Thermal Dynamics Pak Master 50 User manual

Category
Welding System
Type
User manual

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®
A THERMADYNE
®
Company
Manual No. 0-2470
October 20, 1997
Air Plasma Cutting
Power Supply
Instruction Manual
R
The System Includes:
• Pak Master
®
50 Power Supply
• PCH/M-35 Smart Torch
®
with Leads
• Optional Input Power Cable
• Work Cable with Clamp
WARNING
WARNING
Read and understand this entire Instruction Manual and your
employer’s safety practices before installing, operating, or
servicing the equipment.
While the information contained in this Instruction Manual
represents our best judgement, Thermal Dynamics Corporation
assumes no liability for its use.
Pak Master
®
50 Air Plasma Cutting Power Supply
Instruction Manual Number 0-2470
Published by:
Thermal Dynamics Corporation
Industrial Park No. 2
West Lebanon, New Hampshire, USA 03784
(603) 298-5711
Copyright 1995 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 the Pak Master
®
50 Air Plasma Cutting Power Supply
Instruction Manual, whether such error results from negligence,
accident, or any other cause.
Printed in the United States of America
October 20, 1997
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 ...............................................................................6
1.08 Statement of Warranty....................................................................................7
SECTION 2: GENERAL DESCRIPTION ......................................................................................9
2.01 SYSTEM DESCRIPTION ...............................................................................9
2.02 SPECIFICATIONS ........................................................................................10
2.03 OPTIONS AND ACCESSORIES ..................................................................12
SECTION 3: INSTALLATION ......................................................................................................13
3.01 UNPACKING..................................................................................................13
3.03 SETTING UP THE TORCH ..........................................................................15
3.04 INSTALLING THE TORCH ...........................................................................17
3.05 REMOTE CONTROL HARNESS INSTALLATION .......................................18
3.06 ELECTRICAL CONNECTIONS ....................................................................20
3.07 WORK CABLE AND GROUND CONNECTIONS.........................................23
3.08 GAS CONNECTIONS ..................................................................................24
SECTION 4: OPERATION ..........................................................................................................27
4.01 OPERATING CONTROLS............................................................................27
4.02 GETTING STARTED ....................................................................................29
4.03 SEQUENCE OF OPERATION......................................................................30
4.04 TORCH PARTS SELECTION .......................................................................31
4.05 CUT QUALITY ..............................................................................................32
4.06 OPERATING THE SYSTEM.........................................................................34
4.07 OPERATING WITH A HAND TORCH...........................................................36
4.08 OPERATING WITH A MACHINE TORCH ....................................................37
4.09 RECOMMENDED CUTTING SPEEDS ........................................................40
4.10 GOUGING ....................................................................................................41
SECTION 5: CUSTOMER/OPERATOR SERVICE .....................................................................43
5.01 GENERAL POWER SUPPLY MAINTENANCE............................................43
5.02 REPLACING CONSUMABLE TORCH PARTS ............................................44
5.03 GENERAL TORCH MAINTENANCE............................................................45
5.04 SERVICING TORCH HEAD COMPONENTS ..............................................47
5.05 SERVICING TORCH LEADS COMPONENTS.............................................53
5.06 TORCH AND LEADS TROUBLESHOOTING...............................................56
5.07 POWER SUPPLY TROUBLESHOOTING ....................................................58
5.08 SERVICE PROCEDURES............................................................................62
TABLE OF CONTENTS (continued)
SECTION 6: PARTS LIST...........................................................................................................69
6.01 ORDERING INFORMATION ........................................................................69
6.02 SYSTEM COMPONENTS AND ACCESSORIES .........................................70
6.03 FRONT PANEL COMPONENTS ..................................................................71
6.04 REGULATOR/SOLENOID ASSEMBLY ........................................................72
6.05 BASE PANEL COMPONENTS.....................................................................73
6.06 CHASSIS COMPONENTS ...........................................................................74
6.07 REAR PANEL COMPONENTS ....................................................................76
6.08 REPLACEMENT TORCHES AND LEADS ...................................................77
5.9 TORCH HEADS AND SPLIT HOLDERS........................................................78
5.10 CONSUMABLE TORCH PARTS ..................................................................79
6.11 TORCH OPTIONS AND ACCESSORIES .....................................................80
6.12 TORCH SPARE PARTS KITS ......................................................................82
APPENDIX I: SYSTEM SCHEMATIC .........................................................................................84
1 GENERAL INFORMATION
SECTION 1:
GENERAL INFORMATION
1.01 Notes, Cautions and Warnings
Throughout this manual, notes, cautions, and warnings
are used to highlight important information. These high-
lights are categorized as follows:
NOTE
An operation, procedure, or background informa-
tion which requires additional emphasis or is help-
ful in efficient operation of the system.
