Thermal Dynamics PCH-25/38 Instruction Manual

PLASMA CUTTING

POWER SUPPLY

DRAG-GUN™ 38

For 220VAC 50/60Hz

Air Plasma Cutting Systems

( Australia)

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Instruction Manual

December 9, 2002

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Manual No. 0-2729

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™ 38
Instruction Manual Number 0-2729

Published by:
Thermal Dynamics Corporation
82 Benning Street
West Lebanon, New Hampshire, USA 03784
[phone]

www.thermadyne.com

Copyright 1998 by
Thermal Dynamics Corporation

All rights reserved.

Reproduction of this work, in whole or in part, without written per­mission of the publisher is prohibited.

The publisher does not assume and hereby disclaims any liability to
any party for any loss or damage caused by any error or omission in
this Manual, whether such error results from negligence, accident, or
any other cause.

Printed in the United States of America

Publication Date: December 9, 2002

Record the following information for Warranty purposes:

Where Purchased: _______________________________________

Purchase Date: _______________________________________

Power Supply Serial #: _______________________________________

Torch Serial #: _______________________________________

TABLE OF CONTENTS

SECTION 1: GENERAL INFORMATION ...................................................................................... 1

1.01 Notes, Cautions and Warnings........................................................................ 1

1.02 Important Safety Precautions ........................................................................ 1

1.03 Publications ................................................................................................... 2

1.04 Note, Attention et Avertissement ................................................................... 3

1.05 Precautions De Securite Importantes............................................................. 3

1.06 Documents De Reference .............................................................................. 5

1.07 Declaration of Conformity............................................................................... 7

1.08 Statement of W arranty.................................................................................... 8

SECTION 2: INTRODUCTION & DESCRIPTION ......................................................................... 9

2.01 Scope of Manual............................................................................................ 9

2.02 General Description........................................................................................ 9

2.03 Specifications & Design Features .................................................................. 9

2.04 Options And Accessories .............................................................................10

SECTION 3: INSTALLATION PROCEDURES .............................................................................11

3.01 Introduction ...................................................................................................11

3.02 Site Location.................................................................................................11

3.03 Unpacking.....................................................................................................11

3.04 Electrical Connection ....................................................................................11

3.05 Handle Installation ........................................................................................11

SECTION 4: OPERATION...........................................................................................................13

4.01 Introduction ...................................................................................................13

4.02 Functional Overview......................................................................................13

4.03 Operating Controls/Connections....................................................................13

4.04 Getting Started .............................................................................................13

4.05 Torch Consumab le Parts Selection................................................................14

4.06 Cut Quality....................................................................................................15

4.07 Operating the System ...................................................................................16

4.08 Hand Torch Operation....................................................................................17

4.09 Recommended Cutting Speeds .....................................................................17

SECTION 5: CUST OMER/OPERATOR SERVICE .......................................................................19

5.01 Introduction ...................................................................................................19

5.02 General Maintenance ....................................................................................19

5.03 Common Operating Faults.............................................................................20

5.04 Inspection and Replacement Consumable T orch Parts ..................................20

5.05 Troubleshooting Guides .................................................................................21

5.06 Basic Troub leshooting Guide .........................................................................21

5.07 Advanced T roub leshooting Guide...................................................................22

5.08 Troubleshooting Flo w Charts .........................................................................23

5.09 Test Procedures ............................................................................................23

5.10 Torch and Leads Troubleshooting ...................................................................33

5.11 Po wer Supply Component Replacement Procedures .....................................34

5.12 Torch and Leads Replacement Procedure......................................................40

5.13 Servicing Torch Head Components................................................................41

TABLE OF CONTENTS (continued)

SECTION 6: PAR TS LISTS.........................................................................................................45

6.01 Introduction ...................................................................................................45

6.02 Ordering Information......................................................................................45

6.03 Pow er Supply Replacement Parts .................................................................46

6.04 Complete Assembly Replacement ................................................................48

6.05 Torch Replacement Parts ..............................................................................49

6.06 Options and Accessories ..............................................................................50

APPENDIX I: SEQUENCE OF OPERATION BLOCK DIAGRAM ................................................51

APPENDIX II: SYSYTEM SCHEMATIC......................................................................................52

APPENDIX III: CUTTING SPEED CHART..................................................................................54

SECTION 1:

GENERAL INFORMATION

1.01 Notes, 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 backgr ound 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.

1.02 Important Safety Precautions

WARNINGS

OPERATION AND MAINTENANCE OF
PLASMA ARC EQUIPMENT CAN BE DAN­GEROUS AND HAZARDOUS TO YOUR
HEAL TH.

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 1-603­298-5711 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 pr ocesses. Y ou must
be very careful when cutting or welding any met­als which may contain one or more of the follow­ing:

Antimony Chromium Mercury
Arsenic Cobalt Nickel
Barium Copper Selenium
Beryllium Lead Silver
Cadmium Manganese Vanadium

• Always read the Material Safety Data Sheets
(MSDS) that should be supplied with the 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

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.”

Date: No v ember 15, 2001 1 GENERAL INFORMATION

• 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.

• 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. T rapped 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.

• T o protect your hearing from loud noise, wear pr o­tective 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 RA YS

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 pr otected.

• 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 Protective Suggested

Arc Current Shade No. Shade No.

Less Than 300* 8 9

300 - 400* 9 12
400 - 800* 10 14

* These values apply where the actual arc is clearly
seen. Experience has shown that lighter filters
may be used when the arc is hidden by the work­piece.

1.03 Publications

Refer to the following standards or their latest revisions
for more information:

1. OSHA, SAFETY AND HEAL TH 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 OCCU­P ATION AND EDUCA TIONAL EYE AND F ACE 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

GENERAL INFORMATION 2 Date: Nov ember 15, 2001

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 Standar d 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. NFP A 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 W1 17.2, 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 A WSF4.1, RECOM­MENDED SAFE PRACTICES FOR THE PREPARA­TION FOR WELDING AND CUTTING OF CONT AIN­ERS AND PIPING THAT HA VE HELD HAZARDOUS
SUBSTANCES, obtainable fr om the American Welding
Society, 550 N.W. LeJeune Rd, Miami, FL 33126

ATTENTION

Toute procédure pouvant résulter
l’endommagement du matériel en cas de non­respect de la procédur e 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.

1.05 Precautions 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.

15. ANSI Standard Z88.2, PRACTICE FOR RESPIRAT ORY
PROTECTION, obtainable from American National
Standards Institute, 1430 Broadway, New York, NY
10018

1.04 Note, Attention et

Avertissement

Dans ce manuel, les mots “note,” “attention,” et
“avertissement” sont utilisés pour mettre en relief des
informations à caractère important. Ces mises en relief
sont classifiées comme suit :

NOTE

Toute opération, procédure ou renseignement
général sur lequel il importe d’insister davantage
ou qui contribue à l’efficacité de fonctionnement
du système.

Date: No v ember 15, 2001 3 GENERAL INFORMATION

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 votr e distributeur
local si vous avez des questions.

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.

• 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.

• 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.

• 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 différ ents
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 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.

• 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

• Prenez des soins particuliers lorsque la zone de tra­vail est humide ou moite.

• Montez et maintenez le matériel conformément au
Code électrique national des Etats-Unis. (V oir la page
5, article 9.)

• Débranchez l’alimentation électrique avant tout tra­vail d’entretien ou de réparation.

• Lisez et respectez toutes les consignes du Manuel de
consignes.

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.

Les chocs électriques peuvent blesser ou même tuer. Le
procédé au jet de plasma requiert et produit de l’éner gie
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.

GENERAL INFORMATION 4 Date: Nov ember 15, 2001

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 oculair e.

• 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 Minimum Nuance Suggerée

Courant Arc Protective Numéro Numéro

Moins de 300* 8 9

300 - 400* 9 12
400 - 800* 10 14

* Ces valeurs s’appliquent ou l’arc actuel est observé
clairement. L ’experience a démontrer que les filtres
moins foncés peuvent être utilisés quand l’arc est
caché par moiceau de travail.

1.06 Documents 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 TRA VAIL 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 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 TRA­V AIL ET DANS LES ECOLES, disponible de l’Institut
Américain des Normes Nationales (American Na­tional Standards Institute), 1430 Broadway, New Y ork,
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

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. V ous dú4ez vous pr otéger 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.

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 Y ork,
NY 10018

7. Norme A6.0 de l’Association Américaine du Soudage
(AWS), LE SOUDAGE ET LA COUPE DE
CONTENEURS A YANT 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, Batterymar ch Park,
Quincy, MA 02269

Date: No v ember 15, 2001 5 GENERAL INFORMATION

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. B rochure 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 PRÉPARA TION 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, PRA TIQUES DE PROTECTION
RESPIRATOIRE, disponible auprès de l’American
National Standards Institute, 1430 Broadway, New
York, NY 10018

GENERAL INFORMATION 6 Date: Nov ember 15, 2001

1.07 Declaration of Conformity

Manufacturer: Thermal Dynamics Corporation
Address: 82 Benning Street

W est 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.

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 r equirements. Among them are:

* CSA (Canadian Standards Association) standard C22.2 number 60 for Arc welding equipment.

* UL (Underwriters Laboratory) rating 94VO flammability testing for all printed-circuit boar ds used.

* 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 manufac-

turing 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: Giorgio Bassi

Managing Director
Thermal Dynamics Europe
Via rio Fabbiani 8A
40067 Rastignano (BO)
Italy

Date: No v ember 15, 2001 7 GENERAL INFORMATION

1.08 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 stor ed, 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, corr ect such defects by suitable r epair 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
PAR TICULAR 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 Series , 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 Series shall be as follows: A maximum of four (4) years from date
of sale to an authorized distributor and a maximum of three (3) years from date of sale by such distributor to the Purchaser, and
with the further limitations on such three (3) year period (see chart below).

The limited warranty period for Cougar and DRAG-GUN shall be as follows: A maximum of two (2) years from date of sale to an
authorized distributor and a maximum of one (1) year from date of sale by such distributor to the Purchaser, and with the further
limitations on such two (2) year period (see chart below).

