Operating Manual. For Models: 100 VAC 50 Hz/110 VAC 60Hz 120 VAC 50Hz 120 VAC 60Hz 220 VAC 50Hz 208/230 VAC 60Hz Manual No

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1 TM 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 Manual No

2 WARNING Read and understand this entire manual and your employer s safety practices before installing, operating, or servicing the equipment. WARNING 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 Published by: Thermal Dynamics Corporation Industrial Park No. 2 West Lebanon, New Hampshire, USA (603) Copyright 1998 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 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

3 TABLE OF CONTENTS 1: GENERAL INFORMATION Notes, Cautions and Warnings Important Safety Precautions Publications Note, Attention et Avertissement Precautions De Securite Importantes Documents De Reference Declaration of Conformity Statement of Warranty INTRODUCTION What is Plasma? General Product Description Technical Specifications Dimensions CONTROLS: LOCATION & FUNCTION INSTALLATION OPERATION Cutting Techniques Cut Quality Recommended Cutting Speeds Common Cutting Faults Common Operating Problems MAINTENANCE Recommended Maintenance Schedule Power Supply Cleaning Torch Cleaning Inspection and Replacement of Consumable Torch Parts PARTS REPLACEMENT Torch & Leads Replacement Work Cable Replacement Input Power Cable Replacement PARTS LIST Returns Parts Replacement Power Supply Replacement Parts Options & Accessories (not shown) Torch Replacement Parts APPENDIX I: CABLING DETAILS APPENDIX II: INTERCONNECTING DIAGRAM APPENDIX III: INTERCONNECTING DIAGRAM... 28

4 Allmän information 1.01 Noteringar, anmärkningar och varningar I denna manual används tre begrepp för att påtala viktig information: Notera, Anmärkning och Varning! Dessa begrepp används på följande sätt: OBS Ett arbetssätt eller en procedur som kan behöva poängteras extra eller som kan hjälpa till att uppnå ett effektivt arbetsresultat. ANMÄRKNING En procedur som vid felaktigt handhavande kan skada utrustningen. VARNING! En procedur som vid felaktigt handhavande kan skada användaren av maskinen eller andra som finns i närheten av arbetsområdet. : GAS OCH RÖK Gas och rök som produceras vid plasmaskärningsprocessen kan vara farliga och hälsovådliga, därför skall följande råd alltid följas Se alltid till att undvika att andas in röken. Använd ett friskluftsmatat andningskydd om ventilation eller utsug inte är tillräcklig för att ge en bra arbetsmiljö. Den typ av rök eller gaser som kan uppkomma vid plasmaskärning beror på vilken typ av material som används och om materialet är ytbehandlat på något sätt. Var alltid extra försiktig om material som innehåller något av följande ämnen används: Antimon Krom Kvicksliver Arsenik Kobolt Nickel Barium Koppar Selen Beryllium Bly Silver Kadmium Mangan Vanadium Läs igenom de materialdatablad som finns för det material som används. Materaldatabladet skall ge information om vilken typ av gas och rök som kan uppstå vid användning av materialet. Använd speciell utrustning såsom rökutsug eller vattenskärbord för att eliminera spridning av rök och gas. Använd inte plasmabrännaren i områden där instabila eller explosiva gaser eller material förvaras. Fosgen, en giftig gas, uppkommer vid avdunstning av klorerade lösningsmedel och rengöringsmedel. Ta bort allt som kan ge upphov till detta från arbetsplatsen Viktiga säkerhetsaspekter VARNING! ANVÄNDANDE OCH UNDERHÅLL AV PLASMA- SKÄRUTRUSTNING KAN VARA FARLIGT OCH RISKFYLLT FÖR DIN HÄLSA. För att undvika möjliga skador, läs och sätt Dig in i alla varningar och säkerhetsföreskrifter innan utrustningen används. Kontakta Din lokala återförsäljare om några frågor uppstår. 3 ELEKTRISKA STÖTAR Elektriska stötar kan skada eller döda. Plasmaskärutrustningen använder och producerar högspänningselektricitet. Denna elektricitet kan orsaka skador på användaren eller andra som finns i arbetsområdet om utrustningen används på fel sätt. Vidrör aldrig några delar som är strömförande. Använd alltid torra handskar och arbetskläder för att isolera kroppen från arbetsstället. Byt alltid ut skadade eller slitna delar innan utrustningen används. Var alltid extra försiktig vid användning på blöta eller fuktiga arbetsstycken Koppla alltid bort maskinen från elnätet innan service utförs. Läs och följ alla instruktioner i manualen.

