Thermal Dynamics Drag-gun User manual

Manual No. 0-2682
April 26, 2000
Operating Manual
Includes:
• 12 Amp Power Supply
• PCH-10 Torch with Leads
• Work Cable with Clamp
• Input Power Cable
TM
For Models:
• 100 VAC 50 Hz/110 VAC 60Hz
• 120 VAC 50Hz
• 120 VAC 60Hz
• 220 VAC 50Hz
• 208/230 VAC 60Hz

Read and understand this entire manual and your employer’s
safety practices before installing, operating, or
servicing the equipment.
While the information contained in this manual represents our
best judgement, Thermal Dynamics Corporation assumes no
liability for its use.
DRAG-GUN Plasma Cutter Operating Manual
Number 0-2682
Published by:
Thermal Dynamics Corporation
Industrial Park No. 2
West Lebanon, New Hampshire, USA 03784
[phone]
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 liabil-
ity to any party for any loss or damage caused by any error or
omission in the DRAG-GUN Plasma Cutter Operating Manual,
whether such error results from negligence, accident, or any
other cause.
Printed in the United States of America
April 2000
WARNING
WARNING

TT
TT
TABLE OF CONTENTSABLE OF CONTENTS
ABLE OF CONTENTSABLE OF CONTENTS
ABLE OF CONTENTS
1: GENERAL INFORMATION ..............................................................................................................1
1.1 Notes, Cautions and Warnings ........................................................................................1
1.2 Important Safety Precautions ..........................................................................................1
1.3 Publications ....................................................................................................................2
1.4 Note, Attention et Avertissement......................................................................................3
1.5 Precautions De Securite Importantes...............................................................................3
1.6 Documents De Reference.................................................................................................5
1.7 Declaration of Conformity ...............................................................................................7
1.8 Statement of Warranty ....................................................................................................8
2.0 INTRODUCTION ..........................................................................................................................9
2.1 What is Plasma? ..............................................................................................................9
2.2 General Product Description..........................................................................................10
2.3 Technical Specifications ................................................................................................ 10
2.4 Dimensions ................................................................................................................... 11
3.0 CONTROLS: LOCATION & FUNCTION ........................................................................................ 11
4.0 INSTALLATION .......................................................................................................................... 12
5.0 OPERATION............................................................................................................................... 14
5.1 Cutting Techniques ....................................................................................................... 14
5.2 Cut Quality ................................................................................................................... 16
5.3 Recommended Cutting Speeds ...................................................................................... 16
5.4 Common Cutting Faults ................................................................................................17
5.5 Common Operating Problems ........................................................................................ 17
6.0 MAINTENANCE.......................................................................................................................... 18
6.1 Recommended Maintenance Schedule ........................................................................... 18
6.2 Power Supply Cleaning.................................................................................................. 18
6.3 Torch Cleaning.............................................................................................................. 18
6.4 Inspection and Replacement of Consumable Torch Parts ............................................... 18
7.0 PARTS REPLACEMENT.............................................................................................................. 19
7.1 Torch & Leads Replacement .......................................................................................... 19
7.2 Work Cable Replacement ............................................................................................... 20
7.3 Input Power Cable Replacement .................................................................................... 20
8.0 PARTS LIST ............................................................................................................................... 20
8.1 Returns ........................................................................................................................ 20
8.2 Parts Replacement ........................................................................................................ 21
8.3 Power Supply Replacement Parts................................................................................... 22
8.4 Options & Accessories (not shown) ................................................................................ 22
8.5 Torch Replacement Parts............................................................................................... 24
APPENDIX I: CABLING DETAILS ...................................................................................................... 25
APPENDIX II: INTERCONNECTING DIAGRAM ..................................................................................26
APPENDIX III: INTERCONNECTING DIAGRAM .................................................................................28

5/21/99 1 GENERAL INFORMATION
1: GENERAL1: GENERAL
1: GENERAL1: GENERAL
1: GENERAL
INFORMAINFORMA
INFORMAINFORMA
INFORMATIONTION
TIONTION
TION
1.1 Notes, Cautions and Warnings
Throughout this manual, notes, cautions, and warnings
are used to highlight important information. These high-
lights are categorized as follows:
NOTE
An operation, procedure, or background informa-
tion which requires additional emphasis or is help-
ful in efficient operation of the system.
CAUTION
A procedure which, if not properly followed, may
cause damage to the equipment.
WARNING
A procedure which, if not properly followed, may
cause injury to the operator or others in the oper-
ating area.
1.2 Important Safety Precautions
WARNING
OPERATION AND MAINTENANCE OF
PLASMA ARC EQUIPMENT CAN BE DAN-
GEROUS AND HAZARDOUS TO YOUR
HEALTH.
Plasma arc cutting produces intense electric and
magnetic emissions that may interfere with the
proper function of cardiac pacemakers, hearing
aids, or other electronic health equipment. Per-
sons who work near plasma arc cutting applica-
tions should consult their medical health profes-
sional and the manufacturer of the health
equipment to determine whether a hazard exists.
To prevent possible injury, read, understand and
follow all warnings, safety precautions and in-
structionsbeforeusing the equipment. Call1-603-
298-5711 or your local distributor if you have any
questions.
GASES AND FUMES
Gases and fumes produced during the plasma cutting
process can be dangerous and hazardous to your health.
•Keep all fumes and gases from the breathing area.
Keep your head out of the welding fume plume.
•Use an air-supplied respirator if ventilation is not
adequate to remove all fumes and gases.
•The kinds of fumes and gases from the plasma arc
depend on the kind of metal being used, coatings
on the metal, and the different processes.You must
be very careful when cutting or welding any met-
als which may contain one or more of the follow-
ing:
Antimony Chromium Mercury
Arsenic Cobalt Nickel
Barium Copper Selenium
Beryllium Lead Silver
Cadmium Manganese Vanadium
•Alwaysreadthe MaterialSafetyData Sheets(MSDS)
that should be supplied with the material you are
using. These MSDSs will give you the information
regarding the kind and amount of fumes and gases
that may be dangerous to your health.
•For information on how to test for fumes and gases
in your workplace, refer to item 1 in Subsection
1.3, Publications in this manual.
•Use special equipment, such as water or down draft
cutting tables, to capture fumes and gases.
•Do not use the plasma torch in an area where com-
bustibleor explosivegases ormaterials are located.
•Phosgene, a toxic gas, is generated from the vapors
of chlorinated solvents and cleansers. Remove all
sources of these vapors.
ELECTRIC SHOCK
Electric Shock can injure or kill. The plasma arc process
uses and produces high voltage electrical energy. This
electric energy can cause severe or fatal shock to the op-
erator or others in the workplace.
•Never touch any parts that are electrically “live”or
“hot.”
•Weardrygloves and clothing. Insulateyourselffrom
the work piece or other parts of the welding cir-
cuit.
•Repair or replace all worn or damaged parts.
•Extra care must be taken when the workplace is
moist or damp.

