Manual No. 0-2780
July 30, 1999
Operating Manual
A-02464
Air Plasma Cutting
Power Supply (CE)
WARNING
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 our
best judgement, Thermal Dynamics Corporation assumes no
liability for its use.
Pak Master
®
50XL PLUS Air Plasma Cutting Power Supply
Operating Manual (CE) Number 0-2780
Published by:
Thermal Dynamics Corporation
Industrial Park No. 2
West Lebanon, New Hampshire, USA 03784
(603) 298-5711
Copyright 1999 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 liabil-
ity to any party for any loss or damage caused by any error or
omission in the Pak Master
®
50XL PLUS Air Plasma Cutting
Power Supply Operating Manual (CE), whether such error
results from negligence, accident, or any other cause.
Printed in the United States of America
July 1999
Purchase Date
Power Supply
Torch
Record Serial Numbers For Warranty Purposes
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TABLE OF CONTENTS
SECTION 1:
GENERAL INFORMATION ................................................................................................... 1
1.01 Notes, Cautions and Warnings........................................................................ 1
1.02 Important Safety Precautions ........................................................................ 1
1.03 Publications ................................................................................................... 2
1.04 Note, Attention et Avertissement ................................................................... 3
1.05 Precautions De Securite Importantes............................................................. 3
1.06 Documents De Reference .............................................................................. 5
1.07 Declaration of Conformity............................................................................... 7
1.08 Statement of Warranty.................................................................................... 8
SECTION 2:
INTRODUCTION .................................................................................................................. 9
2.01 Scope of Manual............................................................................................ 9
2.02 General Description of System ...................................................................... 9
2.03 Specifications/Design Features...................................................................... 9
2.04 Power Supply Options and Accessories........................................................10
SECTION 3:
INSTALLATION PROCEDURES ..........................................................................................11
3.01 Introduction ...................................................................................................11
3.02 Site Selection ...............................................................................................11
3.03 Unpacking .....................................................................................................11
3.04 Lifting Options...............................................................................................11
3.05 Input Power Connections...............................................................................12
3.06 Input Voltage Selection..................................................................................12
3.07 Primary Input Power Cable Connections........................................................13
3.08 Gas Connections ..........................................................................................14
3.09 Connecting Torch Leads ................................................................................16
3.10 Work Cable And Ground Connections............................................................16
SECTION 4:
OPERATION........................................................................................................................19
4.01 Introduction ...................................................................................................19
4.02 Functional Overview......................................................................................19
4.03 Operating Controls ........................................................................................19
4.04 Sequence of Operation..................................................................................21
4.05 Preparations for Operating ............................................................................22
4.06 Cut Quality....................................................................................................23
SECTION 5:
CUSTOMER/OPERATOR SERVICE ....................................................................................25
5.01 Introduction ...................................................................................................25
5.02 General Maintenance ....................................................................................25
5.03 Common Operating Problems .......................................................................26
5.04 Troubleshooting Guide ...................................................................................27
5.05 Power Supply Parts Replacement .................................................................29
TABLE OF CONTENTS (continued)
SECTION 6:
PARTS LISTS .....................................................................................................................31
6.01 Introduction ...................................................................................................31
6.02 Ordering Information......................................................................................31
6.03 Complete Power Supply Replacement...........................................................32
6.04 Replacement Parts .......................................................................................32
6.05 Options and Accessories ..............................................................................32
APPENDIX I: INPUT WIRING REQUIREMENTS ........................................................................33
APPENDIX II: SEQUENCE OF OPERATION (BLOCK DIAGRAM) .............................................34
APPENDIX III: SYSTEM SCHEMATIC .......................................................................................36
Date: 6/22/99 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
WARNINGS
OPERATION AND MAINTENANCE OF
PLASMA ARC EQUIPMENT CAN BE DAN-
GEROUS 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. Per-
sons who work near plasma arc cutting applica-
tions should consult their medical health profes-
sional 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 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 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 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 cir-
cuit.
• Repair or replace all worn or damaged parts.
• Extra care must be taken when the workplace is
moist or damp.
GENERAL INFORMATION 2 Date 6/22/99
• Install and maintain equipment according to NEC
code, refer to item 9 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.
