Thermal Dynamics Drag-Gun 38 Instruction Manual

PLASMA CUTTING

POWER SUPPLY

Drag-Gun™ 38

Used With PCH-42 RPT SureLok™ Torch

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A-02145

Instruction Manual

December 9, 2002 Manual No. 0-2879

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
Drag-Gun™ 38
Instruction Manual Number 0-2879

Published by:
Thermal Dynamics Corporation
82 Benning Street
West Lebanon, New Hampshire, USA 03784
[phone]

www.thermadyne.com

Copyright 2001 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: December 9, 2002

Record the following information for W arranty 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.................................................................................................. 1-2

1.04 Note, Attention et Avertissement .................................................................. 1-3

1.05 Precautions De Securite Importantes........................................................... 1-3

1.06 Documents De Reference ............................................................................ 1-5

1.07 Declaration of Conformity ............................................................................. 1-7

1.08 Statement of Warranty.................................................................................. 1-8

SECTION 2:

INTRODUCTION & DESCRIPTION.................................................................................. 2-1

2.01 Scope of Manual .......................................................................................... 2-1

2.02 General Description ..................................................................................... 2-1

2.03 Specifications & Design Features................................................................. 2-1

SECTION 3:

INST ALLATION PROCEDURES ....................................................................................... 3-1

3.01 Introduction .................................................................................................. 3-1

3.02 Site Location ................................................................................................ 3-1

3.03 Unpacking .................................................................................................... 3-1

3.04 Handle Installation........................................................................................ 3-1

3.05 Electrical Connection ................................................................................... 3-1

3.06 Torch Connection ......................................................................................... 3-2

SECTION 4:

OPERATION ..................................................................................................................... 4-1

4.01 Introduction .................................................................................................. 4-1

4.02 Operating Controls ....................................................................................... 4-1

4.03 Getting Started ............................................................................................. 4-1

4.04 Operating the System .................................................................................. 4-2

4.05 Recommended Cutting Speeds.................................................................... 4-3

SECTION 5:

SERVICE ......................................................................................................................... 5-1

5.01 Introduction .................................................................................................. 5-1

5.02 General Maintenance................................................................................... 5-1

5.03 Common Operating Faults ........................................................................... 5-1

5.04 Troubleshooting Guides................................................................................ 5-2

5.05 Basic T roubleshooting Guide........................................................................ 5-2

5.06 Advanced T roubleshooting Guide ................................................................. 5-3

5.07 T roub leshooting Flow Charts........................................................................ 5-3

5.08 Test Procedures ......................................................................................... 5-10

5.09 Power Supply Component Replacement Procedures................................. 5-15

5.10 T orch and Leads Replacement Procedure ................................................. 5-20

TABLE OF CONTENTS (continued)

SECTION 6:

PARTS LISTS.................................................................................................................... 6-1

6.01 Introduction .................................................................................................. 6-1

6.02 Ordering Information .................................................................................... 6-1

6.03 Power Supply Replacement P arts ................................................................ 6-2

6.04 Rear Panel Replacement Parts .................................................................... 6-4

6.05 Complete Assembly Replacement ............................................................... 6-6

APPENDIX 1: SEQUENCE OF OPERATION BLOCK DIAGRAM.............................................A-1

APPENDIX 2: ROUTINE MAINTENANCE SCHEDULE............................................................ A-2

APPENDIX 3: RECOMMENDED CUTTING SPEEDS..............................................................A-3

APPENDIX 4: NON-CE SYSTEM SCHEMATIC........................................................................ A-4

APPENDIX 5: CE & AUSTRALIA SYSTEM SCHEMATIC.........................................................A-6

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 1-1 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. Yo u
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 1-2 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. NFP A Standar d 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 Welding 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 r ésulter
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 1-3 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 respiratoire 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 1-4 Date: Nov ember 15, 2001

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

RAYONS D’ARC DE PLASMA

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 trouvant 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 York,
NY 10018

5. Norme ANSI Z41.1, NORMES POUR LES
CHAUSSURES PROTECTRICES, disponible auprès
de l’American National Standards Institute, 1430
Broadway, New York, NY 10018

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’assurer que
les décibels (le bruit) ne dépassent pas les niveaux
sûrs.

• Pour des renseignements sur la manière de tester le
bruit, consultez l’article 1, page 5.

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 1-5 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 PRÉPARATION À LA COUPE ET
AU SOUDAGE DE CONTENEURS ET TUYAUX
AYANT RENFERMÉ DES PRODUITS
DANGEREUX , disponible auprès de la American
Welding Society, 550 N.W. LeJeune Rd., Miami, FL
33126

15. Norme ANSI Z88.2, PRA TIQUES DE PROTECTION
RESPIRATOIRE, disponible auprès de l’American
National Standards Institute, 1430 Broadway, New
York, NY 10018

GENERAL INFORMATION 1-6 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 ar e:

* 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 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 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 1-7 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 Y ears 1 Year 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 Y ear 1 Year
Exchanges, And Accessory Equipment

Torch And Leads

Maximizer 300 Torch 1 Y ear 1 Year
SureLok T orches 1 Y ear 1 Y ear 1 Year
All Other Torches 180 Days 180 Days 180 Days 180 Days

Repair/Replacement Parts 90 Days 90 Days 90 Days None

Warranty repairs or replacement claims under this limited warranty must be submitted by an authorized Thermal Dynamics® repair
facility within thirty (30) days of the repair . No transportation costs of any kind will be paid under this warranty. Transportation charges
to send products to an authorized warranty repair facility shall be the responsibility of the customer. All returned goods shall be at the
customer ’s risk and expense. This warranty supersedes all previous Thermal warranties.

Effective: November 15, 2001

GENERAL INFORMATION 1-8 Date: Nov ember 15, 2001

SECTION 2:

INTRODUCTION &

DESCRIPTION

4. Output Power

Continuously variable from 12 to 29 Amps maximum.

5. OCV

375 vdc

2.01 Scope of Manual

This manual contains descriptions, operating instructions
and maintenance procedures for the Drag-Gun 38 Plasma
Cutting System. Service of this equipment is restricted
to properly trained personnel; unqualified personnel are
strictly cautioned against attempting repairs or adjust­ments not covered in this manual, at the risk of voiding
the W arranty.

Read this manual thoroughly. A complete understand­ing of the characteristics and capabilities of this equip­ment will assure the dependable operation for which it
was designed.

2.02 General Description

The Plasma Cutting System can cut most metals from
gauge thickness up to 3/8 inch (9.5 mm).

The Power Supply provides 29 amps maximum output
cutting current. All electrical, pilot, built-in air compr es­sor, wheels and handle are included.

2.03 Specifications & Design

Features

The following applies to the Power Supply only:

1. Controls

• AC POWER ON/OFF Switch

• CURRENT Output Control

2. Panel LED Indicators

6. Duty Cycle (see NOTE)

NOTE

The duty cycle will be reduced if the primary in­put voltage (AC) is low or the DC voltage is higher
than shown in the chart.

Power Supply Duty Cycle

Ambient

Temperature

Duty Cy cle

Current

DC Voltage

7. Work Lead

20 ft (6 m) Cable with Clamp

8. Cut Capacity

3/8 inch (9.5 mm) mild steel

9. Pilot Circuitry

Capacitor Discharge (CD), Pulsed DC

10. Gas Requirements

Built-in Air Compressor

11. Weight (with Leads)

• Domestic Units

87 lbs (39.5 kg)

104° F

(40° C)

40% 60% 100%

29 Amps N/A Amp s N/A Amps

92 vdc N/A vdc N/A vdc

104° F

(40° C)

104° F

(40° C)

AC , GAS , DC , OverTEMP

3. Input Power

• Domestic Units

208/230 VAC (±10%), Single-Phase, 60 Hz
Unit supplied with 10 ft (3 m) Input Power Cable

and Plug

• CE and Australian Units

220 VAC (±10%), Single-Phase, 50/60 Hz
Unit supplied with 9.5 ft (2.9 m) Input Power Cable

without Plug

Manual 0-2879 2-1 INTRODUCTION & DESCRIPTION

• CE and Australian Units

90 lbs (41 kg)

12. Dimensions

38.5 inches
(977.9 mm)

22 inches (558.8 mm) (incl. wheels)

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INTRODUCTION & DESCRIPTION 2-2 Manual 0-2879

SECTION 3:

INSTALLATION

PROCEDURES

3.01 Introduction

B. Removing Skid

The base of the power supply is secured to the skid with
lag screws. Remove the power supply from the skid per
the following procedure:

1. Remove the four lag screws securing the Power
Supply to the skid. There are two lag screws on
each side.

This section describes installation of the Plasma Cutting
System. These instructions apply to the Power Supply,
T orch and Leads Assemblies only; installation procedures
for any Options or Accessories are given in manuals spe­cifically provided for those components.

