ESAB Plasma Cutting Power Supply User manual

Brand: ESAB

Model: Plasma Cutting Power Supply

Category: Welding System

Type: User manual

Plasma Cutting Power

Supply

Drag-gun

A-03642

Service Manual

November 11, 2003 Manual No. 0-2683

Page is loading ...

WARNINGS

Read and understand this entire Manual and your employer’s safety practices before installing, oper-

ating, or servicing the equipment.

While the information contained in this Manual represents the Manufacturer's best judgement, the

Manufacturer assumes no liability for its use.

Plasma Cutting Power Supply with Built-in Air

Drag-Gun

Service Manual Number 0-2683

Published by:

Thermal Dynamics Corporation

82 Benning Street

West Lebanon, New Hampshire, USA 03784

(603) 298-5711

www.thermal-dynamics.com

Thermal Dynamics Corporation

Reproduction of this work, in whole or in part, without written permission of the

publisher is prohibited.

The publisher does not assume and hereby disclaims any liability to any party for

any loss or damage caused by any error or omission in this Manual, whether such

error results from negligence, accident, or any other cause.

Printed in the United States of America

Publication Date: November 11, 2003

Record the following information for Warranty purposes:

Where Purchased:____________________________________

Purchase Date:_______________________________________

Power Supply Serial #:________________________________

Torch Serial #:________________________________________

TABLE OF CONTENTS

SECTION 1:

GENERAL 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 ................................................................................ 5

1.07 Declaration of Conformity ................................................................................ 7

1.08 Statement of Warranty ..................................................................................... 8

2.0 INTRODUCTION .................................................................................................................... 9

2.1 Scope Of Manual.............................................................................................. 9

2.2 General Service Philosophy.............................................................................. 9

2.3 Service Responsibilities.................................................................................... 9

2.4 Technical Specifications.................................................................................... 9

2.5 Dimensions......................................................................................................10

3.0: TROUBLESHOOTING ..........................................................................................................11

3.1 Introduction......................................................................................................11

3.2 Periodic Inspection & Maintenance ..................................................................11

3.3 Common Cutting Faults ...................................................................................11

3.4 Common Operating Problems ..........................................................................11

3.5 Troubleshooting Guide ......................................................................................12

3.6 Torch & Leads Troubleshooting .........................................................................15

4.0 REPLACEMENT PROCEDURES..........................................................................................17

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

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

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

4.4 Torch Switch Only Replacement .....................................................................19

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

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

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

4.8 Power Relay Replacement ..............................................................................21

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

4.10 Fan Replacement............................................................................................22

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

4.12 Transformer/Ferrite Core Assembly Replacement ...........................................23

4.13 Input Voltage Changeover (For 208/230 VAC Service Only) ............................23

4.14 Torch & Leads Replacement ...........................................................................24

4.15 Work Cable Replacement ...............................................................................25

4.16 Primary Input Power Cable Replacement ........................................................25

TABLE OF CONTENTS (Continued)

5.0 PARTS LIST .........................................................................................................................27

5.1 Returns............................................................................................................27

5.2 Parts Replacement ..........................................................................................27

5.3 Power Supply Replacement Parts....................................................................28

5.4 Options & Accessories (not shown) .................................................................28

5.5 Torch Replacement Parts .................................................................................30

APPENDIX I - INTERCONNECTING DIAGRAM ..........................................................................31

APPENDIX II - INTERCONNECTING DIAGRAM .........................................................................32

Page is loading ...

Date: November 15, 2001 1 GENERAL INFORMATION

SECTION 1:

GENERAL INFORMATION

1.01 Notes, Cautions and Warnings

Throughout this manual, notes, cautions, and warnings

are used to highlight important information. These high-

lights are categorized as follows:

NOTE

An operation, procedure, or background informa-

tion which requires additional emphasis or is help-

ful in efficient operation of the system.

CAUTION

A procedure which, if not properly followed, may

cause damage to the equipment.

WARNING

A procedure which, if not properly followed, may

cause injury to the operator or others in the oper-

ating area.

1.02 Important Safety Precautions

WARNINGS

OPERATION AND MAINTENANCE OF

PLASMA ARC EQUIPMENT CAN BE DAN-

GEROUS AND HAZARDOUS TO YOUR

HEALTH.

Plasma arc cutting produces intense electric and

magnetic emissions that may interfere with the

proper function of cardiac pacemakers, hearing

aids, or other electronic health equipment. Per-

sons who work near plasma arc cutting applica-

tions should consult their medical health profes-

sional and the manufacturer of the health

equipment to determine whether a hazard exists.

