibilities.................................................................................... 9
2.4 Technical Specifications.................................................................................... 9
2.5 Dimensions......................................................................................................10
3.0: TROUBLESHOOTING ..........................................................................................................11
3.1 Introduction......................................................................................................11
3.2 Periodic Inspection & Maintenance..................................................................11
3.3 Common Cutting Faults ...................................................................................1 1
3.4 Common Operating Problems ..........................................................................11
3.5 Troubleshooting Guide......................................................................................12
3.6 Torch & Leads Troubleshooting .........................................................................15
4.0 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 .....................................................................19
4.5 Air Compressor Replacement .........................................................................19
4.6 Capacitor Replacement...................................................................................20
4.7 Control PC Board Replacement ......................................................................20
4.8 P ower Relay Replacement ..............................................................................21
4.9 ON/OFF P ower Switch Replacement ..............................................................21
4.10 Fan Replacement............................................................................................22
4.11 Diode Bridge Rectifier Replacement................................................................22
4.12 T r ansformer/Ferrite Core Assembly Replacement ...........................................23
4.1 3 Input V oltage Changeover (For 208/230 V A C Service Only) ............................23
4.14 Torch & Leads Replacement ...........................................................................24
4.15 Work Cable Replacement ...............................................................................25
4.16 Primary Input Pow er Cable Replacement ........................................................25
TABLE OF CONTENTS (Continued)
5.0 PARTS LIST .........................................................................................................................27
5.1 Returns............................................................................................................27
5.2 Parts Replacement ..........................................................................................27
5.3 Pow er Supply Replacement Parts....................................................................28
5.4 Options & Accessories (not shown) .................................................................28
5.5 Torch Replacement Parts .................................................................................30
APPENDIX I - INTERCONNECTING DIAGRAM ..........................................................................31
APPENDIX II - INTERCONNECTING DIAGRAM .........................................................................32
SECTION 1:
GENERAL INFORMATION
1.01 Notes, Cautions and Warnings
Throughout this manual, notes, cautions, and warnings
are used to highlight important information. These highlights are categorized as follows:
NOTE
An operation, procedure, or backgr ound information which requires additional emphasis 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
WARNINGS
OPERATION AND MAINTENANCE OF
PLASMA ARC EQUIPMENT CAN BE DANGEROUS AND HAZARDOUS TO YOUR
HEAL TH.
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. 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 equipment. Call 1-603298-5711 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 pr ocesses. Y ou must
be very careful when cutting or welding 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 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 1.03,
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 vapors
of chlorinated solvents and cleansers. Remove all
sources of these vapors.
• This product, when used for welding or cutting,
produces fumes or gases which contain chemicals
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 process
uses and produces high voltage electrical energy. 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.”
Date: No v ember 15, 2001 1 GENERAL INFORMATION
• 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, Publications.
• Disconnect power source before performing any
service or repairs.
• Read and follow all the instructions in the Operating 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 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 underwater 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. T rapped hydrogen gas that is ignited will
cause an explosion.
NOISE
Noise can cause permanent hearing loss. Plasma arc processes can cause noise levels to exceed safe limits. You
must protect your ears from loud noise to prevent permanent loss of hearing.
• T o protect your hearing from loud noise, wear pr otective 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 RA YS
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 pr otected.
• To protect your eyes, always wear a welding helmet or shield. Also always wear safety glasses with
side shields, goggles or other protective eye wear.
• Wear welding gloves and suitable clothing to protect 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 workpiece.
1.03 Publications
Refer to the following standards or their latest revisions
for more information:
1. OSHA, SAFETY AND HEAL TH 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 Superintendent of Documents, U.S. Government Printing Office, Washington, D.C. 20402
4. ANSI Standard Z87.1, SAFE PRACTICES FOR OCCUP ATION AND EDUCA TIONAL 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 Broadway, New
York, NY 10018
GENERAL INFORMATION 2 Date: Nov ember 15, 2001
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 Standar d A6.0, WELDING AND CUTTING CONTAINERS 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,
obtainable 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 W1 17.2, 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
obtainable from the National Welding Supply Association, 1900 Arch Street, Philadelphia, PA 19103
14. American W elding Society Standard A WSF4.1, RECOMMENDED SAFE PRACTICES FOR THE PREPARATION FOR WELDING AND CUTTING OF CONT AINERS AND PIPING THAT HAVE HELD HAZARDOUS
SUBSTANCES, obtainable fr om the American Welding
Society, 550 N.W. LeJeune Rd, Miami, FL 33126
ATTENTION
Toute procédure pouvant résulter
l’endommagement du matériel en cas de nonrespect de la procédur e 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.
1.05 Precautions De Securite
Importantes
AVERTISSEMENTS
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.
15. ANSI Standard Z88.2, PRACTICE FOR RESPIRATOR Y
PROTECTION, obtainable 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 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.
Date: No v ember 15, 2001 3 GENERAL INFORMATION
Il faut communiquer aux opérateurs et au personnel 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 votr e 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 respiration. Gardez votre tête hors de la plume de fumée
provenant du chalumeau.
• Utilisez un appareil respiratoir e à alimentation en air
si l’aération fournie ne permet pas d’éliminer la fumée
et les gaz.
• 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 parties du circuit
de soudage.
• Réparez ou remplacez toute pièce usée ou
endommagée.
• 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 différ ents
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 5.
• 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.
• Ce produit, dans le procéder de soudage et de coupe,
produit de la fumée ou des gaz pouvant contenir des
éléments reconnu dans L’état de la Californie, qui
peuvent causer des défauts de naissance et le cancer .
(La sécurité de santé en Californie et la code sécurité
Sec. 25249.5 et seq.)
CHOC ELECTRIQUE
• Prenez des soins particuliers lorsque la zone de travail est humide ou moite.
• Montez et maintenez le matériel conformément au
Code électrique national des Etats-Unis. (V oir la page
5, article 9.)
• Débranchez l’alimentation électrique avant tout travail 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 combustibles ou provoquer l’explosion de fumées
inflammables.