Parts

XL Plus & Parts Parts

PAK Units, Power Supplies CutMaster Series Cougar/Drag-Gun All Others Labor

Main Power Magnetics 3 Years 1 Y ear 2 Years 1 Year
Original Main Power Rectifier 3 Y ears 1 Year 2 Years 1 Year
Control PC Board 3 Y ears 1 Year 2 Years 1 Year
All Other Circuits And Components Including, 1 Year 1 Year 1 Y ear 1 Year

But Not Limited To, Starting Circuit,
Contactors, Relays, Solenoids, Pumps,
Power Switching Semi-Conductors

Consoles, Control Equipment, Heat 1 Y ear 1 Year 1 Year
Exchanges, And Accessory Equipment

Torch And Leads

Maximizer 300 Torch 1 Y ear 1 Year
SureLok T orches 1 Y ear 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. T ransportation 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: November 15, 2001

GENERAL INFORMATION 8 Date: Nov ember 15, 2001

SECTION 2:

A-02146

15.5 inches (393.7 mm)

22 inches (558.8 mm) (incl. wheels)

17 inches
(39.37mm)

38.5 inches
(977.9 mm)

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INTRODUCTION &

DESCRIPTION

3. Input Power

208/230 Volts (±10%), Single Phase, 50/60 Hz

4. Output Power

Continuously variable from 12 to 29 Amps maximum.

2.01 Scope of Manual

This manual contains descriptions, operating instructions
and maintenance procedures for the DRAG-GUN 38
Plasma Cutting System. Service of this equipment is re­stricted to properly trained personnel; unqualified per­sonnel are strictly cautioned against attempting repairs
or adjustments not covered in this manual, at the risk of
voiding the W arranty.

Read this manual thoroughly. A complete understand­ing of the characteristics and capabilities of this equip­ment will assure the dependable operation for which it
was designed.

2.02 General Description

The DRAG-GUN 38 Air Plasma Cutting System includes
the following:

• DRAG-GUN 38 Power Supply including built-in air
compressor

• PCH/M 25/38 torch (70°, 90°, or 180°) as purchased,
with 25 ft. (7.6 mm) leads

• 20 ft. (6 m) work cable with clamp

• 9.5 ft. (2.9 m) input power cable

• Wheels and handle

• PCH-25/38 T or ch Spare Parts Kit.

5. OCV

375 VDC

6. Duty Cycle

40%

7. W ork Lead

20 ft. (6 m) with clamp

8. Cut Capacity

3/8 inch (9.5mm) mild steel

9. Pilot Circuitry

Capacitor Discharge (CD), Pulsed DC

10. W eight (with Leads)

90 lbs (41 kg)

11. Power Supply Dimensions

2.03 Specifications & Design
Features

A. DRAG-GUN 38 Power Supply

The following applies to the DRAG-GUN 38 Power Sup­ply only:

1. Controls

• AC POWER ON/OFF Switch

• CURRENT Output Control

2. Panel LED Indicators

AC, GAS, DC, OverTEMP

Manual 0-2729 9 SECTION 2: INTRODUCTION & DESCRIPTION

Figure 2-1 Dimensions

B. PCH-25/38 Torch

10. W eight (without leads)

The following applies to the PCH-25/38 T or ch only:

1. PCH-25/38 T orch Configuration

The PCH-25/38 Torch is available in 70°, 90°, or
180° Hand T orch configurations.

70˚ Hand Torch

90˚ Hand Torch

180˚ Hand Torch

A-02132

1.0 lb (.45 kg)

11. Torch Dimensions

1.06 in (27 mm)

7.98 in (203 mm)

7.31 in (186 mm)

8.90 in (226 mm)

A-02133

2.95 in

(75 mm)

3.13 in

(80 mm)

1.06 in

(27 mm)

70˚

90˚

180˚

Figure 2-2 Torch Configurations

2. T orch Leads Length

25 ft. (7.6 m)

3. Current Rating

30 Amps Max., DC, Straight Polarity

4. Duty Cycle

100%

5. Cutting Range

Maximum cut capacity 3/8" (9.5 mm) on mild steel.

6. Pierce Rating

3/16 inch (4.8 mm)

7. Transfer Distance

1/8 inch (3.2 mm)

8. Torch Parts

Gas Distributor , Electrode, T ip, Shield Cup

2-3 Torch Dimensions

2.04 Options And Accessories

These items can be used to customize a standard system
for a particular application or to further enhance perfor­mance (refer to Section 6 for ordering information).

• Cutting Guide Kit
This device provides precise cutting capability

with a hand torch. The guide fits 70° and 90° hand
torches. The kit includes roller guides and pivots
that attach to the torch.

9. Gas Requirements

Included (compressed air)

SECTION 2: INTRODUCTION & DESCRIPTION 10 Manual 0-2729

SECTION 3:

INSTALLATION

PROCEDURES

(1) Handle - including hex head bolts (4).
(1) Spare Parts Kit - includes:

• Tips (5 each)

• Electrodes (3 each)

3.01 Introduction

This section describes installation of the DRAG-GUN 38
Plasma Cutting System. These instructions apply to the
Power Supply, T orch and Leads Assemblies only; instal­lation procedures for any Options or Accessories are given
in manuals specifically provided for those components.

3.02 Site Location

Select a clean, dry location with good ventilation and ad­equate working space around all components.

CAUTIONS

Operation without proper air flow will inhibit
proper cooling and reduce duty cycle.

To prevent entry of cutting or other metal debris,
the power supply must not be operated in the hori­zontal position. Operate the power supply in the
vertical position only with the handle in the up­right position.

The power supply is cooled by air flow through the end
and side panels. Air flow must not be obstructed. Provide
at least 12 inches (300 mm) clearance on each side. Pro­vide sufficient clearance above unit to allow access to top
panel controls (minimum 12 inches or 300 mm).

• Gas Distributor (1 each)

B. Unpacking Procedure

1. Unpack each item and remove all packing material.

2. Locate the 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 distributor and/or
shipping company before proceeding with system
installation.

C. Removing Skid

The base of the power supply is secured to the skid with
lag screws. Remove the power supply from the skid per
the following procedure:

1. Remove the screws securing the base assembly of

the power supply to the skid.

2. Lift unit from skid and place in proper location.

3.04 Electrical Connection

A. Power Requirements

The unit will operate on single phase 220VAC
±10%, 50/60 Hz. The service must be fused for at
least 25 amps.

NOTE

Review the safety precautions in the front of this
manual to be sure that the location meets all safety
requirements.

3.03 Unpacking

The system is packaged with a carton and packing mate­rial to prevent damage during shipping.

A. System Components

Included with each system is the following:

(1) Power Supply with the following installed:

• PCH-25/38 T o rch and Leads (1 each)

• W ork Cable with Clamp attached (1 each)

• Input Power Cable

(1) Instruction Manual

Manual 0-2729 11 SECTION 3: INSTALLATION PROCEDURES

CAUTION

The primary power source, power cable, and plug
all must conform to local electrical codes and recom­mended circuit protection and wiring requirements.

3.05 Handle Installation

1. Connect the handle to the rear panel of the power sup­ply using four (4) hex head bolts, two on each side.
Tighten secur ely .

SECTION 3: INSTALLATION PR OCEDURES 12 Manual 0-2729

SECTION 4:

OPERATION

4.01 Introduction

This section provides a description of the DRAG-GUN 38
Plasma Cutting System followed by the operating proce­dures.

4. OverTEMP Indicator

Indication is off during normal operation. Yellow light
indicates overheating; unit must be allowed to cool.
The indicator will also flash momentarily if the torch
is shorted.

5 CURRENT Control

Adjusts output current from 12 to 29 amps.

6. TORCH Lead Connection

4.02 Functional Overview

The DRAG-GUN 38 Plasma Cutting System is designed to
cut most metals from gauge thickness up to 3/8 inch (9.5
mm).

4.03 Operating Controls/
Connections

AC

1

GAS

2

DC

345

Figure 4-1 Front Panel Contols and Indicators

A. Top Panel

OVER

TEMP

20

12

29

A-02134

Input for interfacing the torch to the Power Supply .

7. WORK Cable Connection

Input for the work cable on the system.

B. Back Panel

1. AC POWER ON/OFF Switch

ON position supplies AC power to activate all system
circuits. OFF position deactivates circuits.

2. Input Power Cable

Strain relief and input power cable for main AC power
to the unit.

4.04 Getting Started

This procedure should be followed at the beginning of
each shift:

W ARNING

1. AC Indicator

Disconnect primary power at the source before as­sembling or disassembling torch parts, or torch and

Green light indicates AC input power is present in the

leads assemblies.

system when the ON/OFF switch is in ON position.
Indicator will flash and the air compressor will run for
3-5 seconds when first turned on until the power cir­cuits are ready.

2. GAS Indicator

Green light indicates adequate gas pressure (35 psi or

2.5 bar) or greater flowing to the torch when torch is
activated.

3. DC Indicator

Green light indicates adequate DC power output for
main arc when the torch is activated.

A. Torch Par ts

Check the torch for proper assembly. Install proper
torch parts for the desired application (refer to Section

4.05, T orch Consumable Parts Selection).

NOTE

The power supply will not operate unless the torch
shield cup is fully seated against the PIP (Parts in
Place) pins in the torch head.

B. Input Power

1. Make sure the power source meets circuit protection
and wiring requirements. The unit will operate on
single phase 220VAC ±10%, 50/60 Hz. The ser­vice must be fused for at least 25 amps.

Manual 0-2729 13 SECTION 4: OPERATION

CAUTION

The primary power source, power cable, and plug
all must conform to local electrical codes and recom­mended circuit protection and wiring requirements.

2. Plug unit in and close main disconnect switch to
supply primary power to the system.

C. Work Cable

Check for a solid work cable connection to the
workpiece.

D. Purge System

Place the ON/OFF switch to the ON position. Gas will
flow for 3 seconds to purge the torch leads.

E. Current Output Level

Set the desired current output level for the desired op­eration (12 to 29 amps).

F. Ready for Operation

The system is now ready for operation.

