Thermal Dynamics DRAG-GUN 38 Instruction Manual
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Thermal Dynamics DRAG-GUN 38 Instruction Manual

Plasma cutting power supply
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PLASMA CUTTING

POWER SUPPLY

DRAG-GUN™ 38
For 220VAC 50/60Hz
Air Plasma Cutting Systems
( Australia)
23
x4
33
4 RE
V
A
A
U S
E
TM
T H
IN
D E
M A
TM
M A
D E
IN
T H
E
U S
A
V
A
4 RE
33
23
x4
A-02145
Instruction Manual
Manual No. 0-2729
December 9, 2002

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  • Page 1: Power Supply

    PLASMA CUTTING POWER SUPPLY DRAG-GUN™ 38 For 220VAC 50/60Hz Air Plasma Cutting Systems ( Australia) 4 RE 4 RE A-02145 Instruction Manual Manual No. 0-2729 December 9, 2002...
  • Page 3 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 0-2729 Published by: Thermal Dynamics Corporation 82 Benning Street West Lebanon, New Hampshire, USA 03784 (603) 298-5711 www.thermadyne.com Copyright 1998 by Thermal Dynamics Corporation All rights reserved.

  • Page 4: Table Of Contents

    TABLE OF CONTENTS SECTION 1: GENERAL INFORMATION ..................1 1.01 Notes, Cautions and Warnings ................ 1 1.02 Important Safety Precautions ................ 1 1.03 Publications ....................2 1.04 Note, Attention et Avertissement ..............3 1.05 Precautions De Securite Importantes ............. 3 1.06 Documents De Reference ................
  • Page 5 TABLE OF CONTENTS (continued) SECTION 6: PARTS LISTS ......................45 6.01 Introduction ....................45 6.02 Ordering Information ..................45 6.03 Power Supply Replacement Parts ..............46 6.04 Complete Assembly Replacement ..............48 6.05 Torch Replacement Parts ................49 6.06 Options and Accessories ................50 APPENDIX I: SEQUENCE OF OPERATION BLOCK DIAGRAM ..........

  • Page 7: Section 1: General Information

    SECTION 1: GASES AND FUMES GENERAL INFORMATION Gases and fumes produced during the plasma cutting process can be dangerous and hazardous to your health. 1.01 Notes, Cautions and Warnings • Keep all fumes and gases from the breathing area. Throughout this manual, notes, cautions, and warnings Keep your head out of the welding fume plume.

  • Page 8: Publications

    • Wear dry gloves and clothing. Insulate yourself from the work piece or other parts of the welding PLASMA ARC RAYS circuit. • Repair or replace all worn or damaged parts. Plasma Arc Rays can injure your eyes and burn your skin. •...

  • Page 9: Note, Attention Et Avertissement

    6. ANSI Standard Z49.2, FIRE PREVENTION IN THE USE ATTENTION OF CUTTING AND WELDING PROCESSES, obtain- able from American National Standards Institute, 1430 Broadway, New York, NY 10018 Toute procédure pouvant résulter l’endommagement du matériel en cas de non- 7. AWS Standard A6.0, WELDING AND CUTTING CON- respect de la procédure en question.
  • Page 10 • Eloignez toute fumée et gaz de votre zone de respira- • Ne touchez jamais une pièce “sous tension” ou “vive”; tion. Gardez votre tête hors de la plume de fumée portez des gants et des vêtements secs. Isolez-vous provenant du chalumeau. de la pièce de travail ou des autres parties du circuit de soudage.

  • Page 11: Documents De Reference

    ultra-violets très forts. Ces rayons d’arc nuiront à vos 1.06 Documents De Reference yeux et brûleront votre peau si vous ne vous protégez pas correctement. Consultez les normes suivantes ou les révisions les plus récentes ayant été faites à celles-ci pour de plus amples •...
  • Page 12 9. Norme 70 de la NFPA, CODE ELECTRIQUE NA- TIONAL, disponible auprès de la National Fire Pro- tection Association, Batterymarch Park, Quincy, MA 02269 10. Norme 51B de la NFPA, LES PROCÉDÉS DE COUPE ET DE SOUDAGE, disponible auprès de la National Fire Protection Association, Batterymarch Park, Quincy, MA 02269 11.

  • Page 13: Declaration Of Conformity

    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.

  • Page 14: Statement Of Warranty

    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.

  • Page 15: Section 2: Introduction & Description

    2.03 Specifications & Design Features 38.5 inches A. DRAG-GUN 38 Power Supply (977.9 mm) 17 inches (39.37mm) The following applies to the DRAG-GUN 38 Power Sup- 4 REV M AD ply only: M AD 1. Controls 4 REV • AC POWER ON/OFF Switch A-02146 •...

