PLASMA
15C
DRAG-GUN
™
LT
PLASMA CUTTING SYSTEM
WITH BUILT IN AIR COMPRESSOR
Operating Manual
Rev. AA.01 Date: June 11, 2007 Manual # 0-4965
Operating Features:
WE APPRECIATE YOUR BUSINESS!
Congratulations on your new Thermal Dynamics product. We are
proud to have you as our customer and will strive to provide you
with the best service and reliability in the industry. This product is
backed by our extensive warranty and world-wide service network.
To locate your nearest distributor or service agency call 1-800-4261888, or visit us on the web at www.thermadyne.com.
This Operating Manual has been designed to instruct you on the
correct use and operation of your Thermal Dynamics product. Your
satisfaction with this product and its safe operation is our ultimate
concern. Therefore please take the time to read the entire manual,
especially the Safety Precautions. They will help you to avoid potential hazards that may exist when working with this product.
YOU ARE IN GOOD COMPANY!
The Brand of Choice for Contractors and Fabricators Worldwide.
Thermal Dynamics is a Global Brand of manual and automation
Plasma Cutting Products for Thermadyne Industries Inc.
We distinguish ourselves from our competition through marketleading, dependable products that have stood the test of time.
We pride ourselves on technical innovation, competitive prices,
excellent delivery, superior customer service and technical support,
together with excellence in sales and marketing expertise.
Above all, we are committed to developing technologically advanced products to achieve a safer working environment within
the welding industry.
!
WARNING
Read and understand this entire Manual and your employer’s safety practices before
installing, operating, or servicing the equipment.
While the information contained in this Manual represents the Manufacturer's best judgement, the Manufacturer assumes no liability for its use.
Plasma Cutting Power Supply, 15C Drag-Gun™LT
PCH 10 Torch
Operating Manual No. 0-4965
Published by:
Thermadyne Corporation
82 Benning Street
West Lebanon, New Hampshire, USA 03784
(603) 298-5711
www.thermadyne.com
© Copyright 2007 by
Thermadyne 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: June 11, 2007
Record the following information for Warranty purposes:
Where Purchased: ___________________________________
Purchase Date:______________________________________
Power Supply Serial #:_______________________________
Torch Serial #:_____________________________________
i
Intentionally blank
TABLE OF CONTENTS
SECTION 1:GENERAL INFORMATION ...................................................................................1-1
1.01 Notes, Cautions and Warnings ...................................................................1-1
1.02 Important Safety Precautions .....................................................................1-1
1.03 Publications.................................................................................................1-3
1.04 Note, Attention et Avertissement ................................................................1-3
1.05 Precautions De Securite Importantes .........................................................1-4
1.06 Documents De Reference ...........................................................................1-5
1.07 Statement of Warranty ................................................................................1-7
SECTION 2:INTRODUCTION ................................................................................................. 2-1
2.01 How To Use This Manual ............................................................................2-1
2.02 Equipment Identification .............................................................................2-1
2.03 Receipt Of Equipment ................................................................................. 2-1
2.04 Introduction .................................................................................................2-1
2.05 General Specification .................................................................................. 2-2
2.06 Features ...................................................................................................... 2-2
2.07 Torch Specifications ....................................................................................2-3
2.08 System Contents ........................................................................................2-3
2.09 Transporting Methods .................................................................................2-3
SECTION 3:INSTALLATION .....................................................................................................3-1
3.01 Site Selection ..............................................................................................3-1
3.02 Electrical Input Connections .......................................................................3-1
3.03 Torch ...........................................................................................................3-1
SECTION 4: OPERATION ........................................................................................................4-1
4.01 Front Control Panel .....................................................................................4-1
4.02 Preparations For Operating ........................................................................4-1
SECTION 5:SERVICE ..............................................................................................................5-1
5.01 General Maintenance .................................................................................5-1
5.02 Basic Troubleshooting Guide ......................................................................5-2
Appendix 1: Operating Sequence, Block Diagram .................................................................. A-1
Appendix 2: Torch Connection ................................................................................................ A-2
Appendix 3: System Schematic 120V .................................................................................... A-3
GLOBAL CUSTOMER SERVICE CONTACT INFORMATION .........................Inside Rear Cover
TABLE OF CONTENTS
This Page Intentionally Blank
SECTION 1:
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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 background information which requires additional emphasis or is
helpful in efficient operation of the system.
CAUTION
A procedure which, if not properly followed, may
cause damage to the equipment.
WARNING
A procedure which, if not properly followed,
may cause injury to the operator or others in
the operating area.
1.02 Important Safety Precautions
WARNING
OPERATION AND MAINTENANCE OF
PLASMA ARC EQUIPMENT CAN BE DANGEROUS AND HAZARDOUS TO YOUR
HEALTH.
