Thermal Dynamics Drag-Gun Operating

TM
Operating Manual
Includes:
• 12 Amp Power Supply
• PCH-10 Torch with Leads
• Work Cable with Clamp
• Input Power Cable
April 26, 2000
For Models:
• 100 VAC 50 Hz/110 VAC 60Hz
• 120 VAC 50Hz
• 120 VAC 60Hz
• 220 VAC 50Hz
• 208/230 VAC 60Hz
Manual No. 0-2682
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 0-2682
Published by:
Thermal Dynamics Corporation
Industrial Park No. 2
West Lebanon, New Hampshire, USA 03784
(603) 298-5711
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
TABLE 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
1: GENERAL
INFORMA
TION
INFORMATION
GASES AND FUMES
Gases and fumes produced during the plasma cutting
process can be dangerous and hazardous to your health.
1.1 Notes, Cautions and Warnings
• Keep all fumes and gases from the breathing area.
Keep your head out of the welding fume plume.
Throughout this manual, notes, cautions, and warnings
are used to highlight important information. These highlights are categorized as follows:
• 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 metals which may contain one or more of the following:
NOTE
An operation, procedure, or background information which requires additional emphasis or is helpful in efficient operation of the system.
CAUTION
Antimony
Arsenic
Barium
Beryllium
Cadmium
A procedure which, if not properly followed, may
cause damage to the equipment.
Chromium
Cobalt
Copper
Lead
Manganese
Mercury
Nickel
Selenium
Silver
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.
WARNING
A procedure which, if not properly followed, may
cause injury to the operator or others in the operating area.
• 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.
1.2 Important Safety Precautions
• Use special equipment, such as water or down draft
cutting tables, to capture fumes and gases.
• Do not use the plasma torch in an area where combustible or explosive gases or materials are located.
WARNING
• Phosgene, a toxic gas, is generated from the vapors
of chlorinated solvents and cleansers. Remove all
sources of these vapors.
OPERATION AND MAINTENANCE OF
PLASMA ARC EQUIPMENT CAN BE DANGEROUS AND HAZARDOUS TO YOUR
HEALTH.
ELECTRIC SHOCK
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.
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 operator or others in the workplace.
To prevent possible injury, read, understand and
follow all warnings, safety precautions and instructions before using the equipment. Call 1-603298-5711 or your local distributor if you have any
questions.
• Wear dry gloves and clothing. Insulate yourself from
the work piece or other parts of the welding circuit.
• Never touch any parts that are electrically “live” or
“hot.”
• Repair or replace all worn or damaged parts.
• Extra care must be taken when the workplace is
moist or damp.
5/21/99
1
GENERAL INFORMATION
• To protect your eyes, always wear a welding helmet or shield. Also always wear safety glasses with
side shields, goggles or other protective eye wear.
• Install and maintain equipment according to NEC
code, refer to item 9 in Subsection 1.3, Publications.
• Disconnect power source before performing any service or repairs.
• Wear welding gloves and suitable clothing to protect your skin from the arc rays and sparks.
• Read and follow all the instructions in the Operating Manual.
• 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.
FIRE AND EXPLOSION
• Use the shade of lens as suggested in the following
per ANSI/ASC Z49.1:
Fire and explosion can be caused by hot slag, sparks, or
the plasma arc.
• Be sure there is no combustible or flammable material in the workplace. Any material that cannot be
removed must be protected.
Arc Current
Minimum Protective
Shade No.
Suggested
Shade No.
Less Than 300*
8
9
• Ventilate all flammable or explosive vapors from
the workplace.
300 - 400*
9
12
400 - 800*
10
14
* These values apply where the actual arc is clearly
seen. Experience has shown that lighter filters
may be used when the arc is hidden by the workpiece.
• 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 underwater or while using a water table. DO NOT cut
aluminum alloys underwater or on a water table
unless the hydrogen gas can be eliminated or dissipated. Trapped hydrogen gas that is ignited will
cause an explosion.
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, Washington, D.C. 20402
NOISE
2. ANSI Standard Z49.1, SAFETY IN WELDING AND
CUTTING, obtainable from the American Welding
Society, 550 N.W. LeJeune Rd, Miami, FL 33126
Noise can cause permanent hearing loss. Plasma arc processes can cause noise levels to exceed safe limits. You
must protect your ears from loud noise to prevent permanent loss of hearing.