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 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.
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
Date: 6/22/99 3 GENERAL INFORMATION
8. NFPA Standard 51, OXYGEN-FUEL GAS SYSTEMS
FOR WELDING, CUTTING AND ALLIED PRO-
CESSES, 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 Asso-
ciation, 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
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
AVERTISSEMENTS
L’OPÉRATION ET LA MAINTENANCE DU
MATÉRIEL DE SOUDAGE À L’ARC AU JET
DE PLASMA PEUVENT PRÉSENTER DES
RISQUES ET DES DANGERS DE SANTÉ.
Coupant à l’arc au jet de plasma produit de l’énergie
électrique haute tension et des émissions
magnétique qui peuvent interférer la fonction
propre d’un “pacemaker” cardiaque, les appareils
auditif, ou autre matériel de santé electronique.
Ceux qui travail près d’une application à l’arc au
jet de plasma devrait consulter leur membre
professionel de médication et le manufacturier de
matériel de santé pour déterminer s’il existe des
risques de santé.
Il faut communiquer aux opérateurs et au 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.
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Date: 6/22/99 5 GENERAL INFORMATION
• 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 afin d’éviter une perte
permanente de l’ouïe.
• Pour protéger votre ouïe contre les bruits forts, portez
des tampons protecteurs et/ou des protections
auriculaires. Protégez également les autres
personnes se trouvant sur le lieu de travail.
• Il faut mesurer les niveaux sonores afin d’assurer
que les décibels (le bruit) ne dépassent pas les
niveaux sûrs.
• Pour des renseignements sur la manière de tester le
bruit, consultez l’article 1, page 5.
1.06 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 Superin-
tendent of Documents, U.S. Government Printing
Office, Washington, D.C. 20402
4. Norme ANSI Z87.1, PRATIQUES SURES POUR LA
PROTECTION DES YEUX ET DU VISAGE AU
TRAVAIL ET DANS LES ECOLES, disponible de
l’Institut Américain des Normes Nationales (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 (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 NA-
TIONAL, disponible auprès de la National Fire Pro-
tection 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, 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
GENERAL INFORMATION 6 Date 6/22/99
14. Norme AWSF4.1 de l’Association Américaine de
Soudage, RECOMMANDATIONS DE PRA-
TIQUES SURES POUR LA PRÉPARATION À LA
COUPE ET AU SOUDAGE DE CONTENEURS
ET TUYAUX AYANT RENFERMÉ DES
PRODUITS DANGEREUX , disponible auprès de
la American Welding Society, 550 N.W. LeJeune
Rd., Miami, FL 33126
15. Norme ANSI Z88.2, PRATIQUES DE PROTEC-
TION RESPIRATOIRE, disponible auprès de
l’American National Standards Institute, 1430
Broadway, New York, NY 10018
Date: 6/22/99 7 GENERAL INFORMATION
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 Direc-
tive’ (European Council Directive 73/23/EEC as amended by Council Directive 93/68/EEC) and to the National
legislation for the enforcement of this Directive.
The equipment described in this manual conforms to all applicable aspects and regulations of the "EMC Directive"
(European Council Directive 89/336/EEC) and to the National legislation for the enforcement of this Directive.
Serial numbers are unique with each individual piece of equipment and details description, parts used to manufacture
a unit and date of manufacture.
National Standard and Technical Specifications
The product is designed and manufactured to a number of standards and technical requirements among them are:
* CSA (Canadian Standards Association) standard C22.2 number 60 for Arc welding equipment.
* UL (Underwriters Laboratory) rating 94VO flammability testing for all printed-circuit boards used.
* CENELEC EN50199 EMC Product Standard for Arc Welding Equipment.
* ISO/IEC 60974-1 (BS 638-PT10) (EN 60 974-1) (EN50192) (EN50078) applicable to plasma cutting equipment and associ-
ated accessories.
* Extensive product design verification is conducted at the manufacturing facility as part of the routine design and
manufacturing process. This is to ensure the product is safe, when used according to instructions in this manual and
related industry standards, and performs as specified. Rigorous testing is incorporated into the manufacturing
process to ensure the manufactured product meets or exceeds all design specifications.