CAUTION
A procedure which, if not properly followed, may
cause damage to the equipment.
WARNING
A procedure which, if not properly followed, may
cause injury to the operator or others in the oper-
ating area.
1.02 Important Safety Precautions
WARNING
OPERATION AND MAINTENANCE OF
PLASMA ARC EQUIPMENT CAN BE DAN-
GEROUS AND HAZARDOUS TO YOUR
HEALTH.
To prevent possible injury, read, understand and
follow all warnings, safety precautions and in-
structions 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 met-
als which may contain one or more of the follow-
ing:
Antimony Chromium Mercury
Arsenic Cobalt Nickel
Barium Copper Selenium
Beryllium Lead Silver
Cadmium Manganese Vanadium
Always read the Material Safety Data Sheets (MSDS)
that should be supplied with the material you are
using. These MSDSs will give you the informa-
tion 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 com-
bustible 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.
ELECTRIC SHOCK
Electric Shock can injure or kill. The plasma arc process
uses and produces high voltage electrical energy. This
electric energy can cause severe or fatal shock to the op-
erator or others in the workplace.
• Never touch any parts that are electrically “live” or
“hot.”
• 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 4 in Subsection 1.03, Publica-
tions.
• Disconnect power source before performing any ser-
vice or repairs.
• Read and follow all the instructions in the Operat-
ing Manual.
GENERAL INFORMATION 2
FIRE AND EXPLOSION
Fire and explosion can be caused by hot slag, sparks, or
the plasma arc.
• Be sure there is no combustible or flammable mate-
rial in the workplace. Any material that cannot be
removed must be protected.
• Ventilate all flammable or explosive vapors from
the workplace.
• 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 under-
water or while using a water table. DO NOT cut
aluminum alloys underwater or on a water table
unless the hydrogen gas can be eliminated or dis-
sipated. Trapped hydrogen gas that is ignited will
cause an explosion.
NOISE
Noise can cause permanent hearing loss. Plasma arc pro-
cesses can cause noise levels to exceed safe limits. You
must protect your ears from loud noise to prevent per-
manent loss of hearing.
To protect your hearing from loud noise, wear pro-
tective ear plugs and/or ear muffs. Protect others
in the workplace.
• Noise levels should be measured to be sure the deci-
bels (sound) do not exceed safe levels.
• For information on how to test for noise, see item 1
in Subsection 1.03, 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 hel-
met or shield. Also always wear safety glasses with
side shields, goggles or other protective eye wear.
• Wear welding gloves and suitable clothing to pro-
tect your skin from the arc rays and sparks.
• Keep helmet and safety glasses in good 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 recommended in Subsec-
tion 1.03, item 4.
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
Documents, U.S. Government Printing Office, Wash-
ington, D.C. 20402
2. ANSI Standard Z49.1, SAFETY IN WELDING AND
CUTTING, obtainable from the American Welding
Society, 550 N.W. LeJeune Rd, Miami, FL 33126
3. NIOSH, SAFETY AND HEALTH IN ARC WELD-
ING AND GAS WELDING AND CUTTING, obtain-
able from the Superintendent of Documents, U.S.