5 BRAND OCH EXPLOSION Brand och explosioner kan orsakas av varm slagg, gnistor, stänk eller av plasmaljusbågen. Kontrollera att inget brännbart eller explosivt material finns i arbetsområdet. Material som inte kan flyttas måste skyddas. Ventilera arbetsplatsen noga om det finns explosiva gaser eller ångor i närheten. Arbeta aldrig på behållare som innehållit explosiva gaser eller vätskor. Se till att en brandvakt finns på ställen där faror kan uppkomma. Hydrogengas kan uppstå vid skärning av aluminium i vattenskärbord eller under vatten. Gasen kan inneslutas under arbetsstycket för att sedan frigöras och orsaka en explosion. Skär aldrig aluminiumlegeringar i vatten om inte hydrogengasen kan elimineras. Buller Buller kan orsaka permanenta hörselskador. Plasmaskärning kan producera bullernivåer som kan skada hörseln. Se alltid till att skydda öronen för att undvika hörselskador. För att undvika hörselskador skall alltid hörselskydd användas. Bullernivån skall mätas för att kontrollera att skadliga nivåer inte överskrids. Utrustningens garanti: Thermal Dynamics Corporation garanterar att dess produkter är fria från fel på material och montering. Skulle något fel uppstå under den tidsperiod som gäller för respektive Thermal Dynamicsprodukt, kommer Thermal Dynamics att rätta till dessa fel om utrustningen har förvarats, installerats, använts och underhållits på ett sätt som motsvarar Thermal Dynamics specifikationer, instruktioner och rekommendationer. Utrustningen skall ha använts på ett normalt industriellt sätt och får inte ha utsatts för felaktigt användande eller reparationer med reservdelar ej godkända av Thermal Dynamics GARANTIN UPPHÖR ATT GÄLLA OM RESERVDELAR ELLER TILLBEHÖR ANVÄNDS SOM KAN ORSAKA SKADOR ELLER PÅVERKA PRESTANDA PÅ THERMAL DYNAMICS PRODUKTER. GARANTIN UPPHÖR ATT GÄLLA OM PRODUKTEN HAR DISTRIBUERATS AV ICKE AUKTORISERAD FÖRSÄLJARE. Den begränsade tidesperioden som garantin gäller är som följande: 3 års garanti från försäljningsdatum, gäller Cutmaster strömkällan. För övriga komponenter i utrustningen är garantin 1 år För brännarkropp och kablar är garantin 180 dagar (ej förslitningsdelar) Transportkostnader för reservdelar till auktoriserad garantireparatör skall bekostas av kunden. Allt returnerande av delar skall ske på kundens ansvar och bekostnad. Plasmaljusbågen Plasmaljusbågen kan skada dina ögon och bränna huden. Ljusbågen producerar kraftig ultraviolett och infraröd strålning. Strålningen kan skada dina ögon och hud om du inte är ordentligt skyddad. För att skydda ögonen skall svetshjälm eller svetsskärm användas. Använd dessutom skyddsglasögon med sidoskydd eller annat ögonskydd. Använd svetshandskar och lämpliga kläder för att skydda mot strålning och stänk. Håll alltid svetshjälm eller svetsskärm i bra skick och byt ut skadade eller slitna glas. Skydda andra som finns i närheten genom att använda draperier eller andra avskärmningar. Använd svetsglas med mörkertal DIN 4

