ESAB DRAG-GUN™ Plasma Cutter User manual

Brand: ESAB

Model: DRAG-GUN™ Plasma Cutter

Category: Welding System

Type: User manual

This manual is also suitable for

DRAG-GUN™ Plasma Cutter with Built-In Air

Manual No. 0-2682

April 26, 2000

Operating Manual

Includes:

• 12 Amp Power Supply

• PCH-10 Torch with Leads

• Work Cable with Clamp

• Input Power Cable

For Models:

• 100 VAC 50 Hz/110 VAC 60Hz

• 120 VAC 50Hz

• 120 VAC 60Hz

• 220 VAC 50Hz

• 208/230 VAC 60Hz

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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 our

best judgement, Thermal Dynamics Corporation assumes no

liability for its use.

DRAG-GUN Plasma Cutter Operating Manual

Number 0-2682

Published by:

Thermal Dynamics Corporation

Industrial Park No. 2

West Lebanon, New Hampshire, USA 03784

(603) 298-5711

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 liabil-

ity to any party for any loss or damage caused by any error or

omission in the DRAG-GUN Plasma Cutter Operating Manual,

whether such error results from negligence, accident, or any

other cause.

Printed in the United States of America

April 2000

WARNING

ABLE OF CONTENTSABLE OF CONTENTS

ABLE OF CONTENTS

1: GENERAL INFORMATION ..............................................................................................................1

1.1 Notes, Cautions and Warnings ........................................................................................1

1.2 Important Safety Precautions ..........................................................................................1

1.3 Publications ....................................................................................................................2

1.4 Note, Attention et Avertissement......................................................................................3

1.5 Precautions De Securite Importantes...............................................................................3

1.6 Documents De Reference.................................................................................................5

1.7 Declaration of Conformity ...............................................................................................7

1.8 Statement of Warranty ....................................................................................................8

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

2.1 What is Plasma? ..............................................................................................................9

2.2 General Product Description.......................................................................................... 10

2.3 Technical Specifications ................................................................................................10

2.4 Dimensions ................................................................................................................... 11

3.0 CONTROLS: LOCATION & FUNCTION ........................................................................................ 11

4.0 INSTALLATION .......................................................................................................................... 12

5.0 OPERATION...............................................................................................................................14

5.1 Cutting Techniques ....................................................................................................... 14

5.2 Cut Quality ................................................................................................................... 16

5.3 Recommended Cutting Speeds ...................................................................................... 16

5.4 Common Cutting Faults ................................................................................................ 17

5.5 Common Operating Problems ........................................................................................17

6.0 MAINTENANCE..........................................................................................................................18

6.1 Recommended Maintenance Schedule ........................................................................... 18

6.2 Power Supply Cleaning..................................................................................................18

6.3 Torch Cleaning..............................................................................................................18

6.4 Inspection and Replacement of Consumable Torch Parts ...............................................18

7.0 PARTS REPLACEMENT..............................................................................................................19

7.1 Torch & Leads Replacement .......................................................................................... 19

7.2 Work Cable Replacement ...............................................................................................20

7.3 Input Power Cable Replacement .................................................................................... 20

8.0 PARTS LIST ............................................................................................................................... 20

8.1 Returns ........................................................................................................................ 20

8.2 Parts Replacement ........................................................................................................ 21

8.3 Power Supply Replacement Parts................................................................................... 22

8.4 Options & Accessories (not shown) ................................................................................22

8.5 Torch Replacement Parts............................................................................................... 24

APPENDIX I: CABLING DETAILS...................................................................................................... 25

APPENDIX II: INTERCONNECTING DIAGRAM ..................................................................................26

APPENDIX III: INTERCONNECTING DIAGRAM .................................................................................28

5/21/99 1 GENERAL INFORMATION

1: GENERAL1: GENERAL

1: GENERAL

INFORMAINFORMA

INFORMA

TIONTION

TION

1.1 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.

1.2 Important Safety Precautions

WARNING

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 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

1.3, 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.

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.”

• Wear dry gloves and clothing. Insulate yourself from

the work piece or other parts of the welding cir-

cuit.

• Repair or replace all worn or damaged parts.

