Rev. AB Date: October 18, 2007 Manual # 0-4750
Operating Features:
PLASMA
WE APPRECIATE YOUR BUSINESS!
Congratulations on your new Thermal Dynamics product. We are proud
to have you as our customer and will strive to provide you with the best
service and reliability in the industry. This product is backed by our
extensive warranty and world-wide service network. To locate your
nearest distributor or service agency call 1-800-426-1888, or visit us
on the web at www.thermal-dynamics.com.
This Operating Manual has been designed to instruct you on the correct
use and operation of your Thermal Dynamics product. Your satisfaction
with this product and its safe operation is our ultimate concern. Therefore
please take the time to read the entire manual, especially the Safety
Precautions. They will help you to avoid potential hazards that may exist
when working with this product.
YOU ARE IN GOOD COMPANY!
The Brand of Choice for Contractors and Fabricators Worldwide.
Thermal Dynamics is a Global Brand of manual and automation Plasma
Cutting Products for Thermadyne Industries Inc.
We distinguish ourselves from our competition through market-leading,
dependable products that have stood the test of time. We pride ourselves
on technical innovation, competitive prices, excellent delivery, superior
customer service and technical support, together with excellence in sales
and marketing expertise.
Above all, we are committed to developing technologically advanced
products to achieve a safer working environment within the welding
industry.
!
WARNINGS
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 35C
PCH 42 Torch
Operating Manual Number 0-4750
Covered under U.S. Patents
Published by:
Thermadyne Industries, Inc.
82 Benning Street
West Lebanon, New Hampshire, USA 03784
(603) 298-5711
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: October 18, 2007
Record the following information for Warranty purposes:
Where Purchased:____________________________________
Appendix 3: System Schematic 230V Non CE .......................................................................... 5-3
GLOBAL CUSTOMER SERVICE CONTACT INFORMATION .............................. Inside Rear Cover
DRAG-GUN PLUS 35C
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SECTION 1:
GENERAL INFORMATION
1.01Notes, Cautions and Warnings
Throughout this manual, notes, cautions, and warnings are used to
highlight important information. These highlights are categorized as
follows:
NOTE
An operation, procedure, or background information which
requires additional emphasis 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.
1.02Important Safety Precautions
• 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:
• Always read the Material Safety Data Sheets (MSDS) that should
be supplied with the material you are using. These MSDSs will
give you the information regarding the kind and amount of fumes
and gases that may be dangerous to your health.
• For information on how to test for fumes and gases in your
workplace, refer to item 1 in Subsection 1.03, 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 vapors of chlorinated solvents and cleansers. Remove all sources of these vapors.
• This product, when used for welding or cutting, produces fumes
or gases which contain chemicals 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
WARNING
OPERATION AND MAINTENANCE OF PLASMA ARC
EQUIPMENT CAN BE DANGEROUS 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. 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 equipment. Call 1-603-298-5711 or your local
distributor if you have any questions.
GASES AND FUMES
Gases and fumes produced during the plasma cutting process can be
dangerous and hazardous to your health.
• Keep all fumes and gases from the breathing area. Keep your head
out of the welding fume plume.
Manual 0-47501-1GENERAL INFORMATION
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.
• Never touch any parts that are electrically “live” or “hot.”
• Wear dry gloves and clothing. Insulate yourself from the work
piece or other parts of the welding 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, Publications.
• Disconnect power source before performing any service or repairs.
• Read and follow all the instructions in the Operating 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 cannot be removed must be protected.
• Ventilate all flammable or explosive vapors from the workplace.
• Do not cut or weld on containers that may have held combustibles.
DRAG-GUN PLUS 35C
• 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.
NOISE
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.
• 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 damage your eyes and burn your skin if you are not properly
protected.
• 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.
• Wear welding gloves and suitable clothing to protect 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 ProtectiveSuggested
Arc CurrentShade No.Shade No.
Less Than 300*89
300 - 400*912
400 - 800*1014
*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.
1.03Publications
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
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 Superintendent of Documents, U.S. Government Printing Office, Washington, D.C. 20402
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
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
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 CONTAINERS
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, 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
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 obtainable from the National Welding Supply Association, 1900
Arch Street, Philadelphia, PA 19103
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
15. ANSI Standard Z88.2, PRACTICE FOR RESPIRATORY PROTECTION, obtainable from American National Standards Institute, 1430 Broadway, New York, NY 10018
GENERAL INFORMATION1-2Manual 0-4750
DRAG-GUN PLUS 35C
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1.04Note, Attention et Avertissement
Dans ce manuel, les mots “note,” “attention,” et “avertissement” sont
utilisés pour mettre en relief des informations à caractère important.