GENERAL INFORMATION 2 5/21/99
•Install and maintain equipment according to NEC
code, refer to item 9 in Subsection 1.3, Publications.
•Disconnectpower sourcebeforeperforminganyser-
vice or repairs.
•Read and follow all the instructions in the Operat-
ing Manual.
FIRE AND EXPLOSION
Fire and explosion can be caused by hot slag, sparks, or
the plasma arc.
•Be sure there is no combustible or flammable mate-
rial in the workplace. Any material that cannot be
removed must be protected.
•Ventilate all flammable or explosive vapors from
the workplace.
•Donot cutor weldon containersthat mayhave held
combustibles.
•Provideafirewatch whenworkingin anareawhere
fire hazards may exist.
•Hydrogen gas may be formed and trapped under
aluminum workpieces when they are cut under-
water or while using a water table. DO NOT cut
aluminum alloys underwater or on a water table
unless the hydrogen gas can be eliminated or dis-
sipated. Trapped hydrogen gas that is ignited will
cause an explosion.
NOISE
Noisecan causepermanent hearing loss. Plasma arcpro-
cesses can cause noise levels to exceed safe limits. You
must protect your ears from loud noise to prevent per-
manent loss of hearing.
•To protect your hearing from loud noise, wear pro-
tective ear plugs and/or ear muffs. Protect others
in the workplace.
•Noise levels should be measured to be sure the deci-
bels (sound) do not exceed safe levels.
•For information on how to test for noise, see item 1
in Subsection 1.3, Publications, in this manual.
PLASMAARC RAYS
PlasmaArcRays caninjureyour eyes andburn your skin.
The plasma arc process produces very bright ultra violet
and infra red light. These arc rays will damage your
eyesand burn yourskin if youarenotproperlyprotected.
•To protect your eyes, always wear a welding hel-
metor shield. Alsoalways wear safetyglasses with
side shields, goggles or other protective eye wear.
•Wear welding gloves and suitable clothing to pro-
tect your skin from the arc rays and sparks.
•Keep helmet and safety glasses in good condition.
Replace lenses when cracked, chipped or dirty.
•Protect others in the work area from the arc rays.
Use protective booths, screens or shields.
•Use the shade of lens as suggested in the following
per ANSI/ASC Z49.1:
Minimum Protective Suggested
Arc Current Shade No. Shade No.
Less Than 300* 8 9
300 - 400* 9 12
400 - 800* 10 14
* Thesevalues applywherethe actual arc is clearly
seen. Experience has shown that lighter filters
may be used when the arc is hidden by the work-
piece.
1.3 Publications
Refer to the following standards or their latest revisions
for more information:
1. OSHA, SAFETY AND HEALTH STANDARDS,
29CFR 1910, obtainable from the Superintendent of
Documents, U.S. Government Printing Office, Wash-
ington, D.C. 20402
2. ANSI Standard Z49.1, SAFETY IN WELDING AND
CUTTING, obtainable from the American Welding
Society, 550 N.W. LeJeune Rd, Miami, FL 33126
3. NIOSH, SAFETY AND HEALTH IN ARC WELD-
INGAND GAS WELDINGAND CUTTING, obtain-
able from the Superintendent of Documents, U.S.
GovernmentPrinting Office,Washington,D.C. 20402
4. ANSI Standard Z87.1, SAFE PRACTICES FOR OC-
CUPATIONAND EDUCATIONAL EYEAND FACE
PROTECTION, obtainable from American National
Standards Institute, 1430 Broadway, New York, NY
10018
5. ANSI Standard Z41.1, STANDARD FOR MEN’S
SAFETY-TOE FOOTWEAR, obtainable from the
American National Standards Institute, 1430 Broad-
way, New York, NY 10018
6. ANSI Standard Z49.2, FIRE PREVENTION IN THE
USE OF CUTTING AND WELDING PROCESSES,
obtainable fromAmerican National Standards Insti-
tute, 1430 Broadway, New York, NY 10018
7. AWS Standard A6.0, WELDING AND CUTTING
CONTAINERS WHICH HAVE HELD COMBUS-
TIBLES, obtainable fromAmerican Welding Society,
550 N.W. LeJeune Rd, Miami, FL 33126

5/21/99 3 GENERAL INFORMATION
8. NFPA Standard 51, OXYGEN-FUEL GAS SYSTEMS
FOR WELDING, CUTTING AND ALLIED PRO-
CESSES, obtainable from the National Fire Protection
Association, Batterymarch Park, Quincy, MA 02269
9. NFPAStandard70,NATIONALELECTRICALCODE,
obtainable from the National Fire Protection Asso-
ciation, Batterymarch Park, Quincy, MA 02269
10. NFPA Standard 51B, CUTTING AND WELDING
PROCESSES, obtainable from the National Fire Pro-
tection Association, Batterymarch Park, Quincy, MA
02269
11. CGA Pamphlet P-1, SAFE HANDLING OF COM-
PRESSED GASES IN CYLINDERS, obtainable from
the Compressed Gas Association, 1235 Jefferson
Davis Highway, Suite 501, Arlington, VA22202
12. CSA Standard W117.2, CODE FOR SAFETY IN
WELDINGAND CUTTING, obtainable from the Ca-
nadian Standards Association, Standards Sales, 178
Rexdale Boulevard, Rexdale, Ontario, Canada M9W
1R3
13. NWSA booklet, WELDING SAFETY BIBLIOGRA-
PHY obtainable from the National Welding Supply
Association, 1900Arch Street, Philadelphia, PA19103
14. American Welding Society StandardAWSF4.1, REC-
OMMENDED SAFE PRACTICES FOR THE PREPA-
RATION FOR WELDINGAND CUTTING OF CON-
TAINERS AND PIPING THAT HAVE HELD
HAZARDOUS SUBSTANCES, obtainable from the
American Welding Society, 550 N.W. LeJeune Rd,
Miami, FL 33126
15. ANSI Standard Z88.2, PRACTICE FOR RESPIRA-
TORY PROTECTION, obtainable from American
National Standards Institute, 1430 Broadway, New
York, NY 10018
1.4 Note, Attention et
Avertissement
Dans ce manuel, les mots “note,”“attention,”et
“avertissement”sont utilisés pour mettre en relief des
informations àcaractère important. Ces mises en relief
sont classifiées comme suit :
NOTE
Toute opération, procédure ou renseignement
général sur lequel il importe d’insister davantage
ou qui contribue à l’efficacité de fonctionnement
du système.
ATTENTION
Toute procédure pouvant résulter
l’endommagement du matériel en cas de non-
respect de la procédure en question.
AVERTISSEMENT
Toute procédure pouvant provoquer des blessures
de l’opérateur ou des autres personnes se trouvant
dans la zone de travail en cas de non-respect de la
procédure en question.
1.5 Precautions De Securite
Importantes
AVERTISSEMENT
L’OPÉRATION ET LA MAINTENANCE DU
MATÉRIEL DE SOUDAGE À L’ARC AU JET
DE PLASMA PEUVENT PRÉSENTER DES
RISQUES ET DES DANGERS DE SANTÉ.
Plasma arc cutting produces intense electric and
magnetic emissions that may interfere with the
properfunctionof cardiac pacemakers,hearingaids,
or other electronic health equipment. Persons who
work near plasma arc cutting applications should
consult their medical health professional and the
manufacturer of the health equipment to determine
whether a hazard exists.
Il faut communiquer aux opérateurs et au person-
nel TOUS les dangers possibles. Afin d’éviter les
blessures possibles, lisez, comprenez et suivez tous
lesavertissements, toutes lesprécautionsde sécurité
et toutes les consignes avant d’utiliser le matériel.
Composez le + 603-298-5711 ou votre distributeur
local si vous avez des questions.
FUMÉE et GAZ
La fumée et les gaz produits par le procédéde jet de
plasma peuvent présenter des risques et des dangers de
santé.
•Eloignez toute fumée et gaz de votre zone de respi-
ration. Gardez votre tête hors de la plume de fumée
provenant du chalumeau.
•Utilisez un appareil respiratoire àalimentation en
air si l’aération fournie ne permet pas d’éliminer la
fumée et les gaz.
•Les sortes de gaz et de fumée provenant de l’arc de
plasma dépendent du genre de métal utilisé, des
revêtementssetrouvantsur le métaletdesdifférents