3. NIOSH, SAFETY AND HEALTH IN ARC WELDING AND GAS WELDING AND CUTTING, obtainable from the Superintendent of Documents, U.S.
Government Printing Office, Washington, D.C. 20402
• To protect your hearing from loud noise, wear protective ear plugs and/or ear muffs. Protect others
in the workplace.
4. ANSI Standard Z87.1, SAFE PRACTICES FOR OCCUPATION AND EDUCATIONAL EYE AND FACE
PROTECTION, obtainable from American National
Standards Institute, 1430 Broadway, New York, NY
10018
• Noise levels should be measured to be sure the decibels (sound) do not exceed safe levels.
• For information on how to test for noise, see item 1
in Subsection 1.3, Publications, in this manual.
5. ANSI Standard Z41.1, STANDARD FOR MEN’S
SAFETY-TOE FOOTWEAR, obtainable from the
American National Standards Institute, 1430 Broadway, New York, NY 10018
PLASMA ARC RAYS
6. ANSI Standard Z49.2, FIRE PREVENTION IN THE
USE OF CUTTING AND WELDING PROCESSES,
obtainable from American National Standards Institute, 1430 Broadway, New York, NY 10018
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.
GENERAL INFORMATION
7. AWS Standard A6.0, WELDING AND CUTTING
CONTAINERS WHICH HAVE HELD COMBUSTIBLES, obtainable from American Welding Society,
550 N.W. LeJeune Rd, Miami, FL 33126
2
5/21/99
8. NFPA Standard 51, OXYGEN-FUEL GAS SYSTEMS
FOR WELDING, CUTTING AND ALLIED PROCESSES, obtainable from the National Fire Protection
Association, Batterymarch Park, Quincy, MA 02269
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.
9. NFPA Standard 70, NATIONAL ELECTRICAL CODE,
obtainable from the National Fire Protection Association, Batterymarch Park, Quincy, MA 02269
10. NFPA Standard 51B, CUTTING AND WELDING
PROCESSES, obtainable from the National Fire Protection Association, Batterymarch Park, Quincy, MA
02269
1.5 Precautions De Securite
Importantes
11. CGA Pamphlet P-1, SAFE HANDLING OF COMPRESSED GASES IN CYLINDERS, obtainable from
the Compressed Gas Association, 1235 Jefferson
Davis Highway, Suite 501, Arlington, VA 22202
AVERTISSEMENT
12. CSA Standard W117.2, CODE FOR SAFETY IN
WELDING AND CUTTING, obtainable from the Canadian Standards Association, Standards Sales, 178
Rexdale Boulevard, Rexdale, Ontario, Canada M9W
1R3
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.
13. NWSA booklet, WELDING SAFETY BIBLIOGRAPHY obtainable from the National Welding Supply
Association, 1900 Arch Street, Philadelphia, PA 19103
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.
14. American Welding Society Standard AWSF4.1, RECOMMENDED SAFE PRACTICES FOR THE PREPARATION FOR WELDING AND CUTTING OF CONTAINERS AND PIPING THAT HAVE HELD
HAZARDOUS SUBSTANCES, obtainable from the
American Welding Society, 550 N.W. LeJeune Rd,
Miami, FL 33126
Il faut communiquer aux opérateurs et au personnel 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.
15. ANSI Standard Z88.2, PRACTICE FOR RESPIRATORY 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 :
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.
NOTE
Toute opération, procédure ou renseignement
général sur lequel il importe d’insister davantage
ou qui contribue à l’efficacité de fonctionnement
du système.
• Eloignez toute fumée et gaz de votre zone de respiration. 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.
ATTENTION
Toute procédure pouvant résulter
l’endommagement du matériel en cas de nonrespect de la procédure en question.
5/21/99
• 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
3
GENERAL INFORMATION
procédés. Vous devez prendre soin lorsque vous
coupez ou soudez tout métal pouvant contenir un
ou plusieurs des éléments suivants:
antimoine
argent
arsenic
baryum
béryllium
cadmium
chrome
cobalt
cuivre
manganèse
INCENDIE ET EXPLOSION
mercure
nickel
plomb
sélénium
vanadium
Les incendies et les explosions peuvent résulter des scories
chaudes, des étincelles ou de l’arc de plasma. Le procédé
à l’arc de plasma produit du métal, des étincelles, des
scories chaudes pouvant mettre le feu aux matières combustibles ou provoquer l’explosion de fumées
inflammables.