• Extra care must be taken when the workplace is

moist or damp.

GENERAL INFORMATION 2 5/21/99

• Install and maintain equipment according to NEC

code, refer to item 9 in Subsection 1.3, Publications.

• Disconnect power source before performing any ser-

vice 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 mate-

rial 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 1.3, 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.

1.3 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

Documents, U.S. Government Printing Office, Wash-

ington, 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 WELD-

ING AND GAS WELDING AND CUTTING, obtain-

able from the Superintendent of Documents, U.S.

Government Printing Office, Washington, D.C. 20402

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

CUPATION AND EDUCATIONAL 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 Broad-

way, New York, NY 10018

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

USE OF CUTTING AND WELDING PROCESSES,

obtainable from American National Standards Insti-

tute, 1430 Broadway, New York, NY 10018

7. AWS Standard A6.0, WELDING AND CUTTING

CONTAINERS WHICH HAVE HELD COMBUS-

TIBLES, obtainable from American Welding Society,

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

5/21/99 3 GENERAL INFORMATION

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 Asso-

ciation, Batterymarch Park, Quincy, MA 02269

10. NFPA Standard 51B, CUTTING AND WELDING

PROCESSES, obtainable from the National Fire Pro-

tection 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

WELDING AND CUTTING, obtainable from the Ca-

nadian Standards Association, Standards Sales, 178

Rexdale Boulevard, Rexdale, Ontario, Canada M9W

1R3

13. NWSA booklet, WELDING SAFETY BIBLIOGRA-

PHY obtainable from the National Welding Supply

Association, 1900 Arch Street, Philadelphia, PA 19103

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

OMMENDED SAFE PRACTICES FOR THE PREPA-

RATION FOR WELDING AND CUTTING OF CON-

TAINERS 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 RESPIRA-

TORY PROTECTION, obtainable from American

National Standards Institute, 1430 Broadway, New

York, NY 10018

1.4 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.

1.5 Precautions De Securite

Importantes

AVERTISSEMENT

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.

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.

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.

• Eloignez toute fumée et gaz de votre zone de respi-

ration. 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.

• 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 différents

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5/21/99 5 GENERAL INFORMATION

• Use the shade of lens as suggested in the following

chart per ANSI/ASC Z49.1:

• 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.

1.6 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 Docu-

ments, U.S. Government Printing Office, Washing-

ton, 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

TRAVAIL ET DANS LES ECOLES, disponible de

l’Institut Américain des Normes Nationales (Ameri-

can 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

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 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

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. ivret 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

GENERAL INFORMATION 6 5/21/99

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 PROTEC-

TION RESPIRATOIRE, disponible auprès de

l’American National Standards Institute, 1430

Broadway, New York, NY 10018

5/21/99 7 GENERAL INFORMATION

1.7 Declaration of Conformity

Manufacturer: Thermal Dynamics Corporation

Address: Industrial Park #2

West Lebanon, New Hampshire 03784

USA

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

tive’ (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 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.

* 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

Director of Operations

Thermadyne UK

Chorley England

GENERAL INFORMATION 8 5/21/99

1.8 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 80XL , 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 80XL 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 Series & Parts Parts

PAK Units, Power Supplies CutMaster 80XL 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

Consolles, Control Equipment, Heat 1 Year 1 Year 1 Year

Exchanges, And Accessory Equipment

Torch And Leads

Maximizer 300 Torch 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 May 6, 1999

Operating Manual 0-2682 9 DRAG-GUN Plasma Cutter

2.0 INTRODUCTION2.0 INTRODUCTION

2.0 INTRODUCTION

This manual contains descriptions, operating instructions

and basic maintenance procedures for the DRAG-GUN

Plasma Cutter. Read this manual thoroughly. A com-

plete understanding of the characteristics and capabili-

ties of this equipment will assure the dependable opera-

tion for which it was designed.

WARNING

Service of this equipment is restricted to Thermal

Dynamics® trained personnel; unqualified person-

nel are strictly cautioned against attempting re-

pairs or adjustments not covered in this manual,

at the risk of personal injury and/or voiding the

Warranty.