Plasma arc cutting produces intense electric and
magnetic emissions that may interfere with the
proper function of cardiac pacemakers, hearing
aids, or other electronic health equipment. Persons
who work near plasma arc cutting applications
should consult their medical health professional
and the manufacturer of the health equipment to
determine whether a hazard exists.
To prevent possible injury, read, understand
and follow all warnings, safety precautions
and instructions before using the equipment.
Call 1-603-298-5711 or your local distributor
if you have any questions.
GASES AND FUMES
Gases and fumes produced during the plasma cutting process can be dangerous and hazardous to
your health.
• Keep all fumes and gases from the breathing area. Keep your head out of the welding
fume plume.
• Use an air-supplied respirator if ventilation
is not adequate to remove all fumes and
gases.
• The kinds of fumes and gases from the plasma arc depend on the kind of metal being
used, coatings on the metal, and the different
processes. You must be very careful when
cutting or welding any metals which may
contain one or more of the following:
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.)
Manual 0-4965 1-1 GENERAL INFORMATION
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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.”
• 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.
• Besurethereisnocombustibleorammable material in the workplace. Any material
that cannot be removed must be protected.
• Ventilateallammableorexplosivevapors
from the workplace.
• Do not cut or weld on containers that may
have held combustibles.
• Providearewatchwhenworkinginan
areawhererehazardsmayexist.
• Hydrogen gas may be formed and trapped
under aluminum work pieces when they are
cut underwater or while using a water table.
DO NOT cut aluminum alloys underwater
or on a water table unless the hydrogen gas
can be eliminated or dissipated. Trapped
hydrogen gas that is ignited will cause an
explosion.
NOISE
Noise can cause permanent hearing loss. Plasma
arc processes can cause noise levels to exceed
safe limits. You must protect your ears from loud
noise to prevent permanent loss of hearing.
• To protect your hearing from loud noise,
wear protective ear plugs and/or ear muffs.
Protect others in the workplace.
• Noise levels should be measured to be sure
the decibels (sound) do not exceed safe levels.
• For information on how to test for noise, see
item 1 in Subsection 1.03, Publications, in
this manual.
PLASMA ARC RAYS
Plasma Arc Rays can injure your eyes and burn
your skin. The plasma arc process produces very
bright ultra violet and infra red light. These arc
rays will damage your eyes and burn your skin if
you are not properly protected.
• To protect your eyes, always wear a welding
helmet or shield. Also always wear safety
glasses with side shields, goggles or other
protective eye wear.
• Wear welding gloves and suitable clothing
to protect your skin from the arc rays and
sparks.
• Keep helmet and safety glasses in good
condition. Replace lenses when cracked,
chipped or dirty.
• Protect others in the work area from the
arc rays. Use protective booths, screens or
shields.
• Use the shade of lens as suggested in the following per ANSI/ASC Z49.1:
Minimum 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
work piece.
General Information 1-2 Manual 0-4965
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1.03 Publications
Refer to the following standards or their latest
revisions for more information:
1. OSHA, SAFETY AND HEALTH STANDARDS, 29CFR
1910, obtainable from the Superintendent of Docu-
ments, U.S. Government Printing Office, Washington,
D.C. 20402
2. ANSI Standard Z49.1, SAFETY IN WELDING AND
CUTTING, obtainable from the American Welding
Society, 550 N.W. LeJeune Rd, Miami, FL 33126
3. NIOSH, SAFETY AND HEALTH IN ARC WELDING
AND GAS WELDING AND CUTTING, obtainable
from the Superintendent of Documents, U.S. Government Printing Office, Washington, D.C. 20402
4. ANSI Standard Z87.1, SAFE PRACTICES FOR OCCUPATION AND EDUCATIONAL EYE AND FACE
PROTECTION, obtainable from American National
Standards Institute, 1430 Broadway, New York, NY
10018
5. ANSI Standard Z41.1, STANDARD FOR MEN’S SAFETY-TOE FOOTWEAR, obtainable from the American
National Standards Institute, 1430 Broadway, New
York, NY 10018
14. American Welding Society Standard AWSF4.1, RECOMMENDED SAFE PRACTICES FOR THE PREPARATION FOR WELDING AND CUTTING OF CONTAINERS AND PIPING THAT HAVE HELD HAZARDOUS
SUBSTANCES, obtainable from the American Welding
Society, 550 N.W. LeJeune Rd, Miami, FL 33126
15. ANSI Standard Z88.2, PRACTICE FOR RESPIRATORY
PROTECTION, obtainable from American National
Standards Institute, 1430 Broadway, New York, NY
10018
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
enreliefsontclassiéescommesuit:
NOTE
Toute opération, procédure ou renseignement
général sur lequel il importe d’insister davantage
ou qui contribue à l’efficacité de fonctionnement
du système.