To prevent possible injury, read, understand and

follow all warnings, safety precautions and in-

structions before using the equipment. Call 1-603-

298-5711 or your local distributor if you have any

questions.

GASES AND FUMES

Gases and fumes produced during the plasma cutting

process can be dangerous and hazardous to your health.

• Keep all fumes and gases from the breathing area.

Keep your head out of the welding fume plume.

• Use an air-supplied respirator if ventilation is not

adequate to remove all fumes and gases.

• The kinds of fumes and gases from the plasma arc

depend on the kind of metal being used, coatings

on the metal, and the different processes. You must

be very careful when cutting or welding any met-

als which may contain one or more of the follow-

ing:

Antimony Chromium Mercury

Arsenic Cobalt Nickel

Barium Copper Selenium

Beryllium Lead Silver

Cadmium Manganese Vanadium

• Always read the Material Safety Data Sheets

(MSDS) that should be supplied with the material

you are using. These MSDSs will give you the in-

formation 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 com-

bustible or explosive gases or materials are located.

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

of chlorinated solvents and cleansers. Remove all

sources of these vapors.

• This product, when used for welding or cutting,

produces fumes or gases which contain chemicals

known to the State of California to cause birth de-

fects 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 op-

erator or others in the workplace.

• Never touch any parts that are electrically “live”

or “hot.”

GENERAL INFORMATION 2 Date: November 15, 2001

• 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, Publica-

tions.

• Disconnect power source before performing any

service or repairs.

• Read and follow all the instructions in the Operat-

ing Manual.

FIRE AND EXPLOSION

Fire and explosion can be caused by hot slag, sparks, or

the plasma arc.

• Be sure there is no combustible or flammable ma-

terial in the workplace. Any material that cannot

be removed must be protected.

• Ventilate all flammable or explosive vapors from

the workplace.

• Do not cut or weld on containers that may have

held combustibles.

• Provide a fire watch when working in an area where

fire hazards may exist.

• Hydrogen gas may be formed and trapped under

aluminum workpieces when they are cut under-

water or while using a water table. DO NOT cut

aluminum alloys underwater or on a water table

unless the hydrogen gas can be eliminated or dis-

sipated. Trapped hydrogen gas that is ignited will

cause an explosion.

NOISE

Noise can cause permanent hearing loss. Plasma arc pro-

cesses can cause noise levels to exceed safe limits. You

must protect your ears from loud noise to prevent per-

manent loss of hearing.

• To protect your hearing from loud noise, wear pro-

tective ear plugs and/or ear muffs. Protect others

in the workplace.

• Noise levels should be measured to be sure the deci-

bels (sound) do not exceed safe levels.

• For information on how to test for noise, see item 1

in Subsection 1.03, Publications, in this manual.

PLASMA ARC RAYS

Plasma Arc Rays can injure your eyes and burn your skin.

The plasma arc process produces very bright ultra violet

and infra red light. These arc rays will damage your

eyes and burn your skin if you are not properly protected.

• To protect your eyes, always wear a welding hel-

met or shield. Also always wear safety glasses with

side shields, goggles or other protective eye wear.

• Wear welding gloves and suitable clothing to pro-

tect your skin from the arc rays and sparks.

• Keep helmet and safety glasses in good condition.

Replace lenses when cracked, chipped or dirty.

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

Use protective booths, screens or shields.

• Use the shade of lens as suggested in the following

per ANSI/ASC Z49.1:

Minimum Protective Suggested

Arc Current Shade No. Shade No.

Less Than 300* 8 9

300 - 400* 9 12

400 - 800* 10 14

* These values apply where the actual arc is clearly

seen. Experience has shown that lighter filters

may be used when the arc is hidden by the work-

piece.

1.03 Publications

Refer to the following standards or their latest revisions

for more information:

