Thermal Dynamics 35C User manual

PLASMA
DRAG-GUN™PLUS
Service Manual
35C
PLASMA CUTTING
SYSTEM
Rev. AA.01 Issue Date: March 26, 2007 Manual 0-4751
Operating Features:

!
WARNING
Read and understand this entire Manual and your employer’s safety practices before installing,
operating, or servicing the equipment.
While the information contained in this Manual represents the Manufacturer's best judgement,
the Manufacturer assumes no liability for its use.
Plasma Cutting Power Supply
Drag-Gun Plus
PCH 42 Torch
Service Manual Number 0-4751
Covered under U.S. Patents.
Published by:
Thermadyne Corporation
82 Benning Street
West Lebanon, New Hampshire, USA 03784
[phone]
www.thermal-dynamics.com
©Copyright 2006, 2007 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: March 26, 2007
Record the following information for Warranty purposes:
Where Purchased:____________________________________
Purchase Date:_______________________________________
Power Supply Serial #:________________________________
Torch Serial #:________________________________________

TABLE OF CONTENTS
SECTION 1:
GENERAL INFORMATION ................................................................................................ 1-1
1.01 Notes, Cautions and Warnings ...................................................................... 1-1
1.02 Important Safety Precautions ....................................................................... 1-1
1.03 Publications .................................................................................................. 1-3
1.04 Declaration of Conformity ............................................................................. 1-4
1.05 Statement of Warranty .................................................................................. 1-5
SECTION 2:
INTRODUCTION ............................................................................................................... 2-1
2.01 INTRODUCTION .......................................................................................... 2-1
2.02 GENERAL SPECIFICATION ......................................................................... 2-1
2.03 Features ....................................................................................................... 2-1
2.04 Torch Specifications ..................................................................................... 2-2
2.05 System Contents .......................................................................................... 2-2
2.06 Transporting Methods ................................................................................... 2-2
SECTION 3:
INSTALLATION ................................................................................................................. 3-1
3.01 Site Selection ............................................................................................... 3-1
3.02 Electrical Input Connections ......................................................................... 3-1
3.03 Torch ............................................................................................................ 3-1
SECTION 4:
OPERATION .................................................................................................................... 4-1
4.01 Front Control Panel ....................................................................................... 4-1
4.02 Preparations For Operating ........................................................................... 4-2
SECTION 5: MAINTENANCE .................................................................................................... 5-1
5.01 General Maintenance .................................................................................... 5-1
SECTION 6:
TROUBLESHOOTING ....................................................................................................... 6-1
6.01 Normal Setup and Operation ........................................................................ 6-1
6.02 Basic Trouble Shooting Guide ....................................................................... 6-2
6.03 Control PCB Indicators ................................................................................. 6-3
6.04 Open Circuit Voltage Check .......................................................................... 6-4
6.05 Detailed Fault Finding / Error Indicators ........................................................ 6-5
6.06 Torch Tests ................................................................................................... 6-9
SECTION 7:
PARTS LIST ...................................................................................................................... 7-1
7.01 Parts List Power Supply................................................................................ 7-2
7.02 Replacement Hand Torch Parts With Ergonomic Handle ................................ 7-6

TABLE OF CONTENTS (Con't)
Appendix 1: Operating Sequence, Block Diagram ..................................................................... A-1
Appendix 2: Torch Connection ................................................................................................... A-2
Appendix 3: Microchip Pin-Out .................................................................................................. A-3
Appendix 4: System Schematic 230V CE ................................................................................. A-4
Appendix 5: System Schematic 230V ....................................................................................... A-6
GLOBAL CUSTOMER SERVICE CONTACT INFORMATION .............................. Inside Rear Cover

Manual 0-4751 1-1 GENERAL INFORMATION
SECTION 1:
GENERAL INFORMATION
1.01 Notes, Cautions and Warnings
Throughout this manual, notes, cautions, and warn-
ings are used to highlight important information. These
highlights are categorized as follows:
NOTE
An operation, procedure, or background in-
formation which requires additional empha-
sis or is helpful in efficient operation of the
system.
CAUTION
A procedure which, if not properly followed,
may cause damage to the equipment.
!
WARNING
A procedure which, if not properly followed,
may cause injury to the operator or others
in the operating area.
1.02 Important Safety Precautions
!
WARNING
OPERATION AND MAINTENANCE OF PLASMA
ARC EQUIPMENT CAN BE DANGEROUS AND
HAZARDOUS TO YOUR HEALTH.
Plasma arc cutting produces intense elec-
tric and magnetic emissions that may inter-
fere with the proper function of cardiac
pacemakers, hearing aids, or other elec-
tronic health equipment. Persons who work
near plasma arc cutting applications should
consult their medical health professional and
the manufacturer of the health equipment
to determine whether a hazard exists.
To prevent possible injury, read, understand
and follow all warnings, safety precautions
and instructions before using the equip-
ment. Call 1-603-298-5711 or your local
distributor if you have any questions.
GASES AND FUMES
Gases and fumes produced during the plasma cut-
ting process can be dangerous and hazardous to your
health.
• Keep all fumes and gases from the breathing area.
Keep your head out of the welding fume plume.
• Use an air-supplied respirator if ventilation is not
adequate to remove all fumes and gases.
• The kinds of fumes and gases from the plasma
arc depend on the kind of metal being used, coat-
ings on the metal, and the different processes.
You must be very careful when cutting or weld-
ing any metals which may contain one or more
of the following:
Antimony Chromium Mercury
Arsenic Cobalt Nickel
Barium Copper Selenium
Beryllium Lead Silver
Cadmium Manganese Vanadium
• Always read the Material Safety Data Sheets
(MSDS) that should be supplied with the mate-
rial you are using. These MSDSs will give you
the information regarding the kind and amount
of fumes and gases that may be dangerous to
your health.
• For information on how to test for fumes and
gases in your workplace, refer to item 1 in Sub-
section 1.03, Publications in this manual.
• Use special equipment, such as water or down
draft cutting tables, to capture fumes and gases.
• Do not use the plasma torch in an area where
combustible or explosive gases or materials are
located.
• Phosgene, a toxic gas, is generated from the va-
pors of chlorinated solvents and cleansers. Re-
move all sources of these vapors.