• Lisez toujours les fiches de données sur la sécurité
des matières (sigle américain “MSDS”); celles-ci
devraient être fournies avec le matériel que vous
utilisez. Les MSDS contiennent des renseignements
quant à la quantité et la nature de la fumée et des
gaz pouvant poser des dangers de santé.
• Soyez certain qu’aucune matière combustible ou inflammable ne se trouve sur le lieu de travail.
Protégez toute telle matière qu’il est impossible de
retirer de la zone de travail.
• Pour des informations sur la manière de tester la
fumée et les gaz de votre lieu de travail, consultez
l’article 1 et les documents cités à la page 4.
• Procurez une bonne aération de toutes les fumées
inflammables ou explosives.
• Ne coupez pas et ne soudez pas les conteneurs ayant
pu renfermer des matières combustibles.
• Utilisez un équipement spécial tel que des tables de
coupe à débit d’eau ou à courant descendant pour
capter la fumée et les gaz.
• Prévoyez une veille d’incendie lors de tout travail
dans une zone présentant des dangers d’incendie.
• N’utilisez pas le chalumeau au jet de plasma dans
une zone où se trouvent des matières ou des gaz
combustibles ou explosifs.
• Le gas hydrogène peut se former ou s’accumuler
sous les pièces de travail en aluminium lorsqu’elles
sont coupées sous l’eau ou sur une table d’eau. NE
PAS couper les alliages en aluminium sous l’eau ou
sur une table d’eau à moins que le gas hydrogène
peut s’échapper ou se dissiper. Le gas hydrogène
accumulé explosera si enflammé.
• Le phosgène, un gaz toxique, est généré par la fumée
provenant des solvants et des produits de nettoyage
chlorés. Eliminez toute source de telle fumée.
CHOC ELECTRIQUE
RAYONS D’ARC DE PLASMA
Les chocs électriques peuvent blesser ou même tuer. Le
procédé au jet de plasma requiert et produit de l’énergie
électrique haute tension. Cette énergie électrique peut
produire des chocs graves, voire mortels, pour l’opérateur
et les autres personnes sur le lieu de travail.
Les rayons provenant de l’arc de plasma peuvent blesser
vos yeux et brûler votre peau. Le procédé à l’arc de plasma
produit une lumière infra-rouge et des rayons ultra-violets très forts. Ces rayons d’arc nuiront à vos yeux et
brûleront votre peau si vous ne vous protégez pas
correctement.
• Ne touchez jamais une pièce “sous tension” ou
“vive”; portez des gants et des vêtements secs.
Isolez-vous de la pièce de travail ou des autres parties du circuit de soudage.
• Pour protéger vos yeux, portez toujours un casque
ou un écran de soudeur. Portez toujours des lunettes
de sécurité munies de parois latérales ou des lunettes de protection ou une autre sorte de protection oculaire.
• Réparez ou remplacez toute pièce usée ou
endommagée.
• Prenez des soins particuliers lorsque la zone de travail est humide ou moite.
• Portez des gants de soudeur et un vêtement
protecteur approprié pour protéger votre peau
contre les étincelles et les rayons de l’arc.
• Montez et maintenez le matériel conformément au
Code électrique national des Etats-Unis. (Voir la
page 4, article 9.)
• Maintenez votre casque et vos lunettes de protection en bon état. Remplacez toute lentille sale ou
comportant fissure ou rognure.
• Débranchez l’alimentation électrique avant tout travail d’entretien ou de réparation.
• Protégez les autres personnes se trouvant sur la zone
de travail contre les rayons de l’arc en fournissant
des cabines ou des écrans de protection.
• Lisez et respectez toutes les consignes du Manuel
de consignes.
GENERAL INFORMATION
4
5/21/99
• Use the shade of lens as suggested in the following
chart per ANSI/ASC Z49.1:
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 (American National Standards Institute), 1430 Broadway,
New York, NY 10018
• Utilisez la nuance de lentille qui est suggèrée dans
le recommendation qui suivent ANSI/ASC Z49.1:
Courant Arc
Nuance Minimum
Protective Numéro
Nuance Suggerée
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.
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
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.
8. Norme 51 de l’Association Américaine pour la Protection 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 National Fire Protection Association, Batterymarch
Park, Quincy, MA 02269
• 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.
9. Norme 70 de la NFPA, CODE ELECTRIQUE NATIONAL, disponible auprès de la National Fire Protection Association, Batterymarch Park, Quincy, MA
02269
• 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.
