Thermal Dynamics 35C User manual

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

!
WARNING
Read and understand this entire Manual and your employer’s safety practices before installing,
operating, or servicing the equipment.
While the information contained in this Manual represents the Manufacturer's best judgement,
the Manufacturer assumes no liability for its use.
Plasma Cutting Power Supply
Drag-Gun Plus
PCH 42 Torch
Service Manual Number 0-4751
Covered under U.S. Patents.
Published by:
Thermadyne Corporation
82 Benning Street
West Lebanon, New Hampshire, USA 03784
[phone]
www.thermal-dynamics.com
©Copyright 2006, 2007 by
Thermal Dynamics Corporation
All rights reserved.
Reproduction of this work, in whole or in part, without written permission of the publisher is prohibited.
The publisher does not assume and hereby disclaims any liability to any party for any loss or damage
caused by any error or omission in this Manual, whether such error results from negligence, accident, or
any other cause.
Printed in the United States of America
Publication Date: March 26, 2007
Record the following information for Warranty purposes:
Where Purchased:____________________________________
Purchase Date:_______________________________________
Power Supply Serial #:________________________________
Torch Serial #:________________________________________

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

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

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

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

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

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

Manual0-4751 1-5 GENERAL INFORMATION
1.05 Statement of Warranty
LIMITED WARRANTY: Subject to the terms and conditions established below, Thermadyne® Corporation warrants to the original retail purchaser that
new Thermadyne CutSkill Series plasma cutting systems sold after the effective date of this warranty are free of defects in material and workmanship.
Should any failure to conform to this warranty appear within the applicable period stated below, Thermadyne Corporation shall, upon notification thereof
and substantiation that the product has been stored operated and maintained in accordance with Thermadyne’s specifications, instructions,
recommendations and recognized industry practice, correct such defects by suitable repair or replacement.
This warranty is exclusive and in lieu of any warranty of merchantability or fitness for a particular purpose.
Thermadyne will repair or replace, at its discretion, any warranted parts or components that fail due to defects in material or workmanship within the time
periods set out below. Thermadyne Corporation must be notified within 30 days of any failure, at which time Thermadyne Corporation will provide
instructions on the warranty procedures to be implemented.
Thermadyne Corporation will honor warranty claims submitted within the warranty periods listed below. All warranty periods begin on the date of sale
of the product to the original retail customer or 1 year after sale to an authorized Thermadyne Distributor.
LIMITED WARRANTY PERIOD
Product Power Supply Componants
(Parts and Labor) Torch and Leads (Parts and Labor)
Drag-Gun Plus 2 Year 1 Year
This warranty does not apply to:
1. Consumable Parts, such as tips, electrodes, shield cups, o - rings, starter cartridges, gas distributors, fuses, filters.
2. Equipment that has been modified by an unauthorized party, improperly installed, improperly operated or misused based upon
industry standards.
In the event of a claim under this warranty, the remedies shall be, at the discretion of Thermadyne Corporation:
1. Repair of the defective product.
2. Replacement of the defective product.
3. Reimbursement of reasonable costs of repair when authorized in advance by Thermadyne.
4. Payment of credit up to the purchase price less reasonable depreciation based on actual use.
These remedies may be authorized by Thermadyne and are FOB West Lebanon, NH or an authorized Thermadyne service station. Product returned for
service is at the owner’s expense and no reimbursement of travel or transportation is authorized.
LIMITATION OF LIABILITY: Thermadyne Corporation 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 customer of distributors (hereinafter “Purchaser”) for service interruption.
The remedies of the Purchaser set forth herein are exclusive and the liability of Thermadyne 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 the goods covered by or furnished by
Thermadyne 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 liability is based.
This warranty becomes invalid if replacement parts or accessories are used which may impair the safety or performance of any Thermadyne
product.
This warranty is invalid if the Thermadyne product is sold by non - authorized persons.
Effective January 3, 2006