GENERAL INFORMATION 4 5/21/99
procédés. Vous devez prendre soin lorsque vous
coupez ou soudez tout métal pouvant contenir un
ou plusieurs des éléments suivants:
antimoine cadmium mercure
argent chrome nickel
arsenic cobalt plomb
baryum cuivre sélénium
béryllium manganèse vanadium
•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 àla quantitéet la nature de la fumée et des
gaz pouvant poser des dangers de santé.
•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 àla page 4.
•Utilisez un équipement spécial tel que des tables de
coupe àdébit d’eau ou àcourant descendant pour
capter la fumée et les gaz.
•N’utilisez pas le chalumeau au jet de plasma dans
une zone oùse trouvent des matières ou des gaz
combustibles ou explosifs.
•Le phosgène, un gaz toxique, est générépar la fumée
provenantdessolvants etdes produits de nettoyage
chlorés. Eliminez toute source de telle fumée.
CHOC ELECTRIQUE
Les chocs électriques peuvent blesser ou même tuer. Le
procédéau jet de plasma requiert et produit de l’énergie
électrique haute tension. Cette énergie électrique peut
produiredes chocs graves,voiremortels, pour l’opérateur
et les autres personnes sur le lieu de travail.
•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 par-
ties du circuit de soudage.
•Réparez ou remplacez toute pièce usée ou
endommagée.
•Prenez des soins particuliers lorsque la zone de tra-
vail est humide ou moite.
•Montez et maintenez le matériel conformément au
Code électrique national des Etats-Unis. (Voir la
page 4, article 9.)
•Débranchez l’alimentation électrique avant tout tra-
vail d’entretien ou de réparation.
•Lisez et respectez toutes les consignes du Manuel
de consignes.
INCENDIE ET EXPLOSION
Lesincendieset lesexplosionspeuventrésulterdesscories
chaudes, des étincelles ou de l’arc de plasma. Le procédé
àl’arc de plasma produit du métal, des étincelles, des
scories chaudes pouvant mettre le feu aux matières com-
bustibles ou provoquer l’explosion de fumées
inflammables.
•Soyez certain qu’aucune matière combustible ou in-
flammable ne se trouve sur le lieu de travail.
Protégez toute telle matière qu’il est impossible de
retirer de la zone de travail.
•Procurez une bonne aération de toutes les fumées
inflammables ou explosives.
•Necoupez paset nesoudez pasles conteneurs ayant
pu renfermer des matières combustibles.
•Prévoyez une veille d’incendie lors de tout travail
dans une zone présentant des dangers d’incendie.
•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 àmoins que le gas hydrogène
peut s’échapper ou se dissiper. Le gas hydrogène
accumuléexplosera si enflammé.
RAYONS D’ARC DE PLASMA
Les rayons provenant de l’arc de plasma peuvent blesser
vosyeux et brûlervotrepeau.Le procédéàl’arc de plasma
produit une lumière infra-rouge et des rayons ultra-vio-
lets très forts. Ces rayons d’arc nuiront àvos yeux et
brûleront votre peau si vous ne vous protégez pas
correctement.
•Pour protéger vos yeux, portez toujours un casque
ouun écran desoudeur. Porteztoujoursdes lunettes
de sécuritémunies de parois latérales ou des lu-
nettes de protection ou une autre sorte de protec-
tion oculaire.
•Portez des gants de soudeur et un vêtement
protecteur appropriépour protéger votre peau
contre les étincelles et les rayons de l’arc.
•Maintenez votre casque et vos lunettes de protec-
tion en bon état. Remplacez toute lentille sale ou
comportant fissure ou rognure.
•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.