• Soyez certain qu’aucune matière combustible ou inflammable 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.
Les chocs électriques peuvent blesser ou même tuer. Le
procédé au jet de plasma requiert et produit de l’éner gie
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.
GENERAL INFORMATION 4 Date: Nov ember 15, 2001
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-violets 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 lunettes de
protection ou une autre sorte de protection oculair e.
• 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 protection
en bon état. Remplacez toute lentille sale ou
comportant fissure ou rognure.
• Protégez les autres personnes se tr ouvant sur la zone
de travail contre les rayons de l’arc en fournissant des
cabines ou des écrans de protection.
• 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.
1.06 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 TRA VAIL ET DE
PROTECTION DE LA SANTÉ, 29CFR 1910,
disponible auprès du Superintendent of Documents,
U.S. Government Printing Office, Washington, 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 Superintendent 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 TRAV AIL ET DANS LES ECOLES, disponible de l’Institut
Américain des Normes Nationales (American National Standards Institute), 1430 Broadway, New Y ork,
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
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. V ous dú4ez vous pr otéger 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’assur er 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.
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 Y ork,
NY 10018
7. Norme A6.0 de l’Association Américaine du Soudage
(AWS), LE SOUDAGE ET LA COUPE DE
CONTENEURS A YANT 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 Protection 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 National Fire Protection Association, Batterymar ch Park,
Quincy, MA 02269
Date: No v ember 15, 2001 5 GENERAL INFORMATION
9. Norme 70 de la NFPA, CODE ELECTRIQUE NATIONAL, disponible auprès de la National Fire Protection 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, Standards Sales, 178 Rexdale Boulevard, Rexdale,
Ontario, Canada, M9W 1R3
13. Livret 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
14. Norme AWSF4.1 de l’Association Américaine de
Soudage, RECOMMANDATIONS DE PRATIQUES
SURES POUR LA PRÉPARA TION 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, PRA TIQUES DE PROTECTION
RESPIRATOIRE, disponible auprès de l’American
National Standards Institute, 1430 Broadway, New
York, NY 10018
GENERAL INFORMATION 6 Date: Nov ember 15, 2001
1.07 Declaration of Conformity
Manufacturer: Thermal Dynamics Corporation
Address: 82 Benning Street
W est 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 National legislation for
the enforcement of this Directive.
The equipment described in this manual conforms to all applicable aspects and regulations of the "EMC Directive" (European Council Directive 89/336/EEC) and to the National legislation for the enforcement of this Directive.
Serial numbers are unique with each individual piece of equipment and details description, parts used to manufacture a unit
and date of manufacture.
National Standard and Technical Specifications
The product is designed and manufactured to a number of standards and technical requir ements. 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 boar ds used.
* CENELEC EN50199 EMC Product Standard for Ar c W elding Equipment.
* ISO/IEC 60974-1 (BS 638-PT10) (EN 60 974-1) (EN50192) (EN50078) applicable to plasma cutting equipment and associ-
ated accessories.
* For environments with increased hazard of electrical shock, Power Supplies bearing the S mark conform to EN50192
when used in conjunction with hand torches with properly installed standoff guides.
* Extensive product design verification is conducted at the manufacturing facility as part of the routine design and manufac-
turing 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: Giorgio Bassi
Managing Director
Thermal Dynamics Europe
Via rio Fabbiani 8A
40067 Rastignano (BO)
Italy
Date: No v ember 15, 2001 7 GENERAL INFORMATION
1.08 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 stor ed, 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, corr ect such defects by suitable r epair 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
PAR TICULAR 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 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 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 Series 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 & Parts Parts
PAK Units, Power Supplies CutMaster Series Cougar/Drag-Gun All Others Labor
Main Power Magnetics 3 Years 1 Y ear 2 Years 1 Year
Original Main Power Rectifier 3 Y ears 1 Year 2 Years 1 Year
Control PC Board 3 Y ears 1 Year 2 Years 1 Year
All Other Circuits And Components Including, 1 Year 1 Y ear 1 Y ear 1 Year
But Not Limited To, Starting Circuit,
Contactors, Relays, Solenoids, Pumps,
Power Switching Semi-Conductors
Consoles, Control Equipment, Heat 1 Y ear 1 Year 1 Year
Exchanges, And Accessory Equipment
Torch And Leads
Maximizer 300 Torch 1 Y ear 1 Year
SureLok T orches 1 Y ear 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 char ges
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: November 15, 2001
GENERAL INFORMATION 8 Date: Nov ember 15, 2001
2.0 INTRODUCTION
2.1 Scope Of Manual
This manual provides service instructions for the Thermal Dynamics® DRAG-GUN Plasma Cutter .
Information in this edition is particularly applicable to
the T r oubleshooting and Repair of the equipment, and is
intended for use by properly trained Service T echnicians
familiar with this equipment.
2.3 Service Responsibilities
The Service T echnician should be familiar with the equipment and its capabilities and should be prepared to recommend arrangements of components which will provide
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 T echnical Services
Department in W est Lebanon for assistance.
Read this manual and the DRAG-GUN Operating Manual,
0-2682, thoroughly. A complete understanding of the capabilities and functions of the equipment will assure obtaining the performance for which it was designed.
2.2 General Service Philosophy
Several key points are essential to properly support the
application and operation of this equipment.
A. Application
The equipment should satisfy the customer’s requirements
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. Modifications
No physical or electrical modifications other than selection of standard options and accessories are to be made to
this equipment.
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 malicious
damage.
D. Repair Restrictions
The electronics consists of a Printed Circuit Board Assembly which must be carefully handled, and must be replaced
as a unit. No replacement of printed circuit solder-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 packaged in protective
material and returned intact per normal procedures.
2.4 Technical Specifications
A. System Specifications
System Specifications
Input Power
Output Power See subsection 2.3B
Duty Cycle See subsection 2.3B
M axi mum 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)
Wor k Cable 15 ft. (4.6 m)
Input Pow er Cable 6.6 ft. (2 m) minimum
Torch Style
Torch Dimensions
Cutting Rating 12 Amps Max. Straight Polarity
Cut Capacity Most metals up to 1/8 in. (3.2 mm) max.