1. OSHA, SAFETY AND HEALTH STANDARDS, 29CFR

1910, obtainable from the Superintendent of Docu-

ments, U.S. Government Printing Office, Washington,

D.C. 20402

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

CUTTING, obtainable from the American Welding So-

ciety, 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. Govern-

ment Printing Office, Washington, D.C. 20402

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

PATION AND EDUCATIONAL EYE AND FACE PRO-

TECTION, obtainable from American National Stan-

dards Institute, 1430 Broadway, New York, NY 10018

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

SAFETY-TOE FOOTWEAR, obtainable from the Ameri-

can National Standards Institute, 1430 Broadway, New

York, NY 10018

Date: November 15, 2001 3 GENERAL INFORMATION

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

OF CUTTING AND WELDING PROCESSES, obtain-

able from American National Standards Institute, 1430

Broadway, New York, NY 10018

7. AWS Standard A6.0, WELDING AND CUTTING CON-

TAINERS WHICH HAVE HELD COMBUSTIBLES, ob-

tainable 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 PRO-

CESSES, obtainable from the National Fire Protection

Association, Batterymarch Park, Quincy, MA 02269

9. NFPA Standard 70, NATIONAL ELECTRICAL CODE,

obtainable from the National Fire Protection Associa-

tion, Batterymarch Park, Quincy, MA 02269

10. NFPA Standard 51B, CUTTING AND WELDING PRO-

CESSES, obtainable from the National Fire Protection

Association, Batterymarch Park, Quincy, MA 02269

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

PRESSED GASES IN CYLINDERS, obtainable from the

Compressed Gas Association, 1235 Jefferson Davis

Highway, Suite 501, Arlington, VA 22202

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

ING 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 Associa-

tion, 1900 Arch Street, Philadelphia, PA 19103

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

MENDED SAFE PRACTICES FOR THE PREPARA-

TION FOR WELDING AND CUTTING OF CONTAIN-

ERS AND PIPING THAT HAVE HELD HAZARDOUS

SUBSTANCES, obtainable from the American Welding

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

15. ANSI Standard Z88.2, PRACTICE FOR RESPIRATORY

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.

ATTENTION

Toute procédure pouvant résulter

l’endommagement du matériel en cas de non-

respect de la procédure en question.

AVERTISSEMENT

Toute procédure pouvant provoquer des blessures

de l’opérateur ou des autres personnes se trouvant

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

procédure en question.

1.05 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.

Il faut communiquer aux opérateurs et au person-

nel TOUS les dangers possibles. Afin d’éviter les

blessures possibles, lisez, comprenez et suivez tous

les avertissements, toutes les précautions de sécurité

et toutes les consignes avant d’utiliser le matériel.

Composez le + 603-298-5711 ou votre distributeur

local si vous avez des questions.

FUMÉE et GAZ

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

plasma peuvent présenter des risques et des dangers de

santé.

Page is loading ...

Date: November 15, 2001 5 GENERAL INFORMATION

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 oculaire.

• Portez des gants de soudeur et un vêtement protecteur

approprié pour protéger votre peau contre les

étincelles et les rayons de l’arc.

• Maintenez votre casque et vos lunettes de 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.

BRUIT

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

Les procédés de soudage à l’arc de plasma peuvent

provoquer des niveaux sonores supérieurs aux limites

normalement acceptables. Vous dú4ez vous protéger les

oreilles contre les bruits forts afin d’éviter une perte

permanente de l’ouïe.

• Pour protéger votre ouïe contre les bruits forts, portez

des tampons protecteurs et/ou des protections

auriculaires. Protégez également les autres personnes

se trouvant sur le lieu de travail.

• Il faut mesurer les niveaux sonores afin d’assurer que

les décibels (le bruit) ne dépassent pas les niveaux

sûrs.

• Pour des renseignements sur la manière de tester le

bruit, consultez l’article 1, page 5.

1.06 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 TRAVAIL 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 Superin-