Thermal Dynamics has been manufacturing products for more than 30 years, and will continue to achieve excellence in our
area of manufacture.
Manufacturers responsible representative: Steve Ward
Director of Operations
Thermadyne UK
Chorley England
GENERAL INFORMATION 8 Date 6/22/99
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 XL Plus Series, CutMaster 80XL , Cougar
and DRAG-GUN): A maximum of three (3) years from date of sale to an authorized distributor and a maximum of two (2) years from
date of sale by such distributor to the Purchaser, and with the further limitations on such two (2) year period (see chart below).
The limited warranty period for XL Plus Series and CutMaster 80XL shall be as follows: A maximum of four (4) years from date
of sale to an authorized distributor and a maximum of three (3) years from date of sale by such distributor to the Purchaser, and
with the further limitations on such three (3) year period (see chart below).
The limited warranty period for Cougar and DRAG-GUN shall be as follows: A maximum of two (2) years from date of sale to an
authorized distributor and a maximum of one (1) year from date of sale by such distributor to the Purchaser, and with the further
limitations on such two (2) year period (see chart below).
Parts
XL Plus Series & Parts Parts
PAK Units, Power Supplies CutMaster 80XL Cougar/Drag-Gun All Others Labor
Main Power Magnetics 3 Years 1 Year 2 Years 1 Year
Original Main Power Rectifier 3 Years 1 Year 2 Years 1 Year
Control PC Board 3 Years 1 Year 2 Years 1 Year
All Other Circuits And Components Including, 1 Year 1 Year 1 Year 1 Year
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
Maximizer 300 Torch 1 Year 1 Year
All Other Torches 180 Days 180 Days 180 Days 180 Days
Repair/Replacement Parts 90 Days 90 Days 90 Days None
Warranty repairs or replacement claims under this limited warranty must be submitted by an authorized Thermal Dynamics® repair
facility within thirty (30) days of the repair. No transportation costs of any kind will be paid under this warranty. 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.
Effective May 6, 1999
Manual 0-2780 9 SECTION 2: INTRODUCTION
SECTION 2:
INTRODUCTION
2.01 Scope of Manual
This manual contains descriptions, operating instructions
and basic maintenance procedures for the PAK Master
®
50XL PLUS Air Plasma Cutting Power Supply (CE). Ser-
vice of this equipment is restricted to Thermal Dynamics
trained personnel; unqualified personnel are strictly cau-
tioned against attempting repairs or adjustments not cov-
ered in this manual, at the risk of voiding the Warranty.
Read this manual thoroughly. A complete understand-
ing of the characteristics and capabilities of this equip-
ment will assure the dependable operation for which it
was designed.
2.02 General Description of System
The 50XL PLUS (CE) System includes a power supply,
PCH/M-40 torch & leads and work cable & clamp and
input power cable.
The Power Supply provides 40 amp maximum output
and includes all control circuitry, electrical and gas in-
puts and outputs, pilot circuitry, torch leads receptacle,
work cable with clamp, and input power cable.
NOTE
The power supply can be ordered in various con-
figurations with various options factory installed.
A-02462
Torch and Leads
Work Cable and Clamp
XL PLUS Power Supply
Figure 2-1 Pak Master 50XL PLUS (CE) System
The PCH/M-40 torch provides a maximum 1/2 inch (12.7
mm) cut capacity. Hand torches are available in either a
70° or 90° head configuration. Machine torches are avail-
able in a 180° head configuration. Torch leads are avail-
able in 25 ft (7.6 m), or 50 ft (15.2 m) lengths with fittings
for simple installation. Spare Parts Kits are available for
the torches which provide an assortment of replacement
torch parts.
NOTE
Refer to Section 2.04 for list of power supply op-
tions and accessories.