  • Page 16: Options And Accessories

    B. PCH-25/38 Torch 10. Weight (without leads) 1.0 lb (.45 kg) The following applies to the PCH-25/38 Torch only: 11. Torch Dimensions 1. PCH-25/38 Torch Configuration The PCH-25/38 Torch is available in 70°, 90°, or 180° Hand Torch configurations. 2.95 in 70˚...

  • Page 17: Section 3: Installation Procedures

    • Gas Distributor (1 each) 3.01 Introduction B. Unpacking Procedure This section describes installation of the DRAG-GUN 38 1. Unpack each item and remove all packing material. Plasma Cutting System. These instructions apply to the Power Supply, Torch and Leads Assemblies only; instal- 2.
  • Page 18 SECTION 3: INSTALLATION PROCEDURES Manual 0-2729...

  • Page 19: Section 4: Operation

    The indicator will also flash momentarily if the torch is shorted. 4.01 Introduction 5 CURRENT Control This section provides a description of the DRAG-GUN 38 Adjusts output current from 12 to 29 amps. Plasma Cutting System followed by the operating proce- dures.

  • Page 20: Torch Consumable Parts Selection

    CAUTION Electrode The primary power source, power cable, and plug Catalog No. 9-6506 all must conform to local electrical codes and recom- mended circuit protection and wiring requirements. Gas Distributor Catalog No. 9-6507 2. Plug unit in and close main disconnect switch to supply primary power to the system.

  • Page 21: Cut Quality

    2. Remove the tip, gas distributor, and electrode. C. Bevel Angle 3. Install the electrode, gas distributor, and tip. The angle between the surface of the cut edge and a plane perpendicular to the surface of the plate. A per- 4.

  • Page 22: Operating The System

    A. Sequence of Operation C u t Q u a l i t y o n V a r i o u s M a t e r i a l s T y p e o f M a t e r i a l T y p e M a t e r i a l C a r b o n...

  • Page 23: Hand Torch Operation

    D. Dross B. Piercing with a Hand Torch 1. When piercing with a hand torch, angle the torch When dross is present on carbon steel, it is commonly slightly so that blowback particles blow away from referred to as either “high speed, slow speed, or top the torch tip (and operator) rather than directly back dross”.
  • Page 24 SECTION 4: OPERATION Manual 0-2729...

  • Page 25: Section 5: Customer/Operator Service

    SECTION 5: 5.02 General Maintenance CUSTOMER/OPERATOR A. Recommended Maintenance Schedule SERVICE NOTE The actual frequency of maintenance may need to be adjusted according to usage and the environment. 5.01 Introduction This section describes basic maintenance procedures that can be performed by operating personnel, and R e c o m m e n d e d R o u tin e M a in te n a n c e advanced procedures that can be performed by qualified S c h e d u le...

  • Page 26: Common Operating Faults

    Do not blow air into the power supply during cleaning. b. Torch standoff too high from workpiece Blowing air into the unit can cause metal particles to inter- c. AC line too low - reduce output current fere with sensitive electrical components and cause dam- age to the unit.

  • Page 27: Troubleshooting Guides

    5. Remove the electrode. Refer to Figure 5-4 and check the face of the electrode for excessive wear. The face of the Basic troubleshooting of the DRAG-GUN 38 Plasma Cut- electrode should not be recessed more than 0.10 inch ting System can be performed without special equipment (2.5 mm).

  • Page 28: Advanced Troubleshooting Guide

    For problems not covered here, refer to the Advanced D. AC indicator ON, Over TEMP indicator dark, no gas Troubleshooting Guide or contact your authorized dis- flow when torch switch pressed. tributor. 1. Shield cup not properly installed on torch. If a product must be returned for service, contact your au- a.