tendent of Documents, U.S. Government Printing

Office, Washington, D.C. 20402

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

PROTECTION DES YEUX ET DU VISAGE AU TRA-

VAIL ET DANS LES ECOLES, disponible de l’Institut

Américain des Normes Nationales (American Na-

tional Standards Institute), 1430 Broadway, New York,

NY 10018

5. Norme ANSI Z41.1, NORMES POUR LES

CHAUSSURES PROTECTRICES, disponible auprès

de l’American National Standards Institute, 1430

Broadway, New York, NY 10018

6. Norme ANSI Z49.2, PRÉVENTION DES INCENDIES

LORS DE L’EMPLOI DE PROCÉDÉS DE COUPE ET

DE SOUDAGE, disponible auprès de l’American Na-

tional Standards Institute, 1430 Broadway, New York,

NY 10018

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

(AWS), LE SOUDAGE ET LA COUPE DE

CONTENEURS AYANT RENFERMÉ DES PRODUITS

COMBUSTIBLES, disponible auprès de la American

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

33126

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

tection contre les Incendies (NFPA), LES SYSTEMES

À GAZ AVEC ALIMENTATION EN OXYGENE

POUR LE SOUDAGE, LA COUPE ET LES

PROCÉDÉS ASSOCIÉS, disponible auprès de la Na-

tional Fire Protection Association, Batterymarch Park,

Quincy, MA 02269

GENERAL INFORMATION 6 Date: November 15, 2001

9. Norme 70 de la NFPA, CODE ELECTRIQUE NA-

TIONAL, disponible auprès de la National Fire Pro-

tection Association, Batterymarch Park, Quincy, MA

02269

10.Norme 51B de la NFPA, LES PROCÉDÉS DE

COUPE ET DE SOUDAGE, disponible auprès de la

National Fire Protection Association, Batterymarch

Park, Quincy, MA 02269

11. Brochure GCA P-1, LA MANIPULATION SANS

RISQUE DES GAZ COMPRIMÉS EN CYLINDRES,

disponible auprès de l’Association des Gaz

Comprimés (Compressed Gas Association), 1235

Jefferson Davis Highway, Suite 501, Arlington, VA

22202

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

LE SOUDAGE ET LA COUPE, disponible auprès

de l’Association des Normes Canadiennes, Stan-

dards Sales, 178 Rexdale Boulevard, Rexdale,

Ontario, Canada, M9W 1R3

13. 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, PRATIQUES DE PROTECTION

RESPIRATOIRE, disponible auprès de l’American

National Standards Institute, 1430 Broadway, New

York, NY 10018

Date: November 15, 2001 7 GENERAL INFORMATION

1.07 Declaration of Conformity

Manufacturer: Thermal Dynamics Corporation

Address: 82 Benning Street

West Lebanon, New Hampshire 03784

USA

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

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

pean 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 requirements. Among them are:

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

* UL (Underwriters Laboratory) rating 94VO flammability testing for all printed-circuit boards used.

* CENELEC EN50199 EMC Product Standard for Arc Welding Equipment.

* ISO/IEC 60974-1 (BS 638-PT10) (EN 60 974-1) (EN50192) (EN50078) applicable to plasma cutting equipment and associ-

ated accessories.

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

mark conform to EN50192

when used in conjunction with hand torches with 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

GENERAL INFORMATION 8 Date: November 15, 2001

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 stored, installed, operated,

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

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

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

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

PARTICULAR PURPOSE.

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

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

service interruption. The remedies of the Purchaser set forth herein are exclusive and the liability of Thermal with respect to any

contract, or anything done in connection therewith such as the performance or breach thereof, or from the manufacture, sale, delivery,

resale, or use of any goods covered by or furnished by Thermal whether arising out of contract, negligence, strict tort, or under any

warranty, or otherwise, shall not, except as expressly provided herein, exceed the price of the goods upon which such liability is based.

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

SAFETY OR PERFORMANCE OF ANY THERMAL PRODUCT.

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

The limited warranty periods for Thermal products shall be as follows (with the exception of XL Plus Series, CutMaster Series , Cougar

and DRAG-GUN): A maximum of three (3) years from date of sale to an authorized distributor and a maximum of two (2) years from

date of sale by such distributor to the Purchaser, and with the further limitations on such two (2) year period (see chart below).

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

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

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

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

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

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

Parts

XL Plus & Parts Parts

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

Main Power Magnetics 3 Years 1 Year 2 Years 1 Year

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

Control PC Board 3 Years 1 Year 2 Years 1 Year

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

But Not Limited To, Starting Circuit,

Contactors, Relays, Solenoids, Pumps,

Power Switching Semi-Conductors

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

Exchanges, And Accessory Equipment

Torch And Leads

Maximizer 300 Torch 1 Year 1 Year

SureLok Torches 1 Year 1 Year 1 Year

All Other Torches 180 Days 180 Days 180 Days 180 Days

Repair/Replacement Parts 90 Days 90 Days 90 Days None

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

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

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

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

Effective: November 15, 2001

Manual 0-2683 9 Introduction

2.3 Service Responsibilities

The Service Technician should be familiar with the equip-

ment and its capabilities and should be prepared to rec-

ommend arrangements of components which will provide

the most efficient layout, utilizing the equipment to its best

possible advantage.

Maintenance work should be accomplished in a timely

manner. If problems are encountered, or the equipment

does not function as specified, contact Technical Services

Department in West Lebanon for assistance.