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
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 :
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
1. OSHA, NORMES DE SÉCURITÉ DU TRAVAIL ET
DE PROTECTION DE LA SANTÉ, 29CFR 1910,
disponible auprès du Superintendent of Documents, U.S. Government Printing Office, Washington, D.C. 20402
12. Norme CSA W117.2, CODE DE SÉCURITÉ POUR
LE SOUDAGE ET LA COUPE, disponible auprès
de l’Association des Normes Canadiennes, Standards Sales, 178 Rexdale Boulevard, Rexdale,
Ontario, Canada, M9W 1R3
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
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
3. NIOSH, LA SÉCURITÉ ET LA SANTÉ LORS DES
OPÉRATIONS DE COUPE ET DE SOUDAGE À
L’ARC ET AU GAZ, disponible auprès du Superintendent of Documents, U.S. Government Printing
Office, Washington, D.C. 20402
5/21/99
5.
5
GENERAL INFORMATION
14. Norme AWSF4.1 de l’Association Américaine de
Soudage, RECOMMANDATIONS DE PRATIQUES
SURES POUR LA PRÉPARATION À LA COUPE ET
AU SOUDAGE DE CONTENEURS ET TUYAUX
AYANT
RENFERMÉ
DES
PRODUITS
DANGEREUX , disponible auprès de la American
Welding Society, 550 N.W. LeJeune Rd., Miami, FL
33126
15. Norme ANSI Z88.2, PRATIQUES DE PROTECTION RESPIRATOIRE, disponible auprès de
l’American National Standards Institute, 1430
Broadway, New York, NY 10018
GENERAL INFORMATION
6
5/21/99
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 Directive’ (European Council Directive 73/23/EEC as amended by Council Directive 93/68/EEC) and to the National
legislation for the enforcement of this Directive.
The equipment described in this manual conforms to all applicable aspects and regulations of the "EMC Directive"
(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 associated 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:
5/21/99
Steve Ward
Director of Operations
Thermadyne UK
Chorley England
7
GENERAL INFORMATION
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
PAK Units, Power Supplies
XL Plus Series &
CutMaster 80XL
Parts
Cougar/Drag-Gun
Parts
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,
But Not Limited To, Starting Circuit,
Contactors, Relays, Solenoids, Pumps,
Power Switching Semi-Conductors
1 Year
1 Year
1 Year
1 Year
1 Year
1 Year
1 Year
1 Year
Consolles, Control Equipment, Heat
Exchanges, And Accessory Equipment
1 Year
Torch And Leads
Maximizer 300 Torch
All Other Torches
Repair/Replacement Parts
180 Days
180 Days
180 Days
180 Days
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
GENERAL INFORMATION
8
5/21/99
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.
_
;
;;
;;
;
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Power
Supply
+
WARNING
A
B
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?
Workpiece
C
Figure 2-1 Typical Torch Head Detail
B. Gas Distribution
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.
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.
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.
Operating Manual 0-2682
A-00002
9
DRAG-GUN Plasma Cutter
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.
and work lead (with torch consumable parts installed),
work cable and clamp, primary input cable, extra consumable torch parts, and this instruction manual.
NOTE
The DRAG-GUN Cutter requires no assembly.
2.3 Technical Specifications
G. Parts-in-Place (PIP)
The torch head has replaceable contacts called PartsIn-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.
A. System Specifications
System
Input Power
Torch Switch
Specifications
100 VAC 50Hz, 110 VAC 60Hz, Single Phase
PIP Pin
To Control
Cable Wiring
Shield Cup
PIP Pin
Butt Splice
A-00784
Output Power
Duty Cycle
Maximum OCV
Pilot Circuitry
Weight with Leads
Power Supply
L
Dimensions
W
H
Work Cable
Input Power Cable
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.
Torch Style
Torch Dimensions
Cutting Rating
Cut Capacity
Severance
Pierce Rating
Transfer Distance
Gas Requirements
Leads Length
WARNING
When unit shuts down due to thermal overload,
power is still present throughout the entire system.
L
W
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
See subsection 2.3B
See subsection 2.3B
280 VDC
Capacitive Discharge (CD), Constant DC
55 lbs (24.9 kg)
16 in. (406 mm)
9 in. (229 mm)
10 in. (254 mm)
15 ft. (4.6 m)
6.6 ft. (2 m) minimum
PCH-10 70°
PCH-10 180°
See subsection 2.4
See subsection 2.4
12 Amps Max. Straight Polarity
Most metals up to 1/8 in. (3.2 mm) max.