3.02 Site Location

Select a clean, dry location with good ventilation and ad­equate working space around all components.

CAUTIONS

Operation without proper air flow will inhibit
proper cooling and reduce duty cycle.

To prevent entry of cutting or other metal debris,
the power supply must not be operated in the hori­zontal position. Operate the power supply in the
vertical position only with the handle in the up­right position.

The power supply is cooled by air flow through the end
and side panels. Air flow must not be obstructed. Pro­vide at least 12 inches (300 mm) clearance on each side.
Provide sufficient clearance above unit to allow access to
top panel controls (minimum 12 inches or 300 mm).

NOTE

Review the safety precautions in Section 1 of this
manual to be sure that the location meets all safety
requirements.

3.03 Unpacking

A. Shipping Box

The product is packaged and protected to prevent dam­age during shipping.

1. Unpack each item and remove all packing mate­rial.

2. Locate the packing list(s) and use the list to iden­tify and account for each item.

2. Lift unit from the skid and set the unit aside.

3.04 Handle Installation

The Handle must be attached to the Power Supply.

1. Locate the Handle and four hex head bolts (1/4­20 x 1-1/4 inch) in the shipping package.

2. Align the holes in the Handle with the four holes
in the Rear Panel.

3. Secure the Handle to the Rear Panel with the sup­plied hex head bolts.

4. T ighten the bolts being careful not to over tighten.

3.05 Electrical Connection

CAUTION

The primary power source, power cable, and plug
all must conform to local electrical codes, recom­mended circuit protection and wiring r equirements.

• Domestic Units

The Power Supply operates on 208/230 VAC
(±10%), single-phase, 60 Hz input power. The
208VAC unit draws 26 amperes and the 230VAC
unit draws 23 amperes of input current. The in­put power electrical service for the Power Supply
must be fused for at least 30 amperes. The electri­cal outlet should be within 10 ft (3.0 m) of the
Power Supply.

• CE and Australian Units

The Power Supply operates on 220 VAC (±10%),
single-phase, 50/60 Hz input power. The input
power electrical service for the Power Supply must
be fused for at least 25 amperes. The electrical
outlet should be within 9 ft (2.9 m) of the Power
Supply.

3. Inspect each item for possible shipping damage.
If damage is evident, contact your distributor or
shipping company before proceeding with sys­tem installation.

Manual 0-2879 3-1 INST ALLATION PROCEDURES

3.06 Torch Connection

The T orch is installed to the Power Supply when or dered
as part of the system. Use the following procedure only
if the Power Supply and Torch were ordered separately:

1. Remove the Right Side Panel of the Power Sup­ply per Section 5.08-A-1.

2. Locate the Torch Block area as shown in the fol­lowing Figure.

A-03238

Torch Block

Area

Figure 3-1 Torch Block Area Location

NOTE

Note that all wires are outside the protective insu­lating sheet.

3. Remove the strain relief nut from the strain relief
on the Torch Leads Assembly.

4. Feed the ends of the Torch Leads Assembly
through the hole in the Power Supply Panel.

5. Place the strain relief nut back over the end of the
Torch Leads and secure the strain relief to the
panel with the nut.

Nylon Screw

Removal

A-03247

Figure 3-2 Nylon Screw

7. Connect the Torch Negative Lead to the fitting in
the brass torch bulkhead.

Torch Negative

Lead

Torch Lead

Fitting

Bulkhead

A-03240

Figure 3-3 Negative Torch Lead Connection

6. Remove the nylon screw holding the protective
insulating sheet to the bulkhead.

8. Close the protective insulating sheet back over the
torch bulkhead and secure with the nylon screw
removed earlier (see CAUTION).

CAUTION

Be sure all wires are outside the pr otective insulat­ing sheet when the nylon screw is reinstalled. High
voltage is present on the torch negative lead.

INST ALLATION PROCEDURES 3-2 Manual 0-2879

9. Connect the two torch control connectors and the
pilot wire to the Main PC Board Assembly con­nections.

Torch Control

Connectors

Pilot Wire

A-03239

Connection

Figure 3-4 Wiring Connections

10. Close the Power Supply by reinstalling the Right
Side panel.

Manual 0-2879 3-3 INST ALLATION PROCEDURES

INST ALLATION PROCEDURES 3-4 Manual 0-2879

SECTION 4:

OPERATION

6. CURRENT Control Guards

Guards used to protect the Current Control from
damage.

4.01 Introduction

This section provides a description of the Plasma Cut­ting System followed by operating procedures.

4.02 Operating Controls

A. Top Panel

8

WORK

TORCH

MADE IN THE USA

A-03229

AC

1 2

7

TM

OVER

DC

GAS

R

3

TEMP

4 5

12

CURRENT

20

29

6

7. TORCH Lead

Access hole used to interface the Torch to the
Power Supply .

8. WORK Cable

Access hole used to interface the work cable to
the Power Supply.

B. Back Panel

• AC POWER ON/OFF Switch

ON position supplies AC power to activate all sys­tem circuits. OFF position deactivates circuits.

• Input Power Cable

Strain relief and input power cable for main AC
power to the unit.

4.03 Getting Started

This procedure should be followed at the beginning of
each shift:

1. AC Indicator

Green light indicates AC input power is present
in the system when the ON/OFF switch is in ON
position. Indicator will flash and the air compres­sor will run for 3-5 seconds when first turned on
until the power circuits are ready.

2. GAS Indicator

Green light indicates minimum gas pressure of
35 psi (2.5 bar) is flowing to the torch when the
torch is activated.

3. DC Indicator

Green light indicates adequate DC power output
for main arc when the torch is activated.

4. OverTEMP Indicator

Indication is off during normal operation. Yellow
light indicates overheating; unit must be allowed
to cool. The indicator will also flash momentarily
if the torch is shorted.

5. CURRENT Control

WARNING

Disconnect primary power at the source before as­sembling or disassembling torch parts, or torch and
leads assemblies.

A. T or ch Parts

Check the torch for proper assembly. Install proper
torch consumables for the desired application (refer
to Manual supplied with the Torch for proper Torch
Consumables Selection).

NOTE

The power supply will not operate unless the torch
shield cup is fully seated against the PIP (Parts in
Place) pins in the torch head.

B. Input Power

1. Make sure the power source meets circuit protec­tion and wiring requirements per Section 3.05.

2. Plug unit in and close main disconnect switch to
supply primary power to the system.

Adjusts output current from 12 to 29 amps.

Manual 0-2879 4-1 OPERA TION

C. Work Cable

2. Wear protective clothing then activate the torch.

Check for a solid work cable connection to the work­piece.

D. Purge System

Place the ON/OFF switch to the ON position. Gas
will flow for three seconds to purge the torch leads.

E. Current Output Level

Set the desired current output level for the desired
operation (12 to 29 amps).

F. Ready for Operation

The system is now ready for operation.

4.04 Operating the System

WARNINGS

Disconnect primary power at the source before dis­assembling the power supply, torch, or tor ch leads.

Frequently review the Important Safety Precau­tions in Section 1 of this manual. Be sure the op­erator is equipped with proper gloves, clothing, eye
and ear protection. Make sure no part of the
operator’s body comes into contact with the work­piece while the torch is activated.

Sparks from the cutting process can cause damage
to coated, painted, and other surfaces such as glass,
plastic and metal.

Handle torch leads with care and protect them fr om
damage.