2.12.1

2.1

What is Plasma?What is Plasma?

What is Plasma?

A. Plasma Gas FlowA. Plasma Gas Flow

A. Plasma Gas Flow

Plasma is defined as a gas which has been heated to

an extremely high temperature and ionized so that it

becomes electrically conductive. The plasma arc cut-

ting and gouging process use this plasma to transfer

an electrical arc to the workpiece. The metal to be cut

or removed is melted by the heat of the arc and then

blown away.

In a Plasma Cutting Torch a cool gas (in this case, air)

enters Zone B (refer to Figure 2-1), where a pilot arc

between the electrode and the torch tip heats and ion-

izes the gas. The main cutting arc then transfers to

the workpiece through the column of plasma gas in

Zone C.

By forcing the plasma gas and electric arc through a

small orifice, the torch delivers a high concentration

of heat to a small area. The stiff, constricted plasma

arc is shown in Zone C (Figure 2-1). Direct current

(DC) straight polarity is used for plasma cutting, as

shown in the illustration.

Zone A (Figure 2-1) is used as a secondary gas that

cools the torch. This gas assists the high velocity

plasma gas in blowing the molten metal out of the cut

allowing for a fast, slag-free cut.

A-00002

Workpiece

Power

Supply

Figure 2-1 Typical Torch Head Detail

B. Gas DistributionB. Gas Distribution

B. Gas Distribution

The single gas used is internally split into plasma and

secondary gases. The plasma gas flows into the torch

through the negative lead, through the gas distribu-

tor, around the electrode, and out through the tip ori-

fice. The secondary gas flows down around the out-

side of the torch gas distributor, and out between the

tip and shield cup around the plasma arc.

C. Pilot ArcC. Pilot Arc

C. Pilot Arc

When the torch is started a pilot arc is established be-

tween the electrode and cutting tip. This pilot arc cre-

ates a path for the main arc to transfer to the work.

D. Capacitive Discharge (CD)D. Capacitive Discharge (CD)

D. Capacitive Discharge (CD)

Because direct current (DC) alone is not sufficient to

strike and maintain the pilot arc, CD is also used. The

capacitive discharge jumps between the tip and elec-

trode with the DC following. (Note: This may not ap-

ply to all unit models).

E. Main Cutting ArcE. Main Cutting Arc

E. Main Cutting Arc

DC power is also used for the main cutting arc. The

negative output is connected to the torch electrode

through the torch lead. The positive output is con-

nected to the workpiece via the work cable and to the

torch through a pilot wire.

DRAG-GUN Plasma Cutter 10 Operating Manual 0-2682

F. InterlocksF. Interlocks

F. Interlocks

If supply pressure falls below minimum requirements,

the lockout circuit will open, shutting off the DC Cir-

cuit. Similarly, the overtemp switch will open if the

unit becomes overheated, and will close again when

the unit cools to an acceptable temperature.

G. Parts-in-Place (PIP)G. Parts-in-Place (PIP)

G. Parts-in-Place (PIP)

The torch head has replaceable contacts called Parts-

In-Place (PIP). These two contacts are made through

the brass washer inside the shield cup when it is in-

stalled. The torch will fail to operate if these contacts

are not made.

Torch Switch

PIP Pin

Shield Cup

To Control

Cable Wiring

Butt Splice

A-00784

Figure 2-2 Parts-In-Place (PIP) Diagram

H. Duty CycleH. Duty Cycle

H. Duty Cycle

Duty cycle is the percentage of on-time (measured in

minutes) in a 10 minute period in which a system can

be operated, in an environment of a specified tem-

perature.

Exceeding duty cycle ratings will cause the thermal

overload protection circuit to become energized and

shut down output until the unit cools to normal oper-

ating temperature. Continual exceeding of duty cycle

ratings can cause damage to the cutting power source.

WARNING

When unit shuts down due to thermal overload,

power is still present throughout the entire sys-

tem.

2.2 General Product Description2.2 General Product Description

2.2 General Product Description

The DRAG-GUN Plasma Cutter is a small, easy-to-use

plasma cutting system which provides 12 amp maximum

output and a cut capacity of up to 1/8" (3.2 mm) of most

metals.