Most metals up to 3/16 in. (4.8 mm)
1/16 in. (1.6 mm)
Approx. 1/8 in. (3.2 mm)
Compressed Air (Built-in)
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 0-2682
B. Input/Output Specifications
Model
Hz
100/110V
50/60
120V *
50
120V
60
220V *
50
208/230V
60
* CE approved.
Input
Amps
RMS
Output
Amps
(DC)
Output
Voltage
(DC)
Duty
Cycle %
25/24
22
20
13
10
12
12
12
12
12
85
95
70
85
78
30
30
30
30
30
3.0 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
2.4 Dimensions
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.
10.0 in.
(254 mm)
A-02004
3. Work Cable & Clamp
The work cable & clamp are factory installed. Attach
the work cable to the workpiece before cutting.
16.0 in
(406 mm)
Power
ON/OFF
Switch
9.0 in
(229 mm)
Front Panel
Figure 2-3 Power Supply Dimensions
PCH 10 Torch
& Leads
2.9 in
(75 mm)
70˚
1.1 in (27 mm)
Work Cable
& Clamp
Arc ON/OFF
Switch
8 in (203 mm)
8.9 in (226 mm)
Rear Panel
180˚
1.1 in
(27 mm)
A-02385
Primary Input
Power Cable
Figure 2-4 Torch Dimensions
A-02005
Figure 3-1 Front & Rear Panel Controls
B. Rear Panel
1. Primary Input Power Cable
Operating Manual 0-2682
11
DRAG-GUN Plasma Cutter
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.
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 clearance in front of the unit to allow access to the front panel
controls (minimum 6 inches or 152 mm).
• 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.
CAUTION
Operation without proper air flow will inhibit
proper cooling and reduce duty cycle.
Always use the correct extension cord size.
B. Lifting & Transporting
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.
WARNINGS
2. 120 VAC Service (50Hz)
Do not touch live electrical parts.
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 4.0E for wire connections).
Disconnect input power conductors from de-energized supply line before moving unit.
WARNINGS
3. 120 VAC Service (60Hz)
This unit operates on single phase 120VAC (± 10%)
60Hz. Service must be fused for at least 20 amps.
FALLING EQUIPMENT can cause serious personal injury and equipment damage.
4. 220VAC Service (50Hz)
• 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.
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 4.0E for wire connections).
• Do Not pull or lift by input power cable, work
cable or torch leads.
DRAG-GUN Plasma Cutter
12
Operating Manual 0-2682
5. 208/230VAC Service (60Hz)
G. Torch Consumable Parts Selection
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.
The torch consumable parts are factory installed, as shown
in Figure 4-2.
PCH-10
6. Extension Cords
Electrode
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
Up to 50 ft. (15.2 m)
Recommended Size (Min.)
12 AWG (4 mm 2)
10 AWG (6 mm 2)
Up to100 ft. (30.5 m)
Figure 4-1 Extension Cord Sizes for Input Voltage
Standard
Shield Cup
A-02007
Figure 4-2 Exploded View of Torch Parts
To change the consumable parts, use the following procedure:
WARNING
Recommended Size (Min.)
14 AWG (2.5 mm 2)
12 AWG (4 mm 2)
Up to100 ft. (30.5 m)
Tip
Torch Head Assembly
220 VAC Service
Ext. Cord Length
Up to 50 ft. (15.2 m)
Gas
Distributor
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.
E. Input Power Cable Connections
CAUTION
NOTE
The primary input cable is factory installed for one of the
following configurations:
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.
• 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)
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.
• White (or blue) wire to Neutral (ACC)
CAUTION
• Green (or green-yellow) wire to Ground
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.
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.
Operating Manual 0-2682
13
DRAG-GUN Plasma Cutter
H. Work Cable Connection
CAUTION
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.
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. Do NOT exceed indicated duty cycles.
NOTE
Connect clamp to the main part of the workpiece,
not the part being removed.
Sequence of Operation
Make a solid work cable
connection to the workpiece or cutting table
The following is a typical sequence of
operation for this cutting system:
A-02022
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.
1 Place the primary
power ON/OFF
switch on front
panel to the ON
position.
AC POWER
indicator light
comes on.
2 Wear protective
clothing (refer to
Section 1); activate
torch switch.