Government Printing Office, Washington, D.C. 20402
4. ANSI Standard Z87.1, SAFE PRACTICES FOR OC-
CUPATION 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 Broad-
way, New York, NY 10018
6. ANSI Standard Z49.2, FIRE PREVENTION IN THE
USE OF CUTTING AND WELDING PROCESSES,
obtainable from American National Standards Insti-
tute, 1430 Broadway, New York, NY 10018
7. AWS Standard A6.0, WELDING AND CUTTING
CONTAINERS WHICH HAVE HELD COMBUS-
TIBLES, obtainable 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 PRO-
CESSES, obtainable from the National Fire Protec-
tion 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 Pro-
tection Association, Batterymarch Park, Quincy, MA
02269
11. CGA Pamphlet P-1, SAFE HANDLING OF COM-
PRESSED GASES IN CYLINDERS, obtainable from
the Compressed Gas Association, 1235 Jefferson
Davis Highway, Suite 501, Arlington, VA 22202
3 GENERAL INFORMATION
12. CSA Standard W117.2, CODE FOR SAFETY IN
WELDING AND CUTTING, obtainable from the Ca-
nadian Standards Association, Standards Sales, 178
Rexdale Boulevard, Rexdale, Ontario, Canada M9W
1R3
13. NWSA booklet, WELDING SAFETY BIBLIOGRA-
PHY obtainable from the National Welding Supply
Association, 1900 Arch Street, Philadelphia, PA 19103
14. American Welding Society Standard AWSF4.1, REC-
OMMENDED SAFE PRACTICES FOR THE PREPA-
RATION FOR WELDING AND CUTTING OF CON-
TAINERS AND PIPING THAT HAVE HELD
HAZARDOUS SUBSTANCES, obtainable from the
American Welding Society, 550 N.W. LeJeune Rd,
Miami, FL 33126
15. ANSI Standard Z88.2, PRACTICE FOR RESPIRA-
TORY PROTECTION, obtainable from American
National Standards Institute, 1430 Broadway, New
York, NY 10018
1.04 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.
ATTENTION
Toute procédure pouvant résulter
l’endommagement du matériel en cas de non-
respect de la procédure en question.
AVERTISSEMENT
Toute procédure pouvant provoquer des blessures
de l’opérateur ou des autres personnes se trouvant
dans la zone de travail en cas de non-respect de la
procédure en question.
1.05 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.
Il faut communiquer aux opérateurs et au person-
nel 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 respi-
ration. 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.
GENERAL INFORMATION 4
• 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.
CHOC ELECTRIQUE
Les chocs électriques peuvent blesser ou même tuer . Le
procédé au jet de plasma requiert et produit de l’énergie
électrique haute tension. Cette énergie électrique peut
produire des chocs graves, voire mortels, pour l’opérateur
et les autres personnes sur le lieu de travail.
• Ne touchez jamais une pièce “sous tension” ou
“vive”; portez des gants et des vêtements secs.
Isolez-vous de la pièce de travail ou des autres par-
ties du circuit de soudage.
• Réparez ou remplacez toute pièce usée ou
endommagée.
• Prenez des soins particuliers lorsque la zone de tra-
vail est humide ou moite.
• Montez et maintenez le matériel conformément au
Code électrique national des Etats-Unis. (Voir la
page 5, article 9.)
• Débranchez l’alimentation électrique avant tout tra-
vail d’entretien ou de réparation.
• Lisez et respectez toutes les consignes du Manuel
de consignes.
INCENDIE ET EXPLOSION
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 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.
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-vio-
lets 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 lu-
nettes de protection ou une autre sorte de protec-
tion oculaire.
• Portez des gants de soudeur et un vêtement
protecteur approprié pour protéger votre peau
contre les étincelles et les rayons de l’arc.
• Maintenez votre casque et vos lunettes de protec-
tion en bon état. Remplacez toute lentille sale ou
comportant fissure ou rognure.