6 1.07 Överensstämelsedeklaration Tillverkare: Adress: Thermal Dynamics Corporation 82 Benning Street West Lebanon, New Hampshire USA Utrustningen som beskrivs i denna manual överensstämmer med alla applicerbara aspekter och regler för Låg spännings Direktivet" (European Council Directive 73/23/EEC enl. Council Directive 93/68/EEC) och Nationel lagstiftning tillämpning. Serie nr. är unika för varje individuel del av utrustningen och detaljerna beskrivna, delarna som används för att tillverka en enhet och data för tillverkningen. Nationela Standards och Tekniska Specifikationer Produkten är designad och tillverkad enligt standards och tekniska krav. Bland dem : * CSA (Canadian Standards Association) standard C22.2 nr 60 för Bågsvetsningsutrustning. * UL (Underwriters Laboratory) klassificering 94VO flambarhets test for all printed-circuit boards used. * ISO/IEC (BS 638-PT10) (EN ) (EN50192) (EN50078) lämplig för plasma skärningsutrustning. Ansvarig tillverkar : Giorgio Bassi Managing Director Thermal Dynamics Europe Via rio Fabbiani 8A Rastignano (BO) Italy 1.08 Garanti Begränsad Garanti: Thermal Dynamics Corporation ( Thermal ) garanterar att produkten var fri från defekter och tillverkningensfel Skulle något fel som överenstämmer med garantianspråken dyka upp inom den tidsperiod som gäller enligt Thermal, som anges nedan, kommer Thermal att rätta till dessa fel under förutsättning att produkten har lagrats, installerats, använts och underhållts i enlighet med Thermals specifikationer, instruktioner, rekommendationer och erkända industristandard praxis, och inte har blivit felaktigt använd, reparerad, försummad eller ändrad. DENNA GARANTI ÄR EXKLUSIV FÖR DENNA PRODUKT Thermal Dynamics kommer att reparera eller byta ut defektadelar som har tillverkningsfel eller har felmontering i fabrik (se nedan) Eventuella fel skall meddelas inom 30 dagar efter inköp Reparationer utförs av återförsäljares servicepersonal som har exclusivitet av Thermals Dynamic Kontraktet upphör att gälla om detta missbrukas. GARANTIN UPPHÖR ATT GÄLLA OM RESERVDELAR ELLER TILLBEHÖR ANVÄNDTS SOM KAN ORSAKA SKADOR ELLER PÅVERKA SÄKERHETEN ELLER PRESTANDAN PÅ THERMAL DYNAMICS PRODUKTER. GARANTIN UPPHÖR ATT GÄLLA OM PRODUKTEN HAR DISTIBUERATS AV ICKE AUKTORISERAD ÅTERFÖRSÄLJARE. Produkt Strömkällanskomponenter Brännare och slangpaket Reservdelar/arbetstid Reservdelar/arbetstid Cutmaster 38 3 år 6 månader Cutmaster 51 3 år 6 månader Cutmaster 81 3 år 6 månader Cutmaster år 6 månader Gäller EJ: Slitdelar som munstycken, elektrod skyddskåpor, o-ringar, filter, säkringar, gasmunstycken Gäller EJ: Utrustning som på någotsätt ändrats eller modifierats av ej auktoriserad person, felaktigt installerad, felaktigt använd. Allt returnerande av delar skall ske på kundens ansvar och bekostnad. Gällande från januari 15,

7 2.0 INTRODUCTION This manual contains descriptions, operating instructions and basic maintenance procedures for the DRAG-GUN Plasma Cutter. Read this manual thoroughly. A complete understanding of the characteristics and capabilities of this equipment will assure the dependable operation for which it was designed. WARNING Service of this equipment is restricted to Thermal Dynamics trained personnel; unqualified personnel are strictly cautioned against attempting repairs or adjustments not covered in this manual, at the risk of personal injury and/or voiding the Warranty. 2.1 What is Plasma? 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 cutting 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 ionizes 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. _ Power Supply + ;; ;; A ;; ;;; ;;; C Workpiece A Figure 2-1 Typical Torch Head Detail 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 distributor, around the electrode, and out through the tip orifice. The secondary gas flows down around the outside of the torch gas distributor, and out between the tip and shield cup around the plasma arc. C. Pilot Arc When the torch is started a pilot arc is established between the electrode and cutting tip. This pilot arc creates a path for the main arc to transfer to the work. 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 electrode with the DC following. (Note: This may not apply to all unit models). 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 connected to the workpiece via the work cable and to the torch through a pilot wire. B Operating Manual DRAG-GUN Plasma Cutter