Everything you need to start cutting right away is in-

cluded with the DRAG-GUN - power supply with built-

in air compressor, pilot circuitry, all control circuitry, torch

and work lead (with torch consumable parts installed),

work cable and clamp, primary input cable, extra con-

sumable torch parts, and this instruction manual.

NOTE

The DRAG-GUN Cutter requires no assembly.

2.3 Technical Specifications2.3 Technical Specifications

2.3 Technical Specifications

A. System SpecificationsA. System 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

Operating Manual 0-2682 11 DRAG-GUN Plasma Cutter

B. Input/Output SpecificationsB. Input/Output Specifications

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.

2.4 Dimensions2.4 Dimensions

2.4 Dimensions

16.0 in

(406 mm)

9.0 in

(229 mm)

10.0 in.

(254 mm)

A-02004

Figure 2-3 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 2-4 Torch Dimensions

3.0 CONTROLS:3.0 CONTROLS:

3.0 CONTROLS:

LOCATION & FUNCTIONLOCATION & FUNCTION

LOCATION & FUNCTION

A. Front PanelA. Front Panel

A. Front Panel

1. Primary Power ON/OFF Switch

ON position supplies the AC power to activate all sys-

tem control circuits. OFF position deactivates control

circuits. In ON position, this switch is lighted; in the

OFF position, there is no light.

2. Torch & Leads

Torch & leads (including torch tip, gas distributor, elec-

trode, shield cup), are factory installed, ready to cut.

The torch handle (Arc ON/OFF) switch controls the

arc. Push the switch to activate the arc; release the

switch to stop the arc.

3. Work Cable & Clamp

The work cable & clamp are factory installed. Attach

the work cable to the workpiece before cutting.

Rear Panel

Primary Input

Power Cable

Front Panel

PCH 10 Torch

& Leads

Work Cable

& Clamp

Power

ON/OFF

Switch

A-02005

Arc ON/OFF

Switch

Figure 3-1 Front & Rear Panel Controls

B. Rear PanelB. Rear Panel

B. Rear Panel

1. Primary Input Power Cable

DRAG-GUN Plasma Cutter 12 Operating Manual 0-2682

This unit is supplied with a primary input power cable

capable of handling the input voltage designed for

this unit. If using with an extension cord, be sure cord

meets or exceeds the cord sizes recommended in Fig-

ure 4-1 to maintain proper operation.

4.0 INSTALLATION4.0 INSTALLATION

4.0 INSTALLATION

A. Site SelectionA. Site Selection

A. Site Selection

Select a clean, dry location with good ventilation and ad-

equate working space around all components.

NOTE

Review Important Safety Precautions at the front

of this manual to be sure that the selected location

meets all safety requirements.

The power supply is fan cooled by air flow through the

rear panel. Air flow must not be obstructed. Provide at

least 2 feet (0.61 m) in the rear and at least 6 inches (152

mm) on each side for clearance. Provide sufficient clear-

ance in front of the unit to allow access to the front panel

controls (minimum 6 inches or 152 mm).

CAUTION

Operation without proper air flow will inhibit

proper cooling and reduce duty cycle.

B. Lifting & TransportingB. Lifting & Transporting

B. Lifting & Transporting

WARNINGS

Do not touch live electrical parts.

Disconnect input power conductors from de-ener-

gized supply line before moving unit.

WARNINGS

FALLING EQUIPMENT can cause serious per-

sonal injury and equipment damage.

• This unit has a built-in handle on the top end of

case for hand lifting only. The HANDLE is not

for mechanical lifting. Be sure unit is lifted and

transported safely and securely.

• Do Not pull or lift by input power cable, work

cable or torch leads.

• If using a fork lift vehicle, place and secure unit

on a proper skid before transporting.

C. Unpacking ProcedureC. Unpacking Procedure

C. Unpacking Procedure

1. Unpack each item and remove all packing material.

2. Locate packing list(s) and use the list to identify and

account for each item.

3. Inspect each item for possible shipping damage. If

damage is evident, contact your distribution center.

D. Electrical ConnectionsD. Electrical Connections

D. Electrical Connections

The DRAG-GUN Cutter is available in various models.