NOTE

Refer to Appendix I for a detailed block diagram of
the Sequence of Operation.

4.05 Torch Consumable Parts
Selection

A. Torch Par ts

Electrode

Catalog No. 9-6506

Gas Distributor

Catalog No. 9-6507

Cutting Tip 30A

Catalog No. 9-6501

Standard Shield Cup

Catalog No. 9-6003

A-02147

Figure 4-3 Torch Consumable Parts Selection

B. Changing Parts

To change the torch consumable parts use the following
procedure:

W ARNING

The same torch parts are used for drag or standoff cutting.
Refer to Figure 4-3 for the various torch parts.

SECTION 4: OPERATION 14 Manual 0-2729

Disconnect primary power at the source before chang­ing torch consumables.

NOTE

The tip, gas distributor, and electrode are held in
place by the shield cup. Position the torch with the
shield cup facing upward to prevent these parts from
falling out when the cup is removed.

Standard

Shield Cup

A-00780

Gas

Distributor TipElectrode

Torch Head Assembly

Figure 4-4 Consumable Parts

1. Unscrew and remove the shield cup from the Torch
Head Assembly .

2. Remove the tip, gas distributor , and electrode.

C. Bevel Angle

3. Install the electrode, gas distributor , and tip.

4. Hand tighten the shield cup until it is seated on the
torch head. If resistance is felt when installing the cup,
check the threads before proceeding.

CAUTION

Improper assembly or use of non-standard torch parts
can cause the torch head to short and may overheat
or damage the torch.

4.06 Cut Quality

NOTE

Cut quality depends heavily on set-up and param­eters such as torch standoff, alignment with the work­piece, cutting speed, gas pressures, and operator
ability.

Cut quality requirements differ depending on application.
For instance, nitride build-up and bevel angle may be major
factors when the surface will be welded after cutting.
Dross-free cutting is important when finish cut quality is
desired to avoid a secondary cleaning operation. The fol­lowing cut quality characteristics are illustrated in Figure
4-5:

Kerf Width

Cut Surface
Bevel Angle

Top

Spatter

The angle between the surface of the cut edge and a
plane perpendicular to the surface of the plate. A per­fectly perpendicular cut would result in a 0° bevel angle.

D. Top-Edge Rounding

Rounding on the top edge of a cut due to wearing from
the initial contact of the plasma arc on the workpiece.

E. Bottom Dross Build-up

Molten material which is not blown out of the cut area
and re-solidifies on the plate. Excessive dross may
require secondary clean-up operations after cutting.

F. Kerf Width

The width of the cut (or the width of material removed
during the cut).

G. Top Spatter (Dross)

Top Spatter or dross on the top of the cut caused by
slow travel speed, excess cutting height, or cutting tip
whose orifice has become elongated. Excessive dross
may require secondary clean-up operations after cut­ting.

H. V arious Materials and Thicknesses

The following table defines the cut quality on various
materials and thicknesses:

Description of Cut Characteristics:
Excellent - Minimum bevel (0 - 4°), minimum kerf (2 x tip

orifice diameter), little or no dross, smooth cut
surface.

Top Edge

Rounding

Good - Slight bevel (0 - 10°), slightly wider kerf (2-1/2 x tip

orifice diameter), some dross (easily removed), me­dium-smooth cut surface, slight top edge round-

Dross

Build-Up

Cut Surface

Drag Lines

A-00007

ing.

Figure 4-5 Cut Quality Characteristics

A. Cut Surface

The desired or specified condition (smooth or rough)
of the face of the cut.

B. Nitride Build-Up

Nitride deposits can be left on the surface of the cut
when nitrogen is present in the plasma gas stream.
These buildups may create difficulties if the material is
to be welded after the cutting process.

Manual 0-2729 15 SECTION 4: OPERATION

Cu t Quality on Various M aterials

Type of M aterial

Type

Gas

Air

Material

Thickness

Gage to 3/8 inch

(9 .5 m m )

Carbon

Steel

Good -

E x c e llent

Stainless Aluminum

Good -

E x c e llent

Figure 4-6 Cut Quality

4.07 Operating the System

W ARNINGS

Disconnect primary power at the source before dis­assembling the power supply, torch, or torch leads.

Frequently review the Important Safety Precautions
at the front of this manual. Be sure the operator is
equipped with proper gloves, clothing, eye and ear
protection. Make sure no part of the operator’s
body comes into contact with the workpiece while
the torch is activated.

CAUTION

Sparks from the cutting process can cause damage
to coated, painted, and other surfaces such as glass,
plastic and metal.

Good

A. Sequence of Operation

Sequence of Operation

The following is a typical sequence of operation for this

cutting system:

1 Place the primary power

ON/OFF switch on rear
panel to the ON
position.

2 Wear protective clothing

(refer to S e ctio n 1 o f
Ma n u al) th en a ctiv a te
torch s w itch .

3 M o ve to rch within

transfer d istance of work
piece (or start with tip
on the work piece).

4 Co m p le te c uttin g

opera tio n . T u rn to rch
switch o ff.

Note : T o in itiate cu ttin g
after po st-flo w e n d s w a it
1-2 seconds before
activa ting to rc h sw itc h .

5 When finished cutting

session, place the
primary power ON /OFF
switch to th e O F F
position.

AC POWE R indicator
light com es on.

Fan turns on.
Com p ressor r uns 3-5

seconds.
Main pow er relay closes.

Compressor p re -flo w 1­1/2 to 2 seconds.

Pilot arc is esta b lish ed .

Main arc transfer.
Pilot arc off.

Ma in A rc o ff.
Compressor p o s t-flo w 1 5

seconds.

AC Po w e r I ndicat or light
off. Fa n tu rn s o ff.

NOTE

Handle torch leads with care and protect them from
damage.

Figure 4-7 Sequence of Operation

B. Piloting

Piloting is harder on parts life than actual cutting be­cause the pilot arc is directed from the electrode to the
tip rather than to a workpiece. Whenever possible,
avoid excessive pilot arc time to improve parts life.

C. Torch Standoff

Improper standoff (the distance between the torch tip
and workpiece) can adversely affect tip life as well as
shield cup life. Standoff may also significantly affect
the bevel angle. Reducing standoff will generally re­sult in a reduced bevel angle.

SECTION 4: OPERATION 16 Manual 0-2729

D. Dross

B. Piercing with a Hand Torch

When dross is present on carbon steel, it is commonly
referred to as either “high speed, slow speed, or top
dross”. Dross present on top of the plate is normally
caused by too great a torch to plate distance. "Top
dross" is normally very easy to remove and can often
be wiped off with a welding glove. "Slow speed dross"
is normally present on the bottom edge of the plate. It
can vary from a light to heavy bead, but does not ad­here tightly to the cut edge, and can be easily scraped
off. "High speed dross" usually forms a narrow bead
along the bottom of the cut edge and is very difficult to
remove. When cutting a troublesome steel, it is some­times useful to reduce the cutting speed to produce
"slow speed dross". Any resultant cleanup can be ac­complished by scraping, not grinding.

4.08 Hand Torch Operation

A. Cutting with a Hand Torch

1. The torch can be comfortably held in one hand or

steadied with two hands. Choose the technique
that feels most comfortable and allows good con­trol and movement. Position the index finger or
thumb to press the control switch on the torch
handle.

1. When piercing with a hand torch, angle the torch
slightly so that blowback particles blow away from
the torch tip (and operator) rather than directly back
into it.

2. Complete the pierce off the cutting line and then
continue the cut onto the line. Hold the torch per­pendicular to the workpiece after the pierce is com­plete.

3. Clean spatter and scale from the shield cup and the
tip as soon as possible. Spraying the shield cup
(shield cup only - no other parts) in anti-spatter
compound will minimize the amount of scale
which adheres to it.

4.09 Recommended Cutting
Speeds

Cutting speed depends on material, thickness, and the
operator’s ability to accurately follow the desir ed cut line.
The following factors may have an impact on system per­formance:

• T o rch parts wear

• Air quality

2. For edge starts, hold the torch perpendicular to the
workpiece with the front of the tip on the edge of
the workpiece at the point where the cut is to start.
For piercing, angle the torch slightly to direct sparks
away from the torch until the pierce is complete.

3. For drag cuts keep the torch in contact with the
workpiece. For standoff cutting, hold the torch 1/16

-1/8 in (2-3 mm) from the work.

4. With the tor ch in starting position, press and hold
the control switch. After an initial gas purge, the
pilot arc will come on and remain on until the cut­ting arc starts.

5. Once on, the main arc remains on as long as the
control switch is held down, unless the torch is
withdrawn from the work or torch motion is too
slow. If the cutting arc is interrupted, the pilot arc
comes back on automatically .

6. T o shut off the torch simply r elease the control switch.
When the switch is released a 15 second post-flow
will occur. If the torch switch is closed during the
post-flow , the cutting ar c will restart immediately
when the torch is brought within range of the
workpiece.

• Operator experience

• T or ch standoff height

• Proper work cable connection

• Alloy content of material

NOTE

This information represents realistic expectations
using recommended practices and well maintained
systems. Actual speeds may vary from those shown
in the charts depending on the alloy content of the
selected material.

For complete cutting speed chart data refer to Appendix
III.

Manual 0-2729 17 SECTION 4: OPERATION

SECTION 4: OPERATION 18 Manual 0-2729

SECTION 5:

5.02 General Maintenance

CUSTOMER/OPERATOR

SERVICE

5.01 Introduction

This section describes basic maintenance procedures
that can be performed by operating personnel, a nd
adv anced p roced ures tha t c an be per forme d b y qualified
technicians. No other adjustments or repairs other than
those described are to be attempted.

W ARNINGS

Disconnect primary power at the source before dis­assembling the torch, torch leads, or power supply.

DO NOT touch any internal torch parts while the
AC indicator light on the front panel of the power
supply is ON.

Frequently review the Important Safety Precautions
at the front of this Manual. Be sure the operator is
equipped with proper gloves, clothing, eye and ear
protection. Make sure no part of the operator’ s body
comes into contact with the workpiece while the torch
is activated.