8 F. Interlocks If supply pressure falls below minimum requirements, the lockout circuit will open, shutting off the DC Circuit. 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) 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 installed. The torch will fail to operate if these contacts are not made. To Control Cable Wiring Torch Switch PIP Pin PIP Pin Butt Splice A Shield Cup Figure 2-2 Parts-In-Place (PIP) Diagram 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 temperature. 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. 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 system. and work lead (with torch consumable parts installed), work cable and clamp, primary input cable, extra consumable torch parts, and this instruction manual. The DRAG-GUN Cutter requires no assembly. 2.3 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 Torch Style Torch Dimensions PCH PCH 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) 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 included with the DRAG-GUN - power supply with builtin air compressor, pilot circuitry, all control circuitry, torch DRAG-GUN Plasma Cutter 10 Operating Manual

9 B. Input/Output Specifications Model Hz Input Amps RMS Output Amps (DC) Output Voltage (DC) Duty Cycle % 100/110V 50/60 25/ V * V V * /230V * CE approved. 2.4 Dimensions 10.0 in. (254 mm) A CONTROLS: LOCATION & FUNCTION A. Front Panel 1. Primary Power ON/OFF Switch ON position supplies the AC power to activate all system 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, electrode, 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 in 9.0 in (406 mm) (229 mm) Figure 2-3 Power Supply Dimensions Power ON/OFF Switch Front Panel PCH 10 Torch & Leads 1.1 in (27 mm) 8 in (203 mm) 2.9 in (75 mm) 70 Work Cable & Clamp Arc ON/OFF Switch 8.9 in (226 mm) 180 Rear Panel 1.1 in (27 mm) A Figure 2-4 Torch Dimensions Primary Input Power Cable A Figure 3-1 Front & Rear Panel Controls B. Rear Panel 1. Primary Input Power Cable Operating Manual DRAG-GUN Plasma Cutter

10 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 Figure 4-1 to maintain proper operation. 4.0 INSTALLATION A. Site Selection Select a clean, dry location with good ventilation and adequate working space around all components. 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 clearance 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 & Transporting WARNINGS Do not touch live electrical parts. Disconnect input power conductors from de-energized supply line before moving unit. WARNINGS FALLING EQUIPMENT can cause serious personal 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 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 Connections The DRAG-GUN Cutter is available in various models. VAC is preset at the factory and cannot be changed, except 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 configuration 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 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 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 disconnect or with appropriate plug (refer to subsection 4.0- E for wire connections) VAC Service (60Hz) This unit operates on single phase 120VAC (± 10%) 60Hz. Service must be fused for at least 20 amps VAC 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 disconnect or with appropriate plug(refer to subsection 4.0- E for wire connections). DRAG-GUN Plasma Cutter 12 Operating Manual

11 5. 208/230VAC Service (60Hz) This unit operates on single phase 208 or 230VAC (± 10%) 60Hz. Units are factory set for 230V use. Service must be fused for at least 15 amps. For information on voltage changeover, call your local distributor. 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 service 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 2 ) Up to100 ft. (30.5 m) 10 AWG (6 mm 2 ) 220 VAC Service Ext. Cord Length Recommended Size (Min.) Up to 50 ft. (15.2 m) 14 AWG (2.5 mm 2 ) Up to100 ft. (30.5 m) 12 AWG (4 mm 2 ) Figure 4-1 Extension Cord Sizes for Input Voltage E. Input Power Cable Connections 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 208/230 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 Selection The torch consumable parts are factory installed, as shown in Figure 4-2. Torch Head Assembly Electrode PCH-10 Gas Distributor Tip Standard Shield Cup Figure 4-2 Exploded View of Torch Parts A To change the consumable parts, use the following procedure: WARNING Disconnect primary power at the source before disassembling the power supply or torch. 1. Place the unit Power ON/OFF Switch to the OFF position. 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 distributor, 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. Operating Manual DRAG-GUN Plasma Cutter