Ces mises en relief sont classifiées comme suit :
NOTE
Toute opération, procédure ou renseignement général sur
lequel il importe d’insister davantage ou qui contribue à
l’efficacité de fonctionnement du système.
ATTENTION
Toute procédure pouvant résulter l’endommagement du
matériel en cas de non-respect de la procédure en
question.
AVERTISSEMENT
Toute procédure pouvant provoquer des blessures de
l’opérateur ou des autres personnes se trouvant dans la
zone de travail en cas de non-respect de la procédure en
question.
•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.
•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 procédés. Vous devez prendre soin lorsque vous
coupez ou soudez tout métal pouvant contenir un ou plusieurs des
éléments suivants:
•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.
•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 5.
•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.
1.05Precautions De Securite Importantes
AVERTISSEMENTS
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.
Coupant à l’arc au jet de plasma produit de l’énergie
électrique haute tension et des émissions magnétique qui
peuvent interférer la fonction propre d’un “pacemaker”
cardiaque, les appareils auditif, ou autre matériel de santé
electronique. Ceux qui travail près d’une application à
l’arc au jet de plasma devrait consulter leur membre
professionel de médication et le manufacturier de matériel
de santé pour déterminer s’il existe des risques de santé.
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.
•N’utilisez pas le chalumeau au jet de plasma dans une zone où se
trouvent des matières ou des gaz combustibles ou explosifs.
•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.
•Ce produit, dans le procéder de soudage et de coupe, produit de la
fumée ou des gaz pouvant contenir des éléments reconnu dans
L’état de la Californie, qui peuvent causer des défauts de naissance et
le cancer. (La sécurité de santé en Californie et la code sécurité Sec.
25249.5 et seq.)
CHOC ELECTRIQUE
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.
•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.
•Réparez ou remplacez toute pièce usée ou endommagée.
•Prenez des soins particuliers lorsque la zone de travail est humide
ou moite.
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.
Manual 0-47501-3GENERAL INFORMATION
•Montez et maintenez le matériel conformément au Code électrique
5,
national des Etats-Unis. (Voir la page
•Débranchez l’alimentation électrique avant tout travail d’entretien ou
de réparation.
•Lisez et respectez toutes les consignes du Manuel de consignes.
article 9.)
DRAG-GUN PLUS 35C
INCENDIE ET EXPLOSION
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.
•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.
•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.
•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 à moins que le gas hydrogène peut
s’échapper ou se dissiper. Le gas hydrogène accumulé explosera si
enflammé.
BRUIT
Le bruit peut provoquer une perte permanente de l’ouïe. Les procédés
de soudage à l’arc de plasma peuvent provoquer des niveaux sonores
supérieurs aux limites normalement acceptables. Vous dú4ez vous
protéger les oreilles contre les bruits forts afin d’éviter une perte
permanente de l’ouïe.
•Pour protéger votre ouïe contre les bruits forts, portez des tampons
protecteurs et/ou des protections auriculaires. Protégez également
les autres personnes se trouvant sur le lieu de travail.
•Il faut mesurer les niveaux sonores afin d’assurer que les décibels
(le bruit) ne dépassent pas les niveaux sûrs.
•Pour des renseignements sur la manière de tester le bruit, consultez
l’article 1, page 5.
1.06Documents De Reference
Consultez les normes suivantes ou les révisions les plus récentes ayant
été faites à celles-ci pour de plus amples renseignements :
1. OSHA, NORMES DE SÉCURITÉ DU TRAVAIL ET DE PROTECTION
DE LA SANTÉ, 29CFR 1910, disponible auprès du Superintendent
of Documents, U.S. Government Printing Office, Washington, D.C.
20402
2. Norme ANSI Z49.1, LA SÉCURITÉ DES OPÉRATIONS DE COUPE
RAYONS D’ARC DE PLASMA
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.
•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.
•Portez des gants de soudeur et un vêtement protecteur approprié
pour protéger votre peau contre les étincelles et les rayons de l’arc.
•Maintenez votre casque et vos lunettes de protection 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.