2.4 Technical Specifications

A. System Specifications

System Specifications

Input Power

100 VAC 50Hz, 110 VAC 60Hz, Single Phase

100/110 VAC, 50/60Hz, Single Phase

120VAC ±10%, 50Hz, Single Phase

120VAC ±10%, 60Hz, Single Phase

220VAC ±10%,50Hz, Single Phase

208/230VAC ±10%, 60Hz, Single Phase

Output Power See subsection 2.3B

Duty Cycle See subsection 2.3B

Maximum OCV 280 VDC

Pilot Circuitry Capacitive Discharge (CD), Constant DC

Weight with Leads 55 lbs (24.9 kg)

Power Supply L 16 in. (406 mm)

Dimensions W 9 in. (229 mm)

H 10 in. (254 mm)

Work Cable 15 ft. (4.6 m)

Input Power Cable 6.6 ft. (2 m) minimum

PCH-10 70°

PCH-10 180°

L See subsection 2.4

W See subsection 2.4

Cutting Rating 12 Amps Max. Straight Polarity

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

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

Pierce Rating 1/16 in. (1.6 mm)

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

Gas Requirements Compressed Air (Built-in)

Leads Length 20 ft. (6.1 m)

Torch Style

Torch Dimensions

2.0 INTRODUCTION

2.1 Scope Of Manual

This manual provides service instructions for the Ther-

mal Dynamics® DRAG-GUN Plasma Cutter.

Information in this edition is particularly applicable to

the Troubleshooting and Repair of the equipment, and is

intended for use by properly trained Service Technicians

familiar with this equipment.

Read this manual and the DRAG-GUN Operating Manual,

0-2682, thoroughly. A complete understanding of the ca-

pabilities and functions of the equipment will assure ob-

taining the performance for which it was designed.

2.2 General Service Philosophy

Several key points are essential to properly support the

application and operation of this equipment.

A. Application

The equipment should satisfy the customer’s requirements

as supplied and as described in Section 3 of this manual.

Be sure to confirm that the equipment is capable of the

application desired.

B. Modifications

No physical or electrical modifications other than selec-

tion of standard options and accessories are to be made to

this equipment.

C. Customer/Operator Responsibilities

It is the customer/operator's responsibility to maintain

the equipment and peripheral accessories provided by

Thermal Dynamics in good operating order in accordance

with the procedures outlined in the Operating Manual,

and to protect the equipment from accidental or malicious

damage.

D. Repair Restrictions

The electronics consists of a Printed Circuit Board Assem-

bly which must be carefully handled, and must be replaced

as a unit. No replacement of printed circuit solder-mounted

components is allowed except as noted in this manual. If

PC Board is to be returned, the replaced Printed Circuit

Board Assembly must be properly packaged in protective

material and returned intact per normal procedures.

Introduction 10 Manual 0-2683

B. Input/Output Specifications

Model Hz

Input

Amps

RMS

Output

Amps

(DC)

Output

Voltage

(DC)

Duty

Cycle %

100/110V 50/60 25/24 12 85 30

120V *5022129530

120V 60 20 12 70 30

220V *5013128530

208/230V 60 10 12 78 30

* CE approved.

2.5 Dimensions

16.0 in

(406 mm)

9.0 in

(229 mm)

10.0 in.

(254 mm)

A-02004

Figure 2-1 Power Supply Dimensions

8 in (203 mm)

1.1 in (27 mm)

2.9 in

(75 mm)

8.9 in (226 mm)

1.1 in

(27 mm)

A-02385

180˚

70˚

Figure 2-2 Torch Dimensions

Manual 0-2683 11 TROUBLE-SHOOTING

3.0: TROUBLESHOOTING

3.1 Introduction

This section provides service diagnostics for the DRAG-

GUN Plasma Cutter with PCH-10 Torch, aiding the tech-

nician to isolate faulty subassemblies.

Under no circumstances are field repairs to be attempted

on Printed Circuit Boards or other subassemblies of this

unit. Evidence of unauthorized repairs will void the fac-

tory warranty.

WARNING

There are extremely dangerous voltage and power

levels present inside this unit. Do not attempt to

diagnose or repair unless you have had training in

power electronics measurement and troubleshoot-

ing techniques.

3.2 Periodic Inspection &

Maintenance

The DRAG-GUN Operating Manual 0-2682, describes the

inspection and maintenance procedures which should be

performed at periodic intervals. Routine Maintenance

ensures optimum performance of equipment and can pre-

vent the user from encountering problems with this equip-

ment. Refer to that manual for instructions on power sup-

ply and torch maintenance.

3.3 Common Cutting Faults

Poor or lackluster performance can often be improved by

slight modifications to technique or equipment. For ex-

ample:

A. Insufficient Penetration

1. Cutting speed too fast

2. Torch tilted too much

3. Metal too thick

4. Worn torch parts

5. Standoff too high

6. Line voltage too low

7. Extension cord with inadequate rating

B. Main Arc Extinguishes

1. Cutting speed too slow

2. Torch standoff too high from workpiece

3. Work cable disconnected

4. Worn torch parts

C. Excessive Dross Formation

1. Cutting speed too slow

2. Torch standoff too high from workpiece

3. Worn torch parts

D. Short Torch Parts Life

1. Exceeding system capability (material too thick)

2. Excessive pilot arc time

3. Improperly assembled torch

4. Inadequate air supply (check filter on Compressor)

5. Faulty Air Compressor

6. Ground or work lead not connected

3.4 Common Operating Problems

Getting used to the way the system sounds and feels while

it is operating properly will help to determine the nature

of problems if they arise.