VAC is preset at the factory and cannot be changed, ex-

cept with 208/230 VAC units (Refer to subsection 4.0-F

for procedure on changing voltage on unit). Always use

the correct service for your unit configuration (the con-

figuration is noted on the Data Tag on the unit.

WARNING

Make sure power is serviced correctly for your

power supply. The power source must conform to

local and national electric codes.

Always use the correct extension cord size.

1. 100 VAC 50Hz, 110 VAC 60Hz Service

This unit operates on single phase 100VAC (± 10%)

50Hz or 110 VAC (± 10%) 60Hz. Service must be fused

for at least 20 amps.

2. 120 VAC Service (50Hz)

This unit operates on single phase 120VAC (± 10%)

50Hz. Service must be fused for at least 20 amps. This

unit must be wired by customer - directly to discon-

nect or with appropriate plug (refer to subsection 4.0-

E for wire connections).

3. 120 VAC Service (60Hz)

This unit operates on single phase 120VAC (± 10%)

60Hz. Service must be fused for at least 20 amps.

4. 220VAC Service (50Hz)

This unit operates on single phase 220VAC (± 10%)

50Hz. Service must be fused for at least 15 amps. This

unit must be wired by customer - directly to discon-

nect or with appropriate plug(refer to subsection 4.0-

E for wire connections).

Operating Manual 0-2682 13 DRAG-GUN Plasma Cutter

5. 208/230VAC Service (60Hz)

This unit operates on single phase 208 or 230VAC (±

10%) 60Hz. Units are factory set for 230V use. Ser-

vice must be fused for at least 15 amps. For informa-

tion on voltage changeover, call your local distribu-

tor.

6. Extension Cords

Extension cords must meet National Electric Code

Guidelines (and OSHA Guidelines, where applicable).

Extension cords must have the same rating as the ser-

vice and must have a three-pronged plug. Refer to

the following table for recommended cord sizes:

110 VAC & 120 VAC Service

Ext. Cord Length Recommended Size (Min.)

Up to 50 ft. (15.2 m) 12 AWG (4 mm

)

Up to100 ft. (30.5 m)

10 AWG (6 mm

)

220 VAC Service

Ext. Cord Length Recommended Size (Min.)

Up to 50 ft. (15.2 m) 14 AWG (2.5 mm

)

Up to100 ft. (30.5 m)

12 AWG (4 mm

)

Figure 4-1 Extension Cord Sizes for Input Voltage

E. Input Power Cable ConnectionsE. Input Power Cable Connections

E. Input Power Cable Connections

NOTE

The primary input cable is factory installed for one of the

following configurations:

• 100VAC 50Hz/110VAC 60 Hz, single phase, with

plug

• 120VAC 50Hz, single phase, no plug

• 120VAC 60Hz, single phase, with plug

• 220VAC 50Hz, single phase, no plug

• 208/230VAC 60Hz, with plug

For those units where a plug is not installed on the end of

the input power cable, connect the ends of the individual

wires to a customer supplied plug or main disconnect

per the following:

• Black (or brown) wire to Line (AC or Live)

• White (or blue) wire to Neutral (ACC)

• Green (or green-yellow) wire to Ground

F. Input Voltage Selection (For 208/230F. Input Voltage Selection (For 208/230

F. Input Voltage Selection (For 208/230

VAC Service Only)VAC Service Only)

VAC Service Only)

All 208/230 VAC units are factory set for 230 VAC. To

switch to 208VAC input power operation, contact your

local distributor.

G. Torch Consumable Parts SelectionG. Torch Consumable Parts Selection

G. Torch Consumable Parts Selection

The torch consumable parts are factory installed, as shown

in Figure 4-2.

Torch Head Assembly

Electrode

Tip

Standard

Shield Cup

Gas

Distributor

PCH-10

A-02007

Figure 4-2 Exploded View of Torch Parts

To change the consumable parts, use the following pro-

cedure:

WARNING

Disconnect primary power at the source before dis-

assembling the power supply or torch.

1. Place the unit Power ON/OFF Switch to the OFF posi-

tion.