•Utilisez la nuance de lentille qui est suggèrée dans le recommendation qui suivent ANSI/ASC Z49.1:
Nuance MinimumNuance Suggerée
Courant ArcProtective NuméroNuméro
Moins de 300*89
300 - 400*912
400 - 800*1014
ET DE SOUDAGE, disponible auprès de la Société Américaine de
Soudage (American Welding Society), 550 N.W. LeJeune Rd., Miami, FL 33126
3. NIOSH, LA SÉCURITÉ ET LA SANTÉ LORS DES OPÉRATIONS DE
COUPE ET DE SOUDAGE À L’ARC ET AU GAZ, disponible auprès
du Superintendent of Documents, U.S. Government Printing Office,
Washington, D.C. 20402
4. Norme ANSI Z87.1, PRATIQUES SURES POUR LA PROTECTION
DES YEUX ET DU VISAGE AU TRAVAIL ET DANS LES ECOLES,
disponible de l’Institut Américain des Normes Nationales (American National Standards Institute), 1430 Broadway, New York, NY
10018
5. Norme ANSI Z41.1, NORMES POUR LES CHAUSSURES
PROTECTRICES, disponible auprès de l’American National Standards Institute, 1430 Broadway, New York, NY 10018
6. Norme ANSI Z49.2, PRÉVENTION DES INCENDIES LORS DE
L’EMPLOI DE PROCÉDÉS DE COUPE ET DE SOUDAGE, disponible
auprès de l’American National Standards Institute, 1430 Broadway,
New York, NY 10018
7. Norme A6.0 de l’Association Américaine du Soudage (AWS), LE
SOUDAGE ET LA COUPE DE CONTENEURS AYANT RENFERMÉ
DES PRODUITS COMBUSTIBLES, disponible auprès de la American Welding Society, 550 N.W. LeJeune Rd., Miami, FL 33126
8. Norme 51 de l’Association Américaine pour la 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
*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.
GENERAL INFORMATION1-4Manual 0-4750
9. Norme 70 de la NFPA, CODE ELECTRIQUE NATIONAL, disponible
auprès de la National Fire Protection Association, Batterymarch
Park, Quincy, MA 02269
10. Norme 51B de la NFPA, LES PROCÉDÉS DE COUPE ET DE
SOUDAGE, disponible auprès de la National Fire Protection Association, Batterymarch Park, Quincy, MA 02269
11. Brochure GCA P-1, LA MANIPULATION SANS RISQUE DES GAZ
COMPRIMÉS EN CYLINDRES, disponible auprès de l’Association
des Gaz Comprimés (Compressed Gas Association), 1235 Jefferson
Davis Highway, Suite 501, Arlington, VA 22202
12. Norme CSA W117.2, CODE DE SÉCURITÉ POUR LE SOUDAGE ET
LA COUPE, disponible auprès de l’Association des Normes
Canadiennes, Standards Sales, 178 Rexdale Boulevard, Rexdale,
Ontario, Canada, M9W 1R3
13. Livret 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
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
DRAG-GUN PLUS 35C
Manual 0-47501-5GENERAL INFORMATION
DRAG-GUN PLUS 35C
1.06Declaration Of Conformity
Manufacturer:Thermadyne 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 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 No. 60 for Arc Welding Equipment.
• CENELEC EN50199 EMC Product Standard for Arc Welding Equipment.
• IEC/EN 60974-1 (EN50192) (EN50078) Arc Welding Equipment Part 1: Welding Power Supplies
• IEC/EN 60974-5 Arc Welding Equipment Part 5: Wire Feeders
• IEC/EN 60974-7 Arc Welding Equipment Part 7: Torches
• 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.
Thermadyne 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
GENERAL INFORMATION1-6Manual 0-4750
DRAG-GUN PLUS 35C
1.05Statement 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 Thermadynes’ 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 S upply Componants
(Parts and Labor)
Torch and Leads
(Parts and Labor)
Drag-Gun Plus2 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 August 28, 2005
Manual 0-47501-7GENERAL INFORMATION
DRAG-GUN PLUS 35C
This Page Left Blank
GENERAL INFORMATION1-8Manual 0-4750
DRAG-GUN PLUS 35C
SECTION 2:
INTRODUCTION
2.01INTRODUCTION
Plasma is a gas which has been heated to an extremely high
temperature and ionized so that it becomes electrically conductive. The plasma arc cutting process uses this plasma to
transfer an electrical arc to the workpiece. The metal to be cut
is melted by the heat of the arc and then blown away.