Main power relay
closes.
3 Move torch within
transfer distance of
workpiece (or start
with tip on the
workpiece).
Main arc transfer.
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.
Fan turns on.
Pilot arc is
established.
Pilot arc off.
Figure 5-1 Sequence of Operation
5.1 Cutting Techniques
CAUTION
NOTE
Sparks from the cutting process can cause damage
to coated, painted, and other surfaces such as glass,
plastic and metal.
DRAG-GUN Plasma Cutter
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.
14
Operating Manual 0-2682
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.
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 operation. Always wear light cutting gloves when
changing torch parts just after operating the DragGun 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
Operating Manual 0-2682
2. Initiate the pilot arc and lower the tip of the torch until
the main cutting arc transfers, sparks start.
15
DRAG-GUN Plasma Cutter
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:
Figure 5-6 Cut Sample
NOTE
Material
Thickness
20 Gauge
16 Gauge
10 Gauge
7 Gauge
Mild Steel
Excellent
Very Good
Very Good
Severance
Stainless
Steel
Excellent
Excellent
Good
Severance
Aluminum Galvanized
Steel
Very Good
Excellent
Good
Excellent
NR
Good
NR
Severance
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
Figure 5-5 Cut Characteristics
Excellent - No bevel or dross*
• crooked cut
5.3
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
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:
NOTES
• Torch parts wear
• Line voltage fluctuations
• Torch standoff height
NOTE
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.
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
DRAG-GUN Plasma Cutter
16
Operating Manual 0-2682
5.4 Common Cutting Faults
WARNING
A.
. Insufficient Penetration
a. Cutting speed too fast
Do not operate unit without filter installed.
b. Torch tilted too much
c. Metal too thick
B. Power Source Related
d. Worn torch parts
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:
B. Main Arc Extinguishes
a. Cutting speed too slow
• 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.
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
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
5.5
Common Operating
Problems
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).
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.
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.
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.
Operating Manual 0-2682
17
DRAG-GUN Plasma Cutter
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 result in a more square cut.
NOTE
Although the DRAG-GUN will cut using standoff, this unit is primarily a drag-cutting machine.
6.0
6.1
MAINTENANCE
Recommended Maintenance
Schedule
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.
WARNING
Disconnect primary power to the system before disassembling the power supply.
NOTE
CAUTION
Dry the torch thoroughly before reinstalling.
6.4 Inspection and Replacement
of Consumable Torch Parts
The actual frequency of maintenance may need to
be adjusted according to usage and the environment.
1.
2.
3.
1.
2.
Recommended Routine Maintenance
Schedule
Daily Operational Checks or Every 6
Cutting Hours:
Check torch consumables. Replace if
damaged.
Inspect torch for any cracks or exposed
wires. Repair or replace before
proceeding.
Inspect input power cable for damage or
exposed wires. Repair or replace before
proceeding.
Weekly or Every 30 Cutting Hours:
Check for proper fan operation.
Blow or vacuum dust and dirt out of the
entire machine, including the air filter.
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 0-2682
7.0 PARTS
REPLACEMENT
PCH-10
Electrode
Gas
Distributor
Tip
Standard
Shield Cup
NOTE
Torch Head Assembly
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.
A-02007
Figure 6-2 Consumable Torch Parts
2. Remove the tip. Check for excessive wear (indicated
by an elongated or oversized orifice). Replace the tip
if necessary.
WARNING
NOTE
Disconnect primary power to the system before disassembling the torch & leads, or power supply.
The following may also indicate a worn torch tip:
• reduced speed
7.1 Torch & Leads Replacement
• voltage drop
• crooked cut
NOTE
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.
;
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):
New Electrode
a. 2-pin Connector
b. Faston Connector to Resistor (red)
c. Faston Connector to CD Coil (white)
Worn Electrode
A-01270
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.
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 0-2682
19
DRAG-GUN Plasma Cutter
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.
NOTE
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.
NOTE
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 1-888-832-4250. Items return to the manufacturer without proper authorization
will not be accepted.
DRAG-GUN Plasma Cutter
20
Operating Manual 0-2682
8.2 Parts Replacement
NOTE: Refer to Power Supply data tag to identify model of your unit.
Description
Ref
Catalog #
A. Complete Systems
Includes Power Supply, PCH-10 70° Torch with Leads, Spare Consumable Parts, Input Power Cord, and Work Cable.