Severance Most meta ls 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 Compres sed Air (Built-in)
Leads Length 20 ft. (6.1 m)
100 V AC 50Hz , 110 VAC 60Hz, Singl e Phase
100/110 VAC, 50/60Hz, Single Phase
120VAC ±10%, 50Hz, Single Phase
120VAC ±10%, 60Hz, Single Phase
220VAC ±10%,50Hz, Single Phase
208/230VAC ±10%, 60Hz, Single Phase
H 10 in. (254 mm)
PCH-10 70°
PCH-10 180°
L See subsection 2.4
W See subsection 2.4
Manual 0-2683 9 Introduction
B. Input/Output Specifications
Input
Model Hz
100/110V 50/60 25/24 12 85 30
120V *5022129530
120V 60 20 12 70 30
220V *5013128530
208/230V 60 10 12 78 30
* CE approved.
Amps
RMS
Output
Amps
(DC)
Output
Voltage
(DC)
Duty
Cycle %
2.5 Dimensions
10.0 in.
(254 mm)
A-02004
16.0 in
(406 mm)
Figure 2-1 Power Supply Dimensions
1.1 in (27 mm)
8 in (203 mm)
8.9 in (226 mm)
A-02385
Figure 2-2 Torch Dimensions
9.0 in
(229 mm)
2.9 in
(75 mm)
1.1 in
(27 mm)
70˚
180˚
Introduction 10 Manual 0-2683
3.0: TROUBLESHOOTING
B. Main Arc Extinguishes
1. Cutting speed too slow
3.1 Introduction
This section provides service diagnostics for the DRAGGUN Plasma Cutter with PCH-10 T orch, aiding the technician 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 factory warranty .
W ARNING
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 troubleshooting techniques.
3.2 Periodic Inspection &
Maintenance
The DRAG-GUN Operating Manual 0-2682, describes the
inspection and maintenance procedures which should be
performed at periodic intervals. Routine 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 Faults
Poor or lackluster performance can often be improved by
slight modifications to technique or equipment. For example:
A. Insufficient Penetration
1. Cutting speed too fast
2. Torch standoff too high from workpiece
3. Work cable disconnected
4. Worn torch parts
C. Excessive Dross Formation
1. Cutting speed too slow
2. Torch standoff too high from workpiece
3. Worn torch parts
D. Short Torch 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 Operating Problems
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. Compressor 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, approximately 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 quality 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.
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
Manual 0-2683 11 TROUBLE-SHOOTING
B. Power Source Related
2. Torch Standoff
If the service available is saggy , pilot and cut performance
will be degraded. In some cases, the service circuit breaker
may open during use. Some things that will help:
• Use a service fused or circuit breaker for the specified amps. (Refer to Operator’s Manual 0-2682, subsection 4.0-D for service amperage.)
• Use heavy gauge extension cords (Refer to Operator’s
Manual 0-2682, subsection 4.0-D for sizes).
• Use as short an extension cord as possible.
• T ry different outlets on dif ferent branch circuits. Use
the one that gives the strongest pilot.
C. Power Supply/Torch 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 letting 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 Related
1. Piloting
One of the features of this plasma cutter is the constant 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 (essentially 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") 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.
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 result in a more square cut.
NOTE
Although the DRAG-GUN will cut using standoff,
this unit is primarily a drag-cutting machine.
3.5 Troubleshooting Guide
A. General
The troubleshooting covered in this Service Manual requires power supply disassembly and live measurements.
T roubleshooting and repairing this unit is a process which
should be undertaken only by those familiar with high
voltage high power electronic equipment.
W ARNING
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 troubleshooting techniques.
B. How To 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:
Symptom (Bold type)
Cause (Italic type)
Remedy (T est 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 Power, AC switch on, red (amber for 220V)
indicator dark, no fan.
1. No power from wall unit.
a. T est electrical outlet with voltmeter or some other
known good load (trouble light, hand drill, etc).
TROUBLE-SHOOTING 12 Manual 0-2683
If AC line voltage is present, go to next step.
If AC line voltage is not present, replace fuse or
reset circuit breaker .
2. Damaged power cord.
4. Torch switch may have br oken or shorted wir es.
a. Confirm with voltmeter if AC line voltage is
present at input to power switch.
If AC voltage is present, proceed to next step.
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 (C13) terminals when
power switch is on.
If AC line voltage is not present, replace Power
Switch.
D. Power OK, service circuit breaker or fuse opens
after the power switch is 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 , r eplace Fan.
2. Faulty T ransformer Assembly or Capacitor.
a. W ith 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 compressor operation or
pilot when torch switch pressed.
1. Shield cup loose, PIP not making contact.
a. Reseat the torch parts, tighten shield cup.
2. Unit overheated.
a. Refer to subsection 3.6, T orch and Leads T rouble-
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 Compressor motor feels very warm, allow it to cool
and try again. The Compressor has its own
overtemp cutout switch.
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 T ransformer
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 hazards. 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 measuring 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 arcing 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.
F . Power OK, fan runs, compressor runs intermit-
tently , Relay Case shows arcing when the torch
switch is held 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.
a. Leave power on so fan can cool unit, test again
after 10 minutes.
3. Shorted torch parts.
a. Replace torch consumables.
Manual 0-2683 13 TROUBLE-SHOOTING
G. Power OK, fan runs, compressor starts then shuts
down as soon as the torch switch is pressed.
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) V oltage 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 , closest to Chassis).
7. Faulty Ferrite/T ransformer 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 itself should be free of large ferrite chips and
cracks along the core.
I. Torch 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 .
H. Power OK, fan runs, compressor runs, no pilot or
cutting arc with the torch switch pressed.
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. Replace 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 Assembly. If nothing is heard, the PCB should be replaced.
5. Faulty (open) Pilot Resistor .
a. The Pilot Resistor is mounted closest to the chas-
sis. Disconnect the push on connectors and
measure the resistor with an ohmmeter . It should
read 0.5 ohms (essentially a short).