A. Compressor Related

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

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

depressed, the unit will click once and nothing more will

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

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

If the air filter on the compressor becomes clogged, the

compressor may sound more labored, cut speed and qual-

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

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

blow air through it, then reinstall it.

TROUBLE-SHOOTING 12 Manual 0-2683

B. Power Source Related

If the service available is saggy, pilot and cut performance

will be degraded. In some cases, the service circuit breaker

may open during use. Some things that will help:

• Use a service fused or circuit breaker for the speci-

fied amps. (Refer to Operator’s Manual 0-2682, sub-

section 4.0-D for service amperage.)

• Use heavy gauge extension cords (Refer to Operator’s

Manual 0-2682, subsection 4.0-D for sizes).

• Use as short an extension cord as possible.

• Try different outlets on different branch circuits. Use

the one that gives the strongest pilot.

C. Power Supply/Torch Related

In some instances when the torch switch is pressed there

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

torch fires.

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

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

ting the leads bleed down before trying again. This should

help because the torch fires best at a lower voltage with

lower air pressure at the torch.

D. Cutting Related

1. Piloting

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

stant DC pilot. This means the plasma arc is always

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

a very smooth, forgiving system. This also means that

the torch tip will wear fairly rapidly if you pilot for an

extended time or cut with too great a standoff (essen-

tially switching from a transferred cutting arc back to

the constant DC pilot arc).

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

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

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

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

some materials, holding a slight standoff (1/16") may

provide a better cut.

NOTE

Piloting is harder on parts life than actual cutting

because the pilot arc is directed from the electrode to

the tip rather than to a workpiece. Whenever pos-

sible, avoid excessive pilot arc time to improve parts

life.

2. Torch Standoff

Improper standoff (the distance between the torch tip

and workpiece) can adversely affect tip life as well as

shield cup life. Reducing standoff will generally re-

sult in a more square cut.

NOTE

Although the DRAG-GUN will cut using standoff,

this unit is primarily a drag-cutting machine.

3.5 Troubleshooting Guide

A. General

The troubleshooting covered in this Service Manual re-

quires power supply disassembly and live measurements.

Troubleshooting and repairing this unit is a process which

should be undertaken only by those familiar with high

voltage high power electronic equipment.

WARNING

There are extremely dangerous voltage and power

levels present inside this unit. Do not attempt to

diagnose or repair unless you have had training in

power electronics measurement and troubleshoot-

ing techniques.

B. How To Use This Guide

The following information is a guide to help determine the

most likely causes for various symptoms. The guide is set

up in the following manner:

Symptom (Bold type)

Cause (Italic type)

Remedy (Test type)

Locate your symptom, check causes (easiest is usually first;

sometimes the order is important, if noted), then remedies.

Repair as needed being sure to verify that the unit is fully

operational after any repairs.

C. No Power, AC switch on, red (amber for 220V)

indicator dark, no fan.

1. No power from wall unit.

a. Test electrical outlet with voltmeter or some other

known good load (trouble light, hand drill, etc).

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

If AC line voltage is not present, replace fuse or

reset circuit breaker.

Manual 0-2683 13 TROUBLE-SHOOTING

2. Damaged power cord.

a. Confirm with voltmeter if AC line voltage is

present at input to power switch.

If AC voltage is present, proceed to next step.

If ac line voltage is not present, replace Power

Cord.

3. Power Switch faulty.

a. Confirm with voltmeter if AC line voltage is

present at main Capacitor (C13) terminals when

power switch is on.

If AC line voltage is not present, replace Power

Switch.

D. Power OK, service circuit breaker or fuse opens

after the power switch is switched on.

NOTE

Proceed with troubleshooting for these components

in order:

1. Faulty Fan.

a. Disconnect the Fan and insulate the two wires

going to the Fan with tape (separately), then

reapply power.

If the circuit breaker or fuse opens after the

power switch is switched on, go to next step.

If the circuit breaker or fuse is okay, replace Fan.

2. Faulty Transformer Assembly or Capacitor.

a. With the Fan still disconnected, disconnect two

leads from the transformer that are connected

to the Capacitor (C13) , then apply power.