A. Sequence of Operation

The following is a typical sequence of operation for this
cutting system:

NOTE

Refer to Appendix 1 for a detailed block diagram of
the Sequence of Operation.

1. Place the primary power ON/OFF switch on rear
panel to the ON position.

• AC POWER indicator comes on.

• Fan turns on.

• Compressor runs 3-5 seconds.

• Main power relay closes.

• Compressor pre-flow 1-1/2 to 2 seconds.

• Pilot arc is established.

3. Move torch within transfer distance of work piece
(or start with tip on the work piece).

• Main arc transfer.

• Pilot arc off.

4. Complete cutting operation and deactivate torch.

NOTE

To initiate cutting after post-flow ends wait 1-2
seconds before activating torch.

• Main Arc off.

• Compressor post-flow 15 seconds.

5. When finished cutting session, place the primary
power ON/OFF switch to the OFF position.

• AC Power Indicator light off.

• Fan turns off.

B. Piloting

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.

C. Torch Standoff

Improper standoff (the distance between the torch
tip and workpiece) can adversely affect tip life as well
as shield cup life. Standoff may also significantly
affect the bevel angle. Reducing standoff will gener­ally result in a reduced bevel angle.

D. Dross

When dross is present on carbon steel, it is commonly
referred to as either “high speed, slow speed, or top
dross”. Dross present on top of the plate is normally
caused by too great a torch to plate distance. "Top
dross" is normally very easy to remove and can often
be wiped off with a welding glove. "Slow speed
dross" is normally present on the bottom edge of the
plate. It can vary from a light to heavy bead, but
does not adhere tightly to the cut edge, and can be
easily scraped off. "High speed dross" usually forms
a narrow bead along the bottom of the cut edge and
is very difficult to remove. When cutting a trouble­some steel, it is sometimes useful to reduce the cut­ting speed to produce "slow speed dross". Any re­sultant cleanup can be accomplished by scraping, not
grinding.

OPERA TION 4-2 Manual 0-2879

4.05 Recommended Cutting Speeds

Cutting speed depends on the type of material, material
thickness and operator ability to accurately follow the de­sired cut line. The following factors may have an impact
on system performance:

• Torch parts wear

• Air quality

• Operator experience

• Tor ch standof f height

• Proper work cable connection

• Alloy content of material

For complete cutting speed data refer to Appendix 3.

NOTE

The information represents realistic expectations
using recommended practices and well maintained
systems. Actual speeds may vary from those shown
in the chart depending on the alloy content of the
selected material.

Manual 0-2879 4-3 OPERA TION

OPERA TION 4-4 Manual 0-2879

SECTION 5:

CAUTIONS

SERVICE

5.01 Introduction

This section d escribes basic maintenance p roc edures that
can be performed by operating personnel, and advanced
procedures that can be performed by qualified
technicians. No other adjustments or repairs other than
those described are to be attempted.

WARNINGS

Disconnect primary power at the source before dis­assembling the torch, 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.

Frequently review the Important Safety Precau­tions in Section 1 of this Manual. Be sure the op­erator is equipped with proper gloves, clothing, eye
and ear protection. Make sure no part of the
operator’s body comes into contact with the work­piece while the torch is activated.

Sparks from the cutting process can cause damage
to coated, painted, and other surfaces such as glass,
plastic and metal.

Do not blow air into the power supply during clean­ing. Blowing air into the unit can cause metal par­ticles to interfere with sensitive electrical compo­nents and cause damage to the unit.

When cleaning, care must be taken not to move or
damage the electronic components.

5.03 Common Operating Faults

The following lists the more common cutting faults and
what is the possible cause:

1. Insufficient Penetration

a. Cutting speed too fast
b. Torch tilted too much
c. Metal too thick
d. Worn torch parts
e. Cutting current too low
f. Non-genuine Thermal Dynamics torch parts
g. Low air flow for plasma gas

2. Main Arc Extinguishes

a. Cutting speed too slow
b. Cutting current too high
c. Tor ch standoff too high from workpiece

5.02 General Maintenance

The only routine maintenance required for the power sup­ply is a thorough cleaning and inspection, with the fre­quency depending on the usage and the operating envi­ronment.

Refer to Appendix 2, Maintenance Schedule, for specific
procedures.

WARNING

Disconnect primary power to the system before dis­assembling the torch, leads, or power supply.

T o clean the unit, open the enclosure (refer to Section 5.08­A, Opening Enclosure) and use a vacuum cleaner to re­move any accumulated dirt and dust. The unit should
also be wiped clean. If necessary, solvents that are rec­ommended for cleaning electrical apparatus may be used.

d. AC line too low - reduce output current
e. Work cable disconnected
f. Worn torch parts
g. Non-Genuine Thermal Dynamics Tor ch Parts

3. Excessive Dross Formation

a. Cutting speed too slow (bottom dross)
b. Cutting speed too fast (top dross)
c. Tor ch standoff too high from workpiece
d. Worn torch parts
e. Improper cutting current
f. Non-genuine Thermal Dynamics torch parts

4. Short Torch Parts Life

a. Oil or moisture in air source
b. Exceeding system capability (material too thick)
c. Excessive pilot arc time

Manual 0-2879 5-1 SERVICE

d. Low air flow for plasma gas

This guide is set up in the following manner:

e. Improperly assembled torch
f. Output current too high
g. Torch tip contacting workpiece
h. Damaged or loose torch head components
i. Non-genuine Thermal Dynamics torch parts

5. Poor Pilot Starting

a. Non-genuine Thermal Dynamics torch parts
b. Worn torch parts
c. Damaged or loose torch head parts

5.04 Troubleshooting Guides

There are two Troubleshooting Guides, Basic and Ad­vanced, provided in this Instruction Manual. The Basic
Troubleshooting Guide uses symptom, cause, and rem­edy for fault isolation. The Advanced Troubleshooting
Guide uses Flow Charts and test procedures for fault iso­lation.

Basic troubleshooting is limited to non-power checks and
external Power Supply faults. Advanced troubleshoot­ing requires fault isolation to the Power Supply or Torch,
Power Supply disassembly, voltage measurements and
major component replacement.

The guides are as follows:

Section 5.05 - Basic Troubleshooting Guide
Section 5.06 - Advanced Troubleshooting Guide

Depending on the level of repair to be done, refer to the
desired troubleshooting guide.

X. Symptom (Bold Type)

Any Special Instructions (Text Type)

1. Cause (Italic Type)

a. Check/Remedy (Text Type)

Locate your symptom, check the causes (easiest listed first)
then remedies. Repair as needed being sure to verify that
the unit is fully operational after any repairs.

A. AC Indicator OFF, Fans do not operate.

1. ON/OFF Switch not on.

a. Turn ON/OFF Switch to ON position.

2. No power from main disconnect.

a. Reset breaker or replace fuse (refer to Section

3.05 for proper size circuit protection).

B. Temperature indicator on.

1. Unit is overheated due to exceeding duty cycle.

a. Allow unit to cool and reduce duty cycle.

2. Unit is overheated due to obstructed air flow.

a. Provide proper clearance (r efer to Section 3.02)
b. Clean unit (refer to Section 5.02).

3. Shorted torch. TEMP Indicator lights momentarily
then unit stops cutting or piloting.

a. Check for proper torch parts assembly or

shorted torch head (refer to Torch Manual sup­plied with the T o rch).

4. Input voltage too high.

5.05 Basic T roubleshooting Guide

A. General

Basic troubleshooting of the Plasma Cutting System can
be performed without special equipment or knowledge,
and without opening the enclosure.

This basic troubleshooting guide covers input power , gas
supply, and torch problems.

For problems not covered here, refer to the Advanced
Troubleshooting Guide or contact your authorized dis­tributor .

B. How to Use This Guide

The following information is a guide to help determine
the most likely causes for various symptoms.

SERVICE 5-2 Manual 0-2879

C. AC Indicator blinks for four seconds when power

a. Check customer supplied voltage source (re-

fer to Section 2.03-3).

is turned on but there is no gas flow and the
compressor has power but does not operate.