• Protégez les autres personnes se trouvant sur la zone
de travail contre les rayons de l’arc en fournissant
des cabines ou des écrans de protection.
• Respectez le teint de lentille recommandé dans le
article 4, page 5.
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 protéger les
oreilles contre les bruits forts afin d’éviter une perte
permanente de l’ouïe.
• Pour protéger votre ouïe contre les bruits forts, portez
des tampons protecteurs et/ou des protections
auriculaires. Protégez également les autres
personnes se trouvant sur le lieu de travail.
• Il faut mesurer les niveaux sonores afin d’assurer
que les décibels (le bruit) ne dépassent pas les
niveaux sûrs.
5 GENERAL INFORMATION
• Pour des renseignements sur la manière de tester le
bruit, consultez l’article 1, page 5.
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 Docu-
ments, U.S. Government Printing Office, Washing-
ton, 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 Super-
intendent of Documents, U.S. Government Print-
ing Office, Washington, D.C. 20402
4. Norme ANSI Z87.1, PRATIQUES SURES POUR LA
PROTECTION DES YEUX ET DU VISAGE AU
TRAVAIL ET DANS LES ECOLES, disponible de
l’Institut Américain des Normes Nationales (Ameri-
can National Standards Institute), 1430 Broadway,
New York, NY 10018
5. Norme ANSI Z41.1, NORMES POUR LES
CHAUSSURES PROTECTRICES, disponible
auprès de l’American National Standards Institute,
1430 Broadway, New York, NY 10018
6. Norme ANSI Z49.2, PRÉVENTION DES
INCENDIES LORS DE L’EMPLOI DE PROCÉDÉS
DE COUPE ET DE SOUDAGE, disponible auprès
de l’American National Standards Institute, 1430
Broadway, New York, NY 10018
7. Norme A6.0 de l’Association Américaine du
Soudage (AWS), LE SOUDAGE ET LA COUPE DE
CONTENEURS AYANT RENFERMÉ DES
PRODUITS COMBUSTIBLES, disponible auprès de
la American Welding Society, 550 N.W. LeJeune Rd.,
Miami, FL 33126
8. Norme 51 de l’Association Américaine pour la Pro-
tection contre les Incendies (NFP A), 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 NA-
TIONAL, disponible auprès de la National Fire Pro-
tection Association, Batterymarch Park, Quincy, MA
02269
10. Norme 51B de la NFP A, 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, Stan-
dards Sales, 178 Rexdale Boulevard, Rexdale,
Ontario, Canada, M9W 1R3
13. ivret 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 PRÉP ARATION À LA COUPE
ET AU SOUDAGE DE CONTENEURS ET
TUYAUX AYANT RENFERMÉ DES PRODUITS
DANGEREUX , disponible auprès de la American
Welding Society, 550 N.W. LeJeune Rd., Miami, FL
33126
15. Norme ANSI Z88.2, PRATIQUES DE PROTEC-
TION RESPIRATOIRE, disponible auprès de
l’American National Standards Institute, 1430
Broadway, New York, NY 10018
GENERAL INFORMATION 6
1.07 Declaration of Conformity
Manufacturer: Thermal Dynamics Corporation
Address: Industrial Park #2
West Lebanon, New Hampshire 03784
USA
The equipment described in this manual conforms to all applicable aspects and regulations of the ‘Low Voltage
Directive’ (European Council Directive 73/23/EU, as recently changed in Directive 93/63/EU) 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 manufac-
ture a unit and date of manufacture.
National Standard and Technical Specifications
The product is designed and manufactured to a number of standards and technical requirements among them are:
* CSA (Canadian Standards Association) standard C22.2 number 60-M1990 for Arc welding equipment.
* UL (Underwriters Laboratory) rating 94VO flammability testing for all printed-circuit boards used.
* IEC 974-1 (BS 638-PT10) (EN 60 974-1) applicable to welding equipment and associated accessories.