2.02GENERAL SPECIFICATION
Model DescriptionDrag-Gun Plus
Maximum output35 Amps
Input Voltage & Phase
Frequency50/60Hz
Input power8.3 kVA
Current Input fuse
No Load Voltage330V
Load Voltage94V
Output Current 10 - 35 Amps
Post flow time15 Seconds
Duty cycle @ 104°F /
40° C Ambient
Genuine Cutting
Capacity
Maximum Cutting
Capacity
Dimension (W * D * H)
230V,
Single Phase
U.S. / Canada
40 Amps
All others 20A Slow
Blow Fuse
35% @ 35A @
94vdc
60% @ 27A @
91vdc
100% @ 20A @
88 vdc
3/8"
(9 m m)
1/2"
(12m m )
10.5"x15.5"x11"
(267 mm x 394 mm
x 279 mm )
2.03Features
• COMPACT and LIGHT - Designed for easy transportation.
• ENERGY EFFICIENCY - Advanced technology reduces
power consumption.
• HIGH SPEED GENUINE CUTTING - The constricted
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 metals such
as stainless steel, aluminum, mild steel, copper and their
alloys.
• PILOT ARC IGNITION FROM TORCH - The Pilot Arc ignites the cutting arc.
• 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.
NOTE:
Refer to Local and National Codes or local authority having jurisdiction for proper wiring requirements.
Manual 0-47501-1Introduction
DRAG-GUN PLUS 35C
g
m
peak
g
y
2.04Torch Specifications
10.5 in (266.7 mm)
PCH-42 Torch Rat in
Torch Configuration
Torch Leads Len
Ambient
Temperature
Duty Cycle
Maximum Current
Voltage (V
Arc Striking Voltage12kV
Type of Cooling
Parts-in-Place:
Gas Requirement:
Input
Gas Pressure
Mini mum Gas Fl ow
Direct Contact Hazard
Plasma Power Supply
used with:
th20 feet / 6.1
)500V
Torch Head at 70° to
Ambient air and gas
st ream through torch
Compressed Air Only
200 SCFH (142 lpm)
recommended standoff
1/8 - 3/8" (3-9 mm).
3 in
(76.2 mm)
Art # A-04653
s
Torch Handle
104° F
40° C
100% @ 40 Amps
@ 200 scfh
40 Amps, DC,
Straight Polarity
Built-in Switch
in Torch Head
Single Gas,
65 psi (4.5 bar)
(.45MPa)-
125 psi (8.6 bar)
(.86MPa)
For operation with
exposed tip the
height is
Drag-Gun Plus
2.05System Contents
DescriptionITEMSQ't
Power SourceModel Drag-Gun Plus1
PCH-42, with 20'
Torch Set
Accessories &
Consumables
Input Power
Cable U.S. /
CAN.
Input Power
Cable Outside
of U. S. / CAN.
(6.1 m) leads
Work Cable
Manual
Torch Electrodes
Torch Tips
3 Meter NEMA 10 AWG /
4.8 mm
3 Meter 3x2.5 sq mm
2
with 6 - 50 P
molded plug
rubber wire
1
1
1
2
3
1
1
2.06Transporting 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.
Inroduction1-2Manual 0-4750
DRAG-GUN PLUS 35C
!
SECTION 3:
INSTALLATION
3.01Site Selection
• Place in a clean and dry area.
• Provide adequate ventilation and fresh air supply.
• 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.
3.02Electrical Input Connections
3.03Torch
• 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 to stop, then turn the machine off.
• Always use original manufacturers parts. The use of
aftermarket parts could result in lower parts life and in
unsatisfactory cutting results. Any warranty claims
would be waived.
• Recycle worn parts according to local requirements.
NOTE
• Input voltage is 230V ± 10%, 50/60 Hz single phase.
CAUTION
Check your power source for correct voltage before plugging in or connecting the unit. The primary power source, fuse, and any extension
cords used must conform to local electrical code
and the recommended circuit protection and wiring requirements as specified in Section 2.
Repairs must be done by skilled and qualified
personnel only.