GENERAL INFORMATION 1-6 Manual0-4751
This Page Left Blank

Introduction 2-1 Manual 0-4751
SECTION 2:
INTRODUCTION
2.01 INTRODUCTION
Plasma is a gas which has been heated to an extremely
high temperature and ionized so that it becomes elec-
tricallyconductive. The plasma arccuttingprocessuses
this plasma to transfer an electrical arc to the work-
piece. The metal to be cut is melted by the heat of the
arc and then blown away.
2.02 GENERAL SPECIFICATION
Model Description Drag-Gun Plus
Maximum output 35 Amps
Input Voltage & Phase
230V,
Single Phase
Frequency 50/60Hz
Input power 8.3 kVA
Current Input fuse
U.S. / Canada 40
Amps
All others 20A Slow
Blow Fuse
No Load Voltage 330V
Load Voltage 94V
Output Current 10 - 35 Amps
Post flow time 15 Seconds
35% @ 35A @
94vdc
60% @ 27A @
91vdc
100% @ 20A @
88 vdc
Genuine Cutting
Capacity 3/8" (9 mm)
Maximum Cutting
Capacity
1/2"
(12mm)
Dimension (W * D * H) 10.5"x15.5"x11"
(267 mm x 394 mm
x 279 mm )
Duty cycle @ 104°F /
40° C Ambient
NOTE:
Refer to Local and National Codes or local au-
thority having jurisdiction for proper wiring re-
quirements.
2.03 Features
• COMPACT and LIGHT - Designed for easy trans-
portation.
• ENERGY EFFICIENCY - Advanced technology
reduces power consumption.
• HIGH SPEED GENUINE CUTTING - The con-
stricted plasma arc provides high speed cutting
as well as a good quality genuine, narrow cut.
• LOW COST WITH COMPRESSED AIR - The
Drag-Gun Plus operates on compressed air.
• ALL KINDS OF METALS - Useful for most met-
als such as stainless steel, aluminum, mild steel,
copper and their alloys.
• PILOT ARC IGNITION FROM TORCH - The Pi-
lot Arc ignites the cutting arc.
• POWERFUL CUTTING PERFORMANCE -
Genuine cutting capacity is 3/8” (9 mm).
• ABLE TO CUT PAINTED MATERIALS - Pilot Arc
ignition allows the Drag-Gun Plus to cut painted
materials.
• EXTENDED PARTS LIFE - Consumable parts life
is longer.

Introduction 2-2 Manual 0-4751
2.04 Torch Specifications
Art # A-0465
3
10.5 in (266.7 mm)
3 in
(76.2 mm)
Torch Configuration Torch Head at 70° to
Torch Handle
Torch Leads Length
20 feet / 6.1 m
Ambient
Temperature 104° F 40° C
Duty Cycle 100% @ 40 Amps
@ 200 scfh
Maximum Current 40 Amps, DC,
Straight Polarity
Voltage (V
peak
)500V
Arc Striking Voltage 12kV
Type of Cooling Ambient air and gas
stream through torch
Parts-in-Place: Built-in Switch
in Torch Head
Gas Requirement: Single Gas,
Compressed Air Only
Input
Gas Pressure
65 psi (4.5 bar)
(.45MPa)-
125 psi (8.6 bar)
(.86MPa)
Minimum Gas Flow 200 SCFH (142 lpm)
Direct Contact Hazard
For operation with
exposed tip the
recommended standoff
height is
1/8 - 3/8" (3-9 mm).
Plasma Power
Supply Used With: Drag-Gun Plus
PCH-42 Torch Ratings
2.05 System Contents
Description
ITEMS
Q'ty
Power source Model Drag-Gun Plus 1
Torch Set PCH-42, with 20' (6.1 m) leads 1
Accessories &
Consumables
Work Cable
Manual
Torch Electrodes
Torch Tips
1
1
2
3
Input Power
Cable U.S. /
CAN.
3 Meter NEMA 10 AWG /
4.8 mm2with 6 - 50 P
molded plug 1
Input Power
Cable Outside
of U.S. / CAN.
3 Meter 3x2.5 sq mm
rubber wire 1
2.06 Transporting Methods
Lift unit with handle on top of case. Use handcart or
similar device of adequate capacity for transporting.
WARNING
ELECTRIC SHOCK can kill. DO NOT
TOUCH live electrical parts. Disconnect input
power from supply before moving the power
source.
FALLING EQUIPMENT cancause seriousper-
sonal injury and equipment damage.

Manual 0-4751 3-1 Installation
SECTION 3:
INSTALLATION
3.01 Site Selection
• Place in a clean and dry area.
• Provide adequate ventilation and fresh air sup-
ply.
• Ideal ambient temperature should not exceed
40°C / 104°F. Temperatures exceeding that may
diminish cutting capacity or quality.
• The cutting machine must be placed on an even,
firm surface so that it stands firmly.
!
WARNING
This equipment must be electrically connected
by a qualified electrician.
3.02 Electrical Input Connections
• Input voltage is 230V ± 10%, 50/60 Hz single
phase.
CAUTION
Check your power source for correct voltage be-
fore plugging in or connecting the unit. The
primary power source, fuse, and any extension
cords used must conform to local electrical code
andthe recommended circuitprotectionand wir-
ing requirements as specified in Section 2.
3.03 Torch
• Make sure that the torch cable and torch switch
terminals are connected to front panel.
• Make sure the Work Cable is connected properly
to front panel.
• Before activating, turn torch away from yourself
and others.
DANGER
Do not cut in humid or wet surroundings.
• Before you maintain or replace torch parts, wait
for the post flow air cycle (approximately 15 sec-
onds), to stop, then turn the machine off.
• Always use originalmanufacturersparts. The use
of aftermarket parts could result in lower parts
lifeandin unsatisfactory cutting results. Any war-
ranty claims would be waived.
• Recycle worn parts according to local require-
ments.
NOTE
Repairs must be done by skilled and qualified
personnel only.