GENERAL INFORMATION 1-2 Manual0-4751
• This product, when used for welding or cutting,
produces fumes or gases which contain chemi-
cals known to the State of California to cause birth
defects and, in some cases, cancer. (California
Health & Safety Code Sec. 25249.5 et seq.)
ELECTRIC SHOCK
Electric Shock can injure or kill. The plasma arc pro-
cess uses and produces high voltage electrical en-
ergy. This electric energy can cause severe or fatal
shock to the operator or others in the workplace.
• Never touch any parts that are electrically “live”
or “hot.”
• Wear dry gloves and clothing. Insulate yourself
from the work piece or other parts of the weld-
ing circuit.
• Repair or replace all worn or damaged parts.
• Extra care must be taken when the workplace is
moist or damp.
• Install and maintain equipment according to NEC
code, refer to item 9 in Subsection 1.03, Publi-
cations.
• Disconnect power source before performing any
service or repairs.
• Read and follow all the instructions in the Oper-
ating Manual.
FIRE AND EXPLOSION
Fire and explosion can be caused by hot slag, sparks,
or the plasma arc.
• Be sure there is no combustible or flammable
material in the workplace. Any material that can-
not be removed must be protected.
• Ventilate all flammable or explosive vapors from
the workplace.
• Do not cut or weld on containers that may have
held combustibles.
• Provide a fire watch when working in an area
where fire hazards may exist.
• Hydrogen gas may be formed and trapped un-
der aluminum workpieces when they are cut un-
derwater or while using a water table. DO NOT
cut aluminum alloys underwater or on a water
table unless the hydrogen gas can be eliminated
or dissipated. Trapped hydrogen gas that is ig-
nited will cause an explosion.
NOISE
Noise can cause permanent hearing loss. Plasma arc
processes can cause noise levels to exceed safe lim-
its. You must protect your ears from loud noise to
prevent permanent loss of hearing.
• To protect your hearing from loud noise, wear
protective ear plugs and/or ear muffs. Protect
others in the workplace.
• Noise levels should be measured to be sure the
decibels (sound) do not exceed safe levels.
• For information on how to test for noise, see item
1 in Subsection 1.03, Publications, in this manual.
PLASMA ARC RAYS
Plasma Arc Rays can injure your eyes and burn your
skin. The plasma arc process produces very bright
ultra violet and infra red light. These arc rays will dam-
age your eyes and burn your skin if you are not prop-
erly protected.
• To protect your eyes, always wear a welding hel-
met or shield. Also always wear safety glasses
with side shields, goggles or other protective eye
wear.
• Wear welding gloves and suitable clothing to pro-
tect your skin from the arc rays and sparks.
• Keep helmet and safety glasses in good condi-
tion. Replace lenses when cracked, chipped or
dirty.
• Protect others in the work area from the arc rays.
Use protective booths, screens or shields.