CAUTION

Consumable parts may be HOT! Torch parts may

get quite hot during normal operation. Always

wear light cutting gloves when changing torch

parts just after operating the Drag-Gun system.

2. Position the torch with the shield cup facing upward

and unscrew and remove the shield cup from the torch

head assembly (The shield cup holds the tip, gas dis-

tributor, and electrode in place).

3. Remove the tip, gas distributor, and electrode.

4. Install the electrode, gas distributor, and tip. Replace

worn parts, as necessary.

5. Install and hand tighten the shield cup until it is seated

on the torch head. If resistance is felt when installing

the cup, check the threads and parts configuration

before proceeding.

CAUTION

Improper assembly or use of nonstandard torch

parts can cause the torch head to short and may

overheat or damage the torch. Check the torch for

proper assembly and appropriate front end torch

parts.

DRAG-GUN Plasma Cutter 14 Operating Manual 0-2682

H. Work Cable ConnectionH. Work Cable Connection

H. Work Cable Connection

Best results will be obtained with a good work cable con-

nection to the workpiece. Check for a solid and clean

work cable connection. The area must be free from rust

and paint.

NOTE

Connect clamp to the main part of the workpiece,

not the part being removed.

Make a solid work cable

connection to the work-

piece or cutting table

A-02022

Figure 4-3 Work Cable Connection

5.0 OPERATION5.0 OPERATION

5.0 OPERATION

WARNINGS

Disconnect primary power at the source before dis-

assembling the power supply or torch.

Frequently review the Important Safety Precau-

tions (page 1). 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 acti-

vated.

CAUTION

Sparks from the cutting process can cause damage

to coated, painted, and other surfaces such as glass,

plastic and metal.

CAUTION

EXCEEDING DUTY CYCLE RATINGS will

cause the thermal overload protection circuit to

become energized and shut down output until the

unit cools to normal operating temperature. CON-

TINUAL EXCEEDING OF DUTY CYCLE

RATINGS can cause damage to the cutting power

source. Do NOT exceed indicated duty cycles.

Sequence of Operation

The following is a typical sequence of

operation for this cutting system:

1 Place the primary

power ON/OFF

switch on front

panel to the ON

position.

AC POWER

indicator light

comes on.

Fan turns on.

2 Wear protective

clothing (refer to

Section 1); activate

torch switch.

Main power relay

closes.

Pilot arc is

established.

3 Move torch within

transfer distance of

workpiece (or start

with tip on the

workpiece).

Main arc transfer.

Pilot arc off.

4 Complete cutting

operation; turn torch

switch off.

Main Arc off.

5 When finished

cutting session,

place the primary

power ON/OFF

switch to the OFF

position.

AC Power

Indicator light off.

Figure 5-1 Sequence of Operation

5.1 Cutting Techniques5.1 Cutting Techniques

5.1 Cutting Techniques

NOTE

Drag cutting - the torch tip is dragged along the

surface of the workpiece while cutting.

Standoff cutting - the torch tip is elevated from the

workpiece slightly while cutting. Standoff height

should be no more than 1/8" (3.2 mm); place your

other hand underneath to steady.

Operating Manual 0-2682 15 DRAG-GUN Plasma Cutter

The DRAG-GUN is primarily designed for drag cutting,

but in some instances can be used successfully for stand-

off cutting.

A. CuttingA. Cutting

A. Cutting

1. The torch can be comfortably held in one hand or stead-

ied with two hands. Choose the technique that feels

most comfortable and allows good control and move-

ment. Position the index finger or thumb to press the

control switch on the torch handle.

Figure 5-2 Using One Hand to Cut

Figure 5-3 Using Second Hand for Support When

Cutting

2. Hold the torch on a slight angle to the workpiece with

the front of the tip at the edge of the workpiece (or

slightly above) at the point where the cut is to start.

When starting at the edge of the plate, do not pause

at the edge and force the arc to "reach" for the edge of

the metal. Establish the cutting arc as quickly as pos-

sible.

3. With the torch in starting position, press and hold the

torch switch. The pilot arc will come on and remain

on until the cutting arc starts.

NOTE

Limit piloting time to conserve torch parts. Refer

to section 5.5C for more information.