2.03 Specifications/Design Features
A. Power Supply Technical Specifications
The following specifications apply to the Power Supply
only:
1. Front Panel Controls
ON/OFF Switch, RUN/SET/LATCH Switch and
Output Current Control
2. Front Panel LED Indicators
AC, TEMP, GAS, DC
3. Rear Panel
Input Power Cable, Gas Connection, Gas Regulator/
Filter Assembly
4. Input Power
220 VAC (±10%), 50/60 Hz, Single or Three-Phase
380/415 VAC (±10%), 50/60 Hz, Three-Phase
Supplied with a 10 ft. (3.1 m) 4-Conductor Input
Power Cable with filtering beads.
5. Output Power
Continuously variable from 15 to 40 Amps maximum
6. Duty Cycle
100% Duty Cycle at an output of 96 VDC/40 Amps
7. Cut Capacity (Mild Steel)
1/2 inch (12.7 mm); 3/4 inch (19 mm) severance
8. Pilot Circuitry
Capacitive Discharge (CD), Pulsed DC
9. Weight
69 lbs ( 31.3 kg) w/work lead, input power cable
73 lbs ( 33 kg) w/work lead, torch & lead, input power
cable
10. Overall Dimensions
Overall dimensions are with handle, leads wrap
bracket, and Gas Regulator/Filter Assembly installed.
SECTION 2: INTRODUCTION 10 Manual 0-2780
19" (482 mm) High x 13" (330 mm) Wide x 24.8" (630
mm) Long
B. Gas Regulator/Filter Assembly
Specifications
The following specifications apply to the Gas Regulator/
Filter Assembly only:
1. Gas regulator maximum gauge pressure
160 psi (11 bar)
2. Maximum input gas pressure
125 psi (8.6 bar)
3. Filter
Coalescent type filter
2.04 Power Supply Options and
Accessories
NOTE
Refer to Section 6, Parts Lists, for part numbers
and ordering information.
The following are accessories that are available for this
power supply:
A. Dry Air In-Line Filter Kit
An optional in-line filter for use on compressed air
shop systems. Highly effective at removing moisture
and particulate matter from the air stream to at least
.85 microns.
B. Two Stage Air Line Filter
An alternative to the Dry Air Filter, this optional two
stage air line filter is for use on compressed air shop
systems. Filter removes moisture and contaminants
to at least 5 microns. The filter assembly is pre-as-
sembled at the factory and need only be attached to
the power supply.
C. High Pressure Regulators
High pressure regulators are available for air and ni-
trogen. The regulators are used to set the proper pres-
sure for the type gas being used.
NOTE
Regulators should not be installed with filter op-
tions A or B above.
D. Smart Cart
Rugged steel cart on easy rolling 10" pneumatic tires
to provide maximum mobility for the power supply.
Handle is 3/4" tubing with hooks for storage of torch
leads. A tie down strap is also included.
E. Computer Control Cable (CNC)
NOTE
This accessory can be used only with the PCM-40
Torches.
The interface cable is available in two lengths, 25 ft
(7.6 m) and 50 ft (15.2 m). The cable is used to inter-
face the power supply with an auxiliary control de-
vice to provide OK-To-Move and ON/OFF signals.
F. Remote Hand Pendant Control
The remote hand pendant control is avalable with a
25 ft. (7.6 m) cable. An extension cable of 25 ft. (7.6m)
can be added to the standard hand pendant control to
achieve a total length of 50 ft. (15.2 m).
G. Cutting Guide Kit
Easy add-on attachments to allow for straight line,
circle, or bevel cutting.
Manual 0-2780 11 SECTION 3: INSTALLATION PROCEDURES
SECTION 3:
INSTALLATION
PROCEDURES
3.01 Introduction
NOTE
Depending on how the system was ordered, some
Power Supply options may already be installed.
If option(s) have been factory installed some of the
instructions may not apply. It is recommended
that all subsections be read for general informa-
tion.
This section describes installation of the Power Supply
and connecting the Torch.
These instructions apply to the Power Supply only; in-
stallation procedures for the Torch, Options, and Acces-
sories are given in Manuals specifically provided for those
units.
The complete installation consists of:
1. Site selection
2. Unpacking
3. Connections to Power Supply
a. Input power
b. Gas
c. Work cable
d. Torch Leads
4. Grounding
5. Operator training
3.02 Site Selection
Select a clean, dry location with good ventilation and ad-
equate working space around all components.