Manual0-4751 1-3 GENERAL INFORMATION
• Use the shade of lens as suggested in the fol-
lowing per ANSI/ASC Z49.1:
Minimum Protective Suggested
Arc Current Shade No. Shade No.
Less Than 300* 8 9
300 - 400* 9 12
400 - 800* 10 14
* These values apply where the actual arc
is clearly seen. Experience has shown that
lighter filters may be used when the arc is
hidden by the workpiece.
1.03 Publications
Refer to the following standards or their latest revi-
sions for more information:
1. OSHA, SAFETY AND HEALTH STANDARDS, 29CFR 1910,
obtainable from the Superintendent of Documents, U.S.
Government Printing Office, Washington, D.C. 20402
2. ANSI Standard Z49.1, SAFETY IN WELDING AND CUTTING,
obtainable from the American Welding Society, 550 N.W.
LeJeune Rd, Miami, FL 33126
3. NIOSH, SAFETY AND HEALTH IN ARC WELDING AND GAS
WELDING AND CUTTING, obtainable from the Superinten-
dent of Documents, U.S. Government Printing Office, Wash-
ington, D.C. 20402
4. ANSI Standard Z87.1, SAFE PRACTICES FOR OCCUPATION
AND EDUCATIONAL EYE AND FACE PROTECTION, obtain-
able from American National Standards Institute, 1430
Broadway, New York, NY 10018
5. ANSI Standard Z41.1, STANDARD FOR MEN’S SAFETY-TOE
FOOTWEAR, obtainable from the American National Stan-
dards Institute, 1430 Broadway, New York, NY 10018
6. ANSI Standard Z49.2, FIRE PREVENTION IN THE USE OF
CUTTING AND WELDING PROCESSES, obtainable from
American National Standards Institute, 1430 Broadway, New
York, NY 10018
7. AWS Standard A6.0, WELDING AND CUTTING CONTAIN-
ERS WHICH HAVE HELD COMBUSTIBLES, obtainable from
American Welding Society, 550 N.W. LeJeune Rd, Miami,
FL 33126
8. NFPA Standard 51, OXYGEN-FUEL GAS SYSTEMS FOR
WELDING, CUTTING AND ALLIED PROCESSES, obtainable
from the National Fire Protection Association, Batterymarch
Park, Quincy, MA 02269
9. NFPA Standard 70, NATIONAL ELECTRICAL CODE, obtain-
able from the National Fire Protection Association,
Batterymarch Park, Quincy, MA 02269
10. NFPA Standard 51B, CUTTING AND WELDING PROCESSES,
obtainable from the National Fire Protection Association,
Batterymarch Park, Quincy, MA 02269
11. CGA Pamphlet P-1, SAFE HANDLING OF COMPRESSED
GASES IN CYLINDERS, obtainable from the Compressed
Gas Association, 1235 Jefferson Davis Highway, Suite 501,
Arlington, VA 22202
12. CSA Standard W117.2, CODE FOR SAFETY IN WELDING
AND CUTTING, obtainable from the Canadian Standards
Association, Standards Sales, 178 Rexdale Boulevard,
Rexdale, Ontario, Canada M9W 1R3
13. NWSA booklet, WELDING SAFETY BIBLIOGRAPHY obtain-
able from the National Welding Supply Association, 1900
Arch Street, Philadelphia, PA 19103
14. American Welding Society Standard AWSF4.1, RECOM-
MENDED SAFE PRACTICES FOR THE PREPARATION FOR
WELDING AND CUTTING OF CONTAINERS AND PIPING THAT
HAVE HELD HAZARDOUS SUBSTANCES, obtainable from
the American Welding Society, 550 N.W. LeJeune Rd, Mi-
ami, FL 33126
15. ANSI Standard Z88.2, PRACTICE FOR RESPIRATORY PRO-
TECTION, obtainable from American National Standards In-
stitute, 1430 Broadway, New York, NY 10018

GENERAL INFORMATION 1-4 Manual0-4751
1.04 Declaration of Conformity
Manufacturer: Thermal Dynamics Corporation
Address: 82 Benning Street
West Lebanon, New Hampshire 03784
USA
The equipment described in this manual conforms to all applicable aspects and regulations of the ‘Low Voltage
Directive’ (European Council Directive 73/23/EEC as amended by Council Directive 93/68/EEC) and to the Na-
tional legislation for the enforcement of this Directive.
The equipment described in this manual conforms to all applicable aspects and regulations of the "EMC Direc-
tive" (European Council Directive 89/336/EEC) and to the National legislation for the enforcement of this Direc-
tive.
Serial numbers are unique with each individual piece of equipment and details description, parts used to manu-
facture a unit and date of manufacture.
National Standard and Technical Specifications
The product is designed and manufactured to a number of standards and technical requirements. Among
them are:
* CSA (Canadian Standards Association) standard C22.2 number 60 for Arc welding equipment.
* UL (Underwriters Laboratory) rating 94VO flammability testing for all printed-circuit boards used.
* CENELEC EN50199 EMC Product Standard for Arc Welding Equipment.
* ISO/IEC 60974-1 (BS 638-PT10) (EN 60 974-1) (EN50192) (EN50078) applicable to plasma cutting equip-
ment and associated accessories.
* For environments with increased hazard of electrical shock, Power Supplies bearing the
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 manufacturing process. This is to ensure the product is safe, when used according to instructions in this
manual and related industry standards, and performs as specified. Rigorous testing is incorporated into the
manufacturing process to ensure the manufactured product meets or exceeds all design specifications.
Thermal Dynamics has been manufacturing products for more than 30 years, and will continue to achieve
excellence in our area of manufacture.
Manufacturers responsible representative: Steve Ward
Operations Director
Thermadyne Europe
Europa Building
Chorley N Industrial Park
Chorley, Lancashire,
England PR6 7BX