5/21/99 5 GENERAL INFORMATION
•Use the shade of lens as suggested in the following
chart per ANSI/ASC Z49.1:
•Utilisez la nuance de lentille qui est suggèrée dans
le recommendation qui suivent ANSI/ASC Z49.1:
Nuance Minimum Nuance Suggerée
Courant Arc Protective Numéro Numéro
Moins de 300* 8 9
300 - 400* 9 12
400 - 800* 10 14
*Ces valeurs s’appliquentoul’arcactuel est observé
clairement. L’experience a démontrer que les filtres
moins foncés peuvent être utilisés quand l’arc est
caché par moiceau de travail.
BRUIT
Le bruit peut provoquer une perte permanente de l’ouïe.
Les procédés de soudage àl’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.
•Pourprotégervotre ouïe contre les bruitsforts,portez
des tampons protecteurs et/ou des protections
auriculaires. Protégez également les autres
personnes se trouvant sur le lieu de travail.
•Il faut mesurer les niveaux sonores afin d’assurer
que les décibels (le bruit) ne dépassent pas les
niveaux sûrs.
•Pour des renseignements sur la manière de tester le
bruit, consultez l’article 1, page 5.
1.6 Documents De Reference
Consultez les normes suivantes ou les révisions les plus
récentes ayant étéfaites àcelles-ci pour de plus amples
renseignements :
1. OSHA, NORMES DE SÉCURITÉDU TRAVAIL ET
DE PROTECTION DE LA SANTÉ, 29CFR 1910,
disponible auprès du Superintendent of Docu-
ments, U.S. Government Printing Office, Washing-
ton, D.C. 20402
2. Norme ANSI Z49.1, LA SÉCURITÉDES
OPÉRATIONS DE COUPE ET DE SOUDAGE,
disponible auprès de la SociétéAméricaine de
Soudage (American Welding Society), 550 N.W.
LeJeune Rd., Miami, FL 33126
3. NIOSH, LA SÉCURITÉET LA SANTÉLORS DES
OPÉRATIONS DE COUPE ET DE SOUDAGE À
L’ARC ETAU GAZ, disponible auprès du Superin-
tendent of Documents, U.S. Government Printing
Office, Washington, D.C. 20402
4. Norme ANSI Z87.1, PRATIQUES SURES POUR LA
PROTECTION DES YEUX ET DU VISAGE AU
TRAVAIL ET DANS LES ECOLES, disponible de
l’InstitutAméricain des NormesNationales (Ameri-
can National Standards Institute), 1430 Broadway,
New York, NY 10018
5. Norme ANSI Z41.1, NORMES POUR LES
CHAUSSURESPROTECTRICES, 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 LACOUPE DE
CONTENEURS AYANT RENFERMÉDES
PRODUITSCOMBUSTIBLES, disponibleauprèsde
laAmerican Welding Society, 550 N.W.LeJeune Rd.,
Miami, FL 33126
8. Norme 51 de l’AssociationAméricaine pour la Pro-
tectioncontreles Incendies (NFPA),LESSYSTEMES
ÀGAZ AVEC ALIMENTATION EN OXYGENE
POUR LE SOUDAGE, LA COUPE ET LES
PROCÉDÉSASSOCIÉS,disponible auprèsde laNa-
tional Fire Protection Association, Batterymarch
Park, Quincy, MA 02269
9. Norme 70 de la NFPA, CODE ELECTRIQUE NA-
TIONAL,disponible auprès de la National FirePro-
tectionAssociation, BatterymarchPark, Quincy, MA
02269
10. Norme 51B de la NFPA, LES PROCÉDÉS DE
COUPE ET DE SOUDAGE, disponible auprès de
la National Fire Protection Association,
Batterymarch Park, Quincy, MA 02269
11. Brochure GCA P-1, LA MANIPULATION SANS
RISQUE DES GAZ COMPRIMÉS EN CYLINDRES,
disponible auprès de l’Association des Gaz
Comprimés (Compressed Gas Association), 1235
Jefferson Davis Highway, Suite 501, Arlington, VA
22202
12. Norme CSAW117.2, CODE DE SÉCURITÉPOUR
LE SOUDAGE ET LA COUPE, disponible auprès
de l’Association des Normes Canadiennes, Stan-
dards Sales, 178 Rexdale Boulevard, Rexdale,
Ontario, Canada, M9W 1R3
13.ivretNWSA, BIBLIOGRAPHIESURLASÉCURITÉ
DU SOUDAGE, disponible auprès de l’Association
Nationale de Fournitures de Soudage (National
Welding Supply Association), 1900 Arch Street,
Philadelphia, PA 19103

GENERAL INFORMATION 6 5/21/99
14. Norme AWSF4.1 de l’Association Américaine de
Soudage,RECOMMANDATIONSDE PRATIQUES
SURESPOUR LAPRÉPARATIONÀLACOUPE ET
AU SOUDAGE DE CONTENEURS ET TUYAUX
AYANT RENFERMÉDES PRODUITS
DANGEREUX , disponible auprès de la American
Welding Society, 550 N.W. LeJeune Rd., Miami, FL
33126
15. Norme ANSI Z88.2, PRATIQUES DE PROTEC-
TION RESPIRATOIRE, disponible auprès de
l’American National Standards Institute, 1430
Broadway, New York, NY 10018

5/21/99 7 GENERAL INFORMATION
1.7 Declaration of Conformity
Manufacturer: Thermal Dynamics Corporation
Address: Industrial Park #2
West Lebanon, New Hampshire 03784
USA
The equipment described in this manual conforms to all applicable aspects and regulations of the ‘Low Voltage Direc-
tive’(European Council Directive 73/23/EEC as amended by Council Directive 93/68/EEC) and to the National
legislation for the enforcement of this Directive.
The equipment described in this manual conforms to all applicable aspects and regulations of the "EMC Directive"
(European Council Directive 89/336/EEC) and to the National legislation for the enforcement of this Directive.
Serialnumbers areunique witheach individualpiece of equipment and detailsdescription, partsused tomanufacture
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 StandardsAssociation) standard C22.2 number 60 forArc welding equipment.
* UL(Underwriters Laboratory) rating 94VO flammability testing for all printed-circuit boards used.
* CENELEC EN50199 EMC Product Standard forArc Welding Equipment.
* ISO/IEC 60974-1 (BS 638-PT10) (EN 60 974-1) (EN50192) (EN50078) applicable to plasma cutting equipment and associ-
ated accessories.
* Extensive product design verification is conducted at the manufacturing facility as part of the routine design and
manufacturing process. This is to ensure the product is safe, when used according to instructions in this manual and
related industry standards, and performs as specified. Rigorous testing is incorporated into the manufacturing
process to ensure the manufactured product meets or exceeds all design specifications.
Thermal Dynamics has been manufacturing products for more than 30 years, and will continue to achieve excellence in our
area of manufacture.
Manufacturers responsible representative: Steve Ward
Director of Operations
ThermadyneUK
ChorleyEngland