1. Gas (air) flow blocked.

a. Check and clear blockage per Section 5.08-G.

2. Faulty Starting Capacitor (C1).

a. Check Starting Capacitor per Section 5.08-G.

3. Power not getting to Compressor.

a. Check voltage per Section 5.08-G.

4. Faulty Compressor

a. Replace Compressor.

D. AC indicator ON, Over TEMP indicator dark, no

gas flow when torch switch pressed.

1. Shield cup not properly installed on torch.

a. Check that shield cup is fully seated against

torch head.

2. Faulty Torch Switch or PIP Assembly in tor ch holder.

a. Repair Torch components (refer to the Torch

Manual supplied withe the Torch).

5.06 Advanced Troubleshooting Guide

A. General

The troubleshooting covered in this Instruction Manual
requires Power Supply disassembly and live measure­ments. It is helpful for solving the common problems
that may arise with the Power Supply.

3. Faulty Main PC Board.

a. Replace Power Supply.

E. AC indicator ON, Over TEMP indicator dark,

GAS indicator ON, gas flows, DC indicator ON.
Torch does not pilot.

1. Faulty torch consumables.

a. Inspect torch consumables and replace if nec-

essary.

2. Faulty Pilot Resistor (R1).

a. Check for 15 ohms at the Pilot Resistor across

wires #9 & #10.

• If 15 ohms is present, replace Power Sup­ply.

• If 15 ohms is not present, replace Pilot Re­sistor.

F. Torch pilots but does not cut.

1. Work cable not connected.

a. Make sure work cable is connected securely to

bare metal.

2. AC input power too low.

a. Use shortest distance to main disconnect or

breaker panel as possible (refer to Section 3.05).

WARNING

There are extremely dangerous voltage and power
levels present inside this unit. Do not attempt to
diagnose or repair unless you have had training in
power electronics measurement and troubleshoot­ing techniques.

If major complex subassemblies are faulty, the assembly
must be returned to an authorized service center for re­pair .

Follow all instructions as listed and complete each in
the order presented.

The guide has two sections as follows:

Section 5.07 - Troubleshooting Flow Charts
Section 5.08 - Test Procedures

Specific test procedures have been grouped together, and
are refer enced by the flowcharts.

B. How to Use This Guide

The following information is a guide to help the Service
Technician determine the most likely causes for various
failures. This guide is set up in the following manner:

1. Use flowchart(s) to isolate problem to possible
circuit(s).

2. Perform the test procedures as required as noted on
flowcharts.

3. Repair as needed being sure to verify that unit is fully
operational after any repairs.

5.07 Troubleshooting Flow Charts

The following pages are flow charts to be used to isolate
problems in the Plasma Cutting System.

Manual 0-2879 5-3 SERVICE

AC Indicator OFF

on Front Panel

Chart #1: Main Power

System

Operates

Properly?

Yes

Faulty AC Indicator

Replace Power Supply

No

AC POWER
Switch ON?

No

Place AC POWER

Switch to ON

Place Main Power

Disconnect to ON

Yes

No Yes

Power Cable

Plugged In?

Yes

Check Main

Power Disconnect

Main Power

Disconnect ON?

No

Connect AC Power

Input Cable to

AC Source

Check Main Disconnect

Power Line Fuse

Install Proper

Fuse

Check Main Disconnect

No

Power Line Fuses For

Proper Amperage

Unplug Power Supply

From Main Power Source

Proceed to Chart #2B

Yes

Yes

Main Power

Line Fuse

Replaced

Once?

No

Replace Main

Power Line Fuse

No

Main Power

Line FuseOkay?

Yes

Unplug Power Supply

From Main Power Source

Proceed to Chart #2A

SERVICE 5-4 Manual 0-2879

Chart #2: Input Power Checks

B

A

Check 1/2A Fuse (F1) on the

Heatsink/PC Board Assembly

1/2A Fuse

Checks Okay?

No

Yes

Check Input Diode Bridge on

Heatsink/PC Board Assembly

Per Section 5.08-B

Diode Bridge

Checks Okay?

Yes

(See Note)

NOTE

This condition could also result if the input
line voltage was low, using an extension
cable or the user was using a high standoff
while cutting.

Check FET Assemblies on

Heatsink/PC Board Assembly

Per Section 5.08-C

No

FET Assemblies

Check Okay?

Yes

Unplug J2 Connector on the

Heatsink/PC Board Assembly

Replace Fuse (F1) and

Apply AC Power to the

Power Supply per

Section 5.09-F

AC Indicator
Comes ON?

Yes

Replace
Starting Relay (K3)
per Section 5.09-H

No

Replace

Power Supply

No

Unit

Operates

Properly?

Yes

Check Capacitor

PC Board Assembly on

Heatsink/PC Board Assembly

Per Section 5.08-D

Capacitor PC

Board Assembly

Checks Okay?

Yes

Check unit for

proper operation

Replace Panels

and follow

operating procedures

No

Replace Capacitor

PCB per

Section 5.09-N

Manual 0-2879 5-5 SERVICE

Chart #3: Temperature Indicator Checks

AC and Gas Indicators are ON

Temperature Indicator Either

ON or Blinks Once

When Torch is Activated

Temp Indicator

ON Steady

When Torch is

Activated

Yes

No

(blinks once)

Proceed to Chart #4

No

Fan

Operating?

Yes

Temperature
Indicator Still

ON?

Yes

No

No

Duty Cycle

Exceeded?

Use Proper

Operating Procedures

Replace Power Supply

Assembly

Yes

Allow Power Supply

No

Temperature

Indicator ON?

To Cool

Yes

SERVICE 5-6 Manual 0-2879

Chart #4: Shorted Torch or Resistor (R3) Checks

AC and Gas Indicators are ON

DC Indicator Blinks or Momentary ON

When Torch is Activated

Check Pilot Wire

per Section 5.08-E

Pilot Wire

Check Correct?

Yes

Check Resistor (R3) Assembly

per Section 5.08-F

Resistor R3

Check Okay?

Yes

Replace Power Supply

No

No

Replace

Leads Assembly

Replace Resistor (R3)

Assembly

per Section 5.09-P

Manual 0-2879 5-7 SERVICE

Chart #5: Faulty Torch or Torch Switch Checks

A

AC and Gas Indicators are ON

DC Indicator OFF

When Torch is Activated

Check Torch And Leads

Assembly

Torch & Leads

Check Correct?

No

Replace Torch

B

AC Indicator ON

No GAS Flow When Torch

Check Torch Switch

per Section 5.08-H

is Activated

Compressor

operates

4 seconds at

power ON?

Yes

No

Check Troubleshooting

per Section 5.05-C

Yes

Replace Power Supply

Torch Switch

Check Correct?

Yes

Replace Power Supply

No

Replace Torch

SERVICE 5-8 Manual 0-2879

Chart #6: Faulty Current Control

CURRENT Control Knob Turns Completely

Around And Doesn't Stop At Minimum Or

Maximum Positions

Check Shaft Of CURRENT

Control Is Not Loose Or

Broken From PC Board

Is Control

Shaft Okay?

Yes

Secure or Replace
CURRENT Control

Knob per Section 5.09-C

No

Replace Power Supply

Manual 0-2879 5-9 SERVICE

5.08 Test Procedures

The checks in these test procedures are all made with the
main power disconnected.

WARNINGS

Disconnect primary power to the system at the
source before opening the Power Supply.

A. Opening Power Supply Enclosure

1. Left/ & Right Side Panel Removal

The Left and Right Side Panels are removed in the
same manner as follows:

a. Remove the six screws which secure the Side

Panel to unit.

b. Carefully (see NOTE) pull the Side Panel away

from the unit far enough to gain access to the

inside of the unit.

NOTE

There is a ground wire connection to the Side Panel
on the inside of the unit.

2. Top Panel Removal

NOTE

Torch Control

Connectors

Work Cable
Connection

A-03251

Pilot Wire

Connection

Figure 5-1 Wiring Connections

CAUTION

DO NOT overtorque the nuts on the terminals as
the PC Board may be damaged.

d. Disconnect the Pilot Wire from the stud ter-

minal on the Main PC Board.