DRAG-GUN 100V/50Hz 110V/60Hz, PCH-10
1-1111-3
DRAG-GUN 120V 50Hz, PCH-10, "CE"
1-1811-6
DRAG-GUN 120V 60Hz, PCH-10
1-1111-1
DRAG-GUN 220V 50Hz, PCH-10, "CE"
1-1811-5
DRAG-GUN 208/230 60Hz, PCH-10
1-1111-2
Includes Power Supply, PCH-10 180° Torch with Leads, Spare Consumable Parts, Input Power Cord, and Work
Cable.
DRAG-GUN 100V/50Hz 110V/60Hz, PCH-10
1-1111-3-180
DRAG-GUN 120V 50Hz, PCH-10, "CE"
1-1811-6-180
DRAG-GUN 120V 60Hz, PCH-10
1-1111-1-180
DRAG-GUN 220V 50Hz, PCH-10, "CE"
1-1811-5-180
DRAG-GUN 208/230 60Hz, PCH-10
1-1111-2-180
B. Power Supply Only
Includes Power Supply, Input Power Cord, and Work Cable.
DRAG-GUN 100V/50Hz 110V/60Hz
3-1112
DRAG-GUN 120V 50Hz, "CE"
3-1113
DRAG-GUN 120V 60Hz
3-1111
DRAG-GUN 220V 50Hz, "CE"
3-1114
DRAG-GUN 208/230 60Hz
3-1110
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
2-1020
PCH-10 (180°) w/20 ft. (6 m) Leads
2-1021
Operating Manual 0-2682
21
DRAG-GUN Plasma Cutter
8.3 Power Supply Replacement Parts
Item #
1
Qty
1
Description
Ref.
Transformer/Inductor (Incl. Chassis):
DRAG-GUN 100V/50Hz 110V/60Hz
DRAG-GUN 120V 50Hz
DRAG-GUN 120V 60Hz
DRAG-GUN 220V 50Hz
DRAG-GUN 208/230 60Hz
Catalog#
T1/L1
9-0023
9-0024
9-0001
9-0037
9-0036
2
1
Cover (incl. Labels)
9-0002
3
1
Control PCB Assembly
9-0003
4
1
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
9-0004
9-0004
9-0004
9-3924
9-3924
9-0005
5
1
Wire Harness (Not Shown)
6
1
Relay, DPST, -NO, 25A @ 250V
7
1
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
8-3209
8-3209
8-3209
9-7687
9-7687
9-0010
9-7912
K1
9-7508
8
1
1
Compressor, Air, 12VDC, 0.5 CFM
Compressor Disc Filter (not shown)
9
1
Resistor, 0.5ohm, 55 watt, 10%,3/16 Faston
R30
10
1
Resistor, 1Kohm, 55 watt, 5%,3/16 Faston
R31
11
1
Work Cable, 15 ft. (4.57 m) w/Red Handles
9-0013
12
1
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.
9-0052
9-0044
9-0014
9-0044
9-0014
13
1
9-0011
9-0012
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
9-0015
9-0021
9-0029
T2
9-0018
BR1, BR2
7-3345
14
1
CD Transformer/Ferrite Core Assembly
15
2
Bridge Rectifier
16
1
Handle
9-8115
8.4 Options & Accessories (not shown)
1
Circle Cutting Guide Kit
7-8910
1
Leads Wrap - Installs Under Handle
9-7865
DRAG-GUN Plasma Cutter
22
Operating Manual 0-2682
HARDWARE
C
C
16
* 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.
A
B
C
D
E
F
QTY
Screw, #6-32 x 3 3/4 Lg, Phil Pan Hd, Zinc
#6-32 Regular Nylon Lock Nut, Zinc Plated
5/16-18 x 1 3/4 Unc Cap Socket Head Bolt
10-32 x .5 Pph Swageform Stl Zn. Parker Kalon
Screw, Black, 6-32 x 1/2 Pph, Swageform, Steel
10-32 Kepnut w/Star Washer Mild Steel
2
2
2
4
2
2
NOTE: Replacement hardware can be purchased locally.