CAUTION

Torch parts may get quite hot during normal op-

eration. Always wear light cutting gloves when

changing torch parts just after operating the Drag-

Gun system.

4. Once on, the main arc remains on as long as the torch

switch is held down, unless the torch is withdrawn

from the work or torch motion is too slow. If the cut-

ting arc is interrupted, the pilot arc comes back on

automatically. (You may not notice a difference).

5. To shut off the torch simply release the control switch.

B. PiercingB. Piercing

B. Piercing

1. For piercing, position the tip approximately 1/8" (3.2

mm) above the workpiece. Angle the torch slightly to

direct sparks away from the torch tip and operator.

Figure 5-4 Piercing

2. Initiate the pilot arc and lower the tip of the torch until

the main cutting arc transfers, sparks start.

DRAG-GUN Plasma Cutter 16 Operating Manual 0-2682

3. Start the pierce off the cutting line on the scrap piece

or template and then continue the cut onto the cut-

ting line. Hold the torch perpendicular to the

workpiece after the pierce is complete.

4. Clean spatter and scale from the shield cup and the tip

as soon as possible.

5.2 Cut Quality5.2 Cut Quality

5.2 Cut Quality

Cut quality depends heavily on setup and parameters

such as torch alignment with the workpiece, cutting

speed, condition of torch parts, input line voltage, and

operator ability. Cut quality will also vary on different

types of material and thicknesses.

The following table shows the cut quality one can expect

from this equipment for materials with a thickness of

7 gauge or less:

Material

Thickness

Mild Steel Stainless

Steel

Aluminum Galvanized

Steel

20 Gauge Excellent Excellent Very Good Excellent

16 Gauge Very Good Excellent Good Excellent

10 Gauge Very Good Good NR Good

7 Gauge Severance Severance NR Severance

Figure 5-5 Cut Characteristics

Excellent - No bevel or dross*

Very Good -

Negligible bevel; slight dross* (easy to remove)

Good - Slight bevel with some dross* (easy to remove)

Severance - Substantial reduction in cut quality and speed

NR - Not Recommended

NOTES

Pierce Capacity is 1/16" (1.59 mm)

* Dross is molten material which is not blown out

of the cut area and resolidifies on the plate. Top

spatter is dross which accumulates on the top sur-

face of the workpiece. Top spatter is normally

caused by a slow torch travel speed or too high of a

torch standoff distance. Dross normally breaks off

quite easily by simply scraping it off with a piece

of metal.

Figure 5-6 Cut Sample

NOTE

A worn tip can also affect the quality of a cut.

Consider replacing the tip if any of the following

indicators are present:

• reduced speed

• voltage drop

• crooked cut

5.3 Recommended Cutting5.3 Recommended Cutting

5.3 Recommended Cutting

SpeedsSpeeds

Speeds

Cutting speed depends on material type, material thick-

ness, and the operator’s ability to accurately follow the

desired cut line. The following factors may have an im-

pact on system performance:

• Torch parts wear

• Line voltage fluctuations

• Torch standoff height

NOTE

This information represents realistic expectations

using recommended practices and well-maintained

systems. Actual speeds may vary up to 50% from

those shown.

Material Gauge Inches per

Minute

Stainless Steel 20 60

Galvanized Steel 18 60

Aluminum 16 20

Carbon Steel 10 9

Figure 5-7 Cutting Speed Chart

Operating Manual 0-2682 17 DRAG-GUN Plasma Cutter

5.4 Common Cutting Faults5.4 Common Cutting Faults

5.4 Common Cutting Faults

. Insufficient Penetration. Insufficient Penetration

. Insufficient Penetration

a. Cutting speed too fast

b. Torch tilted too much

c. Metal too thick

d. Worn torch parts

B. Main Arc ExtinguishesB. Main Arc Extinguishes

B. Main Arc Extinguishes

a. Cutting speed too slow

b. Torch standoff too high from workpiece

c. Work cable disconnected

d. Worn torch parts

C. Excessive Dross FormationC. Excessive Dross Formation

C. Excessive Dross Formation

a. Cutting speed too slow

b. Torch standoff too high from workpiece

c. Worn torch parts

D. Short Torch Parts LifeD. Short Torch Parts Life

D. Short Torch Parts Life

a. Exceeding system capability (material too thick)

b. Excessive pilot arc time

c. Improperly assembled torch

d. Inadequate air supply (check filter on compressor)

e. Faulty air compressor

5.5 Common Operating5.5 Common Operating

5.5 Common Operating

ProblemsProblems

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 should arise.