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.
6. AC input too low.
a. If the AC line is below about 105vac, the torch
may not always start. T ry an outlet on a dif ferent branch circuit.
TROUBLE-SHOOTING 14 Manual 0-2683
3.6 Torch & Leads Troubleshooting
B. Checking Torch Lead
W ARNINGS
Disconnect primary power to the system before disassembling 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.
T orch parts may get quite hot during normal operation. Always wear light cutting gloves when changing torch parts just after operating the Drag-Gun
system.
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 intended
for the pilot arc may be dissipated into the torch head,
resulting in torch failure.
1. Remove the shield cup, tip, gas distributor, and electrode
from the torch.
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 continuity 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 Control Wires
Check the pilot and switch control wires for continuity
from one end of the torch lead to the other . If no continuity
exists, replace torch and lead assembly.
D. Reassembling Torch and Leads
Replace parts as required, then recheck the torch head,
and lead connections to confirm proper measurements. If
each component is okay , r eassemble torch and leads.
PCH-10
Electrode
Torch Head Assembly
Gas
Distributor
Tip
Standard
Shield Cup
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 resistance
(no continuity) should be found. If there is continuity
between the two, remove the torch head from the lead
and check the torch head separately.
Manual 0-2683 15 TROUBLE-SHOOTING
TROUBLE-SHOOTING 16 Manual 0-2683
4.0 REPLACEMENT
PROCEDURES
4.3 Torch Head Assembly
Replacement
4.1 General Information
• 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 assembly 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 Operating Manual 0-2682. (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 schematic in Appendix II. For units which are rev “D” or
later , r efer 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 applicable, as they pertain to your unit.
W ARNINGS
Disconnect primary power to the system before
disassembling the torch, leads, or power supply.
4.2 Removing Cover/Handle
1. Remove 2 screws in handle, 2 screws in end panels, and four screws near base to remove cover and
handle from unit.
NOTE
W ARNINGS
Disconnect primary power to the system before disassembling the torch or power supply.
T orch parts may get quite hot during normal operation. Always wear light cutting gloves when changing torch parts just after operating the Drag-Gun
system.
To Remove T orch 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" (2.54 cm) 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" 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.
When replacing cover , make sure all wires ar e carefully positioned so that the wires are not pinched
when the cover and handle are secured.
Manual 0-2683 17 REPLACEMENT PROCEDURES
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.
2. Install O-ring removed in step 8 above (L).
3. Optional: Install orange sleeving on replacement
torch head gas input.
Cut Tie Wrap
C
Washer
B
Remove Pilot
Lead Screw
Remove Six Screws
A
Switch
Cut Black
Hose
D
1.000
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
installing screw (O).
9. Push pilot lead under cable jacket until there is no
excess.
New Torch Head
J
Remove Screws
I
H
Place Vise
Grips Here
O-Ring
Cut Cable Here
F
A-02295
Orange Torch
Sleeving
(Optional)
G
Figure 4-1 Removing Torch HeadAssembly
T o 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 connections.
E
Insert Cable Into
Butt Splice & Crimp
Install Screws
K
Install Pilot
Lead Screw
A-02296
L
Install
O-Ring
Washer
O
T eflon Tubing
4-2 Installing Torch Head Assembly
M
Butt Splice
N
REPLACEMENT PROCEDURES 18 Manual 0-2683
4.4 Torch Switch Only
Replacement
NOTE
This procedure requires the following tools (or
equivalent): screwdriver , soldering iron, Flux.
4.5 Air Compressor Replacement
NOTES
Refer to subsection 4.1, General Information, for
information about wire harnesses.
Refer to Appendix II for parts location and orientation.
W ARNING
Disconnect primary power to the system before disassembling the torch, leads, or power supply.
1. Remove consumable parts from front end of torch.
2. Remove the six screws from the torch handle assembly 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.
4. Apply Flux to orange wire and to switch post. Insert orange wire in switch post hole and solder,
keeping solder at a minimum required for good
joint.
5. Repeat steps 3 and 4, this time for the white wire.
Torch Switch
1. Remove cover/handle from unit per subsection 4.2.
2. Locate the nylon nut on the 90° nylon fitting on
side of Air Compressor. Loose the nylon nut and
slide the brass torch lead fitting/faston connector
out.
3. Complete one of the following, as it pertains to
your unit:
• Rev C units or earlier - Disconnect black wire
from Compressor to faston splice & wire #21.
Disconnect red wire from Compressor to upper diode piggy back terminal.
• Rev D units or later - Disconnect black wire
from Compressor to faston splice & wire #29.
Disconnect red wire from Compressor to upper diode piggy back terminal.
4. Slide Compressor out of bracket.
5. Note position and angle of 90° nylon nut connected
to the Air Compressor Remove fitting.
6. Clean old teflon thread sealant from nylon fitting,
apply new thread sealant and install nylon fitting
on replacement Air Compr essor . Make sure fitting
is in proper position.
To Control
Cable Wiring
Butt Splice
PIP Pin
Shield Cup
PIP Pin
A-00784
7. Remove “feet” from Compressor and install on replacement Compressor .
8. Insert replacement Air Compressor into bracket,
insuring “feet” have dropped into slots in bracket.
9. Apply a small amount of O-Ring lubricant to brass
Figure 4-3 Torch Switch Schematic
torch fitting and insert into 90° nylon fitting.
Tighten nylon nut.
6. Place the torch head in the torch handle bottom.
Carefully return the torch switch and button w/
springs to their proper position. Replace cover on
the handle assembly , and scr ew together with six
Be careful not to remove the nylon nut completely
as there are small parts inside that could fall out.
NOTE
screws.
10. Connect the following as it pertains to your unit:
NOTE
• Connect black wire from Compressor to faston
Make sure torch switch wires are seated in their
guides so that the wires are not pinched when the
splice & wire #21. Connect red wire from Compressor to upper diode piggyback terminal.
handle is secured.