  • Page 29: Troubleshooting Flow Charts

    WARNING There are extremely dangerous voltage and power levels present inside this unit. Do not attempt to diagnose or repair unless you have had training in power electronics measurement and troubleshoot- ing techniques. If major complex subassemblies are faulty, the assembly must be returned to an authorized service center for repair.
  • Page 30 Troubleshooting Chart #1: Main Power AC Indicator OFF on Front Panel System Connect AC Power AC POWER Power Cable Operates Input Cable to Switch ON? Plugged In? Properly? AC Source Faulty AC Indicator Check Main Place AC POWER Replace Power Supply Power Disconnect Switch to ON Main Power...
  • Page 31 Troubleshooting Chart #2: Input Power Checks NOTE This Condition could also result if the input line voltage was low or using an extension cable and the user was using a high standoff while cutting. Check Input Diode Bridge on Heatsink/PC Board Assembly Per Section 5.09 A Check FET Assemblies on Diode Bridge...
  • Page 32 Troubleshooting Chart #3: Temperature Indicator Checks AC and Gas Indicators are ON Temperature Indicator Either ON or Blinks Once When Torch Switch (TS) is Pressed Temp Indicator ON Steady (blinks once) When TS is Pressed Disconnect Pilot Wire and retry torch switch Duty Cycle Allow Power Supply Operating?
  • Page 33 Troubleshooting Chart #4: Resistor (R3) Checks AC and Gas Indicators are ON DC Indicator Blinks or Momentary ON When Torch Switch is pressed Check Resistor (R3) Assembly per Section 5.09 E Resistor R3 Replace Resistor (R3) Check Okay? Assembly per Section 5.11.P Replace Power Supply Manual 0-2729 SECTION 5: SERVICE...
  • Page 34 Troubleshooting Chart #5: Faulty Torch AC Indicator ON AC and Gas Indicators are ON No GAS Flow When Torch DC Indicator OFF Switch is Depressed When Torch Switch is Depressed Compressor Check Troubleshooting operates 4 seconds at per Section 5.06 C power ON? Check Torch And Leads per Section 5.10 A&B...
  • Page 35 Troubleshooting 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 Replace Power Supply Shaft Okay? Secure or Replace CURRENT Control Knob per Section 5.11C...
  • Page 36 6. Connect the volt/ohm meter positive lead to the anode of the diode and the negative lead to the cath- WARNINGS ode of the diode for forward bias testing. A prop- erly functioning diode will conduct in the forward bias direction and indicate between 0.3 to 0.9 volts. Disconnect primary power to the system at the source before opening the Power Supply.
  • Page 37 9. If Input Rectifier tests out okay, replace leads. Mounting Standoffs 10. If the diode has visible damage or is shorted, the diode is faulty. Replace the Power Supply. A-00306 Capacitor PC Board Wire #3 Reverse Bias Diode Not Conducting (+) Terminal (-) Terminal VR COM...
  • Page 38 C. Checking Capacitor PC Board D. Checking Pilot Return 1. Remove the top Panel Cover of the Power Supply 1. Remove the right SidePanel of the Power Supply per per subsection 5.11-E. subsection 5.11-D. 2. Using a pair of needle nose pliers remove the red Pilot Return Lead wire from terminal E14 on the Main PC Board.

  • Page 39: Torch And Leads Troubleshooting

    E. Checking Resistor R3 (11k ohms) If power is present and Compressor is hum- ming, check Starting Capacitor C1. 1. Remove the side Panel Cover of Power Supply per NOTE subsection 5.11-D. Capacitors can be fail shorted, open or reduced in 2.
  • Page 40 A. Checking Center Insulator Torch Switch Connector 1. Remove the shield cup, tip, gas distributor, and elec- (Black & WhiteWires) trode from the torch. 2. Disconnect the torch leads from the power supply to Torch Lead isolate the torch from power supply circuits. 3.

  • Page 41: Power Supply Component Replacement Procedures

    C. Current Control Knob Replacement 5.11 Power Supply Component Replacement Procedures 1. Using a small blade screwdriver, loosen the screw securing the knob to the CURRENT Control adjust- NOTES ment shaft. Refer to Section 6, Parts Lists, for replacement parts 2.
  • Page 42 E. Top Panel Cover Removal 9. Disconnect ground wire connection from top panel cover. NOTE 10. Rest cover beside Power Supply. The right side panel must be removed first to pro- NOTE vide internal access to the torch and work cable con- nections.
  • Page 43 I. Input Power Cable Replacement A-02574 1. Loosen Strain Relief on rear of unit. 2. Remove six screws securing rear Filter Panel to the EMC Filter box. 3. Disconnect cables L1, L2, and Ground from the EMC Filter. 4. Install replacement Power Cable, by reversing steps 1-3 and wiring as shown below: Filter Cover...
  • Page 44 J. Pressure Switch Replacement l. Work Cable and Clamp Replacement 1. Remove the right side panel from Power Supply per 1. Remove right side panel per paragraph 'D' above. paragraph 'D' above. 2. Disconnect Work Cable connection at main PC 2.
  • Page 45 4. Remove the three nuts and star washers securing o. Pilot Resistor (R3) Replacement Procedure the Capacitor PC Board to the Main PC Board As- 1. Remove the right panel cover per paragraph 'D' sembly. The nuts are located at terminals (+), (-), above.

  • Page 46: Torch And Leads Replacement Procedure

    P. Starting Capacitor Replacement 5.12 Torch and Leads Replacement Procedure 1. Remove top Panel Cover per paragraph 'E' above. 2. Locate the Starting Capacitor attached to the base of 1. Remove right panel of Power Supply per paragraph the unit, near the Compressor. 'D' above.