A. Compressor RelatedA. Compressor Related

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 over 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, and reinstall it.

WARNING

Do not operate unit without filter installed.

B. Power Source RelatedB. Power Source Related

B. Power Source Related

If the main power service available fluctuates, pilot and

cut performance will be degraded. In some cases, the main

power service circuit breaker may open during use. Some

things that will help:

• Use a service fused or circuit breaker for the correct

amps. (refer to subsection 4.0-D)

• Use heavy gauge extension cords (Refer to subsec-

tion 4.0-D for extension cord lengths).

• 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 RelatedC. Power Supply/Torch Related

C. Power Supply/Torch Related

In some instances, the service may be good but when the

torch switch is pressed the compressor comes on but 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. The torch

pilots best if started under low air pressure. This helps

because the torch fires at a lower voltage with lower air

pressure at the torch.

D. Cutting RelatedD. Cutting Related

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 (es-

sentially 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.

DRAG-GUN Plasma Cutter 18 Operating Manual 0-2682

NOTE

Piloting is harder on parts life than actual cutting

because the pilot arc is directed from the electrode

to the tip rather than to a workpiece. Whenever

possible, avoid excessive pilot arc time to improve

parts life.

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 stand-

off, this unit is primarily a drag-cutting machine.

6.0 MAINTENANCE6.0 MAINTENANCE

6.0 MAINTENANCE

6.1 Recommended Maintenance6.1 Recommended Maintenance

6.1 Recommended Maintenance

ScheduleSchedule

Schedule

WARNING

Disconnect primary power to the system before dis-

assembling the power supply.

NOTE

The actual frequency of maintenance may need to

be adjusted according to usage and the environ-

ment.

Recommended Routine Maintenance

Schedule

Daily Operational Checks or Every 6

Cutting Hours:

1. Check torch consumables. Replace if

damaged.

2. Inspect torch for any cracks or exposed

wires. Repair or replace before

proceeding.

3. Inspect input power cable for damage or

exposed wires. Repair or replace before

proceeding.

Weekly or Every 30 Cutting Hours:

1. Check for proper fan operation.

2. Blow or vacuum dust and dirt out of the

entire machine, including the air filter.

Figure 6-1 Routine Maintenance

6.2 Power Supply Cleaning6.2 Power Supply Cleaning

6.2 Power Supply Cleaning

To clean the unit, open the 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. Do not blow air into the power supply dur-

ing cleaning. Make sure to always blow air out of the unit.

Blowing air into the unit can cause metal particles to in-

terfere with sensitive electrical components and cause

damage to the unit.

6.3 Torch Cleaning6.3 Torch Cleaning

6.3 Torch Cleaning

Even if precautions are taken to use only clean air with a

torch, eventually the inside of the torch becomes coated

with residue. This buildup can affect the pilot arc initia-

tion and the overall cut quality of the torch.

The inside of the torch should be cleaned with electrical

contact cleaner using a cotton swab or soft wet rag. In

severe cases, the torch can be removed from the leads

and cleaned more thoroughly by pouring electrical con-

tact cleaner into the torch and blowing it through with

compressed air.

CAUTION

Dry the torch thoroughly before reinstalling.

6.4 Inspection and Replacement6.4 Inspection and Replacement

6.4 Inspection and Replacement

of Consumable Torch Partsof Consumable Torch Parts

of Consumable Torch Parts

WARNING

Disconnect primary power to the system before

disassembling the torch.

CAUTION

Consumable parts may be HOT! Torch parts may

get quite hot during normal operation. Always

wear light cutting gloves when changing torch

parts just after operating the Drag-Gun system.

1. Remove the shield cup from the torch and inspect the

cup for damage. Wipe it clean or replace if damaged.

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