6. ANSI Standard Z49.2, FIRE PREVENTION IN THE USE
OF CUTTING AND WELDING PROCESSES, obtain-
able from American National Standards Institute, 1430
Broadway, New York, NY 10018
7. AWS Standard A6.0, WELDING AND CUTTING CON-
TAINERS WHICH HAVE HELD COMBUSTIBLES,
obtainable from American Welding Society, 550 N.W.
LeJeune Rd, Miami, FL 33126
8. NFPA Standard 51, OXYGEN-FUEL GAS SYSTEMS
FOR WELDING, CUTTING AND ALLIED PROCESSES, obtainable from the National Fire Protection
Association, Batterymarch Park, Quincy, MA 02269
9. NFPA Standard 70, NATIONAL ELECTRICAL CODE,
obtainable from the National Fire Protection Association, Batterymarch Park, Quincy, MA 02269
10. NFPA Standard 51B, CUTTING AND WELDING PROCESSES, obtainable from the National Fire Protection
Association, Batterymarch Park, Quincy, MA 02269
11. CGA Pamphlet P-1, SAFE HANDLING OF COMPRESSED GASES IN CYLINDERS, obtainable from
the Compressed Gas Association, 1235 Jefferson Davis
Highway, Suite 501, Arlington, VA 22202
ATTENTION
Toute procédure pouvant résulter
l’endommagement du matériel en cas de nonrespect de la procédure en question.
AVERTISSEMENT
Toute procédure pouvant provoquer des blessures de l’opérateur ou des autres personnes
se trouvant dans la zone de travail en cas de
non-respect de la procédure en question.
12. CSA Standard W117.2, CODE FOR SAFETY IN WELDING AND CUTTING, obtainable from the Canadian
Standards Association, Standards Sales, 178 Rexdale
Boulevard, Rexdale, Ontario, Canada M9W 1R3
13. NWSA booklet, WELDING SAFETY BIBLIOGRAPHY
obtainable from the National Welding Supply Association, 1900 Arch Street, Philadelphia, PA 19103
Manual 0-4965 1-3 GENERAL INFORMATION
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1.05 Precautions De Securite Importantes
AVERTISSEMENT
L’OPÉRATION ET LA MAINTENANCE DU
MATÉRIEL DE SOUDAGE À L’ARC AU JET
DE PLASMA PEUVENT PRÉSENTER DES
RISQUES ET DES DANGERS DE SANTÉ.
Coupant à l’arc au jet de plasma produit de
l’énergie électrique haute tension et des émissions
magnétique qui peuvent interférer la fonction
propre d’un “pacemaker” cardiaque, les appareils
auditif, ou autre matériel de santé electronique.
Ceux qui travail près d’une application à l’arc
au jet de plasma devrait consulter leur membre
professionel de médication et le manufacturier de
matériel de santé pour déterminer s’il existe des
risques de santé.
Il faut communiquer aux opérateurs et au
personnel TOUS les dangers possibles.
Afin d’éviter les blessures possibles, lisez,
comprenez et suivez tous les avertissements,
toutes les précautions de sécurité et toutes les
consignes avant d’utiliser le matériel. Composez le + 603-298-5711 ou votre distributeur
local si vous avez des questions.
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 respira-
tion. Gardez votre tête hors de la plume de fumée
provenant du chalumeau.
• Utilisez un appareil respiratoire à alimentation en
air si l’aération fournie ne permet pas d’éliminer la
fumée et les gaz.
• Les sortes de gaz et de fumée provenant de l’arc de
plasma dépendent du genre de métal utilisé, des
revêtements se trouvant sur le métal et des différents
procédés. Vous devez prendre soin lorsque vous
coupez ou soudez tout métal pouvant contenir un ou
plusieurs des éléments suivants:
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
Les chocs électriques peuvent blesser ou même
tuer. Le procédé au jet de plasma requiert et
produit de l’énergie électrique haute tension.
Cette énergie électrique peut produire des chocs
graves, voire mortels, pour l’opérateur et les autres personnes sur le lieu de travail.
• Ne touchez jamais une pièce “sous tension” ou
“vive”; portez des gants et des vêtements secs. Isolezvous de la pièce de travail ou des autres parties du
circuit de soudage.
• Réparez ou remplacez toute pièce usée ou endom-
magée.
• Prenez des soins particuliers lorsque la zone de tra-
vail est humide ou moite.
• Montez et maintenez le matériel conformément au
Code électrique national des Etats-Unis. (Voir la page
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.
General Information 1-4 Manual 0-4965
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 provo-
querl’explosiondefuméesinammables.
• Soyez certain qu’aucune matière combustible ou in-
flammable ne se trouve sur le lieu de travail. Protégez
toute telle matière qu’il est impossible de retirer de
la zone de travail.