Manual 0-47503-1Installation
This Page Left Blank
Installation3-2Manual 0-4750
DRAG-GUN PLUS 35C
SECTION 4:
OPERATION
4.01Front Control Panel
Overheating
Indicator
"On / Off"
Switch
AC Power
Indicator
Air Vents
Work Lead
Connection
Roll bars not shown for clarity
A. INDICATOR LAMP
35C
Art # A-04720
I
O
1
8
17
19
6
1
14
15
16
12
14
13
10
2
1
20
8
11
115VAC
10
230VAC
Air Error Indicator
Torch Switch
Latch Indicator
20
21
22
18
23
2
4
25
A
Torch Switch
Latch Button
Air Set
Button
Current
Control Knob
Torch
Connection
B. BUTTONS
• Torch Switch Latch Button
For continuous cutting performance. Depress this
button ( turn “On” ) while cutting with the torch.
Release the torch trigger and the torch will continue to
cut without depressing the torch trigger.
• 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 increases
the cutting current and counter clockwise decreases the
cutting current.
20
15
25
30
• Power Indicator - Lights when primary power
switch is turned on.
• TEMPERATURE Indicator - Indicator is normally OFF.
Indicator is ON when internal temperature exceeds nor-
mal limits. Shut unit OFF; 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 operate 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.
10
35
A
Art # 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.
Manual 0-47504-1IOperation
DRAG-GUN PLUS 35C
4.02Preparations For Operating
At the start of each operating session:
WARNING
Disconnect primary power at the source before assembling or disassembling power supply, torch
parts, or torch and leads assemblies.
A. Torch Parts Selection
Check the torch for proper assembly and appropriate torch
parts. The torch parts 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.
Electrode, No. 9-6542
Gas Distributor,
No. 9-6507
Torch Head Assembly
Tip, No. 9-6501
Art # A-04655
Shield Cup, No. 9-6003
• Do not place bare hand on work piece.
1. For drag cutting, 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 below.
Torch
Shield Cup
A-00024
Standoff
Distance 1/8" - 3/8"
3. With the torch in starting position, press and hold the
Torch Trigger. After an initial two second pre-flow, the
pilot arc will come on and remain on until the cutting
arc starts.
B. Torch Connection
Check that the torch is properly connected.
C. Connect Work Cable
Make a clean work cable
connection to the workpiece or cutting table
Work Cable
And Clamp
Art # A-04389
D. Torch Operation
• Wear gloves and protective goggles.
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 gas post-flow will occur. If the Torch Trigger is pushed during the postflow, the cutting arc will restart immediately when the
torch is brought within range of the workpiece.
Operation4-2Manual 0-4750
DRAG-GUN PLUS 35C
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.
UnitStandoff
Drag-Gun PlusDrag(10 ga) 0.135" - (3mm)95.0237576.01900
Drag-Gun PlusDrag(7 ga) 0.179" - (4.5mm)57.0142546.01150
Drag-Gun Plus 1/8" - (3mm)1/4" - (6m m)36.090029.0725
Drag-Gun Plus 1/8" - (3mm)3/8" - (9. 5m m )15.037512.0300
Drag-Gun Plus 1/8" - (3mm)7/16" - (11mm)10.02508.0200
Drag-Gun Plus 1/8" - (3mm)1/2" - ( 12mm )82007175
Material
Thickness
Recommended Travel SpeedMaximum Travel S peed
ipmmm/mipmmm/m
F.Filter replacement numbers
If air flow is diminished it may be due to the two stage filter being dirty. Replace elements as needed. See below.
Qty DescriptionCatalog #
1Two Stage Air Line Filter Kit (Includes Hose & Mounting Screws)9-0397
1Bracket, Filter Mounting (Not shown)9-0396
1Dual Stage Air Filter Assembly9-0395
1Replacement First Stage Cartridge9-1021
1Replacement Second Stage Cartridge9-1022
190 degree 1/4 NPT to 6mm fitting (Not shown, requires two)9-0398
Manual 0-47504-3IOperation
First & Second
Stage
Cartridges
(as marked)
Cycle Drain
Art # A-08251
DRAG-GUN PLUS 35C
SECTION 5:
SERVICE
5.01 Basic Troubleshooting Guide
WARNING
There are extremely dangerous voltage and power
levels present inside this unit. Do not attempt to
diagnose or repair unless you have had training in
power electronics measurement and troubleshooting techniques.
A. Basic Troubleshooting, Overview
This guide covers basic troubleshooting. It is helpful for solving many of the common problems that can arise with this
system. If major complex subassemblies are faulty, the unit
must be returned to an authorized service center for repair.