12 H. Work Cable Connection Best results will be obtained with a good work cable connection to the workpiece. Check for a solid and clean work cable connection. The area must be free from rust and paint. Connect clamp to the main part of the workpiece, not the part being removed. Make a solid work cable connection to the workpiece or cutting table A Figure 4-3 Work Cable Connection 5.0 OPERATION WARNINGS Disconnect primary power at the source before disassembling the power supply or torch. Frequently review the Important Safety Precautions (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 activated. 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. 2 Wear protective clothing (refer to Section 1); activate torch switch. 3 Move torch within transfer distance of workpiece (or start with tip on the workpiece). 4 Complete cutting operation; turn torch switch off. 5 When finished cutting session, place the primary power ON/OFF switch to the OFF position. AC POWER indicator light comes on. Fan turns on. Main power relay closes. Pilot arc is established. Main arc transfer. Pilot arc off. Main Arc off. AC Power Indicator light off. Figure 5-1 Sequence of Operation 5.1 Cutting Techniques 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. DRAG-GUN Plasma Cutter 14 Operating Manual

13 The DRAG-GUN is primarily designed for drag cutting, but in some instances can be used successfully for standoff cutting. A. Cutting 1. The torch can be comfortably held in one hand or steadied with two hands. Choose the technique that feels most comfortable and allows good control and movement. Position the index finger or thumb to press the control switch on the torch handle. 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 possible. 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. Limit piloting time to conserve torch parts. Refer to section 5.5C for more information. CAUTION 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. 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 cutting 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. 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 5-2 Using One Hand to Cut Figure 5-4 Piercing Figure 5-3 Using Second Hand for Support When Cutting 2. Initiate the pilot arc and lower the tip of the torch until the main cutting arc transfers, sparks start. Operating Manual DRAG-GUN Plasma Cutter

14 3. Start the pierce off the cutting line on the scrap piece or template and then continue the cut onto the cutting 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 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 S 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 surface 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 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 Cutting Speeds Cutting speed depends on material type, material thickness, and the operator s ability to accurately follow the desired cut line. The following factors may have an impact on system performance: Torch parts wear Line voltage fluctuations Torch standoff height 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 Galvanized Steel Aluminum Carbon Steel 10 9 Figure 5-7 Cutting Speed Chart DRAG-GUN Plasma Cutter 16 Operating Manual

15 5.4 Common Cutting Faults A.. Insufficient Penetration a. Cutting speed too fast b. Torch tilted too much c. Metal too thick d. Worn torch parts 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 Formation a. Cutting speed too slow b. Torch standoff too high from workpiece c. Worn torch parts 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 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 should 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, approximately 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 quality 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 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 subsection 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 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 letting 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 Related 1. Piloting One of the features of this plasma cutter is the constant 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 (essentially 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. Operating Manual DRAG-GUN Plasma Cutter

16 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 result in a more square cut. Although the DRAG-GUN will cut using standoff, this unit is primarily a drag-cutting machine. 6.0 MAINTENANCE 6.1 Recommended Maintenance Schedule WARNING Disconnect primary power to the system before disassembling the power supply. The actual frequency of maintenance may need to be adjusted according to usage and the environment. 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. 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 during cleaning. Make sure to always blow air out of the unit. Blowing air into the unit can cause metal particles to interfere with sensitive electrical components and cause damage to the unit. 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 initiation 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 contact cleaner into the torch and blowing it through with compressed air. CAUTION Dry the torch thoroughly before reinstalling. 6.4 Inspection and Replacement 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. Figure 6-1 Routine Maintenance DRAG-GUN Plasma Cutter 18 Operating Manual