• Procurez une bonne aération de toutes les fumées
inflammables ou explosives.
• 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.
Drag-gun™ lt
• 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.
BRUIT
Le bruit peut provoquer une perte permanente de
l’ouïe. Les procédés de soudage à l’arc de plasma
peuvent provoquer des niveaux sonores supérieurs
aux limites normalement acceptables. Vous dú4ez
vous protéger les oreilles contre les bruits forts
and’éviterunepertepermanentedel’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.
RAYONS D’ARC DE PLASMA
Les rayons provenant de l’arc de plasma peuvent
blesser vos yeux et brûler votre peau. Le procédé
à l’arc de plasma produit une lumière infra-rouge
et des rayons ultra-violets très forts. Ces rayons
d’arc nuiront à vos yeux et brûleront votre peau si
vous ne vous protégez pas correctement.
• Pour protéger vos yeux, portez toujours un casque
ou un écran de soudeur. Portez toujours des lunettes
de sécurité munies de parois latérales ou des lunettes
de protection ou une autre sorte de protection oculaire.
• Portez des gants de soudeur et un vêtement pro-
tecteur 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.
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 TRAVAIL ET
DE PROTECTION DE LA SANTÉ, 29CFR 1910, disponible auprès du Superintendent of Documents,
U.S. Government Printing Office, Washington, D.C.
20402
2. Norme ANSI Z49.1, LA SÉCURITÉ DES OPÉRATIONS DE COUPE 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
Manual 0-4965 1-5 GENERAL INFORMATION
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4. Norme ANSI Z87.1, PRATIQUES SURES POUR
LA PROTECTION DES YEUX ET DU VISAGE AU
TRAVAIL ET DANS LES ECOLES, disponible de
l’Institut Américain des Normes Nationales (American National Standards Institute), 1430 Broadway,
New York, NY 10018
5. Norme A N SI Z4 1 . 1 , N ORMES PO UR L ES
CHAUSSURES PROTECTRICES, disponible auprès
de l’American National Standards Institute, 1430
Broadway, New York, NY 10018
6. Norme ANSI Z49.2, PRÉVENTION DES INCENDIES
LORS DE L’EMPLOI DE PROCÉDÉS DE COUPE ET
DE SOUDAGE, disponible auprès de l’American
National Standards Institute, 1430 Broadway, New
York, NY 10018
7. Norme A6.0 de l’Association Américaine du Soudage (AWS), LE SOUDAGE ET LA COUPE DE CONTENEURS AYANT RENFERMÉ DES PRODUITS
COMBUSTIBLES, disponible auprès de la American
Welding Society, 550 N.W. LeJeune Rd., Miami, FL
33126
8. Norme 51 de l’Association Américaine pour la Protection contre les Incendies (NFPA), LES SYSTEMES À
GAZ AVEC ALIMENTATION EN OXYGENE POUR
LE SOUDAGE, LA COUPE ET LES PROCÉDÉS
ASSOCIÉS, disponible auprès de la National Fire
Protection Association, Batterymarch Park, Quincy,
MA 02269
9. Norme 70 de la NFPA, CODE ELECTRIQUE NATIONAL, disponible auprès de la National Fire
Protection Association, Batterymarch Park, Quincy,
MA 02269
10. Norme 51B de la NFPA, LES PROCÉDÉS DE COUPE
ET DE SOUDAGE, disponible auprès de la National
Fire Protection Association, Batterymarch Park,
Quincy, MA 02269
11. Brochure GCA P-1, LA MANIPULATION SANS
RISQUE DES GAZ COMPRIMÉS EN CYLINDRES,
disponible auprès de l’Association des Gaz Comprimés (Compressed Gas Association), 1235 Jefferson
Davis Highway, Suite 501, Arlington, VA 22202
12. Norme CSA W117.2, CODE DE SÉCURITÉ POUR
LE SOUDAGE ET LA COUPE, disponible auprès de
l’Association des Normes Canadiennes, Standards
Sales, 178 Rexdale Boulevard, Rexdale, Ontario,
Canada, M9W 1R3
General Information 1-6 Manual 0-4965
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1.07 Statement of Warranty
LIMITED WARRANTY: Subject to the terms and conditions established below, Thermadyne® Corporation warrants to the original
retail purchaser that new Thermal Dynamics Series plasma cutting systems sold after the effective date of this warranty are free of
defects in material and workmanship. Should any failure to conform to this warranty appear within the applicable period stated below,
Thermadyne Corporation shall, upon notification thereof and substantiation that the product has been stored operated and maintained
in accordance with Thermadynes’ specifications, instructions, recommendations and recognized industry practice, correct such defects
by suitable repair or replacement.
This warranty is exclusive and in lieu of any warranty of merchantability or fitness for a particular purpose.