A. Recommended Maintenance Schedule

NOTE

The actual frequency of maintenance may need to be
adjusted according to usage and the environment.

Recommen ded R outine M a intenance

Schedule

D a ily Ope r a tio n a l Che ck s o r Eve r y 6

Cutting H ours:

1. C heck torch consumables. Replace if
damaged.

2. Inspect torch and leads for any cracks
or exposed w ires. Repair or replace
before proceeding.

3. Inspect input power cable for damage
or exposed w ires. Repair or replace
before proceeding.

W eek ly or Ev ery 30 C utting Ho urs:

1. C heck for proper fan operation.

2. V acuum dust and dirt out of the entire
m a ch in e , in c lu d in g th e air filte r.

Every T hre e M o nths:

1. R eplace Filter Dryer Element.

(See Replacem ent Procedures)

Every Six Months:

1. Replace Compressor Air Intake Filte r.

Figure 5-1 Routine Maintenance

CAUTION

Sparks from the cutting process can cause damage
to coated, painted, and other surfaces such as glass,
plastic and metal.

B. Power Supply Cleaning

W ARNINGS

Disconnect primary power at the source before dis­assembling the torch, torch leads, or power supply.

CAUTION

When cleaning care must be taken not to move or
damage the electronic components.

To clean the unit, open the enclosure and use a vacuum
cleaner to remove any accumulated dirt and dust. The
unit should also be wiped clean. If necessary, solvents
that are recommended for cleaning electrical apparatus
may be used.

Manual 0-2729 19 SECTION 5: SER VICE

Do not blow air into the power supply during cleaning.
Blowing air into the unit can cause metal particles to inter­fere with sensitive electrical components and cause dam­age to the unit. Make sure to always blow air out of unit.

b. Torch standoff too high from workpiece
c. AC line too low - reduce output current
d. Work cable disconnected

C. Torch Cleaning

W ARNINGS

Disconnect primary power to the system before dis­assembling the torch, or torch leads. DO NOT touch
any internal torch parts while the AC indicator light
is ON.

NOTE

Handle torch leads with care and protect them from
damage.

Even if precautions are taken to use only clean air with
a torch, eventually the inside of the torch becomes
coated with residue. This buildup can affect the pilot
arc initiation and the overall cut quality of the torch.

The inside of the torch should be cleaned with electri­cal contact cleaner using a cotton swab or soft wet rag.
In severe cases, the torch can be removed from the leads
(refer to Section 5.13, Servicing Torch Head Compo­nents) and cleaned more thoroughly by pouring elec­trical contact cleaner into the torch and blowing it
through with compressed air .

e. Worn torch parts
f. Non-Genuine Manufacturer's T or ch Parts

3. Excessive Dross Formation

a. Cutting speed too slow (bottom dross)
b. Cutting speed too fast (top dross)
c. Torch standoff too high from workpiece
d. Worn torch parts
e. Improper cutting current
f. Non-genuine manufacturer's torch parts

4. Short T orch Parts Life

a. Moisture in air source
b. Exceeding system capability (material too thick)
c. Excessive pilot arc time
d. Air flow too low
e. Improperly assembled torch
f. Output current too high
g. T or ch tip contacting workpiece

CAUTION

Dry the torch thoroughly before reinstalling.

5.03 Common Operating Faults

The following lists the more common cutting faults and
what is the possible cause:

1. Insufficient Penetration

a. Cutting speed too fast
b. T or ch tilted too much
c. Metal too thick
d. Worn torch parts
e. Cutting current too low
f. Non-genuine manufacturer's torch parts
g. Low gas flow

2. Main Arc Extinguishes

a. Cutting speed too slow or cutting current too high

h. Damaged or loose torch head components
i. Non-genuine manufacturer's torch parts

5. Poor Pilot Starting

a. Non-genuine manufacturer's torch parts
b. Worn torch parts
c. Damaged or loose torch head parts

5.04 Inspection and Replacement
Consumable Torch Parts

W ARNINGS

Disconnect primary power to the system before dis­assembling the torch or torch leads.

DO NOT touch any internal torch parts while the
AC indicator light on the front panel of the Power
Supply is ON.

SECTION 5: SER VICE 20 Manual 0-2729

Remove the consumable torch parts per the following pro­cedure:

NOTE

The tip, gas distributor, and electrode are held in
place by the shield cup. Position the torch with the
shield cup facing upward to prevent these parts from
falling out when the cup is removed.

1. Unscrew and remove the shield cup from the torch.

NOTE

New Electrode

Worn Electrode

A-01270

Figure 5-4 Electrode Wear

Slag built up on the shield cup that cannot be re­moved may effect the performance of the system.

Standard

Shield Cup

A-00780

Gas

Distributor TipElectrode

Torch Head Assembly

Figure 5-2 Consumable Parts

2. Inspect the cup for damage. Wipe it clean or r eplace if
damaged.

3. Remove the tip. Check for excessive wear (indicated by
an elongated or oversized orifice). Replace the tip if
necessary.

Good Tip

Worn Tip

6. Install the electrode, gas distributor , tip and shield cup.

7. Hand tighten the shield cup until it is seated on the
torch head. If resistance is felt when installing the cup,
check the threads before proceeding.

CAUTION

Improper assembly or use of non-standard torch parts
can cause the torch head to short and may overheat
or damage the torch.

5.05 Troubleshooting Guides

There are two Troubleshooting Guides, Basic and Ad­vanced, provided in this Instruction Manual. The Basic
T roubleshooting Guide uses symptom, cause, and remedy
for fault isolation. The Advanced Troubleshooting Guide
uses Flow Charts and test procedures for fault isolation.

Basic troubleshooting is limited to non-power checks and
external Power Supply faults. Advanced troubleshooting
requires fault isolation to the Power Supply or T or ch, Power
Supply disassembly, voltage measurements and major
component replacement.

A-00323

Figure 5-3 Tip Wear

4. Remove the gas distributor . Check for excessive wear ,
plugged gas slots, or discoloration. Replace if neces­sary.

5. Remove the electrode. Refer to Figure 5-4 and check the
face of the electrode for excessive wear . The face of the
electrode should not be recessed more than 0.10 inch
(2.5 mm). If it is worn beyond this point it must be
replaced.

Manual 0-2729 21 SECTION 5: SER VICE

The guides are as follows:

Section 5.06 - Basic T roubleshooting Guide
Section 5.07 - Advanced T roubleshooting Guide

Depending on the level of repair to be done, refer to the
desired troubleshooting guide.

5.06 Basic Troubleshooting Guide

A. General

Basic troubleshooting of the DRAG-GUN 38 Plasma Cut­ting System can be performed without special equipment
or knowledge, and without opening the enclosure.

This basic troubleshooting guide covers input power , gas
supply , and tor ch problems.

For problems not covered here, refer to the Advanced
Troubleshooting Guide or contact your authorized dis­tributor .

If a product must be returned for service, contact your au­thorized distributor . Materials returned to the Manufac­turer without proper authorization will not be accepted.

B. How to Use This Guide

The following information is a guide to help determine the
most likely causes for various symptoms.

This guide is set up in the following manner:

X. Symptom (Bold T ype)

Any Special Instructions (T ext T ype)

1. Cause (Italic T ype)

D. AC indicator ON, Over TEMP indicator dark, no gas

flow when torch switch pressed.

1. Shield cup not properly installed on torch.

a. Check that shield cup is fully seated against torch

head.

2. Faulty T or ch Switch or PIP Assembly in torch holder .

a. Refer to Servicing T orch Head Components, Sec-

tion 5.13.

3. Faulty Main PC Board

a. Replace Power Supply.

E. AC indicator ON, Over TEMP indicator dark, GAS

indicator ON, gas flows, DC indicator ON. T orch
does not pilot.

a. Check/Remedy (T ext T ype)

Locate your symptom, check the causes (easiest listed first)
then remedies. Repair as needed being sure to verify that
the unit is fully operational after any repairs.

A. AC Indicator OFF , Fans do not operate.

1. ON/OFF Switch not on.

a. T urn ON/OFF Switch to ON position.

2. No power from wall circuit.

a. Reset breaker or replace fuse. For 220 VAC use

30A service or 20A if output is reduced to 20A.

B. T emperature indicator on.

1. Unit is overheated due to exceeding duty cycle.

a. Allow to cool, reduce duty cycle.

2. Unit is overheated due to obstructed air flow .

b. Provide at least 12 inch clearance around unit.
c. Clean unit (see Section 5.02).

3. Shorted torch. TEMP Indicator lights momentarily then
unit stops cutting or piloting.

a. Check for proper torch parts assembly per Sec-

tion 5.04 or shorted torch head per Section 5.10.

1. Faulty torch parts

a. Inspect torch parts and replace if necessary per

Section 5.04.

2. Open torch leads

a. Check torch per test procedure 5.10-C.

3. Faulty Pilot Resistor

a. Check pilot Resistor (R1) across wires #9 & #10

for 15 ohms. If 15 ohms is present, replace Power
Supply . If not present, r eplace Plot Resistor .

F . Torch pilots but does not cut.

1. Work lead not connected.

a. Make sure work lead is connected securely to

bare metal.

2. AC input power too low

a. Use shortest service to breaker panel possible.

Refer to Section 3.04 for input power cable re­quirements.

5.07 Advanced Troubleshooting
Guide

A. General

4. Input voltage too high.

a. Check voltage at wall outlet, must not exceed 253

V AC (230 +10%).

C. AC Indicator blinks for 4 seconds when power is

turned on but there is no gas flow .

1. Compressor not operating.

a. Check Compressor per test procedure 5.09-F.

SECTION 5: SER VICE 22 Manual 0-2729

The troubleshooting covered in this Instruction Manual
requires Power Supply disassembly and live measure­ments. It is helpful for solving the common problems that
may arise with the Power Supply Assembly.

W ARNING

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.

If major complex subassemblies are faulty, the assembly
must be returned to an authorized service center for repair .

Follow all instructions as listed and complete each in the
order presented.