• Connect black wire from Compressor to faston
7. Install consumables parts in front end of torch.
splice & wire #29. Connect red wire from Compressor to upper diode piggyback terminal.
Manual 0-2683 19 REPLACEMENT PROCEDURES
11. Position wire connector L4 so that it runs along
side the Transformer, NOT across the top of the
Transformer.
4.7 Control PC Board
Replacement
12. Install cover/handle by reversing steps in subsection 4.2, keeping in mind the following:
a. The Air Compressor is secured in position by
one of the handle screws on the top side of the
power supply .
b. Make sure that no wires obstruct the cover
when it is installed.
4.6 Capacitor Replacement
W ARNING
Disconnect primary power to the system before disassembling the torch, leads, or power supply.
NOTE
Refer to subsection 4.1, General Information, for
information about wire harnesses.
1. Remove cover/handle from unit per subsection 4.2.
2. Make note of all wire connections and locations to
Capacitor.
3. Remove all wire connections to Capacitor.
The DRAG-GUN Plasma Cutter has been manufactured
using one of two styles of PC Board Assemblies. The
Board will either have round mounting holes in the corners or key slotted mounting holes in the corners.
Follow procedures as they apply to your unit.
NOTES
It may be easier to remove the PC Board if the Capacitor is removed first.
All replacement PC Boards have key slotted holes.
W ARNING
Disconnect primary power to the system before disassembling the torch, leads, or power supply.
A. T o Remove PC Board:
1. Remove cover/handle from unit per subsection 4.2.
2. Remove Capacitor (optional) per subsection 4.6.
3. Note all wiring connections and locations to the
PC Board.
4. Disconnect all wire connections to the PC Board,
removing any tie wraps where necessary.
4. The Capacitor is held in place by a tab located on
the Transformer frame. Using a screw driver or
similar tool, pry the tab back slightly to allow the
Capacitor to slide out of the bracket.
5. Install replacement Capacitor, by reversing steps
1-4, keeping in mind the following:
a. Make sure the Capacitor is securely positioned
behind tab. T ab may need to be bent.
b. Position wire connector L4 so that it runs along
side the Transformer, avoiding contact with
metal parts.
5. Remove PC Board from unit by completing the following, as it applies to your unit:
PC Board with round mounting holes:
a. Remove the two (2) metal “C” clips located on
the top two standoffs that secure the PC Board
to the unit.
b. Gently pry PC Board off the standoffs then re-
move the second set of metal “C” clips (2).
NOTE
In some cases, the PCB may be mounted on standoffs and secured with R TV over the ends. Remove
the RTV and then r emove the PCB from the unit.
PC Board with key slotted mounting holes:
a. Remove two (2) fastener plastic push ons from
key slotted holes in corners of PC Board.
b. Slide PC Board up or down to disengage, then
remove from unit.
REPLACEMENT PROCEDURES 20 Manual 0-2683
B. T o Install Replacement PC Board:
1. Install replacement key slotted PC Board by placing PC Board over standoffs and sliding Board
down into position.
4.9 ON/OFF Power Switch
Replacement
NOTE
2. Push a white fastener plastic push on into each
keyhole (just above standoffs) to secure the PC
Board into position.
3. Reverse steps 1-4, keeping in mind the following:
a. Make sure J2 is not offset by one or more pins.
b. Install new tie wraps on wires connected to the
PC Board, as necessary.
4.8 Power Relay Replacement
NOTES
The Control PC Board must be moved out of the
way before the Power Relay can be replaced. (It may
be easier to move the Control PC Board if the Capacitor is removed first.)
Refer to subsection 4.1, General Information, for
information about wire harnesses.
W ARNING
When ordering a replacement ON/OFF Switch,
order the same as found in your unit. ON/OFF
Switches are as follows:
Switch
Model
Type
5 prong 1" x 2" Red 115 9-0015
A
4 prong 1" x 1-1/4" Red 115 9-0021
B
4 prong
C
6 prong
Disconnect primary power to the system before disassembling the torch, leads, or power supply.
Size
Neon
Color
Amber
or Red
W ARNING
Voltage
220 9-00291" x 1-1/ 4"
A. Models A & B:
1. Remove cover/handle from unit per subsection 4.2.
Catalog
Number
Disconnect primary power to the system before disassembling the torch, leads, or power supply.
1. Remove cover/handle from unit per subsection 4.2.
2. Remove Capacitor (optional step) per instructions
in 4.6.
3. Remove PCB from standoffs per subsection 4.7.B.
4. Slide PC Board away from Relay .
5. Note all wiring connections and locations to the
Relay.
6. Remove wirings connected to Relay.
7. Slide Relay out from bracket, towards the center of
the unit.
8. Install replacement Relay , by reversing the above
steps, keeping in mind the following:
a. Position wire connector L4 so that it runs along
side the T ransformer , NOT across the top of the
Transformer.
2. Note all wiring connections and locations to the
On/Off Switch.
3. Disconnect wires to ON/OFF Switch.
4. Push plastic clips down on top side of Switch and
slide Switch out by pulling it through front panel.
5. Install replacement ON/OFF Switch, by reversing
the above steps, keeping in mind the following:
a. Position wire connector L4 so that it runs along
side the T ransformer , NOT across the top of the
Transformer.
Manual 0-2683 21 REPLACEMENT PROCEDURES
B. Model C:
4.10 Fan Replacement
NOTE
T ype C switch with 6 prongs replaces T ype C switch
with 4 prongs.
1. Remove cover/handle from unit per subsection 4.2.
2. Disconnect wires to ON/OFF Switch.
3. Push plastic clips down on top end of Switch and
slide Switch out through front panel.
4. Check the numbering sequence of the connectors
on the ON/OFF Switch and install the switch as
follows:
a. 1,2,4,5 - Install switch with connectors posi-
tioned towards the bottom of unit.
b. 11,12,24,25 - Install switch with connectors
positioned towards the top of the unit.
c. 1A, 2A, 4B, 5B - Install switch with these con-
nectors positioned towards the top of the unit.