Thermadyne will repair or replace, at its discretion, any warranted parts or components that fail due to defects in material or workmanship
within the time periods set out below. Thermadyne Corporation must be notified within 30 days of any failure, at which time Thermadyne
Corporation will provide instructions on the warranty procedures to be implemented.
Thermadyne Corporation will honor warranty claims submitted within the warranty periods listed below. All warranty periods begin
on the date of sale of the product to the original retail customer or 1 year after sale to an authorized Thermadyne Distributor.
LIMITED WARRANTY PERIOD
Product
Power Supply Components
(Parts and Labor)
Torch and Leads
(Parts and Labor)
Drag-Gun™ LT 1 Year 180 days
This warranty does not apply to:
1. Consumable Parts, such as tips, electrodes, shield cups, o - rings, starter cartridges, gas distributors, fuses, filters.
2. Equipment that has been modified by an unauthorized party, improperly installed, improperly operated or misused
based upon industry standards.
In the event of a claim under this warranty, the remedies shall be, at the discretion of Thermadyne Corporation:
1. Repair of the defective product.
2. Replacement of the defective product.
3. Reimbursement of reasonable costs of repair when authorized in advance by Thermadyne.
4. Payment of credit up to the purchase price less reasonable depreciation based on actual use.
These remedies may be authorized by Thermadyne and are FOB West Lebanon, NH or an authorized Thermadyne service station.
Product returned for service is at the owner’s expense and no reimbursement of travel or transportation is authorized.
LIMITATION OF LIABILITY: Thermadyne Corporation shall not under any circumstances be liable for special or consequential
damages such as, but not limited to, damage or loss of purchased or replacement goods or claims of customer of distributors (hereinafter
“Purchaser”) for service interruption. The remedies of the Purchaser set forth herein are exclusive and the liability of Thermadyne with
respect to any contract, or anything done in connection therewith such as the performance or breach thereof, or from the manufacture,
sale, delivery, resale, or use of the goods covered by or furnished by Thermadyne whether arising out of contract, negligence, strict
tort, or under any warranty, or otherwise, shall not, except as expressly provided herein, exceed the price of the goods upon which
liability is based.
This warranty becomes invalid if replacement parts or accessories are used which may impair the safety or performance of any
Thermadyne product.
This warranty is invalid if the Thermadyne product is sold by non - authorized persons.
Effective May 23, 2007
Manual 0-4965 1-7 GENERAL INFORMATION
Drag-gun™ lt
This Page Intentionally Blank
General Information 1-8 Manual 0-4965
Drag-gun™ lt
!
SECTION 2:
INTRODUCTION
2.01 How To Use This Manual
ThisOwner’sManualappliestojustspecication or part numbers listed on page i.
To ensure safe operation, read the entire manual,
including the chapter on safety instructions and
warnings.
Throughout this manual, the words WARNING,
CAUTION, and NOTE may appear. Pay particular attention to the information provided under
these headings. These special annotations are
easily recognized as follows:
WARNING
A WARNING gives information regarding
possible personal injury.
2.02 Equipment Identification
Theunit’sidenticationnumber(specication or part number), model, and serial number
usually appear on a data tag attached to the rear
panel. Equipment which does not have a data tag
such as torch and cable assemblies are identi-
edonlybythespecicationorpartnumber
printed on loosely attached card or the shipping
container. Record these numbers on the bottom
of page i for future reference.
2.03 Receipt Of Equipment
When you receive the equipment, check it
against the invoice to make sure it is complete
and inspect the equipment for possible damage
due to shipping. If there is any damage, notify
thecarrierimmediatelytoleaclaim.Furnish
complete information concerning damage claims
or shipping errors to the location in your area
listed in the inside back cover of this manual.
Includeallequipmentidenticationnumbersas
described above along with a full description of
the parts in error.
CAUTION
A CAUTION refers to possible equipment
damage.
NOTE
A NOTE offers helpful information concerning
certain operating procedures.
Additional copies of this manual may be purchased by contacting Thermal Dynamics at the
address and phone number in your area listed in
the inside back cover of this manual. Include the
Owner’sManualnumberandequipmentidentication numbers.
Electronic copies of this manual can also be
downloaded at no charge in Acrobat PDF format
by going to the
Thermadyne web site listed below, clicking on
the Thermal Dynamics brand logo and then on
the Literature link:
http://www.thermadyne.com
2.04 Introduction
Plasma is a gas which has been heated to an
extremely high temperature and ionized so that
it becomes electrically conductive. The plasma
arc cutting process uses this plasma to transfer
an electrical arc to the workpiece. The metal to
be cut is melted by the heat of the arc and then
blown away.