* Extensive product design verification is conducted at the manufacturing facility as part of the routine design and
manufacturing process, to ensure the product is safe 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 that perform in a safe manner for more than 30 years and will
continue to achieve excellence in our area of manufacture.
Manufacturers responsible representative: David Ashworth
Vice President & Managing Director
Thermadyne Europe
Chorley England.
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
stored, installed, operated, and maintained in accordance with Thermal’s specifications, instructions, recommendations and
recognized standard industry practice, and not subject to misuse, repair, neglect, alteration, or accident, correct such defects by
suitable repair or replacement, at Thermal’s sole option, of any components or parts of the product determined by Thermal to be
defective.
THIS WARRANTY IS EXCLUSIVE AND IS IN LIEU OF ANY WARRANTY OF MERCHANTABILITY OR FITNESS FOR A
PARTICULAR PURPOSE.
LIMITATION OF LIABILITY: Thermal shall not under any circumstances be liable for special or consequential damages, such
as, but not limited to, damage or loss of purchased or replacement goods, or claims of customers of distributor (hereinafter
“Purchaser”) for service interruption. The remedies of the Purchaser set forth herein are exclusive and the liability of Thermal
with respect to any contract, or anything done in connection therewith such as the performance or breach thereof, or from the
manufacture, sale, delivery, resale, or use of any goods covered by or furnished by Thermal whether arising out of contract,
negligence, strict tort, or under any warranty, or otherwise, shall not, except as expressly provided herein, exceed the price of the
goods upon which such liability is based.
THIS WARRANTY BECOMES INVALID IF REPLACEMENT PARTS OR ACCESSORIES ARE USED WHICH MAY IMPAIR
THE SAFETY OR PERFORMANCE OF ANY THERMAL PRODUCT.
THIS WARRANTY IS INVALID IF THE PRODUCT IS SOLD BY NON-AUTHORIZED PERSONS.
The limited warranty periods for Thermal products shall be as follows (with the exception of STAK PAK II): 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 following further limitations on such two (2) year period. The limited warranty period for STAK
PAK II 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 following further limitations on such three (3) year
period:
PARTS
PAK UNITS, POWER SUPPLIES STAK PAK II All OTHERS LABOR
MAIN POWER MAGNETICS ............................................................ 3 YEARS ..............2 YEARS ................ 1 YEAR
ORIGINAL MAIN POWER RECTIFIER ........................................... 3 YEARS ..............2 YEARS ................ 1 YEAR
CONTROL PC BOARD .......................................................................3 YEARS .............. 2 YEARS ................ 1 YEAR
ALL OTHER CIRCUITS AND COMPONENTS ............................... 1 YEAR ................1 YEAR ................. 1 YEAR
INCLUDING, BUT NOT LIMITED TO, STARTING
CIRCUIT, CONTACTORS, RELAYS, SOLENOIDS, PUMPS,
POWER SWITCHING SEMI-CONDUCTORS
CONSOLES, CONTROL EQUIPMENT, HEAT................................... 1 YEAR ................ 1 YEAR ................ 1 YEAR
EXCHANGES, AND ACCESSORY EQUIPMENT
TORCH AND LEADS............................................................................. 180 DAYS............. 180 DAYS............. 180 DAYS
REPAIR/REPLACEMENT PARTS ......................................................... 90 DAYS............... 90 DAYS.................NONE
Warranty repairs or replacement claims under this limited warranty must be submitted by an authorized Thermal Arc® repair
facility within thirty (30) days of the repair. No transportation costs of any kind will be paid under this warranty. Transportation
charges to send products to an authorized warranty repair facility shall be the responsibility of the customer. All returned goods
shall be at the customer’s risk and expense. This warranty supersedes all previous Thermal warranties.
Thermal Arc® is a Registered Trademark of Thermal Dynamics.