The guide has two sections as follows:

Section 5.08 - T roubleshooting Flow Charts
Section 5.09 - Test Procedures

Specific test procedures have been grouped together, and
are referenced by the flowcharts.

B. How to Use This Guide

The following information is a guide to help the Service
Technician determine the most likely causes for various
failures. This guide is set up in the following manner:

1. Use flowchart(s) to isolate problem to possible circuit(s).

2. Perform the test procedures as required as noted on
flowcharts.

3. Repair as needed being sure to verify that unit is fully
operational after any repairs.

5.08 Troubleshooting Flow Charts

The following pages are flow charts to be used to isolate
problems in the Plasma Cutting System.

5.09 Test Procedures

The checks in these test procedures are all made with the
main power disconnected.

Manual 0-2729 23 SECTION 5: SER VICE

AC Indicator OFF

on Front Panel

Troubleshooting Chart #1: Main Power

System

Operates

No

Properly?

Yes

Faulty AC Indicator

Replace Power Supply

AC POWER

Switch ON?

No

Place AC POWER

Switch to ON

Place Main Power

Disconnect to ON

Yes

Plugged In?

Yes

Check Main

Power Disconnect

Main Power

No Yes

Disconnect ON?

Power Cable

No

Connect AC Power

Input Cable to

AC Source

Check Main Disconnect

Power Line Fuse

Install Proper

Fuse

No

Power Line Fuses For

Proper Amperage

Unplug Power Supply

From Main Power Source

Proceed to Chart #2B

SECTION 5: SER VICE 24 Manual 0-2729

Check Main Disconnect

Yes

Yes

Main Power

Line Fuse

Replaced

Once?

No

Replace Main

Power Line Fuse

No

Line FuseOkay?

Yes

Unplug Power Supply

From Main Power Source

Proceed to Chart #2A

Main Power

Troubleshooting Chart #2: Input Power Checks

A

Check 1/2A Fuse (F1) on the

Heatsink/PC Board Assembly

1/2A Fuse

Checks Okay?

Yes

B

Check Input Diode Bridge on

Heatsink/PC Board Assembly

Per Section 5.09 A

Diode Bridge

Checks Okay?

No

Yes

(See Note)

NOTE
This Condition could also result if the input
line voltage was low or using an extension
cable and the user was using a high standoff
while cutting.

Check FET Assemblies on

Heatsink/PC Board Assembly

Per Section 5.09 B

FET Assemblies

No

Check Okay?

No

Unplug J2 Connector on the

Heatsink/PC Board Assembly

Replace Fuse (F1) and

Apply AC Power to the

Power Supply per

Section 5.11F

AC Indicator
Comes ON?

Yes

Replace

Starting Relay (K3)

per Section 5.11H

No

Replace

Power Supply

No

Unit

Operates

Properly?

Yes

Yes

Check Capacitor

PC Board Assembly on

Heatsink/PC Board Assembly

Per Section 5.09C

Capacitor PC

Board Assembly

Checks Okay?

Yes

Check unit for

proper operation

Replace Cover

and follow

operating procedures

No

Replace Capacitor

PCB per

Section 5.11N

Manual 0-2729 25 SECTION 5: SER VICE

Troubleshooting Chart #3: Temperature Indicator Checks

AC and Gas Indicators are ON

Temperature Indicator Either

ON or Blinks Once

When Torch Switch (TS) is Pressed

No

Fan

Operating?

Yes

Temperature
Indicator Still

ON?

No

Temp Indicator

ON Steady

When TS is

Pressed

No

Duty Cycle

Exceeded?

Use Proper

Operating Procedures

Yes

No

(blinks once)

Yes

No

Allow Power Supply

To Cool

Temperature

Indicator ON?

Disconnect Pilot Wire
and retry torch switch

TEMP LED

Blinks

No

Yes

Replace

Power Supply

Yes

SECTION 5: SER VICE 26 Manual 0-2729

Replace Power Supply

Assembly

Yes

Check Torch & Leads

per Section 5.10 A & B

Troubleshooting Chart #4: Resistor (R3) Checks

AC and Gas Indicators are ON

DC Indicator Blinks or Momentary ON

When Torch Switch is pressed

Check Resistor (R3) Assembly

per Section 5.09 E

Resistor R3

Check Okay?

Yes

Replace Power Supply

No

Replace Resistor (R3)

Assembly

per Section 5.11.P

Manual 0-2729 27 SECTION 5: SER VICE

Troubleshooting Chart #5: Faulty Torch

A

AC and Gas Indicators are ON

DC Indicator OFF

When Torch Switch is Depressed

Check Torch And Leads

per Section 5.10 A&B

Torch

Check Correct?

No

Replace Torch

B

AC Indicator ON

No GAS Flow When Torch

Switch is Depressed

Check Torch Switch

Compressor

operates

4 seconds at

power ON?

Yes

per Section 5.10B

No

Check Troubleshooting

per Section 5.06 C

Yes

Replace Power Supply

SECTION 5: SER VICE 28 Manual 0-2729

Troubleshooting Chart #6: Faulty Current Control

CURRENT Control Knob Turns Completely

Around And Doesn't Stop At Minimum Or

Maximum Positions

Check Shaft Of CURRENT

Control Is Not Loose Or
Broken From PC Board

Is Control

Shaft Okay?

Yes

Secure or Replace

CURRENT Control

Knob per Section 5.11C

No

Replace Power Supply

Manual 0-2729 29 SECTION 5: SER VICE

W ARNINGS

Disconnect primary power to the system at the source
before opening the Power Supply.

A. Checking Input Diode Bridge

T esting of diode modules requires a digital volt/ohm meter
that has a diode test scale or an analog VOM with 1X or
X10 scale. Remember that even if the diode module checks
good, it may still be bad. If in doubt, replace the Power
Supply.

1. Remove the left Side Panel of the Power Supply per

Section 5.11-D.

2. Locate the Input diode Bridge (outside edge of

Heatsink). Make a visual check of the Input Diode
Bridge for damage.

A-02135

6. Connect the volt/ohm meter positive lead to the
anode of the diode and the negative lead to the cath­ode of the diode for forward bias testing. A prop­erly functioning diode will conduct in the forward
bias direction and indicate between 0.3 to 0.9 volts.

7. Reverse the meter leads across the diode for reverse
bias testing. A properly functioning diode will block
in the reverse bias direction and depending on the
meter function will indicate an open or "OL".

AC

AC

( )

( )

(+)

AC

(+)

Input Diode

Location

Figure 5-5 Input Diode Location

3. Set digital volt/ohm meter to diode test scale.

4. Using the Figures for each test, check each diode in
the module. Each diode must be checked in for­ward bias (plus to negative) and reverse bias (nega­tive to plus) direction.

5. Input Rectifier should be isolated for further testing.
Label and disconnect wires attached to Input Rec­tifier.

AC

A-01274

Figure 5-6 Input Diode Diagram

A-00307

0.75

Forward Bias

Diode Conducting

Diode Test Symbol

Anode

Cathode

VR

+

COM

_

A

Figure 5-7 Testing Diode Forward Bias

8. For an analog meter, use the meter set on RX1 or
RX10 scale to measure the resistance of each diode
in both directions. The readings should differ by at
least a factor of 10. If they do not differ (either high
or low in both directions) then replace the diode
module.

SECTION 5: SER VICE 30 Manual 0-2729

9. If Input Rectifier tests out okay , r eplace leads.

10. If the diode has visible damage or is shorted, the
diode is faulty . Replace the Power Supply.

A-00306

OL

Mounting Standoffs

Capacitor

PC Board

Reverse Bias

Diode Not Conducting

Cathode

Anode

+

VR

COM

_

A

Figure 5-8 Testing Diode Reverse Bias

B. Checking FET Assemblies

1. Remove the top Panel Cover of the Power Supply
per subsection 5.11-E.

2. Using an ohmmeter set on the Rx1 scale make the
following checks:

Wire #3

(N)

(-) Terminal

Figure 5-9 FET Assembly Check

a. Measure from Capacitor PC Board (+) to Main

Transformer Wire #3. If the meter indicates a
short the FET Assemblies are faulty.

b. Measure from Capacitor PC Board (-) to Main

Transformer Wire #3. If the meter indicates a
short the FET Assemblies are faulty.

(+) Terminal

A-02122

Manual 0-2729 31 SECTION 5: SER VICE

C. Checking Capacitor PC Board

D. Checking Pilot Return

1. Remove the top Panel Cover of the Power Supply
per subsection 5.11-E.

Capacitor
PC Board

A-02127

1. Remove the right SidePanel of the Power Supply per
subsection 5.11-D.

2. Using a pair of needle nose pliers remove the red
Pilot Return Lead wire from terminal E14 on the
Main PC Board.

A-02123

Figure 5-10 Capacitor PC Board Location

2. Using an ohmmeter set on the Rx1 scale make the
following check:

a. Measure from Capacitor PC Board (+) to (-) (see

Figure 5-9) terminals. The meter should increase
in resistance as the capacitors charge. Reverse
probes and test again. Resistance should de­crease and then increase as the capacitor dis­charges and charges. If meter shows short, open
or does not change, replace Capacitor PC Board.

Pilot Return

Lead

Figure 5-11 Pilot Return Lead Location

3. Using an ohmmeter set on the Rx1 scale make the
following checks:

a. Measure from the T orch Block and the end of the

Pilot Return wire. The meter should indicate
an open.

b. Measure from Pilot Return wire to torch tip.

Should measure short (less than 1 ohm).

4. Reinstall the wire back onto the E14 terminal.

SECTION 5: SER VICE 32 Manual 0-2729

E. Checking Resistor R3 (11k ohms)

1. Remove the side Panel Cover of Power Supply per
subsection 5.11-D.

If power is present and Compressor is hum­ming, check Starting Capacitor C1.

NOTE

2. Using a pair of needle nose pliers, remove the red
wire from the terminal on Resistor R3.

A-02128

Resistor R3

Figure 5-12 Resistor R3 Location

Capacitors can be fail shorted, open or reduced in
capacitance.