Introduction 2-1 Manual 0-4965
Drag-gun™ lt
2.05 General Specification
Model Description
Maximum output 15 Amps
Input Voltage & Phase
Frequency 60Hz
Input power 2.2 kVA
Current Input fuse
No Load Voltage 330V
Load Voltage 86V
Output Current 15 Amps
Post flow time 12 Seconds
Duty cycle @ 104°F /
40° C Ambient
Genuine Cutting
Capacity
Maximum Cutting
Capacity
Dimension (W * D * H)
Gross Weight 30 lbs. (11.2 kg )
NOTE:
Refer to Local and National Codes or local authority having jurisdiction for proper wiring
requirements.
15C Drag-Gun™
LT
120V,
Single Phase
U.S. / Canada 20
Amps
30% @ 15A,
86vdc
3/16”
(4.5 mm)
1/4”
(6.5 mm)
6.5”x18”x9.5” (165
mm x 457 mm x
241 mm )
2.06 Features
• COMPACT and LIGHT - Designed for easy
transportation.
• ENERGY EFFICIENCY - Advanced technology reduces power consumption.
• HIGH SPEED GENUINE CUTTING - The
constricted plasma arc provides high speed
cutting as well as a good quality genuine,
narrow cut.
• LOW COST WITH COMPRESSED AIR
- The Drag-Gun™ LT operates on its owncompressed air.
• ALL KINDS OF METALS - Useful for
most metals such as stainless steel, aluminum, mild steel, copper and their alloys.
• PILOT ARC IGNITION FROM TORCH
- The Pilot Arc ignites the cutting arc.
• POWERFUL CUTTING PERFORMANCE
- Genuine cutting capacity is 3/16” (4.5
mm).
• ABLE TO CUT PAINTED MATERIALS
- Pilot Arc ignition allows the Drag-Gun™
LT to cut painted materials.
• EXTENDED PARTS LIFE - Consumable
parts life is longer.
Introduction 2-2 Manual 0-4965
Drag-gun™ lt
8 in (203 mm)
1.1 in (27 mm)
2.9 in
(75 mm)
Art # A-07719
2.07 Torch Specifications
PCH-10 Torch Ratings
Torch Configuration
Torch Leads Length 20 feet / 6.1 m
Duty Cycle 100% @ 10 Amps
Maximum Current
Type of Cooling
Parts-in-Place:
Gas Requirement:
Plasma Power
Supply Used With:
Torch Head at 70° to
Torch Handle
15 Amps, DC,
Straight Polarity
Ambient air and gas
stream through torch
Built-in Switch
in Torch Head
Single Gas, Internal
Compressed Air Only
Drag-Gun™ LT
2.08 System Contents
Description ITEMS Q’ty
Power source Model Drag-Gun™ LT 1
Torch Set
Accessories &
Consumables
Input Power
Cable U.S.
PCH-10, with 20’
(6.1 m) leads
Work Cable
Manual
Torch Electrodes
Torch Tips
16/3 with molded plug 1
1
1
1
2
3
2.09 Transporting Methods
Lift unit with handle on top of case. Use handcart or similar device of adequate capacity for
transporting over long distances.
WARNINGS
ELECTRIC SHOCK can kill. DO NOT
TOUCH live electrical parts. Disconnect input
power from supply before moving the power
source.
FALLING EQUIPMENT can cause serious
personal injury and equipment damage.
Introduction 2-3 Manual 0-4965
Drag-gun™ lt
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Introduction 2-4 Manual 0-4965
Drag-gun™ lt
SECTION 3:
INSTALLATION
3.01 Site Selection
• Place in a clean and dry area.
• Provide adequate ventilation and fresh air
supply.
• Ideal ambient temperature should not exceed 40°C / 104°F. Temperatures exceeding that may diminish cutting capacity or
quality.
• The cutting machine must be placed on an
even,rmsurface.
3.02 Electrical Input Connections
• Input voltage is 120V ± 10%, 50/60 Hz
single phase.
CAUTION
Check your power source for correct voltage
before plugging in or connecting the unit. The
primary power source, fuse/breaker, and any
extension cords used must conform to local
electrical code and the recommended circuit
protection and wiring requirements as specified
in Section 2.
3.03 Torch
• Make sure that the torch cable and torch
switch terminals are connected to front
panel.
• Make sure the Work Cable is secured properly to front panel.
• Before activating, turn torch away from
yourself and others.
DANGER
Do not cut in humid or wet surroundings.
• Before you maintain or replace torch parts,
waitforthepostowaircycletostop,then
turn the machine off and disconnect from
input power.
• Always use original manufacturers parts.
The use of aftermarket parts could result in
lower parts life and in unsatisfactory cutting results. Any warranty claims would be
waived.
• Recycle worn parts according to local requirements.
NOTE
Repairs must be done by skilled and qualified
personnel only.