If the circuit breaker or fuse opens after power

is applied, the Capacitor is shorted. Replace

Capacitor (C13).

If the circuit breaker or fuse is okay, replace

Transformer.

E. Power OK, fan runs, no compressor operation or

pilot when torch switch pressed.

1. Shield cup loose, PIP not making contact.

a. Reseat the torch parts, tighten shield cup.

2. Unit overheated.

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

after 10 minutes.

3. Shorted torch parts.

a. Replace torch consumables.

4. Torch switch may have broken or shorted wires.

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

shooting.

5. Overheated or faulty Compressor.

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

and/or the Relay is actuating (test button on

side pulls in), the Compressor motor may have

failed or overheated. If the Case of the Com-

pressor motor feels very warm, allow it to cool

and try again. The Compressor has its own

overtemp cutout switch.

If the unit fails to operate once it has cooled

down, replace the compressor.

6. Shorted Bridge Rectifier (BR2)

a. If the Rectifier (upper) is hot and the Transformer

is buzzing or heating up, the rectifier is shorted.

Replace Rectifier.

7 . Faulty Control PCB or Relay

CAUTION

Be sure torch is directed away from people or haz-

ards. A pilot arc may start!

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

the Compressor starts and the torch operates,

the PCB or Relay has most likely failed.

The PCB can be isolated by removing the push

on connectors from the Relay coil and measur-

ing the relay coil with an ohmmeter. If the coil

measures between 50 - 100ohms, the Relay is

good and the PCB should be replaced.

If the Compressor runs intermittently and arc-

ing can be seen in the Relay case while the torch

switch is held on, the Relay contacts are worn

and the Relay should be replaced.

F. Power OK, fan runs, compressor runs intermit-

tently, Relay Case shows arcing when the torch

switch is held on.

1. Faulty Relay.

a. If the Compressor runs intermittently and arc-

ing can be seen in the Relay Case while the torch

switch is held on, the relay contacts are worn

and the Relay should be replaced.

TROUBLE-SHOOTING 14 Manual 0-2683

G. Power OK, fan runs, compressor starts then shuts

down as soon as the torch switch is pressed.

1. Shorted, damaged, or incorrect torch parts.

a. Check that all torch parts are in good condition

and designed for use in the PCH-10 torch.

2. Faulty (open) Voltage Divider Resistor.

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

nect the push-on connectors and measure the

Resistor with an ohmmeter. It should read 1K

ohms. If measurement is not 1K ohms, replace

Resistor.

3. Shorted Bridge Rectifier (BR1).

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

the main transformer after the Relay actuates.

If hum or buzzing noise exists, replace Bridge

Rectifier. (Replace lower Bridge Rectifier, clos-

est to Chassis).

H. Power OK, fan runs, compressor runs, no pilot or

cutting arc with the torch switch pressed.

1. Worn, contaminated, or incorrect torch parts.

a. Check that all torch parts are in good condition

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

place worn parts as necessary.

2. Parts not assembled correctly.

a. Reassemble torch parts.

3. Damaged torch or leads.

a. Check per subsection 3.6, Torch and Leads

Troubleshooting.

4. Faulty Control PCB.

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

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

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

placed.

5. Faulty (open) Pilot Resistor.

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

sis. Disconnect the push on connectors and

measure the resistor with an ohmmeter. It should

read 0.5 ohms (essentially a short).

6. AC input too low.

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

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

ent branch circuit.

7. Faulty Ferrite/Transformer Assembly.

a. The Ferrite Transformer Assembly is used to

generate a high voltage pulse to establish the

pilot arc. Troubleshooting is limited to visual

inspection. The two primary connections and

two secondary connections should be checked

for general integrity and snug fit onto the push

on connectors. The Transformer Assembly it-

self should be free of large ferrite chips and

cracks along the core.

I. Torch pilots but does not cut well.

1. AC input power too low.

a. Use shortest service from AC outlet to breaker

panel as possible or larger gauge extension cord.

2. Work cable not attached.

a. Check work cable connection.

3. Restricted air flow.

a. Check lead for kinks or pinching restricting air

flow.

4. Loose shield cup.

a. Tighten shield cup.

5. One or more gas distributor holes blocked.

a. Replace Gas Distributor.

6. Excessive parts wear.

a. Inspect torch consumables and replace as nec-

essary.

7. Damaged torch insulator

a. Check insulator between anode and cathode for

charring per subsection 3.6, Torch and Leads

Troubleshooting.