GENERAL INFORMATION 8 5/21/99
1.8 Statement of Warranty
LIMITED WARRANTY: Thermal Dynamics®Corporation (hereinafter “Thermal”) warrants that its products will be free of defects in
workmanship or material. Should any failure to conform to this warranty appear within the time period applicable to the Thermal
products as stated below, Thermal shall, upon notification thereof and substantiation that the product has been stored, installed, operated,
and maintained in accordance with Thermal’s specifications, instructions, recommendations and recognized standard industry practice,
and not subject to misuse, repair, neglect, alteration, or accident, correct such defects by suitable repair or replacement, at Thermal’s sole
option, of any components or parts of the product determined by Thermal to be defective.
THIS WARRANTY IS EXCLUSIVE AND IS IN LIEU OF ANY WARRANTY OF MERCHANTABILITY OR FITNESS FOR A
PARTICULAR PURPOSE.
LIMITATION OF LIABILITY: Thermal shall not under any circumstances be liable for special or consequential damages, such as, but
not limited to, damage or loss of purchased or replacement goods, or claims of customers of distributor (hereinafter “Purchaser”) for
service interruption. The remedies of the Purchaser set forth herein are exclusive and the liability of Thermal with respect to any
contract, or anything done in connection therewith such as the performance or breach thereof, or from the manufacture, sale, delivery,
resale, or use of any goods covered by or furnished by Thermal whether arising out of contract, negligence, strict tort, or under any
warranty, or otherwise, shall not, except as expressly provided herein, exceed the price of the goods upon which such liability is based.
THIS WARRANTY BECOMES INVALID IF REPLACEMENT PARTS OR ACCESSORIES ARE USED WHICH MAY IMPAIR THE
SAFETY OR PERFORMANCE OF ANY THERMAL PRODUCT.
THIS WARRANTY IS INVALID IF THE PRODUCT IS SOLD BY NON-AUTHORIZED PERSONS.
The limited warranty periods for Thermal products shall be as follows (with the exception of XL Plus Series, CutMaster 80XL , Cougar
and DRAG-GUN): A maximum of three (3) years from date of sale to an authorized distributor and a maximum of two (2) years from
date of sale by such distributor to the Purchaser, and with the further limitations on such two (2) year period (see chart below).
The limited warranty period for XL Plus Series and CutMaster 80XL shall be as follows: A maximum of four (4) years from date
of sale to an authorized distributor and a maximum of three (3) years from date of sale by such distributor to the Purchaser, and
with the further limitations on such three (3) year period (see chart below).
The limited warranty period for Cougar and DRAG-GUN shall be as follows: Amaximum of two (2) years from date of sale to an
authorized distributor and a maximum of one (1) year from date of sale by such distributor to the Purchaser, and with the further
limitations on such two (2) year period (see chart below).
Parts
XL Plus Series & Parts Parts
PAK Units, Power Supplies CutMaster 80XL Cougar/Drag-Gun All Others Labor
Main Power Magnetics 3 Years 1 Year 2 Years 1 Year
Original Main Power Rectifier 3 Years 1 Year 2 Years 1 Year
Control PC Board 3 Years 1 Year 2 Years 1 Year
All Other Circuits And Components Including, 1 Year 1 Year 1 Year 1 Year
But Not Limited To, Starting Circuit,
Contactors, Relays, Solenoids, Pumps,
Power Switching Semi-Conductors
Consolles, Control Equipment, Heat 1 Year 1 Year 1 Year
Exchanges, And Accessory Equipment
Torch And Leads
Maximizer 300 Torch 1 Year 1 Year
All Other Torches 180 Days 180 Days 180 Days 180 Days
Repair/Replacement Parts 90 Days 90 Days 90 Days None
Warranty repairs or replacement claims under this limited warranty must be submitted by an authorized Thermal Dynamics®repair
facility within thirty (30) days of the repair. No transportation costs of any kind will be paid under this warranty. Transportation
charges to send products to an authorized warranty repair facility shall be the responsibility of the customer. All returned goods shall
be at the customer’s risk and expense. This warranty supersedes all previous Thermal warranties.
Effective May 6, 1999

Operating Manual 0-2682 9 DRAG-GUN Plasma Cutter
2.0 INTRODUCTION2.0 INTRODUCTION
2.0 INTRODUCTION2.0 INTRODUCTION
2.0 INTRODUCTION
Thismanual containsdescriptions, operating instructions
and basic maintenance procedures for the DRAG-GUN
Plasma Cutter. Read this manual thoroughly. A com-
plete understanding of the characteristics and capabili-
ties of this equipment will assure the dependable opera-
tion for which it was designed.
WARNING
Service of this equipment is restricted to Thermal
Dynamics®trainedpersonnel; unqualifiedperson-
nel are strictly cautioned against attempting re-
pairs or adjustments not covered in this manual,
at the risk of personal injury and/or voiding the
Warranty.
2.12.1
2.12.1
2.1 What is Plasma?What is Plasma?
What is Plasma?What is Plasma?
What is Plasma?
A. Plasma Gas FlowA. Plasma Gas Flow
A. Plasma Gas FlowA. Plasma Gas Flow
A. Plasma Gas Flow
Plasma is defined as a gas which has been heated to
an extremely high temperature and ionized so that it
becomes electrically conductive. The plasma arc cut-
ting and gouging process use this plasma to transfer
an electrical arc to the workpiece. The metal to be cut
or removed is melted by the heat of the arc and then
blown away.
In a Plasma Cutting Torch a cool gas (in this case, air)
enters Zone B (refer to Figure 2-1), where a pilot arc
between the electrode and the torch tip heats and ion-
izes the gas. The main cutting arc then transfers to
the workpiece through the column of plasma gas in
Zone C.
By forcing the plasma gas and electric arc through a
small orifice, the torch delivers a high concentration
of heat to a small area. The stiff, constricted plasma
arc is shown in Zone C (Figure 2-1). Direct current
(DC) straight polarity is used for plasma cutting, as
shown in the illustration.
Zone A (Figure 2-1) is used as a secondary gas that
cools the torch. This gas assists the high velocity
plasma gas in blowing the molten metal out of the cut
allowing for a fast, slag-free cut.
;;
;;
;;
;
;
;
;
;
;;
;;
A-00002
Workpiece
Power
Supply
+
_
C
B
A
Figure 2-1 Typical Torch Head Detail
B. Gas DistributionB. Gas Distribution
B. Gas DistributionB. Gas Distribution
B. Gas Distribution
The single gas used is internally split into plasma and
secondary gases. The plasma gas flows into the torch
through the negative lead, through the gas distribu-
tor, around the electrode, and out through the tip ori-
fice. The secondary gas flows down around the out-
side of the torch gas distributor, and out between the
tip and shield cup around the plasma arc.
C. Pilot ArcC. Pilot Arc
C. Pilot ArcC. Pilot Arc
C. Pilot Arc
When the torch is started a pilot arc is established be-
tween the electrode and cutting tip. This pilot arc cre-
ates a path for the main arc to transfer to the work.
D. Capacitive Discharge (CD)D. Capacitive Discharge (CD)
D. Capacitive Discharge (CD)D. Capacitive Discharge (CD)
D. Capacitive Discharge (CD)
Because direct current (DC) alone is not sufficient to
strike and maintain the pilot arc, CD is also used. The
capacitive discharge jumps between the tip and elec-
trode with the DC following. (Note: This may not ap-
ply to all unit models).
E. Main Cutting ArcE. Main Cutting Arc
E. Main Cutting ArcE. Main Cutting Arc
E. Main Cutting Arc
DC power is also used for the main cutting arc. The
negative output is connected to the torch electrode
through the torch lead. The positive output is con-
nected to the workpiece via the work cable and to the
torch through a pilot wire.