5. T o connect the input wiring to the ON/OFF Switch
refer to subsection 4.17, step 6.
6. Install cover/handle by reversing step 1, keeping
in mind the following:
NOTE
Before replacing cover , make sur e all wires are car efully positioned to avoid pinching when the cover
and handle are secured.
1. Remove cover/handle from unit per subsection
4.2.
2. Carefully slide the Air Compressor out of the T ransformer bracket and out of the way of the Fan. Be
careful not to strain wire connections. (If necessary, remove Compressor completely, following
procedures described in subsection 4.5.)
3. For reference, mark wires with correct connection
designation, then disconnect two wires to Fan.
4. Remove two (2) rivets* securing Fan to the front
panel.
NOTE
*Some models may use screws instead of rivets.
5. Install replacement Fan. Refer to Figure 5.1 for
proper Fan orientation (or refer to the arrows
marked on the Fan chassis).
NOTE
Proper fan orientation is essential to ensure proper
cooling of power supply parts.
6. Install Compressor by reversing steps 1-3, keeping
in mind the following:
a. Position wire connector L4 so that it runs along
side the T ransformer , NOT across the top of the
T ransformer or touching any metal parts.
b. The Compressor is secured in position by one
of the handle screws.
REPLACEMENT PROCEDURES 22 Manual 0-2683
4.11 Diode Bridge Rectifier
Replacement
NOTE
Refer to subsection 4.1, General Information, for
information about wire harnesses.
1. Remove cover/handle from unit per subsection 4.2.
2. Note all wire connections and locations to the Diode Bridge Rectifier .
3. Disconnect wires to the Diode(s), and remove Diode from unit.
4. Install replacement Diode, by reversing steps 1-3
above, noting the following:
a. Diode should be oriented with plus sign (+)
down and to the right.
4.12 Transformer/Ferrite Core
Assembly Replacement
W ARNINGS
Disconnect primary power at source before assembling or disassembling t he power supply.
4.13 Input Voltage Chang eover (For
208/230 VAC Service Only)
All 208/230 VAC units are factory set for 230 VAC. To
switch to 208VAC input power operation, complete the
following:
W ARNINGS
1. Remove cover/handle from unit per subsection 4.2.
2. Wire connections are as follows:
Connector Location
L1 E6 on P CB
L2 E1 on P CB
L3 E2 on P CB
L4
3. Disconnect wire connections. Pull L4 connector
through loose tie wrap if available.
4. Remove two Ferrite Core Assembly screws which
hold the Transformer/Ferrite Core Assembly in
position. Remove Transformer/Ferrite Core Assembly from unit.
5. Install replacement Transformer/Ferrite Core Assembly by reversing steps 1-4, keeping in mind the
following:
a. Pull L4 through loose tie wrap if available.
b. Position wire connector L4 so that it runs along
side the T ransformer , NOT across the top of the
T ransformer or near any metal parts.
Bras s Torch
Lead Fit t i ng
Do not touch live electrical parts.
Disconnect primary power at source before assem-
bling or disassembling the power supply, torch parts
or torch and leads assemblies.
1. Remove cover/handle from unit per subsection 4.2.
2. Locate the wiring on the end of the Capacitor.
3. Remove tie wrap and orange sleeving from wire
#208VAC.
4. Remove wire #230V AC from Capacitor and replace
with wire #208VAC.
5. Slide orange sleeving over wire #230V AC, fold over
and secure with a tie wrap.
W ARNING
Do not leave other input wire unprotected inside
unit.
6. Reinstall cover .
Manual 0-2683 23 REPLACEMENT PROCEDURES
4.14 Torch & Leads Replacement
1. Remove cover/handle from unit per subsection 4.2.
2. Disconnect the following (refer to Figure 4-4):
• Faston Connector (to CD Coil) from the Brass
T orch Lead Fitting
• Brass Torch Lead Fitting from the 90 degree
White Nylon Fitting.
• 2-pin Connectors.
• Torch Lead Faston Connector (red) from bottom Resistor .
3. Loosen the Strain Relief Nut from the Strain Relief
and remove T orch Lead Assembly from unit.
4. Install Strain Relief on replacement torch.
5. Insert Torch leads thr ough front hole on unit.
6. Slide Strain Relief Nut over the end of the torch
lead.
7. Allow one inch clearance between the end of the
torch lead sheath and the hole in the front panel
then tighten the Strain Relief Nut. (This allows allow enough length in the torch lead to make all the
connections inside the unit.)
8. Reconnect all connections by reversing step 2.
9. Replace cover by reversing step 1.
Nylon Nut
90˚ White
Nylon Fitting
Torch
Lead
Strain
Relief
Brass Torch
Lead Fitting
Faston Connector
to CD Coil
Strain Relief
2-Pin Connectors
Front Panel
Hole Location
Torch Leads Assembly
Note: Do not remove strain relief from torch lead.
Strain Relief Nut
1" Clearance
A-02009
Torch Lead Faston Connector (Red)
(Connect to Bottom Resistor)
REPLACEMENT PROCEDURES 24 Manual 0-2683
Figure 4-4 Torch & Leads Replacement
4.15 Work Cable Replacement
1. Remove cover/handle from unit per subsection 4.2.
2. Disconnect the W ork Cable Faston from mounting
tab on bottom of Rectifier .
3. Loosen Strain Relief and remove W ork Cable fr om
unit.
4. Install Strain Relief on replacement Work Cable 5
1/2 inches from Faston.
5. Install replacement W ork Cable by r eversing steps
1-3.
A-02011
Work Cable
Bridge
Rectifier
4.16 Primary Input Power Cable
Replacement
1. Remove cover/handle from unit per subsection 4.2.
2. Disconnect Input Power Cable wiring to the ON/
OFF Switch and Ground.
3. Loosen Input Power Cable Strain Relief and remove Input Cable from unit.
4. Install Strain Relief on replacement Input Power
Cable.
5. Install the Input Power Cable through rear panel.
6. Check the wire numbers on the Input Power Cable
and the prong numbers on the ON/OFF Switch.