A short may be detected with an ohmeter . Remove
leads from one of the Capacitor's terminals then
measure across the terminals. If it reads a low
resistance(less than a few thousand ohms) then it is
shorted and should be replaced.

T o check for an open or reduced capacitance r equires
a capacitance meter . If one is not available, try sub­stituting a good Capacitor . If the motor starts using
the good Capacitor, the original Capacitor was
faulty.

4. Check Compressor for Overheating
a. If the unit has just been operated for an extended

time, the Compressor may be overheated. W ait
for it to cool. If it is not overheated, the Compres­sor is defective.

5. Check Compressor for Voltage
a. Test for 208 or 230VAC (during the 4 seconds

after power on) between wires #19 and #23 (on
TB1).

3. Using an ohmmeter set on the Rx100 scale make the
following check:

a. Measure the Resistance of the Resistor R3. The

meter should indicate 11K ohms.

4. Reinstall the wire back onto the Resistor terminal.

5. Check that the other ends of both red and blue wires
are properly attached.

F. Checking Compressor

1. Remove the top Panel cover from Power Supply per
subsection 5.11-E.

2. Check Compressor for Blockage.

a. Check to see if Compressor is humming. If Com-

pressor is humming, the air flow may be blocked.
Remove the Compressor's inlet filter and output
hose. Remove the blockage (clogged filter , torch
leads, torch head, clogged torch tip, etc.) .

3. Check Starting Capacitor

a. Test for 230 or 208VAC (during the 4 seconds

after power on) between wires #19 and #23 (on
TB1).

If voltage is not present, check for 24 VAC on
K3's coil (from J2-3 & 4 on the main P CB). The
K3 Relay controls the 220V to the Compressor .

If 24 V AC is present, K3 is defective.
If the 24 V AC is not pr esent, check that J2 con-

nector is plugged into the main PC Board. If J2
is connected properly, the main PCB is defec­tive - return the unit for service.

5.10 Torch and Leads
Troubleshooting

W ARNINGS

Disconnect primary power to the system before dis­assembling the torch or torch leads.

DO NOT touch any internal torch parts while the
AC indicator light on the front panel of the Power
Supply is ON.

Manual 0-2729 33 SECTION 5: SER VICE

A. Checking Center Insulator

1. Remove the shield cup, tip, gas distributor , and elec­trode from the torch.

2. Disconnect the torch leads from the power supply to
isolate the torch from power supply circuits.

3. Using an ohmmeter (set to 10K or higher), check for
continuity between the positive and negative torch
fittings. (Red Pilot Return wire and Gas Fitting).

If there is continuity between the two torch fittings
proceed to Step 4.

4. Remove the torch head from the leads (refer to Sec­tion 5.13, Servicing T orch Head Components).

5. With the torch head disconnected from the leads,
measure the resistance between negative cathode
body of the torch head (where the electrode seats)
and the positive anode body of the torch head (the
outer threads where the shield cup seats).

Infinite resistance (no continuity) should be mea­sured between negative and positive sections of
the torch head.

If any current can flow through the center insula­tor, the tor ch head is faulty and must be replaced.

If the torch head is okay , the problem is in the leads
assembly . Pr oceed to Step 6.

6. Repeat measurement of step 3 above.

If continuity is found, replace the torch leads.
If no continuity is found, the torch leads are okay

and the problem was in the way the components
were assembled. Proceed to Step 7.

7. Carefully reassemble the components and recheck
the completed assembly per Step 3 to confirm that
the components have been properly assembled.

This completes the checks for the proper operation of the
center insulator of the torch head and leads.

B. Checking Torch Switch

1. Remove right Side Panel of Power Supply per sub­section 5.11-D.

Torch Switch Connector

(Black & WhiteWires)

Torch Lead

Pilot Wire

(Red)

A-02124

Figure 5-13 Torch Switch Connector Location

3. Using an ohmmeter set on the Rx1 scale make the
following check:

a. Measure across the Torch Switch Wiring con-

nector , black to white. The meter should indi­cate an open when the Torch Switch is not
pressed. When pressed the meter should indi­cate a short.

NOTE

The Shield Cup must be installed to complete the
circuit through the Parts-In-Place (PIP) contacts.

4. Reinstall the Torch Switch Wiring connector back
onto the Main PC Board connector .

C. Checking Torch Leads

1. Check continuity between red wire on E14 and tip.

2. Remove tip, measure for continuity between the elec­trode and TB1 on torch block.

If either one is open, replace torch leads.

2. Disconnect the Torch Switch Wire connector from
the Main PC Board at J3 (black and white wires).

SECTION 5: SER VICE 34 Manual 0-2729

5.11 Power Supply Component
Replacement Procedures

NOTES

C. Current Control Knob Replacement

1. Using a small blade screwdriver, loosen the screw
securing the knob to the CURRENT Control adjust­ment shaft.

Refer to Section 6, Parts Lists, for replacement parts
and ordering information.

Refer to Exploded V iew for r eplacement parts and
parts orientation.

W ARNING

Disconnect primary power to the system before dis­assembling the torch, leads, or power supply.

A. Handle Replacement

1. Remove four screws attaching the handle to the rear
panel of the Power Supply .

2. Install replacement handle.

B. Filter Dryer Element Replacement

1. Locate the Filter Dryer on the exterior of the Rear
Panel of the Power Supply .

2. Remove Filter Dryer metal bowl by turning the bowl
counter-clockwise .

3. Remove Element Assembly from plastic bell by turn­ing counter-clockwise.

4. Disassemble Element Assembly, as shown in Fig­ure 5-14, and remove Element.

5. Install replacement Element by reversing above steps.

2. T urn the CURRENT Control adjustment shaft fully
clockwise. This will represent the maximum posi­tion.

3. Slide the replacement knob onto the shaft.

4. Turn the knob so that the line on the knob points
towards the wide end of the current control sym­bol.

5. Tighten the scr ew in the knob to secure the knob to
the shaft.

6. T urn the knob fully counterclockwise.

7. The line should now line up with beginning of the
CURRENT Control adjustment symbol.

8. Adjust the knob as required to align the minimum
and maximum reference points.

D. Side Panel Cover Removal (Left or Right)

1. Remove the six screws securing side panel to unit.

2. Remove side panel from Power Supply, being care­ful not to strain ground wire connection to panel.

3. Rest cover beside Power Supply .

NOTE

T o replace panel, disconnect gr ound wire. Connect
ground wire to replacement panel and reverse above
steps.

Filter Dryer

Figure 5-14 Filter Dryer Assembly

Manual 0-2729 35 SECTION 5: SER VICE

A-02136

Element

Plastic Bell

E. Top Panel Cover Removal

NOTE

The right side panel must be removed first to pro­vide internal access to the torch and work cable con­nections.

1. Remove Current Knob per paragraph 'C' above.

2. Remove right side panel per paragraph 'D' above.

3. Disconnect torch lead from torch block .

9. Disconnect ground wire connection from top panel
cover .

10. Rest cover beside Power Supply .

NOTE

T o r eplace top panel, reverse steps.

F. Fuse Replacement

NOTE

Removal of the Fuse requires the use of needlenose
pliers.

Torch Switch Connector

(Black & WhiteWires)

Torch Lead

Pilot Wire

(Red)

A-02124

Figure 5-15 Torch Connections

CAUTION

DO NOT overtorque the nuts on the terminals as
the PC Board may be damaged.

4. Disconnect red pilot wire from Main PC Board.

5. Disconnect T orch Switch connector (black and white
wires).

1. Remove the left side panel per paragraph 'D' above.

2. Locate the fuse inside the unit on the left side of the
main PC Board.

3. Using a pair of needle nose pliers, carefully remove
the Fuse.

4. Replace the Fuse (F1) with the properly rated and
type fuse only. Fuse F1, is a 1/2 amp 250V fuse.

5. Reinstall left side panel.

G. AC Power ON/OFF Switch Replacement

W ARNING

Disconnect primary power at source before disas­sembling the power supply.

1. Remove left side panel per paragraph 'D' above.

2. Remove five wires connected to Switch.

3. Remove the two nuts securing ON/OFF Switch to
the inside of panel.

4. Note orientation of Switch then remove Switch from
unit.

5. Install the replacement ON/OFF Switch by revers­ing the above steps, connecting wires as shown
below:

6. Disconnect W ork Cable fr om Main PCB by remov­ing nut.

7. Remove 7 screws securing top panel to unit.

8. Remove cover from unit, being careful not to strain
the ground wire connection to top panel or damage
the current control shaft.

SECTION 5: SER VICE 36 Manual 0-2729

A-02574

I. Input Power Cable Replacement

1. Loosen Strain Relief on rear of unit.

2. Remove six screws securing rear Filter Panel to the
EMC Filter box.

#3

#19

#S1

#S2

Figure 5-16 ON/OFF Power Switch Connections

H. Relay Replacement (K3)

1. Remove left side panel of Power Supply per para­graph 'D' above.

2. Remove wires connected to Relay .

3. Locate Relay and remove two screws securing Re­lay to base of unit. Note orientation of Relay .

4. Install replacement Relay, by reversing steps 1-3,
making sure the two prong side of Relay faces the
Capacitor . Connect wires as shown below:

3. Disconnect cables L1, L2, and Ground from the EMC
Filter .

4. Install replacement Power Cable, by reversing steps
1-3 and wiring as shown below:

Filter
Cover

L2

L1

A-02572

EMC
Filter

GND

Input Power Cable

Figure 5-18 Input Power Cable Connections

Red #23

Red #3

Blue #3

Blue #12

Blue #11

A-02608

Capacitor

Figure 5-17 Relay Wiring Connections

Manual 0-2729 37 SECTION 5: SER VICE

J. Pressure Switch Replacement

l. Work Cable and Clamp Replacement

1. Remove the right side panel from Power Supply per
paragraph 'D' above.

2. Disconnect wires to Pressure Switch.

3. Remove Pressure Switch Assembly from top end of
T ee fitting.

4. Replace Pressure Switch by reversing steps 1-3.
Apply Loctite #565(or equivalent thread sealant) to
Pressure Switch threads prior to installing.