DRAG-GUN Plasma Cutter 10 Operating Manual 0-2682
F. InterlocksF. Interlocks
F. InterlocksF. Interlocks
F. Interlocks
Ifsupply pressurefallsbelow minimum requirements,
the lockout circuit will open, shutting off the DC Cir-
cuit. Similarly, the overtemp switch will open if the
unit becomes overheated, and will close again when
the unit cools to an acceptable temperature.
G. Parts-in-Place (PIP)G. Parts-in-Place (PIP)
G. Parts-in-Place (PIP)G. Parts-in-Place (PIP)
G. Parts-in-Place (PIP)
The torch head has replaceable contacts called Parts-
In-Place (PIP). These two contacts are made through
the brass washer inside the shield cup when it is in-
stalled. The torch will fail to operate if these contacts
are not made.
Torch Switch
PIP Pin
PIP Pin Shield Cup
To Control
Cable Wiring
Butt Splice
A-00784
Figure 2-2 Parts-In-Place (PIP) Diagram
H. Duty CycleH. Duty Cycle
H. Duty CycleH. Duty Cycle
H. Duty Cycle
Duty cycle is the percentage of on-time (measured in
minutes) in a 10 minute period in which a system can
be operated, in an environment of a specified tem-
perature.
Exceeding duty cycle ratings will cause the thermal
overload protection circuit to become energized and
shut down output until the unit cools to normal oper-
ating temperature. Continual exceeding of duty cycle
ratingscan causedamage tothe cuttingpower source.
WARNING
When unit shuts down due to thermal overload,
power is still present throughout the entire sys-
tem.
2.2 General Product Description2.2 General Product Description
2.2 General Product Description2.2 General Product Description
2.2 General Product Description
The DRAG-GUN Plasma Cutter is a small, easy-to-use
plasmacutting systemwhich provides12 amp maximum
output and a cut capacity of up to 1/8" (3.2 mm) of most
metals.
Everything you need to start cutting right away is in-
cluded with the DRAG-GUN - power supply with built-
inair compressor,pilot circuitry, allcontrolcircuitry, torch
and work lead (with torch consumable parts installed),
work cable and clamp, primary input cable, extra con-
sumable torch parts, and this instruction manual.
NOTE
TheDRAG-GUN Cutterrequires no assembly.
2.3 Technical Specifications2.3 Technical Specifications
2.3 Technical Specifications2.3 Technical Specifications
2.3 Technical Specifications
A. System SpecificationsA. System Specifications
A. System SpecificationsA. System Specifications
A. System Specifications
System Specifications
InputPower 100 VAC 50Hz, 110 VAC 60Hz, Single Phase
100/110 VAC, 50/60Hz, Single Phase
120VAC ±10%, 50Hz, Single Phase
120VAC ±10%, 60Hz, Single Phase
220VAC ±10%,50Hz, Single Phase
208/230VAC ±10%, 60Hz, Single Phase
OutputPower See subsection 2.3B
Duty Cycle See subsection 2.3B
Maximum OCV 280 VDC
PilotCircuitry CapacitiveDischarge (CD), ConstantDC
Weightwith Leads 55 lbs(24.9 kg)
Power Supply L 16 in. (406 mm)
Dimensions W 9 in. (229 mm)
H 10 in. (254 mm)
WorkCable 15 ft. (4.6 m)
InputPower Cable 6.6 ft. (2 m) minimum
PCH-10 70°
PCH-10 180°
L See subsection 2.4
W See subsection 2.4
Cutting Rating 12 AmpsMax. StraightPolarity
CutCapacity Mostmetals up to 1/8 in. (3.2 mm) max.
Severance Mostmetalsup to 3/16 in.(4.8 mm)
Pierce Rating 1/16 in. (1.6 mm)
Transfer Distance Approx. 1/8 in.(3.2 mm)
GasRequirements Compressed Air (Built-in)
Leads Length 20 ft. (6.1 m)
Torch Style
Torch Dimensions

Operating Manual 0-2682 11 DRAG-GUN Plasma Cutter
B. Input/Output SpecificationsB. Input/Output Specifications
B. Input/Output SpecificationsB. Input/Output Specifications
B. Input/Output Specifications
Model Hz Input Amps
RMS
Output
Amps
(DC)
Output
Voltage
(DC)
Duty
Cycle %
100/110V 50/60 25/24 12 85 30
120V*5022129530
120V 60 20 12 70 30
220V*5013128530
208/230V 60 10 12 78 30
* CE approved.
2.4 Dimensions2.4 Dimensions
2.4 Dimensions2.4 Dimensions
2.4 Dimensions
16.0 in
(406 mm) 9.0 in
(229 mm)
10.0 in.
(254 mm)
A-02004
Figure 2-3 Power Supply Dimensions
8 in (203 mm)
1.1 in (27 mm)
2.9 in
(75 mm)
8.9 in (226 mm)
1.1 in
(27 mm)
A-02385
180˚
70˚
Figure 2-4 Torch Dimensions
3.0 CONTROLS:3.0 CONTROLS:
3.0 CONTROLS:3.0 CONTROLS:
3.0 CONTROLS:
LOCATION & FUNCTIONLOCATION & FUNCTION
LOCATION & FUNCTIONLOCATION & FUNCTION
LOCATION & FUNCTION
A. Front PanelA. Front Panel
A. Front PanelA. Front Panel
A. Front Panel
1. Primary Power ON/OFF Switch
ONposition suppliestheAC powerto activateall sys-
tem control circuits. OFF position deactivates control
circuits. In ON position, this switch is lighted; in the
OFF position, there is no light.
2. Torch & Leads
Torch & leads(includingtorchtip,gas distributor,elec-
trode, shield cup), are factory installed, ready to cut.
The torch handle (Arc ON/OFF) switch controls the
arc. Push the switch to activate the arc; release the
switch to stop the arc.
3. Work Cable & Clamp
The work cable & clamp are factory installed. Attach
the work cable to the workpiece before cutting.
Rear Panel
Primary Input
Power Cable
Front Panel
PCH 10 Torch
& Leads
Work Cable
& Clamp
Power
ON/OFF
Switch
A-02005
Arc ON/OFF
Switch
Figure 3-1 Front & Rear Panel Controls
B. Rear PanelB. Rear Panel
B. Rear PanelB. Rear Panel
B. Rear Panel
1. Primary Input Power Cable