The Right Side Panel must be removed first to pro­vide internal access to the torch and work cable
connections.

a. Remove the Right Side Panel per paragraph

'A-1' above.

b. Remove the Current Knob per Section 5.09-C.
c. Disconnect the Torch Lead from the Torch

Block.

e. Disconnect the T orch Control Connectors from

the wiring harness connected to J3 on the Main
PC Board.

f. Disconnect the Work Cable from the terminal

stud on the Main PC Board.

g. Remove the four screws securing the T op Panel

to the Power Supply.

h. Carefully remove the Top Panel (see NOTE)

from the Power Supply . Be car eful not to dam­age the current control shaft.

NOTE

There is a ground wire connection to the Top Panel
on the inside of the Power Supply.

i. Disconnect the ground wire connection from

the Top Panel.

j. Place the Top Panel aside.

SERVICE 5-10 Manual 0-2879

B. Checking Input Diode Bridge

Testing of diode modules requires a digital volt/ohm
meter that has a diode test scale or an analog VOM with
1X or X10 scale. Remember that even if the diode mod­ule checks good, it may still be bad. If in doubt, replace
the Power Supply.

1. Remove the Left Side Panel of the Power Supply
per paragraph A-1 above.

2. Locate the Input diode Bridge (outside edge of
Heatsink). Make a visual check of the Input Di­ode Bridge for damage.

A-02135

AC

AC

( )

( )

AC

Figure 5-3 Input Diode Diagram

(+)

AC

(+)

A-01274

A-00307

Input Diode

Location

Figure 5-2 Input Diode Location

3. Set digital volt/ohm meter to diode test scale.

4. Using the Figures for each test, check each diode
in the module. Each diode must be checked in
forward bias (plus to negative) and reverse bias
(negative to plus) direction.

5. Input Rectifier should be isolated for further test­ing. Label and disconnect wires attached to In­put Rectifier .

6. Connect the volt/ohm meter positive lead to the
anode of the diode and the negative lead to the
cathode of the diode for forward bias testing. A
properly functioning diode will conduct in the for­ward bias direction and indicate between 0.3 to

0.9 volts.

7. Reverse the meter leads across the diode for re­verse bias testing. A properly functioning diode
will block in the reverse bias direction and de­pending on the meter function will indicate an
open or "OL".

0.75

Forward Bias

Diode Conducting

Diode T est Symbol

Anode

Cathode

+

VR

COM

_

A

Figure 5-4 Testing Diode Forward Bias

8. For an analog meter, use the meter set on X1 or
X10 scale to measure the resistance of each diode
in both directions. The readings should differ by
at least a factor of 10. If they do not differ (either
high or low in both directions) then replace the
diode module.

9. If Input Rectifier tests out okay, r eplace leads.

Manual 0-2879 5-11 SERVICE

10. If the diode has visible damage or is shorted, the
diode is faulty. Replace the Power Supply.

A-00306

OL

Reverse Bias

Diode Not Conducting

D. Checking Capacitor PC Board

1. Remove the Top Panel of the Power Supply per
paragraph A-2 above.

A-03252

Capacitor PC

Board

Cathode

Anode

+

VR

COM

_

A

Figure 5-5 Testing Diode Reverse Bias

C. Checking FET Assemblies

1. Remove the Top Panel of the Power Supply per
paragraph A-2 above.

2. Using an ohmmeter set on the Rx1 scale make
the following checks:

a. Measure from Capacitor PC Board (+) to Main

Transformer Wir e #3. If the meter indicates a
short the FET Assemblies are faulty.

b. Measure from Capacitor PC Board (-) to Main

Transformer Wir e #3. If the meter indicates a
short the FET Assemblies are faulty.

Figure 5-7 Capacitor PC Board Location

2. Using an ohmmeter set on the Rx1 scale make the
following check:

a. Measure from Capacitor PC Board (+) to (-)

terminals. The meter should increase in resis­tance as the capacitors charge. Reverse probes
and test again. Resistance should decrease and
then increase as the capacitor discharges and
charges. If meter shows short, open or does
not change, replace Capacitor PC Board.

Capacitor
PC Board

Wire #3

(+) T erminal

(-) T erminal

Capacitor
PC Board

(N) T erminal

A-03228

Wire #3

(+) T erminal

(-) T erminal

(N) T erminal

A-03228

Figure 5-8 Check At Capacitor PC Board

Figure 5-6 FET Assembly Check At Capacitor PC

Board

SERVICE 5-12 Manual 0-2879

E. Checking Pilot Wire

1. Remove the Right Side Panel of the Power Sup­ply per paragraph A-1 above.

2. Remove the Pilot Wire from the stud terminal on
the Main PC Board.

A-03253

Pilot Wire

Connection

A-03254

Resistor (R3)

Figure 5-10 Resistor R3 Location

3. Using an ohmmeter set on the Rx100 scale make
the following check:

Figure 5-9 Pilot Wire Connection

3. Using an ohmmeter set on the Rx1 scale make the
following checks:

a. Measure from the T orch Block and the end of

the Pilot Wire. The meter should indicate an
open.

b. Measure from Pilot Wir e to the torch tip. Meter

should indicate a short (less than 1 ohm).

• If either test is faulty, replace Torch & Leads

Assembly or repair Torch components per
Manual supplied with the Torch.

4. Reinstall the Pilot Wire back onto the stud termi­nal on the Main PC Board.

F. Checking Resistor R3 (11k ohms)

1. Remove the Right Side Panel of the Power Sup­ply per paragraph A-1 above.

2. Using a pair of needle nose pliers, remove the red
wire from the terminal on Resistor R3.

a. Measure the Resistance of the Resistor R3. The

meter should indicate 11K ohms.

4. Reinstall the wire back onto the Resistor termi­nal.

5. Check that the other ends of both red and blue
wires are properly attached.

G. Checking Built-In Air Compressor Circuits

1. Remove the Top Panel of the Power Supply per
paragraph A-2 above.

2. Check the built-in Air Compr essor for a blockage.
a. Check if the Compressor is humming. If Com-

pressor is humming, the air flow may be
blocked.

Remove the inlet filter and output hose from
the Compressor. Check for a clogged or dirty
filter . Check for a blockage in the output hose,
Torch Leads, Torch Head or Torch Consum­ables.

Replace the filter or remove the blockage.

3. Check the Starting Capacitor (C1) for proper op­eration.

During the four seconds after the ON/OFF Switch
is turned ON make the following check:

Manual 0-2879 5-13 SERVICE

T est for 208 or 230VAC between wires #19 and
#23 on TB1.

• If the voltage is present and the Compres­sor is humming, check the Starting Capaci­tor.

NOTE

Faulty Capacitors can be shorted, open or reduced
in capacitance.

Check the Starting Capacitor for a short, open or
reduced capacitance as follows:

• Check for shorted Capacitor

A shorted Capacitor may be found with an ohm­meter . Remove the leads fr om one of the Capaci­tor terminals then measure across the terminals.
If it reads a low resistance (less than a few thou­sand ohms) then it is shorted and should be re­placed.

• Check for an open Capacitor or reduced capaci­tance

To check a Capacitor for an open or that has re­duced capacitance requires a capacitance meter.
If a meter is not available, try substituting a good
Capacitor . If the compressor starts using the good
Capacitor , then the original Capacitor was faulty.

H. Checking T orch Switch

1. Remove the Right Side Panel of the Power Sup­ply per paragraph A-1 above.

2. Disconnect the T orch Control Connectors fr om the
wiring harness connected to J3 on the Main PC
Board.

Torch Control

Connectors

J3

A-03255

Figure 5-11 Torch Control Connectors

4. Check the built-in Air Compressor for overheat­ing.

a. If the unit has just been operated for an ex-

tended time, the Compressor may be over­heated. W ait for the Compressor to cool down.
If the Compressor is not overheated, then
Compressor is defective.

5. Check the built-in Air Compressor for proper op­erating voltage.

a. During the four seconds after the ON/OFF

Switch is turned ON make the following
check:

T est for 208 or 230VAC between wires #19 and
#23 on TB1.