Match that information to one of the configurations in Figure 4-6 and connect the wires accordingly.
Strain Relief
(Install 5 1/2" from Faston)
Figure 4-5 Work Cable Replacement
Work Cable Faston
(Connect to mounting
tab at bottom of Rectifier
A
White (Blue)
Wire
Black Wire
#21
12
11
Black (Brown)
Wire
25
24
Black Wire
#6
White (Blue)
Wire
)
Black Wire
#5
C
Black Wire
#5
White (Blue)
Wire
Black Wire
#6
5
4
Black (Brown)
Wire
2
1
Black Wire
#21
White (Blue)
Wire
B
12
11
D
5
4
Black (Brown)
Wire
25
24
Black Wire
#22
Black Wire
#22
2
1
Black (Brown)
Wire
A-02652
E
White or
Blue Wire
Wire No. 5
or 21
4B
5B
1A
2A
Brown or
Black Wire
Wire No. 6
or 22
Manual 0-2683 25 REPLACEMENT PROCEDURES
Not Used
6B
3A
A-03649
Not Used
Figure 4-6 Input Power Cable Connections
ON/OFF Input
Power Switch
Green Wire with Tracer
(Connect to
Compressor Frame)
Strain
Primary
Input Power
Cable
A-02653
Relief
Green Wire
(from Primary
Input Power Cable)
Ground Stud
Figure 4-7 Ground Connections
7. Connect the Ground Wires as shown.
8. T ighten Strain Relief.
9. Replace cover/handle by reversing step 1.
NOTE
When replacing cover , make sure all wires ar e carefully positioned so that no wires are pinched.
REPLACEMENT PROCEDURES 26 Manual 0-2683
5.0 PARTS LIST
Order replacement parts by catalog number and complete description of the part or assembly. Also include the model
and serial number of the torch. Address all inquiries to your authorized distributor or call toll free 1-888-832-4250.
NOTE
Standard hardware has been used in this unit. Replacement hardware can be purchased locally.
5.1 Returns
If a product must be returned for service, contact your authorized distributor . Items r eturn to the manufacturer without
proper authorization will not be accepted.
5.2 Parts Replacement
NOTE: Refer to Power Supply data tag to identify model of your unit.
Description Catalog #
A. Complete Systems
Includes Power Supply , PCH-10 70° Torch with Leads, Spare Consumable Parts, Input Power Cord, and Work Cable.
DRAG-GUN 100V/50Hz 110V/60Hz, PCH-10 1-1111-3
DRAG-GUN 120V 50Hz, PCH-10, "CE" 1-1811-6
DRAG-GUN 120V 60Hz, PCH-10 1-11 1 1-1
DRAG-GUN 220V 50Hz, PCH-10, "CE" 1-1811-5
DRAG-GUN 208/230 60Hz, PCH-10 1-1111-2
Includes Power Supply , PCH-10 180° T or ch with Leads, Spare Consumable Parts, Input Power Cord, and Work Cable.
DRAG-GUN 100V/50Hz 110V/60Hz, PCH-10 1-1111-3-180
DRAG-GUN 120V 50Hz, PCH-10, "CE" 1-1811-6-180
DRAG-GUN 120V 60Hz, PCH-10 1-1111-1-180
DRAG-GUN 220V 50Hz, PCH-10, "CE" 1-1811-5-180
DRAG-GUN 208/230 60Hz, PCH-10 1-1111-2-180
B. Power Supply Only
Includes Power Supply , Input Power Cord, and Work Cable.
DRAG-GUN 100V/50Hz 110V/60Hz 3-1112
DRAG-GUN 120V 50Hz, "CE" 3-1113
DRAG-GUN 120V 60Hz 3-11 1 1
DRAG-GUN 220V 50Hz, "CE" 3-1114
DRAG-GUN 208/230 60Hz 3-1110
C. Torch & Leads Only
Includes T orch & Leads, 90° Nylon Air Compressor Fitting. Torch Leads alone are not r eplaceable.
PCH-10 (70°) w/20 ft. (6 m) Leads 2-1020
PCH-10 (180°) w/20 ft. (6m) Leads 2-1021
Manual 0-2683 27 P ARTS LISTS
5.3 Power Supply Replacement Parts
Item # Qty Description Ref. Catalog#
1 1 Transformer/Inductor (Incl. Chassis): T1/L1
DRAG-GUN 100V/50Hz 110V/60Hz 9-0023
DRAG-GUN 120V 50Hz 9-0024
DRAG-GUN 120V 60Hz 9-0001
DRAG-GUN 220V 50Hz 9-0037
DRAG-GUN 208/230 60Hz 9-0036
2 1 Cover (incl. Labels) 9-0002
3 1 Control PCB Assembly 9-0003
4 1 Capacitor: C13
DRAG-GUN 100V 50Hz/110V 60Hz, Capacitor AC 120UF, 180V 9-0004
DRAG-GUN 120V 50Hz, Capacitor AC 120UF, 180V 9-0004
DRAG-GUN 120V 60Hz, Capacitor AC 120UF, 180V 9-0004
DRAG-GUN 220V 50Hz, Capacitor AC, 60MFD, 370V 9-3924
DRAG-GUN 208/230 60Hz, Capacitor AC 60 MFD, 370V 9-3924
5 1 W ire Harness (Not Shown) 9-0005
6 1 Relay, DPST , -NO, 25A @ 250V K1 9-7508
7 1 Fan:
DRAG-GUN 100V/50Hz 110V/60Hz, Fan 115V 8-3209
DRAG-GUN 120V 50Hz, Fan 115V 8-3209
DRAG-GUN 120V 60Hz,Fan 115V 8-3209
DRAG-GUN 220V 50Hz, Fan 220V 9-7687
DRAG-GUN 208/230 60Hz, Fan 220V 9-7687
8 1 Compressor , Air , 12VDC, 0.5 CFM 9-0010
1 Compressor Disc Filter 9-7912
9 1 Resistor, 0.5ohm, 55 watt, 10%,3/16 Faston 9-0011
10 1 Resistor, 1Kohm, 55 watt, 5%,3/16 Faston 9-0012
11 1 W ork Cable, 15 ft. (4.57 m) w/Red Handles 9-0013
12 1 Input Power Cable, 6.5 ft. min. (2 m):