DRAG-GUN Plasma Cutter 12 Operating Manual 0-2682
Thisunit is suppliedwith a primaryinput power cable
capable of handling the input voltage designed for
this unit. If using with an extension cord, be sure cord
meets or exceeds the cord sizes recommended in Fig-
ure 4-1 to maintain proper operation.
4.0 INSTALLATION4.0 INSTALLATION
4.0 INSTALLATION4.0 INSTALLATION
4.0 INSTALLATION
A. Site SelectionA. Site Selection
A. Site SelectionA. Site Selection
A. Site Selection
Select a clean, dry location with good ventilation and ad-
equate working space around all components.
NOTE
Review Important Safety Precautions at the front
of this manual to be sure that the selected location
meets all safety requirements.
The power supply is fan cooled by air flow through the
rear panel. Air flow must not be obstructed. Provide at
least 2 feet (0.61 m) in the rear and at least 6 inches (152
mm) on each side for clearance. Provide sufficient clear-
ance in front of the unit to allow access to the front panel
controls (minimum 6 inches or 152 mm).
CAUTION
Operation without proper air flow will inhibit
proper cooling and reduce duty cycle.
B. Lifting & TransportingB. Lifting & Transporting
B. Lifting & TransportingB. Lifting & Transporting
B. Lifting & Transporting
WARNINGS
Do not touch live electrical parts.
Disconnect input power conductors from de-ener-
gized supply line before moving unit.
WARNINGS
FALLING EQUIPMENT can cause serious per-
sonal injury and equipment damage.
•This unit has a built-in handle on the top end of
case for hand lifting only. The HANDLE is not
for mechanical lifting. Be sure unit is lifted and
transported safely and securely.
•Do Not pull or lift by input power cable, work
cable or torch leads.
•If using a fork lift vehicle, place and secure unit
on a proper skid before transporting.
C. Unpacking ProcedureC. Unpacking Procedure
C. Unpacking ProcedureC. Unpacking Procedure
C. Unpacking Procedure
1. Unpack each item and remove all packing material.
2. Locate packing list(s) and use the list to identify and
account for each item.
3. Inspect each item for possible shipping damage. If
damage is evident, contact your distribution center.
D. Electrical ConnectionsD. Electrical Connections
D. Electrical ConnectionsD. Electrical Connections
D. Electrical Connections
The DRAG-GUN Cutter is available in various models.
VAC is preset at the factory and cannot be changed, ex-
cept with 208/230 VAC units (Refer to subsection 4.0-F
for procedure on changing voltage on unit). Always use
the correct service for your unit configuration (the con-
figuration is noted on the Data Tag on the unit.
WARNING
Make sure power is serviced correctly for your
power supply. The power source must conform to
local and national electric codes.
Always use the correct extension cord size.
1. 100 VAC 50Hz, 110 VAC 60Hz Service
This unit operates on single phase 100VAC (± 10%)
50Hzor 110VAC (± 10%) 60Hz. Servicemust befused
for at least 20 amps.
2. 120 VAC Service (50Hz)
This unit operates on single phase 120VAC (± 10%)
50Hz. Servicemust befused forat least20 amps. This
unit must be wired by customer - directly to discon-
nect or with appropriate plug (refer to subsection 4.0-
E for wire connections).
3. 120 VAC Service (60Hz)
This unit operates on single phase 120VAC (± 10%)
60Hz. Service must be fused for at least 20 amps.
4. 220VAC Service (50Hz)
This unit operates on single phase 220VAC (± 10%)
50Hz. Servicemust befused forat least15 amps. This
unit must be wired by customer - directly to discon-
nect or with appropriate plug(refer to subsection 4.0-
E for wire connections).

Operating Manual 0-2682 13 DRAG-GUN Plasma Cutter
5. 208/230VAC Service (60Hz)
This unit operates on single phase 208 or 230VAC (±
10%) 60Hz. Units are factory set for 230V use. Ser-
vice must be fused for at least 15 amps. For informa-
tion on voltage changeover, call your local distribu-
tor.
6. Extension Cords
Extension cords must meet National Electric Code
Guidelines(and OSHA Guidelines, whereapplicable).
Extension cords must have the same rating as the ser-
vice and must have a three-pronged plug. Refer to
the following table for recommended cord sizes:
110 VAC & 120 VAC Service
Ext. Cord Length Recommended Size (Min.)
Up to 50 ft.(15.2 m) 12 AWG(4 mm2)
Up to100 ft.(30.5 m) 10 AWG(6 mm2)
220 VAC Service
Ext. Cord Length Recommended Size (Min.)
Up to 50 ft. (15.2 m) 14 AWG (2.5 mm2)
Up to100 ft.(30.5 m) 12 AWG(4 mm2)
Figure 4-1 Extension Cord Sizes for Input Voltage
E. Input Power Cable ConnectionsE. Input Power Cable Connections
E. Input Power Cable ConnectionsE. Input Power Cable Connections
E. Input Power Cable Connections
NOTE
The primary input cable is factory installed for one of the
following configurations:
•100VAC 50Hz/110VAC60Hz, singlephase,with
plug
•120VAC 50Hz, single phase, no plug
•120VAC 60Hz, single phase, with plug
•220VAC 50Hz, single phase, no plug
•208/230VAC 60Hz, with plug
For those units where a plug is not installed on the end of
the input power cable, connect the ends of the individual
wires to a customer supplied plug or main disconnect
per the following:
•Black (or brown) wire to Line (AC or Live)
•White (or blue) wire to Neutral (ACC)
•Green (or green-yellow) wire to Ground
F. Input Voltage Selection (For 208/230F. Input Voltage Selection (For 208/230
F. Input Voltage Selection (For 208/230F. Input Voltage Selection (For 208/230
F. Input Voltage Selection (For 208/230
VAC Service Only)VAC Service Only)
VAC Service Only)VAC Service Only)
VAC Service Only)
All 208/230 VAC units are factory set for 230 VAC. To
switch to 208VAC input power operation, contact your
local distributor.
G. Torch Consumable Parts SelectionG. Torch Consumable Parts Selection
G. Torch Consumable Parts SelectionG. Torch Consumable Parts Selection
G. Torch Consumable Parts Selection
Thetorchconsumableparts arefactory installed, asshown
in Figure 4-2.
Torch Head Assembly
Electrode Tip Standard
Shield Cup
Gas
Distributor
PCH-10
A-02007
Figure 4-2 Exploded View of Torch Parts
To change the consumable parts, use the following pro-
cedure:
WARNING
Disconnect primary power at the source before dis-
assembling the power supply or torch.
1. Place the unit Power ON/OFF Switch to the OFF posi-
tion.
CAUTION
Consumable parts may be HOT! Torch parts may
get quite hot during normal operation. Always
wear light cutting gloves when changing torch
parts just after operating the Drag-Gun system.
2. Position the torch with the shield cup facing upward
andunscrewandremovethe shield cupfromthetorch
head assembly (The shield cup holds the tip, gas dis-
tributor, and electrode in place).
3. Remove the tip, gas distributor, and electrode.
4. Install the electrode, gas distributor, and tip. Replace
worn parts, as necessary.
5. Install and hand tighten the shield cup until it is seated
on the torch head. If resistance is felt when installing
the cup, check the threads and parts configuration
before proceeding.
CAUTION
Improper assembly or use of nonstandard torch
parts can cause the torch head to short and may
overheat or damage the torch. Check the torch for
proper assembly and appropriate front end torch
parts.