Effective February 1, 1995
GENERAL INFORMATION 8
Manual 0-2470 9 GENERAL DESCRIPTION
2.01 SYSTEM DESCRIPTION
The Pak Master
®
50
Air Plasma Cutting
System Includes:
• Pak Master
®
50 - The power supply provides 35 amp maximum
output and includes all control circuitry, electrical and gas
inputs and outputs, pilot circuitry, and a quick disconnect torch
leads receptacle. The power supply is shipped with a work
cable and clamp attached. A 230V single-phase primary input
power cable with molded 50 amp plug is optional. Machine
torch systems also include a remote hand control and remote
control wire harness.
• PCH/M-35 Torch with Leads (Packaged Separately) - The torch
provides a maximum 1/2 inch (12 mm) cut capacity. Hand
torches are available in 70° and 90° configurations which
include a handle and multi-position switch assembly. Machine
torches include a rack and pinion mounting assembly. A
phenolic (plastic) pinch block mounting assembly is optional.
Torch leads are available in 12.5, 25, or 50 ft (3.8, 7.6, or 15.2 m)
lengths with a quick disconnect torch leads fitting for simple
installation. The PCH/M-35 includes a spare parts kit which
provides an assortment of replacement consumable torch parts.
• See page 12 for a list of other system options and accessories.
Figure 2-A System Components
SECTION 2: GENERAL DESCRIPTION
Torch
with Leads
Pak Master 50
Power Supply
Work Cable
with Clamp
WORK
TORCH
ON
OFF
AC
TEMP
PIP
GAS
DC
PILOT
CSD
GAS PRESSURE
RUN
SET
CURR
A-00750
GENERAL IDESCRIPTION 10 Manual 0-2470
2.02 SPECIFICATIONS
ON/OFF Switch
RUN/SET Switch
Output Current Control
Corner Slowdown Control
Pressure Regulator Control
LED Indicators:
AC Power, TEMP, PIP (Parts-In-Place), GAS, DC Power, PILOT
Pressure Gauge
200 to 460 VAC (±10%), 50 or 60 Hz, Single or Three-Phase
575V Requires Additional Transformer (Catalog No. 9-6211)
Continuously variable from 15 to 35 Amps maximum
70% Duty Cycle
1/2 in (12.7 mm) at 10 ipm
High Frequency (HF), Constant DC
Remote Start/Stop, OK-to-Move, and Corner Slowdown (CSD)
69.8 lbs (31.7 kg)
18.5" High x 11.1" Wide x 21.7" Long
(470 x 282 x 551 mm)
Controls
Panel Indicators
Input Power
Output Power
Cut Capacity
Pilot Circuitry
CNC Capability
Weight
Dimensions
Configurations
Current Rating
Duty Cycle
Cutting Range
Pierce Rating
Transfer Distance
Consumable Parts
Gases
Pressure Requirements
Flow Requirements
Available Leads Lengths
70° or 90° Hand Torch, 180° Machine Torch
35 amps Maximum, DC Straight Polarity
100% @ 35 amps
Most materials up to 1/2 in (12.7 mm)
1/4 in (6.3 mm)
3/8 in (9.5 mm)
Gas Distributor, Electrode, Tip, Shield Cup
Compressed Air, Nitrogen (N2)
70 psi (4.8 BAR)
Cutting - 200 scfh (94.4 lpm)
Gouging - 230 scfh (108.5 lpm)
12.5 ft (3.8 m), 25 ft (7.2 m), or 50 ft (15.2 m)
Extendable to 150 ft (45.6 m)
Table 2-B Torch Specifications
Table 2-A Power Supply Specifications
Manual 0-2470 11 GENERAL DESCRIPTION
2.02 SPECIFICATIONS (continued)
Figure 2-B PCH/M-35 Torch Dimensions
3.09 in
(78 mm)
9.59 in
(244 mm)
1.06 in
(27 mm)
8.95 in
(227 mm)
1.06 in
(27 mm)
2.95 in
(75 mm)
1.38 in
(35 mm)
0.20 in (5 mm)
6.21 in (158 mm) Min.
14.72 in (374 mm) Max.