NOTE
Review Important Safety Precautions (page 1) to
be sure that the selected location meets all safety
requirements.
The power supply is fan cooled by air flow through the
front panel to the rear panel. Air flow must not be ob-
structed. Provide at least 2 feet (0.6 m) in the rear and at
least 6 inches (0.2 m) on each side for clearance . Provide
sufficient clearance in front of the unit to allow access to
the front panel controls (minimum 6 inches or 0.2 m).
CAUTION
Operation without proper air flow will inhibit
proper cooling and reduce duty cycle.
3.03 Unpacking
Each component of the system is packaged and protected
with a carton and packing material to prevent damage
during shipping.
1. Unpack each item and remove all packing material.
NOTE
The Cutting Spare Parts Kit is shipped in the Torch
Leads Storage Area on the side of the Power Sup-
ply.
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 in-
stallation.
3.04 Lifting Options
WARNINGS
Do not touch live electrical parts.
Disconnect input power conductors from de-ener-
gized supply line before moving unit.
This unit is equipped with one handle mounted onto the
top of the enclosure for hand carrying purposes.
WARNING
FALLING EQUIPMENT can cause serious per-
sonal injury and equipment damage.
• Lift unit with the handle on top of the enclosure.
• Persons only of adequate physical strength should
lift the unit.
• Use hand cart or similar device of adequate capac-
ity.
SECTION 3: INSTALLATION PROCEDURES 12 Manual 0-2780
• If using a fork lift vehicle, place and secure unit on a
proper skid before transporting.
• This unit has a handle mounted on top of the enclo-
sure for hand lifting only. Be sure unit is lifted and
transported safely and securely.
WARNING
HANDLE is not for mechanical lifting.
3.05 Input Power Connections
The 50XL PLUS Power Supply(CE) accepts input volt-
ages of 220V ± 10% single or three phase, or 380/415V ±
10% three phase. Input can be 50 or 60 Hz. All units are
supplied with a six foot EMC input power cable.
A. Input Voltage Selection
The Power Supply is factory wired for 380/415V, three
phase input. For 220V input voltage, the Power Sup-
ply must be changed using the procedures in section
3.06. and 3.07.
B. Electrical Connections
The primary power source must conform to local elec-
tric code. Recommended circuit protection and wir-
ing requirements are shown in Appendix I).
C. Opening Power Supply Enclosure
The left side panel of the Power Supply must be re-
moved to gain access to the input voltage selection.
WARNING
Disconnect primary power at the source before as-
sembling or disassembling the Power Supply, torch
parts, or torch and leads assemblies.
1. Using a phillips head screw driver remove the top two
screws which secure the left side panel (viewed from
front of unit) to the frame assembly. Loosen the bot-
tom three screws.
A-02644
Left Side Panel
Screws
(5 places)
Ground
Wire
Figure 3-1 Removing Left Side Panel
NOTE
There is a ground wire connection to the Left Side
Panel on the inside of the unit.
2. Loosen the bottom three screws, and carefully pull the
Left Side Panel up and away from the unit to gain
access to the inside of the unit.
3. To install the cover, reverse step 2.
3.06 Input Voltage Selection
The Power Supply has two voltage settings: 220VAC or
380/415VAC. All 50XL PLUS Power Supplies are fac-
tory-wired for 380/415VAC. For 220VAC, the unit must
be reconfigured.
Input voltage selection is accomplished by switching a
wire harness connector inside the Power Supply.
Also for single-phase operation a jumper wire must be
properly installed (refer to Section 3.07, Primary Input
Power Cable Connections.)
WARNING
Disconnect primary power at the source before as-
sembling or disassembling the power supply.
To change the voltage selection move the power selec-
tion plug to the desired input connection for 220V or 380/
415V operation. Refer to the label attached to the panel.
Manual 0-2780 13 SECTION 3: INSTALLATION PROCEDURES
Voltage Selection
Connector
380/415 Volts
220 Volts
Voltage Selection
Label
A-02628
Not Used
Figure 3-2 Input Voltage Selection
3.07 Primary Input Power Cable
Connections
All units are supplied from the factory as 380/415V, three
phase with a six foot EMC input power cable installed.