To remove cover, unfasten:
• 4 side panel screws
• 2 handle screws
• 2 end panel screws
2
D
14
D
6
D
B
1
B
3
15
(BR2)
(BR1)
A A
4
8
E
12
Chassis
Rotation
Direction
E
Torch & Leads
7
F
F
11
A-02337
10
Air Flow
Direction
Operating Manual 0-2682
13
9
23
DRAG-GUN Plasma Cutter
8.5 Torch Replacement Parts
Item #
Qty
Description
Catalog#
1
1
PCH-10 (70°) Torch Head Assembly*
PCH-10 (180°) Torch Head Assembly*
9-0016
9-0017
2
1
Torch Handle Only
9-0019
3
1
Torch Switch
9-1058
4
1
Standard Electrode
9-6006
5
1
PCH-10 Tip
9-6099
6
1
Gas Distributor
9-6007
7
1
Shield Cup
9-6003
8
1
Torch Head Split Holders
PCH-10 (70°)
PCH-10 (180°)
9-6259
9-6261
9
1
PIP (Parts-In-Place) Wire Assembly
9-6290
10
1
O-Ring
8-0533
11
1
Torch Switch Button
8-4256
12
2
Torch Switch Button Springs
9-6292
* To be replaced by Qualified Technician only.
10
2
1
11
3
12
B
2
1
8
C
A
A
A
9
4
A
8
6
A
A-02360
5
A
HARDWARE
A
B
C
7
DRAG-GUN Plasma Cutter
24
QTY
#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
6
1
1
Operating Manual 0-2682
APPENDIX I:
CABLING DETAILS
Brass Torch
Lead Fitting
Nylon Nut
Faston Connector
to CD Coil
Front Panel
Hole Location
90˚ White
Nylon Fitting
Strain Relief Nut
Strain Relief
Torch
Lead
1" Clearance
Torch Leads Assembly
Note: Do not remove strain relief from torch lead.
Strain
Relief
2-Pin Connectors
Torch Lead Faston Connector (Red)
(Connect to Bottom Resistor)
A-02009
Torch and Leads Replacement
ON/OFF Input
Power Switch
A-02011
Work Cable
Bridge
Rectifier
Green Wire with Tracer
(Connect to
Compressor Frame)
Strain Relief
(Install 5 1/2" from Faston)
Strain
Relief
Primary
Input Power
Cable
Green Wire
(from Primary
Input Power Cable)
A-02653
Work Cable Faston
(Connect to mounting
tab at bottom of Rectifier)
Work Cable Replacement
Operating Manual 0-2682
Ground Stud
Input Power Cable Replacement
25
DRAG-GUN Plasma Cutter
APPENDIX II:
INTERCONNECTING DIAGRAM
A-02277
DRAG-GUN Plasma Cutter
26
Operating Manual 0-2682
NOTE: Use this diagram for all rev D (or later)
units. Check the data tag on the unit for rev level.
1
1
8063
12/01
98
A-02277
Operating Manual 0-2682
27
DRAG-GUN Plasma Cutter
DRAG-GUN Plasma Cutter
FAN
6
19
-
BLK
28
20
22
21
FAN
C13
6
5
230
208
120vac 120vac
19
T1
4
3
(7) 7A
8
220vac
Single voltage marked #6
Dual voltage marked 208v (tap) & 230v
K1-C
11
29
4
3
(7) 7A
8
T1 PR1
T1
FAN
120µƒ
120µƒ
180vac 180vac
120vac 100vac
+
RED
AIR
COMPRESSOR
12 VDC
C13
5
60µƒ
370vac
220vac
20
22
21
C13
Model:
NOTES
SW1
K1-B
1
BR 2
BRIDGE
35A 1200V
-
+
26
10
+
-
BR1
BRIDGE
35A 1200V
23
K1
12v
Shield
Cup
1K
55 watt
TEMP
PIP Pin
PIP Pin
TORCH
SWITCH
1A (1)
18
15
14
17
16
13
12
11
10
7
4
1
J2
J2
J2
J2
J2
J2
J2
J2
J2
J2
J2
J2
18
15
14
17
16
13
12
11
10
7
4
1
L1
2
CD PCB
50
5 watt
0.5
55 watt
330µƒ
450v
22
3 watt
330µƒ
450v
E2
E1
CD
PRIMARY
SPK1
350V Spark Gap
E5
LOGIC
CIRCUIT
CD
PWR
CIRCUIT
150µƒ
450v
E6
24
CD XFMR
43
27
PILOT
(RED Sleeved)
L1
T
O
R
C
H
WORK
L4
NOTE: Use this diagram for all rev C units (or
earlier). Check the data tag on the unit for rev
level.
A-02012
APPENDIX III:
INTERCONNECTING DIAGRAM
Operating Manual 0-2682