Manual 0-2683 15 TROUBLE-SHOOTING

3.6 Torch & Leads Troubleshooting

WARNINGS

Disconnect primary power to the system before dis-

assembling the torch, leads, or power supply.

DO NOT touch any internal torch parts while the

AC indicator light on the front panel of the power

supply is on.

Torch parts may get quite hot during normal opera-

tion. Always wear light cutting gloves when chang-

ing torch parts just after operating the Drag-Gun

system.

A. Checking the Center Insulator

The Center Insulator separates the negative and positive

charged sections of the torch. If the center insulator does

not provide adequate resistance, current which is intended

for the pilot arc may be dissipated into the torch head,

resulting in torch failure.

1. Remove the shield cup, tip, gas distributor, and electrode

from the torch.

Torch Head Assembly

Electrode

Tip

Standard

Shield Cup

Gas

Distributor

PCH-10

A-02007

Figure 3-1 PCH-10 Torch Head Parts Removal

2. Disconnect the torch lead from the power supply to

isolate the torch from power supply circuits. Refer to

Appendix I for Leads connections.

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

continuity between the electrode seat (negative) and the

brass threads of the torch assembly. Infinite resistance

(no continuity) should be found. If there is continuity

between the two, remove the torch head from the lead

and check the torch head separately.

B. Checking Torch Lead

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

measuring the resistance between the positive pilot lead

connector and the negative lead fitting. If continuity is

found, the insulation between the torch leads is breaking

down and the torch and leads assembly should be replaced.

NOTE

The lead cannot be replaced without replacing the

torch assembly as well.

If no continuity is found, check the resistance between the

negative plasma lead fitting and the electrode seat in torch

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

assembly.

C. Checking Pilot and Switch Control Wires

Check the pilot and switch control wires for continuity

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

exists, replace torch and lead assembly.

D. Reassembling Torch and Leads

Replace parts as required, then recheck the torch head,

and lead connections to confirm proper measurements. If

each component is okay, reassemble torch and leads.

TROUBLE-SHOOTING 16 Manual 0-2683

Manual 0-2683 17 REPLACEMENT PROCEDURES

4.0 REPLACEMENT

PROCEDURES

4.1 General Information

• Failures identified on the Transformer/Inductor/

Chassis Assembly cannot be repaired - the entire

power supply must be replaced. Refer to the Parts

List for the catalog number for a replacement power

supply.

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

sembly are replaceable parts. The torch leads alone

are not serviceable; problems encountered in the

leads will require the torch & leads assembly to be

replaced.

• For instructions on replacing the torch & leads, work

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

ating Manual 0-2682. (Refer to Appendix I, in this

manual, for leads connection diagram.)

• Most replacement hardware can be purchased lo-

cally.

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

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

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

later, refer to the schematic in Appendix III. Check

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

and follow instructions in this section where appli-

cable, as they pertain to your unit.

WARNINGS

Disconnect primary power to the system before

disassembling the torch, leads, or power supply.

4.2 Removing Cover/Handle

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

els, and four screws near base to remove cover and

handle from unit.

NOTE

When replacing cover, make sure all wires are care-

fully positioned so that the wires are not pinched

when the cover and handle are secured.

4.3 Torch Head Assembly

Replacement

WARNINGS

Disconnect primary power to the system before dis-

assembling the torch or power supply.

Torch parts may get quite hot during normal opera-

tion. Always wear light cutting gloves when chang-

ing torch parts just after operating the Drag-Gun

system.

To Remove Torch Head Assembly:

NOTE

Refer to Figure 4-1 for parts identification.

1. Remove consumable parts from front end of torch.

2. Remove six screws from torch handle assembly

(A).

3. Remove both torch handle halves from the torch

and leads assembly , then complete the following:

a. Disconnect positive pilot lead connection at

torch head by removing pilot lead screw (B).

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

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

cut torch lead 1" (2.54 cm) from the end of black

sleeve (D) to reveal butt splice.

4. Pull torch head away from torch lead to expose

1/2"-3/4" of cable.

5. Clamp down with vise grips on black sleeve of

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

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

head assembly (F).

7. Remove orange insulating sleeving from torch head

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

torch assemblies may not have sleeving.

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

9. Remove the two screws from the torch head split

holder and separate the halves (I).

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

disturb PIP connections.

Page is loading ...

ESAB Plasma Cutting Power Supply User manual

Brand: ESAB

Model: Plasma Cutting Power Supply

Category: Welding System

Type: User manual

Download PDF

report

ESAB Plasma Cutting Power Supply User manual

ESAB Plasma Cutting Power Supply User manual

Related papers

Other documents