DRAG-GUN Plasma Cutter 14 Operating Manual 0-2682
H. Work Cable ConnectionH. Work Cable Connection
H. Work Cable ConnectionH. Work Cable Connection
H. Work Cable Connection
Best results will be obtained with a good work cable con-
nection to the workpiece. Check for a solid and clean
work cable connection. The area must be free from rust
and paint.
NOTE
Connect clamp to the main part of the workpiece,
not the part being removed.
Make a solid work cable
connection to the work-
piece or cutting table
A-02022
Figure 4-3 Work Cable Connection
5.0 OPERATION5.0 OPERATION
5.0 OPERATION5.0 OPERATION
5.0 OPERATION
WARNINGS
Disconnect primary power at the source before dis-
assembling the power supply or torch.
Frequently review the Important Safety Precau-
tions(page 1).Be sure the operatoris equippedwith
proper gloves, clothing, eye and ear protection.
Makesureno partof theoperator’s bodycomes into
contact with the workpiece while the torch is acti-
vated.
CAUTION
Sparks from the cutting process can cause damage
tocoated, painted, andother surfacessuch as glass,
plastic and metal.
CAUTION
EXCEEDING DUTY CYCLE RATINGS will
cause the thermal overload protection circuit to
become energized and shut down output until the
unitcools tonormaloperating temperature. CON-
TINUAL EXCEEDING OF DUTY CYCLE
RATINGS can cause damage to the cutting power
source. Do NOT exceed indicated duty cycles.
Sequence of Operation
The following is a typical sequence of
operation for this cutting system:
1 Place the primary
power ON/OFF
switch on front
panel to the ON
position.
AC POWER
indicator light
comes on.
Fan turns on.
2 Wear protective
clothing (refer to
Section 1); activate
torch switch.
Main power relay
closes.
Pilot arc is
established.
3 Move torch within
transfer distance of
workpiece (or start
with tip on the
workpiece).
Main arc transfer.
Pilot arc off.
4 Complete cutting
operation; turn torch
switch off.
Main Arc off.
5 When finished
cutting session,
place the primary
power ON/OFF
switch to the OFF
position.
AC Power
Indicator light off.
Figure 5-1 Sequence of Operation
5.1 Cutting Techniques5.1 Cutting Techniques
5.1 Cutting Techniques5.1 Cutting Techniques
5.1 Cutting Techniques
NOTE
Drag cutting - the torch tip is dragged along the
surface of the workpiece while cutting.
Standoff cutting - the torch tip is elevated from the
workpiece slightly while cutting. Standoff height
should be no more than 1/8" (3.2 mm); place your
other hand underneath to steady.

Operating Manual 0-2682 15 DRAG-GUN Plasma Cutter
The DRAG-GUN is primarily designed for drag cutting,
but in some instances can be used successfully for stand-
off cutting.
A. CuttingA. Cutting
A. CuttingA. Cutting
A. Cutting
1. Thetorchcan be comfortablyheld in onehand or stead-
ied with two hands. Choose the technique that feels
most comfortable and allows good control and move-
ment. Position the index finger or thumb to press the
control switch on the torch handle.
Figure 5-2 Using One Hand to Cut
Figure 5-3 Using Second Hand for Support When
Cutting
2. Hold the torch on a slight angle to the workpiece with
the front of the tip at the edge of the workpiece (or
slightly above) at the point where the cut is to start.
When starting at the edge of the plate, do not pause
at the edge and force the arc to "reach" for the edge of
the metal. Establish the cutting arc as quickly as pos-
sible.
3. With the torch in starting position, press and hold the
torch switch. The pilot arc will come on and remain
on until the cutting arc starts.
NOTE
Limit piloting time to conserve torch parts. Refer
to section 5.5C for more information.
CAUTION
Torch parts may get quite hot during normal op-
eration. Always wear light cutting gloves when
changing torch parts just after operating the Drag-
Gun system.
4. Once on, the main arc remains on as long as the torch
switch is held down, unless the torch is withdrawn
from the work or torch motion is too slow. If the cut-
ting arc is interrupted, the pilot arc comes back on
automatically. (You may not notice a difference).
5. To shut off the torch simply release the control switch.
B. PiercingB. Piercing
B. PiercingB. Piercing
B. Piercing
1. For piercing, position the tip approximately 1/8" (3.2
mm) above the workpiece. Angle the torch slightly to
direct sparks away from the torch tip and operator.
Figure 5-4 Piercing
2. Initiate the pilot arc and lower the tip of the torch until
the main cutting arc transfers, sparks start.

DRAG-GUN Plasma Cutter 16 Operating Manual 0-2682
3. Start the pierce off the cutting line on the scrap piece
or template and then continue the cut onto the cut-
ting line. Hold the torch perpendicular to the
workpiece after the pierce is complete.
4. Clean spatter and scale from the shield cup and the tip
as soon as possible.
5.2 Cut Quality5.2 Cut Quality
5.2 Cut Quality5.2 Cut Quality
5.2 Cut Quality
Cut quality depends heavily on setup and parameters
such as torch alignment with the workpiece, cutting
speed, condition of torch parts, input line voltage, and
operator ability. Cut quality will also vary on different
types of material and thicknesses.
The following table shows the cut quality one can expect
from this equipment for materials with a thickness of
7 gauge or less:
Material
Thickness Mild Steel Stainless Steel Aluminum Galvanized Steel
20 Gauge Excellent Excellent Very Good Excellent
16 Gauge Very Good Excellent Good Excellent
10 Gauge Very Good Good NR Good
7 Gauge Severance Severance NR Severance
Figure 5-5 Cut Characteristics
Excellent - No bevel or dross*
VeryGood- Negligiblebevel; slightdross*(easyto remove)
Good - Slight bevel with some dross* (easy to remove)
Severance- Substantialreductionin cut qualityandspeed
NR - Not Recommended
NOTES
Pierce Capacity is 1/16" (1.59 mm)
* Dross is molten material which is not blown out
of the cut area and resolidifies on the plate. Top
spatter is dross which accumulates on the top sur-
face of the workpiece. Top spatter is normally
caused by a slow torch travel speed or too high of a
torch standoff distance. Dross normally breaks off
quite easily by simply scraping it off with a piece
of metal.
Figure 5-6 Cut Sample
NOTE
A worn tip can also affect the quality of a cut.
Consider replacing the tip if any of the following
indicators are present:
•reduced speed
•voltage drop
•crooked cut
5.3 Recommended Cutting5.3 Recommended Cutting
5.3 Recommended Cutting5.3 Recommended Cutting
5.3 Recommended Cutting
SpeedsSpeeds
SpeedsSpeeds
Speeds
Cutting speed depends on material type, material thick-
ness, and the operator’s ability to accurately follow the
desired cut line. The following factors may have an im-
pact on system performance:
•Torch parts wear
•Line voltage fluctuations
•Torch standoff height
NOTE
This information represents realistic expectations
usingrecommendedpractices andwell-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