  • Page 47: Servicing Torch Head Components

    5.13 Servicing Torch Head Components Torch Switch Connector (Black & WhiteWires) WARNING Torch Lead Disconnect primary power to the system before dis- assembling the torch, leads, or power supply. WARNING NEVER touch any internal torch parts while the Pilot Wire A-02124 AC indicator light on the top panel is lighted.
  • Page 48 3. Slip off the rear O-Ring, remove the two screws from 4. Route the PIP wires around the strain relief bosses the torch head split holder, and separate the halves. as shown. Push the teflon insulation on each PIP Remove the torch head from the holder. wire up to the strain relief boss closest to the back of the split holder for voltage insulation from the brass 4.
  • Page 49 C. Reassembling the Torch Head D. Replacing Torch Switch or Torch Leads to Head 1. Install the two assembly screws to secure the split holder and reinstall the O-ring in the rear groove 1. Unsolder the lead(s) at the torch switch being care- on the back of the torch head assembly.
  • Page 50 SECTION 5: SERVICE Manual 0-2729...

  • Page 51: Section 6: Parts Lists

    SECTION 6: PARTS LISTS 6.01 Introduction A. Parts List Breakdown The parts list provides a breakdown of all replaceable com- ponents. Power Supply and Torch Assembly are field ser- viceable, 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: Complete Assembly Replacements Section 6.05: Torch Assembly Replacement Parts...

  • Page 52: Power Supply Replacement Parts

    6.03 Power Supply Replacement Parts Item # Description Ref. Catalog # Left Side Panel with Labels 9-7707 Right Side Panel with Labels 9-7708 Top Panel with Labels 9-7709 Rear Panel with Labels 9-7705 Front Panel with Labels 9-7706 Current Control Knob Assy 9-7710 Current Control Knob Guards 9-7717...
  • Page 53 A-02302 Manual 0-2729 SECTION 6: PARTS LISTS...

  • Page 54: Complete Assembly Replacement

    6.04 Complete Assembly Replacement Description Catalog # System includes DRAG-GUN 38 (Australia) Power Supply with Built-In Compressor, PCH-25/38 Torch with Leads, Spare Parts Kit, Input and Ground Cables. 70° Torch with 25 ft (7.6 m) Leads 1-8800 90° Torch with 25 ft (7.6 m) Leads 1-8801 180°...

  • Page 55: Torch Replacement Parts

    6.05 Torch Replacement Parts Item # Description Catalog # Assembly, PIP (Parts-In-Place) Pins and Wire 9-6103 O-Ring 8-0533 Holder, Torch, Split, PCH25/38 70° Two Parts w/Screws 9-6259 Holder, Torch, Split, PCH25/38 90° Two Parts w/Screws 9-6260 Holder, Torch Split, PCH25/38 180° Two Parts w/Screws (not shown) 9-6261 Assembly, Basic Head, PCH25/38 70°...

  • Page 56: Options And Accessories

    6.06 Options and Accessories Description Catalog # Circle Guide 7-3291 Cutting Guide Kit 7-8910 6.07 Torch Spare Parts Kit Description Catalog # Spare Parts Kit, PCH-25/38, includes: 5-3800 Tip, Air, 0.031" Orifice, Drag Cutting 9-6501 Electrode, Air 9-6506 Distributor, Gas 9-6507 Box, Utility 8-3/8 x 4-1/2, 1-11/16, Black 8-3141...

  • Page 57: Appendix I: Sequence Of Operation Block Diagram

    APPENDIX I: SEQUENCE OF OPERATION BLOCK DIAGRAM ACTION ACTION ON/OFF switch Plug in to ON. Power Cord RESULT RESULT AC Indicator flashes for Power to system. 3 seconds then stays on. Air Compressor runs for 3 seconds then off. Fan on. ACTION ACTION Torch moved away...

  • Page 58: Appendix Ii: Sysytem Schematic

    APPENDIX II: SYSYTEM SCHEMATIC A-02576 APPENDICES Manual 0-2699...
  • Page 59 A-02576 Manual 0-2699 APPENDICES...

  • Page 60: Appendix Iii: Cutting Speed Chart

    APPENDIX III: CUTTING SPEED CHART PM 38XL CUT SPEEDS (Air @ 50 psi for all settings) Material Thickness Recommended Cut Recommended Cut Max Cut Standoff Speed @ 20 Amps Speed @ 29 Amps Speed @29 Amps (in.) Mild Steel 26 Gauge drag-1/8"...

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Pch-25/38

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