16.60 in (422 mm)
1.06 in
(27 mm)
A-00009
PCM-35 Machine Torch
with Rack and Pinion
Mounting Assembly
PCH-35 70 ° Hand Torch
PCH-35 90 ° Hand Torch
GENERAL IDESCRIPTION 12 Manual 0-2470
• Remote Control (RC) Wire Harness ......................Cat. No. 9-6210
For converting a hand cutting system to mechanized use with a
remote hand pendant control or computer control (CNC) cable.
• Remote Hand Pendant Control..............................Cat. No. 7-3114
Hand-held remote ON/OFF control device for systems with
remote wire harness installed. Includes a 25 ft (7.6 m) cable.
• Computer (CNC) Interface Cable - 25 ft (7.6 m) ..Cat. No. 8-5557
Computer (CNC) Interface Cable - 50 ft (15.2 m) Cat. No. 8-5558
For interfacing the power supply with a computer or auxiliary
control device. Provides ON/OFF, OK-to-move, and corner
slowdown signals. (Remote wire harness must be installed.)
• High Pressure Regulator - Air................................Cat. No. 9-3022
High Pressure Regulator - Nitrogen (N
2) .............Cat. No. 9-2722
• Running Gear............................................................Cat. No. 7-3201
For transporting the system with torch and leads storage.
• Air Line Filter - Single Stage ...................................Cat. No. 7-3265
Air Line Filter - Two Stage......................................Cat. No. 7-3340
Remove damaging moisture and contaminants from the air
stream when using compressed air.
• 575V Transformer Unit............................................Cat. No. 9-6211
For operating standard systems with 575V three-phase input.
• Spare Parts Kit - MaximumLife™..........................Cat. No. 5-6001
Spare Parts Kit - Gouging .......................................Cat. No. 5-6015
Kits contain replacement front-end torch parts (see detailed
description of spare parts kit contents on page 80).
• Leads Extension Kit - PCH-35, 25 ft (7.6 m) .........Cat. No. 4-6007
Leads Extension Kit - PCH-35, 50 ft (15.2 m) .......Cat. No. 4-6008
Leads Extension Kit - PCM-35, 25 ft (7.6 m) .........Cat. No. 4-6009
Leads Extension Kit - PCM-35, 50 ft (15.2 m) .......Cat. No. 4-6010
For extending torch leads up to 150 ft (45.7 m).
• Phenolic Mounting Tube.........................................Cat. No. 7-3251
Phenolic Pinch Block Mounting Assembly ..........Cat. No. 7-3252
For machine mounted torch applications where a non-metal
mounting assembly is desired.
• Switch Lever Kit .......................................................Cat. No. 8-5170
Provides a lever for activating the hand torch control switch.
See System Components and Accessories (page 70) or Torch
Options and Accessories (page 80) for more information.
2.03 OPTIONS AND ACCESSORIES
Pak Master 50
System Options and
Accessories
Torch Options
and Accessories
NOTE
Manual 0-2470 13 INSTALLATION
3.01 UNPACKING
Each component of the system is packaged separately and pro-
tected with a carton and packing material to prevent damage
during shipping.
Included with each power supply is:
(1) Work Cable with Clamp (Attached)
(1) 230V Single-Phase Input Power Cable with Plug (Optional)
(1) Air Q/D Coupling - 1/4 NPT to #6 Barb ..........Cat. No. 9-6258
(1) Fuse - 2 Amp, 600V ...............................................Cat. No. 9-3861
(1) Spare Parts Container (without Parts) ...............Cat. No. 8-3213
(1) Pak Master 50 Instruction Manual .....................Cat. No. 0-2470
Included with each machine torch system is:
(1) Remote Control Hand Pendant ..........................Cat. No. 7-3114
(1) Remote Control Interface Wire Harness ...........Cat. No. 9-6210
Torches are packaged separately. Included with each torch is:
(1) PCH/M-35 Torch (with Shield Cup, Tip, Electrode, and Gas
Distributor Installed)
(1) Torch Leads with Quick Disconnect (Attached)
(1) Torch Handle Assembly (For Hand Torches), or
(1) Machine Torch Mounting Assembly (For Machine Torches)
(1) MaximumLife™ Cutting Spare Parts Kit - Includes:
(1) Shield Cup Attachment.................................Cat. No. 9-6503
(5) Tips (Standoff Cutting) .................................Cat. No. 9-6500
(3) Tips (Drag Cutting)........................................Cat. No. 9-6501
(5) Electrodes ........................................................Cat. No. 9-6506
(1) Gas Distributor ...............................................Cat. No. 9-6507
Other accessories are packaged separately.