• If voltage is not present, check for 24 V AC
on Relay K3 coil from J2-3 to J2-4 on the
Main PC Board. The Relay controls the AC
voltage to the Compressor .

• If 24 VAC is present, Relay K3 is faulty.

• If 24 V AC is not present, check that J2 con­nector is plugged into the Main PC Board.
If J2 is connected properly, the Main PC
Board is faulty. Return the unit for service.

3. Using an ohmmeter set on the Rx1 scale make the
following checks:

a. Measure between the two Torch Contr ol Con-

nectors.

• The meter should indicate an open.

b. Measure between the two T orch Contr ol Con-

nectors while pressing and holding the Torch
Switch (see NOTE).

• The meter should indicate a short.

NOTE

The Shield Cup must be installed to complete the
circuit through the Parts-In-Place (PIP) contacts.

4. Reconnect the Torch Control Connectors to the
wiring harness from J3 on the Main PC Board.

SERVICE 5-14 Manual 0-2879

5.09 Power Supply Component Replacement Procedures

Refer to Section 6 for replacement parts lists, parts orien­tation and ordering information.

WARNING

Disconnect primary power to the system before dis­assembling the torch, leads, or power supply.

A. Handle Replacement

1. Remove four bolts securing the Handle to the Rear
Panel of the Power Supply.

2. Install replacement Handle being careful not to
over tighten the bolts.

B. Filter Dryer Element Replacement

1. Locate the Filter Dryer Assembly on the Rear
Panel of the Power Supply.

2. Remove the metal bowl of the Filter Dryer As­sembly by turning the bowl counterclockwise.

3. Remove the Filter Element Assembly from the
plastic bell by turning counter-clockwise.

4. Disassemble the Filter Element Assembly and re­move the Filter Element.

C. Current Control Knob Replacement

1. Using a small blade screwdriver , loosen the scr ew
securing the knob to the CURRENT Control ad­justment shaft.

2. Turn the CURRENT Control adjustment shaft
fully clockwise. This will represent the maximum
position.

3. Slide the replacement knob onto the shaft.

4. Turn the knob so that the line on the knob points
towards the wide end of the current control sym­bol (maximum position).

5. Tighten the screw in the knob to secure the knob
to the shaft.

6. Turn the knob fully counterclockwise. The line
on the knob should line up with beginning of the
CURRENT Control adjustment symbol (mini­mum position).

7. Adjust the knob as required to align the minimum
and maximum reference points.

D. Left and Right Side Panel Replacement

The Left and Right Side Panels are replaced in the same
manner . Use caution when r emoving the panels as ther e
is a ground wire connected to the inside of each panel.

1. Remove the six screws securing the Side Panel to
the unit.

2. Remove the panel from the Power Supply a short
distance (see note).

A-02136

Filter Dryer

Element

Plastic Bell

Figure 5-12 Filter Dryer Assembly

5. Install the replacement Filter Element by revers­ing the above steps.

NOTE

There is a ground wire attached to the inside of
both side panels.

3. Remove the nut securing the ground wire to the
Side Panel and set the panel aside.

4. To reinstall the replacement Side Panel do the fol­lowing:

a. Reconnect the ground wire to the panel.
b. Place the panel onto the frame.
c. Install all the screws to secure the panel.

Manual 0-2879 5-15 SERVICE

E. Top Panel Replacement

1. Remove the Current Knob per paragraph 'C'
above.

2. Remove the Right Side Panel (see NOTE) per Sec­tion 5.08-A-1.

NOTE

The Right Side Panel must be removed to provide
internal access to the torch and work cable connec­tions.

3. Disconnect the torch lead from the torch block.

Torch Control

Connectors

8. Remove the Top Panel from the Power Supply a
short distance (see note) being careful not to dam­age the current control shaft.

NOTE

There is a ground wire attached to the inside of the
Top Panel.

9. Remove the nut securing the ground wire to the
Top Panel and set the panel aside.

10. To reinstall the replacement Top Panel do the fol­lowing:

a. Reconnect the ground wire to the panel.
b. Place the panel onto the frame.
c. Install all the screws to secure the panel.

F. Fuse (F1) Replacement

1. Remove the Left Side Panel per Section 5.08-A-1.

2. Locate the Fuse inside the unit on the left side of
the Main PC Board.

3. Using a pair of needle nose pliers, carefully re­move the Fuse.

Work Cable

Connection

A-03251

Pilot Wire

Connection

Figure 5-13 Wiring Connections

CAUTION

DO NOT overtorque the nuts on the terminals as
the Main PC Board may be damaged.

4. Disconnect the Pilot Wire from the stud terminal
on the Main PC Board.

5. Disconnect the T orch Control Connectors fr om the
wiring harness connected to J3 on the Main PC
Board.

6. Disconnect the W ork Cable from the terminal stud
on the Main PC Board.

4. Replace the Fuse with the proper rating and type.

5. Reinstall the Left Side Panel.

G. AC Power ON/OFF Switch (SW1)

Replacement

The replacement procedure is the same for all AC Power
Switches. The location of the Switch and wiring to the
Switch are different.

1. Remove the Left Side Panel per Section 5.08-A-1.

2. Label and remove the four wires connected to the
Switch.

3. Note the orientation of the Switch and remove the
two nuts securing the Switch to the inside of the
panel.

4. Remove the Switch from the Power Supply.

7. Remove the four screws securing Top Panel to
Power Supply .

SERVICE 5-16 Manual 0-2879

5. Install the replacement Switch by reversing the
above steps. Depending on the unit, connect the
wires to the Switch per one of the following Fig­ures:

• Domestic Units

H. Relay (K3) Replacement

1. Remove the Left Side Panel per Section 5.08-A-1.

2. Locate the Relay near the Starting Capacitor.

3. Note the orientation of the Relay to the base of
the unit.

ON/OFF Switch

Assembly

Black

Wire #3

Black

Wire #19

A-02137

• CE and Australia Units

Input Power Cable

(White Wire)

Input Power Cable

(Black Wire)

Input Power Cable

(Ground Wire)

A-02574

4. Remove the two screws securing the Relay to the
base of the unit.

5. Note all wiring connections to the Relay.

Red #23

Red #3

Blue #3

Blue #12

Blue #11

A-02608

Capacitor

Figure 5-15 Relay Wiring

#3

#19

#S1

#S2

Figure 5-14 ON/OFF Switch Connections

6. Remove all the connections from the Relay.

7. Install the replacement Relay by reversing the
above steps.

Manual 0-2879 5-17 SERVICE

I. Input Power Cable Replacement

6. Pull the Input Power Cable from the unit.

Depending on the unit, remove the Input Power Cable
per one of the following procedures:

• Domestic Units

1. Remove the Left Side Panel per Section 5.08-A-1.

2. Disconnect the Input Power Cable wires from the
Power Supply at the ground stud and the
ON/OFF Switch.

3. Loosen the Strain Relief on the rear of the unit
and pull the Input Power Cable from the unit.

4. Install replacement Power Cable by reversing the
above steps. Connect the wires as shown in the
following Figure:

ON/OFF Switch

Assembly

Input Power Cable

(Black Wire)

Two Green Wires

with Tracers

Input Power Cable

(White Wire)

7. Install replacement Power Cable by reversing the
above steps. Connect the wires as shown in the
following Figure:

Filter
Cover

L2

L1

A-02572

EMC
Filter

GND

Input Power Cable

Figure 5-17 CE and Australia Units - Input Power

Cable Connections

Input Power Cable

(Green Wire)

A-02139

Ground Stud

Figure 5-16 Domestic Units - Input Power Cable

Connections

• CE and Australia Units

1. Loosen Strain Relief on the rear of the unit.

2. Remove six screws securing rear Filter Cover to
the EMC Filter box.

3. Slide the Filter Cover along the Input Power Cable
to gain access to the wiring connections.

4. Note and label the location of the Input Power
Cable wire connections.

J. Pressure Switch (PS1) Replacement

1. Remove the Right Side Panel per Section 5.08-A-1.

2. Disconnect the wires connected to the Pressure
Switch.

3. Remove the Pressure Switch Assembly from the
T ee Fitting.

4. Install the replacement Pressur e Switch by revers­ing the above steps (see NOTE).

NOTE

Apply a coating of thread sealant (Loctite #565 or
equivalent) to the threads of the replacement Pres­sure Switch prior to installing.