Installation 3-2 Manual 0-4751
This Page Left Blank

Manual 0-4751 4-1 Operation
SECTION 4:
OPERATION
4.01 Front Control Panel
Overheating
Indicator
AC Power
Indicator
Air Error Indicator
Torch Switch
Latch Indicato
r
Torch Switc
h
Latch Butto
n
Air Set
Button
Air Vents
Work Lead
Connection
"On / Off"
Switch
Art # A-04720
Torch
Connection
I
O
115VAC
230VAC
8
10
12
14
10
11
12
13
14
15
17
18
19
20
21
22
23
24
25
A
35C
16
18
20
16
Current
Control Knob
Roll bars not shown for clarity
A. INDICATOR LAMP
• Power Indicator - Lights when primary
power switch is turned on.
• TEMPERATUREIndicator -Indicatoris nor-
mally OFF. Indicator is ON when internal tem-
peratureexceeds normallimits. Shut unitOFF;
let the unit cool before continuing operation.
• Air Error Indicator - This indicator lights
and is accompanied by an intermittent audible
tone when there is not enough air pressure to
operate the power supply.
NOTE
It is possible to have enough air pressure to op-
erate the power supply but not enough air flow
to operate the torch.
• Torch Switch Latch Indicator -
This indicator lights when the Torch Switch
Latch Button has been pressed for continuous
cutting.
B. BUTTONS
• Torch Switch Latch Button - For
continuous cutting performance. Depress this
button( turn “On”) whilecutting withthe torch.
Release the torch trigger and the torch will con-
tinue to cut without depressing the torch trig-
ger.
• Air Set Button - To check for proper air
setting and to cool down heated torch.
C. MAIN CURRENT CONTROL KNOB
To adjust cutting current. Turning clockwise in-
creases the cutting current and counter clock-
wise decreases the cutting current.
10
15
20
25
A
3
0
35
A
rt # A-04387
D. PRIMARY POWER SWITCH, ON / OFF
The power switch is located on the front panel.
Placing the primary power switch to the “ON”
position energizes the power source.
WARNING
When the power source is overloaded, the switch
turns to the OFF position automatically. DO
NOT TURN ON BY FORCE.

Operation 4-2 Manual 0-4751
4.02 Preparations For Operating
At the start of each operating session:
WARNING
Disconnect primary power at the source before
assemblingor disassembling powersupply,torch
parts, or torch and leads assemblies.
A. Torch Parts Selection
Check the torch for proper assembly and appro-
priatetorchparts. The torchparts must correspond
with the type of operation, and with the amperage
output of this Power Supply (35 amps maximum).
Use only genuine manufacturer’s parts with this
torch.
Torch Head Assembly
Shield Cup, No. 9-6003
Gas Distributor,
No. 9-6507
Tip, No. 9-6501
Electrode, No. 9-6542
A
rt # A-04655
B. Torch Connection
Check that the torch is properly connected.
C. Connect Work Cable
Make a clean work cable
connection to the work-
piece or cutting table
W
ork Cable
A
nd Clamp
Art # A-04389
D. Torch Operation
• Wear gloves and protective goggles.
• Do not place bare hand on work piece.
1. For dragcutting, keep the torch in contact with
the workpiece.
2. For standoff cutting, hold the torch 1/8 - 3/8
in (3-9 mm) from the workpiece as shown be-
low.
A-00024
S
hield Cup
Torch
Standoff
Distance 1/8" - 3/
8"
3. With the torch in starting position, press and
hold the Torch Trigger. After an initial two sec-
ond pre-flow, the pilot arc will come on and re-
main on until the cutting arc starts.
4. Once on, the cutting arc remains on as long as
the Torch Trigger is held down, unless the torch
is withdrawn from the work or torch motion is
too slow.
5. To shut off the torch simply release the Torch
Trigger. When the trigger is released a gaspost-
flow will occur. If the Torch Trigger is pushed
during the post-flow, the cutting arc will restart
immediately when the torch is brought within
range of the workpiece.

Manual 0-4751 4-3 Operation
E. Typical Cutting Speeds
Cutting speeds vary according to torch output, the type of material being cut, and operator skill. Speeds
shown are typical for this cutting system using air plasma to cut mild steel, with output current at the
highest setting and torch held at the indicated standoff height.
Unit Standoff Material
Thickness ipm mm/m ipm mm/m
Drag-Gun Plus Drag (10 ga) 0.135" - (3mm) 95.0 2375 76.0 1900
Drag-Gun Plus Drag (7 ga) 0.179" - (4.5mm) 57.0 1425 46.0 1150
Drag-Gun Plus 1/8" - (3mm) 1/4" - (6mm) 36.0 900 29.0 725
Drag-Gun Plus 1/8" - (3mm) 3/8" - (9.5mm) 15.0 375 12.0 300
Drag-Gun Plus 1/8" - (3mm) 7/16" - (11mm) 10.0 250 8.0 200
Drag-Gun Plus 1/8" - (3mm) 1/2" - (12mm) 8 200 7 175
Recommended Travel SpeedMaximum Travel Speed
NOTE:
Drag or Drag mode refers to the torch tip being in contact with the work piece at all times.

Operation 4-4 Manual 0-4751
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