17 Torch Head Assembly Electrode PCH-10 Gas Distributor Tip Figure 6-2 Consumable Torch Parts Standard Shield Cup A Remove the tip. Check for excessive wear (indicated by an elongated or oversized orifice). Replace the tip if necessary. The following may also indicate a worn torch tip: reduced speed voltage drop crooked cut 3. Remove the electrode. Refer to Figure 6-3 and check the electrode for excessive wear. The face of the electrode should not be recessed more than 1/8" (3.2 mm). If the electrode is worn beyond this point it must be replaced. New Electrode ; Worn Electrode A Figure 6-3 Electrode Wear 4. Install the electrode, gas distributor, tip, and shield cup in the torch body. CAUTION Do not overtighten the shield cup. 5. Hand tighten the shield cup using a slight twisting motion until it is properly seated on the torch head. If resistance is felt when installing the cup, check the threads and parts configuration before proceeding. 7.0 PARTS REPLACEMENT All major parts troubleshooting, repairs, or parts replacement should only be conducted by a qualified service technician. All repairs are subject to warranty - tampered parts may void warranty. WARNING Disconnect primary power to the system before disassembling the torch & leads, or power supply. 7.1 Torch & Leads Replacement Prior to removing leads, note all leads connections inside the unit. To remove the leads from the unit: 1. Disconnect the following torch lead connections inside the unit (see Appendix I): a. 2-pin Connector b. Faston Connector to Resistor (red) c. Faston Connector to CD Coil (white) 2. Loosen the 90 nylon fitting nut and remove the brass lead fitting. Remove the torch leads from unit. (Cut lead if necessary). 3. Remove 90 nylon fitting from unit Air Compressor. (You may need to pull the sheet metal back slightly to do this.) To install replacement leads: 4. Remove the securing nut from the strain relief supplied on the end of the replacement torch leads. 5. Feed the end of the replacement torch lead through the hole in the front panel. 6. Tighten the strain relief and securing nut against the sheet metal, allowing approximately 1 inch between the end of the lead and the strain relief nut. 7. Apply teflon thread sealant to the threads of the replacement 90 nylon fitting and install in correct orientation as shown in Appendix I. Operating Manual DRAG-GUN Plasma Cutter

18 8. To connect the brass lead fitting to the 90 nylon fitting, loosen the nut on the nylon fitting until 3 threads are visible. Moisten the end of the torch lead brass fitting with water, then insert it into the nylon fitting until it bottoms on the fitting's shoulder. Tighten nylon nut securely by hand. 9. Make other connections as described in step 1 above. 7.2 Work Cable Replacement Refer to Appendix I: Work Cable Replacement. 7.3 Input Power Cable Replacement Refer to Appendix I: Input Power Cable Replacement. In some models, the power cable plug must be removed by customer and replaced by an appropriate plug or wired directly to disconnect. Refer to Section 8.2 Parts List for those power cords requiring special wiring. 8.0 PARTS LIST Order replacement parts by catalog number and complete description of the part or assembly. Also include the model and serial number of the torch. Address all inquiries to your authorized distributor. Standard hardware has been used in this unit. Replacement hardware can be purchased locally. 8.1 Returns If a product must be returned for service, contact your authorized distributor or call Items return to the manufacturer without proper authorization will not be accepted. DRAG-GUN Plasma Cutter 20 Operating Manual