Installation 3-1 Manual 0-4965
Drag-gun™ lt
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Installation 3-2 Manual 0-4965
Drag-gun™ lt
Overheating
Indicator
AC Power
Indicator
Air Vents
Work Lead
Connection
"On / Off"
Switch
Art # A-07724
Torch Lead
Connection
A-07723
Electrode,
9-6006
Gas Distributor,
9-6007
Tip, 9-6099
Shield Cup,
9-6003
Torch Head
Assembly
SECTION 4:
OPERATION
4.01 Front Control Panel
INDICATOR LAMP
4.02 Preparations For Operating
At the start of each operating session:
WARNING
Disconnect primary power at the source
before assembling or disassembling power
supply, torch parts, or torch and leads assemblies.
Torch Parts Selection
Check the torch for proper assembly and appropriate torch parts. The torch parts must correspond
with the type of operation, and with the amperage
output of this Power Supply (15 amps maximum).
Use only genuine manufacturer’s parts with this
torch.
• Power Indicator - Lights when primary power switch is turned on.
• TEMPERATURE Indicator - Indicator
is normally OFF. Indicator is ON when
internal temperature exceeds normal limits. Shut unit OFF; let the unit cool before
continuing operation.
PRIMARY POWER SWITCH, ON / OFF
The power switch is located on the front panel.
Placing the primary power switch to the “ON”
position energizes the power source.
CAUTION
When the power source is overloaded, the switch
turns to the OFF or neutral position automatically. Return completely to the OFF positioin
before attempting to turn ON again.
Operation 4-1 Manual 0-4965
Drag-gun™ lt
Make a solid work cable
connection to the workpiece or cutting table
A-02022
A-00024
Shield Cup
Torch
Standoff
Distance 1/8" - 3/8"
Connect Work Cable
Torch Operation
• Wear gloves and protective goggles.
• Do not place bare hand on work piece.
1. For drag cutting, keep the torch in contact with the work piece.
2. For standoff cutting, hold the torch 1/8
- 3/8 in (3-9 mm) from the work piece as
shown below.
5. To shut off the torch simply release the
Torch Trigger. When the trigger is re-
leasedagaspost-owwilloccur.Ifthe
Torch Trigger is pushed during the post-
ow,thepilotarcwillrestartimmediately
and the cutting arc will restart when the
torch is brought within range of the work
piece.
Typical Cutting Speeds
Cutting speeds vary according to torch output,
the type of material being cut, and operator skill.
Speeds shown are typical for this cutting system
using air plasma to cut materials shown.
Material Material
1/8” 25.0
Mild Steel
3/16” 16.0
1/4” slow speeds
Inches Per
3. With the torch in starting position, press
and hold the Torch Trigger. The pilot arc
will come on and remain on until the cut-
Operation 4-2 Manual 0-4965
ting arc starts.
4. Once on, the cutting arc remains on as
long as the Torch Trigger is held down.
5.01 General Maintenance
Warning!
Disconnect input power before maintaining.
Each Use
Visual check of
torch tip and electrode
Weekly
Visually inspect the torch body
tip, electrode and shield cup
Visually inspect the
cables and leads.
Replace as needed
3 Months
Clean
exterior
of power supply
6 Months
Replace all
broken parts
Visually check and
Carefully clean the
interior
Maintain more often
if used under severe
conditions
Art # A-07891
Drag-gun™ lt
SECTION 5:
SERVICE
Manual 0-4965 5-1 SERVICE
Drag-gun™ lt
5.02 Basic Troubleshooting Guide
WARNING
There are extremely dangerous voltage and power levels present inside this unit. Do not attempt to
diagnose or repair unless you have had training in power electronics measurement and troubleshooting
techniques.
Basic Troubleshooting, Overview
This guide covers basic troubleshooting. It is helpful for solving many of the common problems that
can arise with this system. If major complex subassemblies are faulty, the unit must be returned to an
authorized service center for repair.
Follow all instructions as listed and complete each section in the order presented.
Common Symptoms
Problem - Symptom Possible Cause Recommended Action
Power Switch is on
but the A/C Indicator
does not light
1. Improper electrical connection.
2. System was overloaded.
3. Switch may be faulty
1. Check input power source and circuit breaker
or fuse. Check input cable and connections.
2. Turn Primary Power Switch Off and then On again.
3. Return to authorized service center for repair or replacement
Primary power switch
is on, but the cooling
fan does not work.
No air flow at torch
when torch switch is
activated.
Torch will not pilot
when torch switch is
activated.
Cut performance is
diminished.
1. No power or incorrect power to fan.
2. Faulty fan.
1. Internal connection is loose or
disconnected.
2. Internal air supply / compressor not
working.