Follow all instructions as listed and complete each section in
the order presented.
B. Common Symptoms
a. Check all air line connections and fittings.
2. Internal air supply / compressor not working.
a. Return to an authorized service center for repair.
3. Control PCB faulty.
a. Return to an authorized service center for repair.
D. Torch will not pilot when torch switch is activated.
1. Gas pressure too high or too low.
a. There is no adjustment. Return to authorized ser-
vice center for repair.
2. Torch tip, gas distributor, or electrode missing.
a. Turn off power supply. Remove shield cup. Install
missing parts.
3. Worn or faulty torch parts
a. Inspect torch consumable parts. Replace if neces-
sary.
E. Cut performance is diminished.
1. Worn torch parts.
a. Check current setting. Check the Electrode and Tip
for excess wear.
A. Primary power switch is ON, but power indicator
doesn’t light.
1. Improper electrical connection.
a. Check the input cable line & connection.
b. Check that input power is turned on.
c. Check the input power fuse.
2. System was overloaded.
a. Turn Primary Power Switch Off and then On again.
3. Switch may be faulty.
a. Return to an authorized service center for repair.
B. Primary power switch is on, but the cooling fan does
not work.
1. No power / incorrect power to fan or failed fan.
a. Return to an authorized service center for repair.
C. No air flow at torch when air check switch is turned on.
1. Internal connection is disconnected or loose.
Art # A-03026
A-00323
New Electrode
Worn Electrode
Good Tip
Worn Tip
Manual 0-47505-1 SERVICE
DRAG-GUN PLUS 35C
2. Poor Work Lead connection.
a. Check the connection of the Work Lead to the work
piece.
Make a clean work cable
connection to the workpiece or cutting table
Work Cable
And Clamp
Art # A-04389
3. Current sensor or PWM PCB faulty.
a. Return to an authorized service center for repair.
F. Air flows continuously and torch switch latch button
doesn't work properly.
1. Torch Switch Latch button on front panel faulty.
a. Return to an authorized service center for repair.
2. Control PCB faulty.
a. Return to an authorized service center for repair.
SERVICE5-2Manual 0-4750
DRAG-GUN PLUS 35C
Appendix 1: Operating Sequence, Block Diagram
Primary Input Power "On" or Plugged in
Power Supply On/Off Switch "On"
Red Air Indicator
Release Torch Switch
Pilot Arc Ignition (3-5 seconds)
Pilot Arc goes out
Green Power Indicator "On" and Fan is Running
Air Set Switch "On"
Compressor Starts and Air Flows at Torch. Turn Air Set Switch "Off"
Check Torch parts
Air Flow at Torch Stops
Torch Switch "On"
Torch Tip to Work within 3-5 seconds of Pilot Arc start
Start Cutting Operation
alignment. PIP switches
need to be repaired by a
Qualified Technician
Release Torch Switch
More air flow is required
for Torch to Pilot than to
run the power supply.
Compressor not functioning
properly need to be repaired
by a Qualified Technician
No Pilot Arc
YES
Note: The Torch will be very hot! Do not set on or near flammable materials!
Art # A-04694
Manual 0-47506-1 APPENDIX
Cutting Done ?
Torch Switch "Off"
Post Flow of Air, Approximately 15 Seconds Then Stops
Power Supply On/Off Switch "Off"
Green Power Indicator "Off" and Fan Stops
Primary Input Power Switch "Off" or Unplugged
NO
DRAG-GUN PLUS 35C
Appendix 2: Torch Connection
Art # A-04695
Disconnect power and air. Lay unit
on its side. Remove two screws and
access plate.
Europe Building
Chorley North Industrial Park
Chorley, Lancashire
England, PR6 7Bx
Telephone: 44-1257-261755
Fax: 44-1257-224800
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Rawang Integrated Industrial Park - Jln Batu Arang
48000 Rawang Selangor Darul Ehsan
West Malaysia
Telephone: 603+ 6092 2988
Fax : 603+ 6092 1085
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71 Gower Street
Preston, Victoria
Australia, 3072
Telephone: 61-3-9474-7400
Fax: 61-3-9474-7510
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Via Benaco, 3
20098 S. Giuliano
Milan, Italy
Tel: (39) 02-98 80320
Fax: (39) 02-98 281773
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RM 102A
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Shanghai, PR, 200052
Telephone: 86-21-69171135
Fax: 86-21-69171139