#7 Connector

Compressor

#6 Connector

Pressure Switch

Tee Fitting

1/8 NPT

5. Disconnect the Input Power Cable wires from the
terminals on the EMC Filter .

Air Intake Filter

A-02609

Figure 5-18 Pressure Switch Wiring Connections

SERVICE 5-18 Manual 0-2879

K. Current Control Knob Guard(s)

Replacement

NOTE

The torch lead and work lead must be disconnected
to replace the Current Control Knob Guards.

1. Remove the Top Panel per Section 5.08-A-2.

2. Remove the nuts securing Current Control Knob
Guard(s) to the Top Panel.

3. Install the replacement Current Control Guard(s)
by reversing the above steps.

L. Work Cable and Clamp Replacement

1. Remove the Right Side Panel per Section 5.08-A-1.

2. Disconnect the Work Cable connection from the
Main PC Board.

3. Remove the W ork Cable Strain Relief from the Top
Panel and remove the cable from unit.

4. Install the replacement Work Cable by reversing
the above steps.

M. Capacitor PC Board Replacement

1. Remove the Top Panel per Section 5.08-A-2.

2. For improved access to the Capacitor PC Board
do the following:

a. Remove the two nuts and washers securing

the Center Divider to the Power Supply Base.

b. Slide the Center Divider towards the Com-

pressor.

3. Remove the black pad located on the Capacitors.

Mounting Standoffs

Capacitor
PC Board

Wire #3

(N)

(-) T erminal

(+) T erminal

A-03256

Figure 5-19 Capacitor PC Board Connections

5. Remove the Capacitor PC Board from the unit.

6. Install the replacement Capacitor PC Board by r e­versing the above steps. Torque the nuts on ter­minals (+), (-), and (N) to 15 inch-lbs (1.7 Nm).

CAUTION

4. The Capacitor PC Board is secured to the Main
PC Board by two methods.

a. Remove the nuts and star washers located at

terminals (+), (-), and (N).

b. Locate the three plastic mounting standoffs.

T wo standof fs are located along the top edge
of the PC Board and a third is located near the
center of the PC Board. To remove the Ca-

DO NOT over torque the nuts on the terminals as
the PC Board may be damaged.

N. Pilot Resistor (R1) Replacement Procedure

1. Remove the Right Side Panel per Section 5.08-A-1.

2. Locate the Pilot Resistor near the outside edge of
the unit, below the Main PC Board Assembly.

NOTE

pacitor PC Board from the standof fs, squeeze
the tab on the mounting standoff while pull­ing up on the PC Board.

There are two resistors mounted in this ar ea, Pilot
Resistor (15 ohms) and Damping Resistor (30
ohms). The Pilot Resistor is mounted on the bot­tom.

Manual 0-2879 5-19 SERVICE

Damping Resistor

Pilot Resistor

(R1)

A-03257

Figure 5-20 Pilot Resistor (R1) Replacement

3. Using a phillips screwdriver, remove the two
screws securing the Pilot and Damping Resistors
to the internal frame.

O. Resistor (R3) Replacement

1. Remove the Right Side Panel per Section 5.08-A-1.

2. Remove the two screws securing the Center Di­vider to the Power Supply Base.

3. Lift the vertical Center Divider up and out to­wards the Compressor to gain access to the Re­sistor. Locate Resistor (R3), as shown in the fig­ure below.

A-03254

4. Pull the Pilot Resistor out far enough to gain ac­cess to the two wiring connections.

5. Note the location of the two wires connected to
the Pilot Resistor and disconnect the wires.

6. Install the replacement Pilot Resistor by revers­ing the above steps.

Resistor (R3)

Figure 5-21 Resistor (R3) Location

4. Note the wiring connections to the Resistor.

5. Remove the wires from the terminals on the Re­sistor.

6. Remove the Resistor from the Power Supply .

7. Install the replacement Resistor by reversing the
above steps.

P. Starting Capacitor (C1) Replacement

1. Remove Top Panel per Section 5.08-A-2.

2. Locate the Starting Capacitor attached to the base
of the Power Supply, near the Compressor.

3. Note all the wiring connections to the Starting
Capacitor.

4. Remove all the wires connected to the starting
capacitor . Remove any tie wraps if necessary.

5. Loosen the Clamp at the base of the Starting Ca­pacitor .

SERVICE 5-20 Manual 0-2879

6. Remove the Starting Capacitor from the Power
Supply.

7. Install the replacement Starting Capacitor by re­versing the above steps. Reconnect the wires as
follows:

Compressor Side

4. Disconnect the two T orch Contr ol Connectors and
the Pilot Wir e from the Main PC Board Assembly
connectors.

Torch Control

Connectors

Plain Wire

Striped Wire

A-02575

Figure 5-22 Starting Capacitor Wiring

5.10 Torch and Leads Replacement
Procedure

1. Remove Right Side Panel per Section 5.08-A-1.

2. Locate the Torch Block area as shown in the fol­lowing Figure.

A-03238

Pilot Wire

A-03239

Connection

Figure 5-24 Torch Wiring Connections

NOTE

All wires are outside the protective insulating sheet.

5. Remove the nylon screw holding the protective
insulating sheet to the Torch Block.

Torch Block

Area

Nylon Screw

Removal

Figure 5-23 Torch Block Area Location

3. Loosen the torch lead strain relief nut inside the

A-03247

Figure 5-25 Nylon Screw Removal

Top Panel. Do not remove the strain relief from
the leads. Replacement torch leads are provided
with strain reliefs.

Manual 0-2879 5-21 SERVICE

6. Loosen the torch lead fitting from the brass torch
block. This fitting must be removed from the
T orch Lead and installed on the replacement lead.

CAUTION

Be sure all wires are outside the pr otective insulat­ing sheet as noted above when it is reinstalled. High
voltage is present on the torch negative lead.

Torch Negative

Lead

Torch Lead

Fitting

Bulkhead

A-03240

Figure 5-26 Torch Lead Connection

7. Install the replacement Torch and Leads Assem­bly by reversing the above steps.

SERVICE 5-22 Manual 0-2879

SECTION 6:

PARTS LISTS

6.01 Introduction

A. Parts List Breakdown

The parts list provides a breakdown of all replaceable
components. Power Supply and T orch Assembly are field
serviceable, so a complete breakdown of parts is provided.
The parts lists are arranged as follows:

Section 6.03 Power Supply Replacement Parts
Section 6.04 Rear Panel Replacement Parts
Section 6.05 Complete Assembly Replacements

NOTE

Parts listed without item numbers are not illus­trated, but may be ordered by the catalog numbers
shown.

B. Returns

If a product must be returned for service, contact your
authorized distributor . Materials returned without proper
authorization will not be accepted.

6.02 Ordering Information

Order replacement parts by catalog number and complete
description of the part or assembly, as listed in the de­scription column of the Parts List. Also include the model
and serial number of the torch. Address all inquiries to
your authorized distributor .

Manual 0-2879 6-1 P A RTS LISTS

6.03 Power Supply Replacement Parts

Item # Qty Description Catalog #

1 1 Left Side Panel with Labels 9-7707
2 1 Right Side Panel with Labels 9-7708
3 1 Top Panel with Labels 9-7709
4 Rear Panel with Labels - Refer to Section 6.04 for Replacement Parts
5 1 Front Panel with Labels 9-7706
6 1 Current Control Knob Assy 9-7710
7 2 Current Control Knob Guards 9-7717
8 1 Pressure Switch - 35 psi PS1 9-1044
9 1 Capacitor PC Board Assembly 9-4607

10 1 Air Compressor, 200-230VAC, 50/60Hz M1 9-7720
11 2 Wheel, 6" diameter 9-4283
12 1 Axle 9-4282
13 2 Retaining Ring, 1/2 in. Dia Shaft (Axle) 9-5539
14 4 Flat Washer - 1/2 in. (13 mm) I.D. (Axle) See Note
15 1 Air Intake Filter Kit - Replacement Filter Pads (One of each Type) 9-7716
16 1 Foot 9-4284
17 1 Relay, SPDT, 15A, 220V 24AC Coil K3 9-7914
18 1 Starting Capacitor C1 9-7722
19 1 Fuse, 1/2 Amp, 250V F1 9-7711
20 1 Resistor, 1 1K ohms 30W R3 9-7701
21 1 Pilot Resistor, 15 ohms 55W R1 9-6323

The following parts are not shown:

1 Work Cable 20 ft (6.0 m) with Clamp 9-6596

NOTE: Hardware can be purchased locally.