19 8.2 Parts Replacement : Refer to Power Supply data tag to identify model of your unit. Description Ref Catalog # A. Complete Systems Includes Power Supply, PCH Torch with Leads, Spare Consumable Parts, Input Power Cord, and Work Cable. DRAG-GUN 100V/50Hz 110V/60Hz, PCH DRAG-GUN 120V 50Hz, PCH-10, "CE" DRAG-GUN 120V 60Hz, PCH DRAG-GUN 220V 50Hz, PCH-10, "CE" DRAG-GUN 208/230 60Hz, PCH Includes Power Supply, PCH Torch with Leads, Spare Consumable Parts, Input Power Cord, and Work Cable. DRAG-GUN 100V/50Hz 110V/60Hz, PCH DRAG-GUN 120V 50Hz, PCH-10, "CE" DRAG-GUN 120V 60Hz, PCH DRAG-GUN 220V 50Hz, PCH-10, "CE" DRAG-GUN 208/230 60Hz, PCH B. Power Supply Only Includes Power Supply, Input Power Cord, and Work Cable. DRAG-GUN 100V/50Hz 110V/60Hz DRAG-GUN 120V 50Hz, "CE" DRAG-GUN 120V 60Hz DRAG-GUN 220V 50Hz, "CE" DRAG-GUN 208/230 60Hz C. Torch & Leads Only Includes Torch & Leads, 90 Nylon Air Compressor Fitting. Torch Leads alone are not replaceable. PCH-10 (70 ) w/20 ft. (6 m) Leads PCH-10 (180 ) w/20 ft. (6 m) Leads Operating Manual DRAG-GUN Plasma Cutter

20 8.3 Power Supply Replacement Parts Item # Qty Description Ref. Catalog# 1 1 Transformer/Inductor (Incl. Chassis): T1/L1 DRAG-GUN 100V/50Hz 110V/60Hz DRAG-GUN 120V 50Hz DRAG-GUN 120V 60Hz DRAG-GUN 220V 50Hz DRAG-GUN 208/230 60Hz Cover (incl. Labels) Control PCB Assembly Capacitor: C13 DRAG-GUN 100V 50Hz/110V 60Hz, Capacitor AC 120UF, 180V DRAG-GUN 120V 50Hz, Capacitor AC 120UF, 180V DRAG-GUN 120V 60Hz, Capacitor AC 120UF, 180V DRAG-GUN 220V 50Hz, Capacitor AC, 60MFD, 370V DRAG-GUN 208/230 60Hz, Capacitor AC 60 MFD, 370V Wire Harness (Not Shown) Relay, DPST, -NO, 250V K Fan: DRAG-GUN 100V/50Hz 110V/60Hz, Fan 115V DRAG-GUN 120V 50Hz, Fan 115V DRAG-GUN 120V 60Hz,Fan 115V DRAG-GUN 220V 50Hz, Fan 220V DRAG-GUN 208/230 60Hz, Fan 220V Compressor, Air, 12VDC, 0.5 CFM Compressor Disc Filter (not shown) Resistor, 0.5ohm, 55 watt, 10%,3/16 Faston R Resistor, 1Kohm, 55 watt, 5%,3/16 Faston R Work Cable, 15 ft. (4.57 m) w/red Handles Input Power Cable, 6.5 ft. min. (2 m): DRAG-GUN 100V/50Hz 110V/60Hz, Power Cable, 14/3 w/molded plug DRAG-GUN 120V 50Hz, Power Cable, "CE", ** DRAG-GUN 120V 60Hz, Power Cable, 16/3 w/molded plug DRAG-GUN 220V 50Hz, Power Cable, "CE" ** DRAG-GUN 208/230 60Hz, Power Cable, 16/3 w/molded plug ** Plug to be supplied by customer ON/OFF Switch: SW1 DRAG-GUN Switch, DPST, 125V 15A w/red NEON (non CSA) DRAG-GUN Switch, DPST, 22A, 125VAC, RED NEON (CSA) DRAG-GUN Switch, 16A, 250VAC, AMBER (or RED) NEON CD Transformer/Ferrite Core Assembly T Bridge Rectifier BR1, BR Handle Options & Accessories (not shown) 1 Circle Cutting Guide Kit Leads Wrap - Installs Under Handle DRAG-GUN Plasma Cutter 22 Operating Manual