#7 Connector

Compressor

Air Intake Filter

#6 Connector

Pressure Switch

Tee Fitting

1/8 NPT

A-02609

Figure 5-19 Pressure Switch Wiring Connections

1. Remove right side panel per paragraph 'D' above.

2. Disconnect Work Cable connection at main PC
Board.

3. Remove Work Cable Strain Relief from top Panel
Cover and remove Cable from unit.

4. Install replacement Work Cable by reversing steps
1-3.

m. Capacitor PC Board Replacement

Procedure

1. Remove the top panel per paragraph 'E' above.

NOTE

For improved access to the Capacitor PC Board,
remove the two nuts and washers securing the cen­ter divider to the unit base, then slide the divider
towards the Compressor .

2. Remove the black pad located on the Capacitors.

3. Squeeze the three plastic mounting standoffs secur­ing the Capacitor PC Board to the Main PC Board.
(T wo are located along the top edge of the PC Board;
the third is located near the center of the PC Board.)

k. Current Control Knob Guard(s)

Replacement

W ARNING

Disconnect primary power at source before disas­sembling the power supply.

NOTE

The torch lead and work lead must be disconnected
in order to replace the Current Control Knob Guards.

1. Remove top panel cover per paragraph 'E' above.

2. Remove nuts securing Current Control Knob
Guard(s) to top Panel Cover .

3. Install replacement Guard(s) by reversing steps 1-3.

W ARNING

Capacitor
PC Board

Wire #3

Mounting Standoffs

(-) Terminal

(+) Terminal

(N)

A-02122

Be careful of ground wire when removing and in­stalling cover .

SECTION 5: SER VICE 38 Manual 0-2729

Figure 5-20 Capacitor PC Board Connections

4. Remove the three nuts and star washers securing
the Capacitor PC Board to the Main PC Board As­sembly. The nuts are located at terminals (+), (-),
and (N). Remove the Capacitor PC Board from unit.

5. Install the replacement Capacitor PC Board by re­versing steps 1-3. Torque the three nuts on termi­nals (+), (-), and (N) to 15 inch-lbs (1.695 mm).

o. Pilot Resistor (R3) Replacement Procedure

1. Remove the right panel cover per paragraph 'D'
above.

2. Remove the two screws securing the center divider
to the unit base. Lift the vertical center divider up
and out towards the Compressor to gain access to
the Resistor .

CAUTION

DO NOT overtorque the nuts on the terminals as
the PC Board may be damaged.

n. Pilot Resistor (R1) Replacement Procedure

1. Remove the right panel per paragraph 'D' above.

2. Locate the Pilot Resistor near the outside edge of the
unit, below the Main PC Board Assembly.

NOTE

There are two resistors mounted to this area, Pilot
Resistor (R1) (15 ohms) and Damping Resistor (30
ohms). The Pilot Resistor is mounted on the bot­tom.

Damping Resistor

3. Locate Resistor (R3), as shown in the figure below .

4. Note wiring locations, then remove the red and blue
wires from the terminals on Resistor R3.

5. Remove Resistor.

6. Install replacement Resistor , by reversing the above
steps.

A-02128

Pilot Resistor

(R1)

Figure 5-21 Pilot Resistor (R1) Replacement

3. Using a phillips screwdriver , remove the two screws
securing the Pilot and Damping Resistors to the
internal frame.

4. Pull the Pilot Resistor out far enough to gain access
to the two wiring connections.

5. Remove the two wires connected to the Pilot Resis­tor noting the location of each.

6. Install the replacement Pilot Resistor by reversing
steps 1-5.

Manual 0-2729 39 SECTION 5: SER VICE

A-02143

Resistor R3

Figure 5-22 Pilot Resistor (R3) Replacement

P. Starting Capacitor Replacement

1. Remove top Panel Cover per paragraph 'E' above.

5.12 Torch and Leads Replacement
Procedure

2. Locate the Starting Capacitor attached to the base of
the unit, near the Compressor .

3. Remove two wires connected to the Starting Capaci­tor.

4. Remove tie wrap securing Capacitor wires to wire
harness.

5. Loosen the Clamp which secures the Starting Ca­pacitor in place inside the bracket on the base of
unit.

6. Remove Starting Capacitor from unit.

7. Install replacement Capacitor by reversing steps 1­6, reconnecting wires as shown below:

Compressor Side

Plain Wire

Striped Wire

A-02575

1. Remove right panel of Power Supply per paragraph
'D' above.

2. Locate the T orch Block.

Torch Block
Area

A-02129

Nylon Screw

Figure 5-23 Starting Capacitor Wiring

Figure 5-24 Torch Block Location

NOTE

All wires are outside the protective insulating sheet.

3. Remove the nylon screw holding the protective in­sulating sheet to the T orch Block.

4. Loosen the torch lead strain relief nut inside the top
panel. Do not remove the strain relief from the leads.
Replacement torch leads are provided with strain
reliefs.

5. Disconnect the two pin torch switch connector
(white and black wires) and the red pilot wire (ter­minal E14) from the Main PC Board Assembly side
connectors.

SECTION 5: SER VICE 40 Manual 0-2729

Torch Switch Connector

(Black & WhiteWires)

5.13 Servicing Torch Head
Components

Torch Lead

Pilot Wire

A-02124

(Red)

Figure 5-25 Wiring Connections

6. Use a 3/8 inch (9.5 mm) open end wrench to loosen
the negative lead fitting to the brass torch block.

CAUTION

Be sure all wires are outside the protective insulat­ing sheet as noted above when it is reinstalled. High
voltage is present on the torch negative lead.

W ARNING

Disconnect primary power to the system before dis­assembling the torch, leads, or power supply.

W ARNING

NEVER touch any internal torch parts while the
AC indicator light on the top panel is lighted.

A. Removing Torch Head

1. Remove the six screws from the torch handle assem­bly . Pull the cover off the handle to expose the leads
and torch switch/PIP connections.

Torch Switch

PIP/Torch Switch
Connections

Torch Lead

A-02126

Torch Block

Figure 5-26 Torch Lead Connection

Negative/Plasma
Torch Handle
O-Ring

Remove consumables from front end
and remove screws to allow disassembly

Pilot Lead Connection

Lead Connection

A-00781

Figure 5-27 Torch Head Assembly in Handle

2. Disconnect the negative/plasma and pilot lead con­nection at the torch head.

Handle O-Ring

(position in rear groove)

Mounting Screws

Position PIP wires
in notches in back
of split holder

Align notch on
pilot lead with
notch in split holder

A-00782

PIP Pin Assemblies

Figure 5-28 Disassembling the Split Holder

Manual 0-2729 41 SECTION 5: SER VICE

3. Slip off the rear O-Ring, remove the two screws from
the torch head split holder , and separate the halves.
Remove the torch head from the holder .

4. Carefully remove the torch switch and switch but­ton from the handle. Make sure the two small
springs stay in place on the switch button. Do not
disturb the PIP wiring in the torch head housing.

W ARNING

Disconnect primary power to the system before dis­assembling the torch, leads, or power supply.

B. Replacing the PIP Assembly

1. Carefully remove the PIP wires from the strain relief
bosses inside the split holder .

4. Route the PIP wires around the strain relief bosses
as shown. Push the teflon insulation on each PIP
wire up to the strain relief boss closest to the back of
the split holder for voltage insulation from the brass
pilot lead connector .

5. Position both PIP leads through the notch where the
negative/plasma lead exits the holder .

6. Position the torch head inside the holder . Align the
notch on the pilot lead with the corresponding tab
on the split holder . Make sure the negative/plasma
fitting is securely inserted in the groove in the holder .
Make sure the crescent on the torch head is inserted
into the mating groove in the holder .

7. Place the second half of the holder over the torch
head. Confirm that the PIP pin assemblies, PIP leads,
and the negative/plasma and pilot leads are prop­erly positioned.

Position PIP wires
through strain relief
bosses as shown

Bend wires to
fit grooves

Teflon wire coating
must cover wire up
to strain relief area.

Position flange
on PIP receptacle flush
with face of split holder.

Install wire A first, then wire B.

Remove and install PIP assemblies
from the front. Position assemblies
in slots in split holder.

AB

A-00783

Figure 5-29 Installing a Replacement PIP Assembly

2. Slide the PIP pin receptacles forward out of the re­tention slots.

CAUTION

Do not lift the PIP pin receptacles out of the split
holder. Damage to holder and/or PIP pin recep­tacles may occur .

CAUTION

Do not force the holder together . Damage to the in­sulation on the leads will cause torch head failure.
The PIP leads must be positioned correctly to allow
reassembly of the torch head.

3. Install replacement PIP pin assemblies by position­ing the square solder post of the PIP pin receptacle
in the retention slot in the split holder and sliding
the assembly up into place. Position the flange on
the PIP pin receptacle flush with the front face of
the split holder .

SECTION 5: SER VICE 42 Manual 0-2729

C. Reassembling the Torch Head

1. Install the two assembly screws to secure the split
holder and reinstall the O-ring in the rear groove
on the back of the torch head assembly.

D. Replacing Torch Switch or Torch Leads to

Head

1. Unsolder the lead(s) at the torch switch being care­ful not to damage the wires.

Handle O-Ring

(position in rear groove)

Position PIP wires
in notches in back
of split holder

Align notch on
pilot lead with
notch in split holder

A-00782

Figure 5-30 Assembling the Split Holder

2. Install the front end torch parts.

W ARNING

Disconnect primary power to the system before dis­assembling the torch, leads, or power supply.

Mounting Screws

PIP Pin Assemblies

2. Carefully solder the wire(s) to the terminals on the
replacement torch switch.

Torch Switch

To Control

Cable Wiring

Butt Splice

PIP Pin

Shield Cup

PIP Pin

A-00784

Figure 5-32 Torch Switch Schematic

NOTE

Be careful not to overheat the torch switch while
soldering the leads to the terminals.