PARTS LISTS 6-2 Manual 0-2879

6

3

7

2

4

8

15

10

18

17

1

16

12

5

13

9

14

11

20

A-03230

19

21

Manual 0-2879 6-3 P A RTS LISTS

6.04 Rear Panel Replacement Parts

Item # Qty Description Catalog #

1 1 Rear Panel with Labels

Domestic Units ------

CE and Australian Units 9-7705
2 1 Handle 9-7712
3 1 ON/OFF Switch SW1 8-4248
4 1 Filter Dryer Replacement Kit 9-6599

1 Filter Dryer Element 9-7718
5 1 Fan 9-1033
6 1 EMC Filter (For CE and Australian Units Only) 9-7950

The following parts are not shown:

1 Input Power Cable

Domestic Units - 10 ft (3.0 m) with 50A Plug 9-7714
CE Units - 9.5 ft (2.9 m) Without Plug 9-7953
Australian Units - 9.5 ft (2.9 m) Without Plug 9-7951

PARTS LISTS 6-4 Manual 0-2879

Domestic Units

2

4

1

5

A-03264

CE & Australia Units

3

4

2

6

1

3

A-03265

Manual 0-2879 6-5 P A RTS LISTS

5

6.05 Complete Assembly Replacement

Description Catalog #

Domestic System includes:

Power Supply with Built-In Air Compressor, Torch with Leads, Spare Parts Kit, Input Power Cable With Plug
and Work Cable With Clamp.

70° Torch with 20 ft (6.1 m) Leads 1-3800
90° Torch with 20 ft (6.1 m) Leads 1-3801

CE and Australian Systems includes:

CE Power Supply with Built-In Air Compressor, Torch with Leads, Spar e Parts Kit, Input Power Cable With­out Plug and Work Cable With Clamp.

70° Torch with 20 ft (6.1 m) Leads 1-8800
90° Torch with 20 ft (6.1 m) Leads 1-8801

Power Supply Only

Domestic Units 3-3800

CE and Australian Units 3-8801

Hand Torches with Two Piece Standard Handle

PCH-42R RPT 70° Hand Torch, 20 ft (6.1 m) Leads 7-4226
PCH-42R RPT 90° Hand Torch, 20 ft (6.1 m) Leads 7-4227

Torch Spare Parts Kit Includes: 5-4204

Qty Description

5 T ip, Air
5 Electrode, 40A SureLok
1 Distributor, Gas
1 Shield Cup, Standard
1 Box, Utility
1 Adhesive Hang Tab
1 Label, Spare Parts Kit

PARTS LISTS 6-6 Manual 0-2879

APPENDIX 1: SEQUENCE OF OPERATION BLOCK

DIAGRAM

ACTION

Plug in

Power Cord

RESULT

Power to system.

ACTION

Protect eyes and

activate torch

RESULT

Compressor starts and

Gas flows

GAS indicator ON

After gas pre-flow:

DC indicator on.

Power supply enabled.

Pilot arc established

ACTION

ON/OFF switch

to ON.

RESULT

AC Indicator flashes for

3 seconds then stays on.

Air Compressor runs

for 3 seconds then off.

Fan on.

PILOT ARC

ACTION

Torch moved away

from work (while

still activated).

RESULT

Main arc stops.

Pilot arc auto-

matically restarts.

ACTION

Torch moved within

transfer distance of

workpiece.

RESULT

Main arc transfer.

ACTION

Torch deactivated by torch

switch release.

RESULT

Main arc stops. Pilot stops.

(Power supply enable signal removed.)

Compressor stops. Gas flow stops.

NOTE - If torch is activated during
post-flow, pilot arc will immediately restart.
If torch is within transfer distance (1/8 in) of

workpiece, main arc will transfer.

DC indicator off.

After post-flow:

GAS indicator OFF.

ACTION

ON/OFF switch

to OFF

RESULT

All indicators off.

Power supply

fan off.

Pilot arc off.

DC indicator still on.

ACTION

Unplug

Power Cord

RESULT

No power to system.

A-02151

Manual 0-2879 A-1 APPENDIX

APPENDIX 2: ROUTINE MAINTENANCE SCHEDULE

This schedule applies to all types of non-liquid cooled plasma cutting systems. Some systems will not have all the
parts listed and those checks need not be performed.

NOTE

The actual frequency of maintenance may need to be adjusted according to the operating environment.

Daily Operational Checks or Every Six Cutting Hours:

1. Check torch consumable parts, replace if damaged or worn.

2. Inspect torch for any cracks or exposed wires, replace if necessary.

3. Check plasma and secondary supply and pressure/flow.

4. Purge plasma gas line to remove any moisture build-up.

5. Inspect input power cable for damage or exposed wires, replace if necessary.

Weekly or Every 30 Cutting Hours:

1. Check fan for proper operation and adequate air flow.

2. Blow or vacuum dust and dirt out of the entire machine.

CAUTION

Do not blow air into the power supply during cleaning. Blowing air into the unit can cause metal particles to
interfere with sensitive electrical components and cause damage to the unit.

Six Months or Every 720 Cutting Hours:

1. Check the in-line air filter(s), clean or replace as required

2. Check cables and hoses for leaks or cracks, replace if necessary .

3. Check all contactor points for severe arcing or pits, replace if necessary.

APPENDIX A-2 Manual 0-2879

APPENDIX 3: RECOMMENDED CUTTING SPEEDS

NOTE

Cutting speeds are for use with PCH-42 RPT Torch.

Drag-Gun 38 Cutting Speeds (Air Pressure @ 50 psi for all settings)

Material Thickness

26 Gauge 250 310 385 drag-1/8"
20 Gauge 125 245 310 drag-1/8"

Mild Steel

24 Gauge 150 310 385 drag-1/8"

Stainless Steel

24 gauge 100 290 360 drag-1/8"

Galvanized Steel

Aluminum

NR = Not Recommended

20 gauge 75 228 310 drag-1/8"
18 gauge 65 172 233 drag-1/8"
16 gauge 45 140 203 drag-1/8"

Recommended

Cut

Speed @ 20 Amps

1/16" 85 140 208 drag-1/8"

1/8 " 25 55 85 drag-1/ 8"

3/16 " 15 30 55 drag-1/16"

1/4 " 8 16 27 drag-1/16"
3/8 " NR 10 14 drag-1/16"

1/16" 40 80 115 drag-1/8"

1/8 " 25 44 70 drag-1/ 8"

3/16 " 10 19 27 drag-1/16"

1/4 " NR 14 20 drag-1/16"

1/16 " 150 223 280 drag-1/8"
3/32 " 25 105 172 drag-1/8"

1/8 " 10 60 85 drag-1/ 8"

3/16 " NR 20 30 drag-1/ 8"

Recommended

Cut

Speed @ 29

Amps

Maxi mu m C u t

Speed @29

Amps

Standoff

Manual 0-2879 A-3 APPENDIX

APPENDIX 4: NON-CE SYSTEM SCHEMATIC

A-02201

APPENDIX A-4 Manual 0-2879

NOTE

Refer to Appendix 5 for CE & Australia Power Supplies.

A-02201

Manual 0-2879 A-5 APPENDIX

APPENDIX 5: CE & AUSTRALIA SYSTEM SCHEMATIC

A-02576

APPENDIX A-6 Manual 0-2879

NOTE

Refer to Appendix 4 for all other Power Supplies.

A-02576

Manual 0-2879 A-7 APPENDIX