21 * For illustration purposes, the Transformer/Inductor Assembly is shown separated from the Chassis. The Transformer/Inductor /Chassis is actually one assembly and should not be disassembled for any field repairs. 16 C C HARDWARE A Screw, #6-32 x 3 3/4 Lg, Phil Pan Hd, Zinc B #6-32 Regular Nylon Lock Nut, Zinc Plated C 5/16-18 x 1 3/4 Unc Cap Socket Head Bolt D x.5 Pph Swageform Stl Zn. Parker Kalon E Screw, Black, 6-32 x 1/2 Pph, Swageform, Steel F Kepnut w/star Washer Mild Steel : Replacement hardware can be purchased locally. QTY To remove cover, unfasten: 4 side panel screws 2 handle screws 2 end panel screws 2 D 14 D 6 3 B D B 1 (BR2) 15 A A E (BR1) Rotation Direction Chassis E Torch & Leads 7 F F A Air Flow Direction Operating Manual DRAG-GUN Plasma Cutter

22 8.5 Torch Replacement Parts Item # Qty Description Catalog# 1 1 PCH-10 (70 ) Torch Head Assembly* PCH-10 (180 ) Torch Head Assembly* Torch Handle Only Torch Switch Standard Electrode PCH-10 Tip Gas Distributor Shield Cup Torch Head Split Holders PCH-10 (70 ) PCH-10 (180 ) PIP (Parts-In-Place) Wire Assembly O-Ring Torch Switch Button Torch Switch Button Springs * To be replaced by Qualified Technician only B C A A 9 4 A A 6 8 A 7 5 A A B C HARDWARE A #2-56 x 5/16" LG Phillips Pan Head #6 Internal Star Washer #6-32 x 3/16" Phillips Pan Head M.S., Zinc Plated QTY DRAG-GUN Plasma Cutter 24 Operating Manual

23 APPENDIX I: CABLING DETAILS Nylon Nut Brass Torch Lead Fitting Faston Connector to CD Coil 90 White Nylon Fitting Front Panel Hole Location Strain Relief Nut Strain Relief Torch Lead 1" Clearance Torch Leads Assembly Note: Do not remove strain relief from torch lead. Strain Relief A Pin Connectors Torch Lead Faston Connector (Red) (Connect to Bottom Resistor) Torch and Leads Replacement ON/OFF Input Power Switch A Work Cable Bridge Rectifier Green Wire with Tracer (Connect to Compressor Frame) Strain Relief (Install 5 1/2" from Faston) Work Cable Faston (Connect to mounting tab at bottom of Rectifier) Primary Input Power Cable A Strain Relief Green Wire (from Primary Input Power Cable) Ground Stud Work Cable Replacement Input Power Cable Replacement Operating Manual DRAG-GUN Plasma Cutter

24 APPENDIX II: INTERCONNECTING DIAGRAM A DRAG-GUN Plasma Cutter 26 Operating Manual

25 : Use this diagram for all rev D (or later) units. Check the data tag on the unit for rev level /01 98 A Operating Manual DRAG-GUN Plasma Cutter

26 APPENDIX III: INTERCONNECTING DIAGRAM L4 T O R C H WORK : Use this diagram for all rev C units (or earlier). Check the data tag on the unit for rev level. SW T1 8 C13 (7) 7A FAN AIR COMPRESSOR 12 VDC RED BLK K1-C S A Model: 220vac 120vac 100vac C13 60µƒ 120µƒ 120µƒ 370vac 180vac 180vac FAN 220vac 120vac 120vac T1 PR1 Single voltage marked #6 Dual voltage marked 208v (tap) & 230v 21 5 T1 8 K1-B 11 1 BR1 BRIDGE 35A 1200V BR 2 BRIDGE 35A 1200V Shield Cup K1 12v TORCH SWITCH PIP Pin PIP Pin TEMP 1K 55 watt J2 J2 J2 J2 J2 J2 J2 J2 J2 J2 J2 J2 L1 CD XFMR 2 L1 PILOT (RED Sleeved) watt E6 E5 150µƒ 450v 50 5 watt 1 SPK1 350V Spark Gap 27 4 CD PWR CIRCUIT E1 CD PRIMARY 43 E µƒ 450v 330µƒ 450v LOGIC CIRCUIT 22 3 watt CD PCB C13 (7) 7A FAN A (1) DRAG-GUN Plasma Cutter 28 Operating Manual