E. Reassembling the Torch Handle and Switch

Assembly

1. Connect the plasma and pilot lead connections at
the torch head.

A-00780

Gas

Distributor TipElectrode

Torch Head Assembly

Figure 5-31 Consumable Parts

Standard

Shield Cup

Torch Switch

Torch Handle
O-Ring

Remove consumables from front end
and remove screws to allow disassembly

PIP/Torch Switch
Connections

Pilot Lead Connection

Negative/Plasma
Lead Connection

A-00781

Figure 5-33 Torch Head Assembly in Handle

2. Place the torch head in the handle and carefully
return the torch switch and button to their proper
position.

NOTE

Make sure torch switch and PIP wires are seated in
their guides so that the wires are not pinched when
the handle is secured.

3. Replace the cover on the handle assembly and tighten
the six retaining screws.

Manual 0-2729 43 SECTION 5: SER VICE

SECTION 5: SER VICE 44 Manual 0-2729

SECTION 6:

PARTS LISTS

6.01 Introduction

A. Parts List Breakdown

The parts list provides a breakdown of all replaceable com­ponents. Power Supply and T orch Assembly are field ser­viceable, so a complete breakdown of parts is provided.
The parts lists are arranged as follows:

Section 6.03: Power Supply Replacement Parts
Section 6.04: Complete Assembly Replacements
Section 6.05: T orch Assembly Replacement Parts
Section 6.06: Options And Accessories
Section 6.07: T orch Spar e Parts Kit

NOTE

Parts listed without item numbers are not illustrated,
but may be ordered by the catalog numbers shown.

B. Returns

If a product must be returned for service, contact your au­thorized distributor . Materials returned to the Manufac­turer without proper authorization will not be accepted.

6.02 Ordering Information

Order replacement parts by catalog number and complete
description of the part or assembly, as listed in the de­scription column of the Parts List. Also include the model
and serial number of the torch. Address all inquiries to
your authorized distributor .

Manual 0-2729 45 SECTION 6: PARTS LISTS

6.03 Power Supply Replacement Parts

Item # Q ty Description Ref . Catalog #

1 1 Left Side Panel with Labels 9-7707
2 1 Right Side Panel with Labels 9-7708
3 1 T op Panel with Labels 9-7709
4 1 Rear Panel with Labels 9-7705
5 1 Front Panel with Labels 9-7706
6 1 Current Control Knob Assy 9-7710
7 2 Current Control Knob Guards 9-7717
8 1 Fuse, 1/2 Amp, 250V (F1) 9-7711

9 1 Pressure Switch - 35 psi 9-1044
10 1 Handle 9-7712
11 1 Pilot Resistor (R3), 11K ohms 30W 9-7701
12 1 ON/OFF Switch 8-4248
13 1 Capacitor PC Board Assembly 9-4607
14 1 Pilot Resistor (R1), 15 ohms 55W 9-6323

15* 1 W ork Cable 20 ft (6 m) with Clamp 9-6596
16* 1 Input Power Cable 9.5ft (2.9 m) 9-7951

17 1 EMC Filter 9-7950
18 1 Air Compressor, 200-230VAC, 50/60Hz 9-7720
19 2 Wheel, 6" diameter 9-4283
20 1 Axle 9-4282
21 2 Retaining Ring, 1/2 in. Dia Shaft (Axle) 9-5539
22 4 Flat Washer- 1/2 in. (13 mm) I.D. (Axle) Purchase Locally
23 1 Air Intake Filter Kit - Replacement Filter Pads (One of Each Type) 9-7716
24 1 Foot 9-4284
25 1 Filter Dryer Replacement Kit 9-6599

1 Filter Dryer Element 9-7718
26 1 Relay K3 9-7914
27 1 Fan 9-1033
28 1 Starting Capacitor, 15 uf 9-7722

* Not illustrated in exploded view of unit.

SECTION 6: PARTS LISTS 4 6 Manual 0-2729

25

R1

R3

17

6

7

3

10

12

2

27

4

23

9

18
28

26

1

24

5

20

19

21

Manual 0-2729 47 SECTION 6: PARTS LISTS

22

13

R3

R1

11
14

A-02302

8

6.04 Complete Assembly Replacement

Description Catalog #
System includes DRAG-GUN 38 (Australia) Power Supply with Built-In Compressor , PCH-25/38 Torch with Leads,

Spare Parts Kit, Input and Ground Cables.

70° T orch with 25 ft (7.6 m) Leads 1-8800
90° T orch with 25 ft (7.6 m) Leads 1-8801
180° T orch with 25 ft (7.6 m) Leads 1-8802

Power Supply (Australia) Only 3-8801
Replacement Hand T orches with Leads Only:

PCH-25/38 70° T or ch with 25 ft (7.6 m) Leads 2-0381
PCH-25/38 90° T or ch with 25 ft (7.6 m) Leads 2-0383
PCH-25/38 180° T or ch with 25 ft (7.6 m) Leads 2-0385

SECTION 6: PARTS LISTS 4 8 Manual 0-2729

6.05 Torch Replacement Parts

Item # Qt y Description Catalog #

1 1 Assembly, PIP (Parts-In-Place) Pins and Wire 9-6103

2 2 O-Ring 8-0533
3 1 Holder, Torch, Split, PCH25/38 70° Two Parts w/Screws 9-6259

1 Holder, Torch, Split, PCH25/38 90° Two Parts w/Screws 9-6260

1 Holder, Torch Split, PCH25/38 180° Two Parts w/Screws (not shown) 9-6261

4 1 Assembly, Basic Head, PCH25/38 70° 9-5807

1 Assembly, Basic Head, PCH25/38 90° 9-5808

1 Assembly, Basic Head, PCH25/38 180° 9-5809

5 1 Distributor, Gas 9-6507
6 1 Tip, Air, 0.031" Orifice (Drag Cutting) 9-6501
7 1 Electrode, Air 9-6506
8 1 Shield Cup 9-6003
9 1 Handle, Split, PCH-25/38 Two Parts (Includes Items #14 -16) 9-6282

10 1 Lead Assembly, Composite Cable

25 ft (7.6m) Length 4-6068
11 1 Switch, Torch 9-1058
12 1 #6-32 x 3/16 Phillips Pan Head Screw

13 1 #6 Internal Star Washer
14 1 Button, Split Holder 8-4256
15 2 Spring 9-6292
16 6 #2-56 x 5/16" Phillips Pan Head Screw

Purchase Locally
Purchase Locally

Purchase Locally

NOTE: Item can be purchased locally.

9

15

2

3

1

7

5

6

4

12

10

14

11

9

13

16

3

A-00777

8

Manual 0-2729 49 SECTION 6: PARTS LISTS

6.06 Options and Accessories

Qty Description Catalog #

1 Circle Guide 7-3291
1 Cutting Guide Kit 7-8910

6.07 Torch Spare Parts Kit

Qty Description Catalog #

1 Spare Parts Kit, PCH-25/38, includes: 5-3800
5 Tip, Air , 0.031" Orifice, Drag Cutting 9-6501
3 Electrode, Air 9-6506
1 Distributor , Gas 9-6507
1 Box, Utility 8-3/8 x 4-1/2, 1-11/16, Black 8-3141

SECTION 6: PARTS LISTS 5 0 Manual 0-2729

APPENDIX I: SEQUENCE OF OPERATION BLOCK

DIAGRAM

ACTION

Plug in

Power Cord

RESULT

Power to system.

ACTION

Protect eyes and

activate torch

RESULT

Compressor starts and

Gas flows

GAS indicator ON

After gas pre-flow:

DC indicator on.

Power supply enabled.

Pilot arc established

ACTION

ON/OFF switch

to ON.

RESULT

AC Indicator flashes for

3 seconds then stays on.

Air Compressor runs

for 3 seconds then off.

Fan on.

PILOT ARC

ACTION

Torch moved away

from work (while

still activated).

RESULT

Main arc stops.

Pilot arc auto-

matically restarts.

ACTION

Torch moved within

transfer distance of

workpiece.

RESULT

Main arc transfer.

ACTION

Torch deactivated by torch

switch release.

RESULT

Main arc stops. Pilot stops.

(Power supply enable signal removed.)

Compressor stops. Gas flow stops.

NOTE - If torch is activated during
post-flow, pilot arc will immediately restart.
If torch is within transfer distance (1/8 in) of

workpiece, main arc will transfer.

DC indicator off.

After post-flow:

GAS indicator OFF.

ACTION

ON/OFF switch

to OFF

RESULT

All indicators off.

Power supply

fan off.

Pilot arc off.

DC indicator still on.

ACTION

Unplug

Power Cord

RESULT

No power to system.

A-02151

Manual 0-2699 51 APPENDICES

APPENDIX II: SYSYTEM SCHEMATIC

A-02576

APPENDICES 52 Manual 0-2699

Manual 0-2699 53 APPENDICES

A-02576

APPENDIX III: CUTTING SPEED CHART

PM 38XL CUT SPEE DS (Air @ 50 psi f or all settings)

Materia l Thickness Recommended Cut Recommended Cut Ma x Cut Stando f f

Speed @ 20 Amps Speed @ 29 Amps Speed @29 Amps (in.)

Mild Steel 26 Gauge 250 310 385 drag-1/8"

20 Gauge 125 245 310 drag-1/8"

1/16" 85 140 208 dr ag-1/8"

1/8 " 25 55 85 drag-1/8"

3/16 " 15 30 55 drag-1/16"

1/4 " 8 16 27 drag-1/16"
3/8 " na 10 14 drag -1/16"

Stainless Steel 24 Gauge 150 310 385 drag-1/8"

1/16" 40 80 115 drag-1/8"

1/8 " 25 44 70 drag-1/8"

3/16 " 10 19 27 drag-1/16"

1/4 " na 14 20 drag -1/16"

Galvanized Steel 24 gauge 100 290 36 0 dr ag-1/8"

20 gauge 75 228 310 drag-1/8"
18 gauge 65 172 233 drag-1/8"
16 gauge 45 140 203 drag-1/8"

Aluminum 1/16 " 150 223 280 drag-1/8"

3/32 " 25 105 172 drag-1/8"

1/8 " 10 60 85 drag-1/8"

3/16 " na 20 30 drag-1/8"

APPENDICES 54 Manual 0-2699