DRAG-GUN 100V/50Hz 110V/60Hz, Power Cable, 14/3 w/molded plug 9-0052
DRAG-GUN 120V 50Hz, Power Cable, "CE", ** 9-0044
DRAG-GUN 120V 60Hz, Power Cable, 16/3 w/molded plug 9-0014
DRAG-GUN 220V 50Hz, Power Cable, "CE" ** 9-0044
DRAG-GUN 208/230 60Hz, Power Cable, 16/3 w/molded plug 9-0014
** Plug to be supplied by customer .
13 1 ON/OFF Switch:
DRAG-GUN Switch, DPST , 125V 15A w/RED NEON (non CSA) 9-0015
DRAG-GUN Switch, DPST , 22A, 125V AC, RED NEON (CSA) 9-0021
DRAG-GUN Switch, 16A, 250V AC, AMBER (or Red) NEON 9-0029
14 1 CD Transformer/Ferrite Core Assembly 9-0018
15 2 Bridge Rectifier 7-3345
16 1 Handle 9-8115
5.4 Options & Accessories (not shown)
Qty Description Catalog#
1 Circle Cutting Guide Kit 7-8910
1 Leads W rap (installed under Handle) 9-7865
PARTS LISTS 28 Manual 0-2683
* For illustration purposes, the
Transformer/Inductor Assembly
is shown separated from the
Chassis. The Transformer/Inductor
/Chassis is actually one assembly
and should not be disassembled
for any field repairs.
To remove cover, unfasten:
• 4 side panel screws
• 2 handle screws
• 2 end panel screws
14
HARDWARE QTY
16
C
C
2
A Screw, #6-32 x 3 3/4 Lg, Phil Pan Hd, Zinc
B #6-32 Regular Nylon Lock Nut, Zinc Plated
C 5/16-18 x 1 3/4 Unc Cap Socket Head Bolt
D 10-32 x .5 Pph Swageform Stl Zn. Parker Kalon
E Screw, Black, 6-32 x 1/2 Pph, Swageform, Steel
F 10-32 Kepnut w/Star Washer Mild Steel
NOTE: Replacement hardware can be purchased locally.
2
2
2
4
2
2
D
D
A
6
3
A
Direction
4
Rotation
12
D
B
B
1
(BR2)
(BR1)
15
8
E
Chassis
E
Torch & Leads
7
Air Flow
Direction
Figure 5-1 Exploded View of Power Supply
Manual 0-2683 29 P ARTS LISTS
10
F
F
A-02337
9
11
13
5.5 Torch Replacement Parts
Item # Qty Description Catalog#
1 1 PCH-10 (70°) T or ch Head Assembly* 9-0016
PCH-10 (180°) T orch Head Assembly* 9-0017
2 1 Torch Handle Only 9-0019
3 1 Torch Switch 9-1058
4 1 Standard Electrode 9-6006
5 1 PCH-10 T ip 9-6099
6 1 Gas Distributor 9-6007
7 1 Shield Cup 9-6003
8 1 Torch Head Split Holders
PCH-10 (70°) 9-6259
PCH-10 (180°) 9-6261
9 1 PIP (Parts-In-Place) W ire Assembly 9-6290
10 1 O-Ring 8-0533
11 1 T orch Switch Button 8-4256
12 2 Tor ch Switch Button Springs 9-6292
* T o be replaced by Qualified Technician only.
2
11
8
3
12
1
B
10
1
2
C
A
A
A
9
4
6
5
7
8
A-02360
A #2-56 x 5/16" LG Phillips Pan Head
B #6 Internal Star Washer
C #6-32 x 3/16" Phillips Pan Head M.S.,
A
A
HARDWARE QTY
Zinc Plated
A
6
1
1
PARTS LISTS 30 Manual 0-2683
Figure 5-2 Exploded View of Torch
APPENDIX I - INTERCONNECTING DIAGRAM
NOTE: Use this diagram for all rev C units (or
earlier). Check the data tag on the unit for rev level.
T
RCH
L41A (1)
O
PILOT
(RED Sleeved)
0.5
WORK
27
43
E1
E2
SPK1
350V Spark Gap
CD
PRIMARY
330µƒ
330µƒ
450v
450v
22
3 watt
55 watt
24
50
5 watt
A-02012
2L1
L1 CD XFMR
-
BR1
BRIDGE
35A 1200V
1
K1-B
8
T1
+
(7) 7A34
450v
150µƒ
E6 E5
10
+
26
CD
PWR
CIRCUIT
1
4
7
10
11
J2
J2
J2
J2
J2
1
4
7
10
11
-
BR 2
BRIDGE
35A 1200V
11
K1-C
29
LOGIC
CIRCUIT
1213161714
J2J2J2J2J2
1213161714
TEMP
TORCH
SWITCH
PIP Pin
PIP Pin
Cup
Shield
CD PCB
15
18
J2
J2
15
18
1K
55 watt
K1
12v
23
8
(7) 7A34
T1
5
21
SW1
6
C13
22
Manual 0-2683 31 APPENDIX
-
230
FAN
20 1920 19
AIR
12 VDC
COMPRESSOR
+
5
RED BLK
21
370vac 180vac 180vac
Dual voltage marked 208v (tap) & 230v
NOTES
Model: 220vac 120vac 100vac
C13 60µƒ 120µƒ 120µƒ
FAN 220vac 120vac 120vac
T1 PR1 Single voltage marked #6
208
6
C13
FAN
22
20 19
APPENDIX II - INTERCONNECTING DIAGRAM
A-02277
APPENDIX 32 Manual 0-2683
NOTE: Use this diagram for all rev D (or later)
units. Check the data tag on the unit for rev level.
1
1
8063
12/01
98
Manual 0-2683 33 APPENDIX
A-02277
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