Thermal Dynamics Pak Master 50 User manual

®

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

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

Thermal Dynamics Corporation

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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