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.
What's Included with
the Power Supply
What's Included
with the Torch
Unpacking Procedure
SECTION 3: INSTALLATION
INSTALLATION 14 Manual 0-2470
Choosing a Location
CAUTION
NOTE
3.02 CHOOSING A LOCATION
Select a clean, dry location with good ventilation and adequate
working space around all components.
The power supply is cooled by air flow through the rear panel.
Air flow must not be obstructed. Provide at least 2 feet (0.61 m) of
clearance in the rear. Provide at least 6 inches (0.15 m) clearance
on each side. Provide sufficient clearance in front of the unit to
allow access to front panel controls (minimum 6 in or 0.15 m).
Operation without proper air flow will inhibit proper cooling and
reduce duty cycle.
Review Important Safety Precautions at the front of this Manual
to be sure that the selected location meets all safety requirements.
Manual 0-2470 15 INSTALLATION
3.03 SETTING UP THE TORCH
Figure 3-A Hand Torch Switch Options
WARNING
Hand Torch Set-Up
Disconnect primary power at the source before disassembling
the power supply, torch, or torch leads.
The torch parts (shield cup, tip, electrode, and gas distributor)
must correspond with the type of operation (drag cutting, stand-
off cutting, or gouging). Refer to Torch Parts Selection (page 31).
The torch is factory assembled with the control switch in the top
front position (see Figure 3-A below). To position the control
switch on the bottom (underside) of the handle, pull the handle
back approximately 2 inches (51 mm) and rotate the handle
assembly 180° (do not rotate beyond 180°). To position the
control switch in the rear position:
1. Locate the tab on the back of the switch track closure. Gently
press in on the tab and carefully pry the closure upward.
2. Remove the switch track insert and the torch control switch.
3. Reinstall the switch track insert, then the switch, then the
switch track closure.
The optional switch lever kit provides a lever for activating the
torch control switch. Refer to Torch Options and Accessories
(page 80) for ordering information.
Bottom mounted
torch switch (shown
with optional switch lever)
Switch Track Closure
Switch Track Insert
Switch Assembly
Switch Track
Switch Lever
with Mounting
Brackets
(Optional)
Reverse view of
closure - press
tab to remove
INSTALLATION 16 Manual 0-2470
3.03 SETTING UP THE TORCH (continued)
WARNING
Machine Torch Set-Up
Figure 3-B Machine Torch Set-Up
Disconnect primary power at the source before disassembling
the power supply, torch, or torch leads.
The torch parts (shield cup, tip, electrode, and gas distributor)
must correspond with the type of operation (drag cutting, stand-
off cutting, or gouging). Refer to Torch Parts Selection (page 23).
Metal mounting tubes with rack and pinion assemblies are
standard for machine torches. Phenolic (plastic) mounting tubes
with pinch blocks are optional (see Torch Options and Accesso-
ries, page 80).
1. Mount the torch assembly on the cutting table.
Refer to Figure 3-B and:
2. To obtain a clean vertical cut, use a square to align the torch
perpendicular to the surface of the workpiece.
Use a square to align
the torch assembly
perpendicular to the surface
of the workpiece
Shown wth
Phenolic Pinch
Block Mounting
Assembly
A-00057
Shown with
Rack and Pinion
Mounting Assembly
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Thermal Dynamics Pak Master 50 User manual

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