3. Control PCB faulty
1. Air pressure too high or too low.
2. Torch consumables missing.
3. Worn or faulty torch parts
4. Thermal Switch activated
1. Worn torch parts.
2. Poor Work Lead connection.
3. Current sensor or PWM PCB faulty.
1. Check electrical connections to fan.
2. Return to authorized service center for repair or replacement
1. Check all air line connections and fittings.
2. Return to an authorized service center for repair.
3. Return to an authorized service center for repair.
1. There is no adjustment, return to an authorized service center
for repair.
2. Turn off power supply. Remove shield cup. Install missing
parts.
3. Inspect torch consumable parts. *Replace if necessary.
4. Allow the cooling fan to run for 2 minutes or longer until it
will resume operation.
1. Check current setting. *Check the Electrode and Tip for
excess wear.
2. *Check the connection of the Work Lead to the work piece.
3. Return to an authorized service center for repair or
replacement.
* See following illustrations for parts wear and work lead connection
SERVICE 5-2 Manual 0-4965
Examples of parts wear.
New Electrode
Worn Electrode
A-01270
Good Tip
Worn Tip
Art# A-07727
Make a solid work cable
connection to the workpiece or cutting table
A-02022
Example of Work Lead connection.
Drag-gun™ lt
Manual 0-4965 5-3 SERVICE
Drag-gun™ lt
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SERVICE 5-4 Manual 0-4965
Drag-gun™ lt
Primary Input Power "On" or Plugged in
Green Power Indicator "On" and Fan is Running
Power Supply On/Off Switch "On"
No Pilot Arc
Compressor and Pilot Arc Ignition starts
Start Cutting Operation
YES
Post Flow of Air, Approximately 12 Seconds Then Stops
Cutting Done ?
Torch Switch "On"
Primary Input Power Switch "Off" or Unplugged
Green Power Indicator "Off" and Fan Stops
Power Supply On/Off Switch "Off"
Check Torch parts alignment.
(PIP switches need to be repaired
by a Qualified Technician.
More air flow is required for
Torch to Pilot than to run the
power supply.
Compressor not functioning
properly needs to be repaired
by a Qualified Technician)
Note: The Torch will be very hot!
Do not set on or near flammable materials!
Art # A-07874
Release Torch Switch
Appendix 1: Operating Sequence, Block Diagram
Manual 0-4965 A-1 APPENDIX
Drag-gun™ lt
Pilot Wire (Pink)
Art # A-07880
To Power
Supply Adapter
Pilot
Black
White
PIP
Switch
Torch
Switch
Torch Leads
Torch Head
Detail
Pilot Wire
Connection
Black
White
Air and Negative /Plasma Lead
Air Line and
To Compressor
Disconnect power. Remove ten
screws from cover and remove
the cover.
Negative / Plasma Lead
Pink
Appendix 2: Torch Connection
APPENDIX A-2 Manual 0-4965
Appendix 3: System Schematic 120V
Art # A-07881
Drag-gun™ lt
Manual 0-4965 A-3 APPENDIX
Drag-gun™ lt
This Page Intentionally Blank
APPENDIX A-4 Manual 0-4965
GLOBAL CUSTOMER SERVICE CONTACT
Thermadyne USA
2800 Airport Road
Denton, Tx 76207 USA
Telephone: (940) 566-2000
800-426-1888
Fax: 800-535-0557
Thermadyne Canada
2070 Wyecroft Road
Oakville, Ontario
Canada, L6L5V6
Telephone: (905)-827-1111
Fax: 905-827-3648
Thermadyne Europe
Europe Building
Chorley North Industrial Park
Chorley, Lancashire
England, PR6 7Bx
Telephone: 44-1257-261755
Fax: 44-1257-224800
Thermadyne Asia Sdn Bhd
Lot 151, Jalan Industri 3/5A
Rawang Integrated Industrial Park - Jln Batu Arang
48000 Rawang Selangor Darul Ehsan
West Malaysia
Telephone: 603+ 6092 2988
Fax : 603+ 6092 1085
Cigweld, Australia
71 Gower Street
Preston, Victoria
Australia, 3072
Telephone: 61-3-9474-7400
Fax: 61-3-9474-7510
Thermadyne Italy
OCIM, S.r.L.
Via Benaco, 3
20098 S. Giuliano
Milan, Italy
Tel: (39) 02-98 80320
Fax: (39) 02-98 281773
Thermadyne, China
RM 102A
685 Ding Xi Rd
Chang Ning District
Shanghai, PR, 200052
Telephone: 86-21-69171135
Fax: 86-21-69171139
Thermadyne International
2070 Wyecroft Road
Oakville, Ontario
Canada, L6L5V6
Telephone: (905)-827-9777
Fax: 905-827-9797
Corporate Headquarters
16052 Swingley Ridge Road
Suite 300
St. Louis, MO 63017
Telephone: 636-728-3000
Email: TDCSales@Thermadyne.com
www.thermadyne.com
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