A. Single or Three Phase Operation
220V units may be either single or three phase. Depend-
ing on the type of operation, the primary power cable
wiring may need to be changed by the user. Refer to the
following procedure to connect the supplied input EMC
power cable to the customer power source:
For Single-Phase Operation:
Single-phase operation requires a 2-conductor cable
with ground.
a. Locate the ground stud and remove the top nut
and washer.
b. Install a lug terminal on the ground wire.
c. Place the ground wire onto the ground stud
and secure with the nut and washer.
d. Insert the other two wires into the L1 and L2
terminals on the contactor.
e. Tighten all set screws.
AC Input
Power Cable
L1
L2
GND
Input Contactor
A-01330
Figure 3-3 Primary Power Cable Connections -
Single-Phase Operation
For Three-Phase Operation:
Three-phase operation requires a 3-conductor cable
with ground.
a. Locate the ground stud and remove the top nut
and washer.
b. Install a lug terminal on the ground wire.
c. Place the ground wire onto the ground stud
and secure with the nut and washer.
d. Insert the other three wires into the L1, L2, and
L3 terminals on the contactor.
e. Tighten all set screws.
AC Input
Power Cable
L1
L2
L3
GND
Input Contactor
A-01329
Figure 3-4 Primary Power Cable Connections -
Three-Phase Operation
SECTION 3: INSTALLATION PROCEDURES 14 Manual 0-2780
B. Connecting the Input Power Cable to
Customer Power Source
Connect the supplied input EMC power cable to the cus-
tomer power source per the following procedure:
NOTE
The input power cable must not be modified in any
way as filtering beads are installed on the cable.
1. Strip back the outer covering approximately 3
inches (76 mm) to expose the individual wires at
the free end of the cable.
2. Cut back the insulation on the individual wires
approximately 1/8 - 3/16 inch (3-5 mm).
3. Connect the ends of the individual wires a cus-
tomer supplied plug or main disconnect per the
following:
NOTE
All the input cable wires must be connected for
three-phase operation.
• Blue wire to Line 2 (Live)
• Black wire to Line 3 (Live), refer to Note above
• Brown wire to Line 1 (Live)
• Green/Yellow wire to Ground (Earth)
3.08 Gas Connections
A. Gas Requirements
WARNING
This unit not to be used with oxygen (O
2
).
Gases: Compressed Air or Nitrogen (N
2
) Only
Pressure: 70 psi (4.8 bar)
CAUTION
Maximum input gas pressure must not exceed 125
psi (8.6 bar)
Flow: Cutting - 200 scfh (94.3 lpm)
Gouging - 230 scfh (108.5 lpm)
B. Checking Air Quality
To test the quality of air, place the RUN/SET/LATCH
switch to SET position, place a welding filter lens in front
of the torch and turn on the gas. Any oil or moisture in
the air will be visible on the lens. Do not initiate an arc!
CAUTION
Air supply must be free of oil, moisture, and other
contaminants. Excessive moisture may cause
double-arcing, rapid tip wear, or even complete
torch failure. Contaminants may cause poor cut-
ting performance and rapid electrode wear.
C. Gas Connections
The gas supply is connected to the Pressure Regulator/
Filter Assembly installed on the rear of the unit. The con-
nection is the same for compressed air or high pressure
gas cylinders.
Connect the gas supply as follows:
1. Locate the 1/4 NPT to #4 (6mm) hose barb fitting
shipped inside the Torch Spare Parts Kit.
2. If an optional air line filter is to be installed, refer to
subsection D.
3. Install the supplied barb fitting as shown below.
4. Tighten the barb fitting.
5. Place an adjustable hose clamp (customer supplied),
1/4" (6.4mm) to 5/8" (15.9mm)) over the gas supply
hose.
Regulator/Filter
Assembly
1/4 NPT to #4 (6 mm) Hose
Fitting
#4 (6 mm) Gas
Supply Hose
Hose Clamp
A-01149
Figure 3-5 Gas Connection To Regulator/Filter
Assembly
Manual 0-2780 15 SECTION 3: INSTALLATION PROCEDURES
D. Optional Air Line Filter Installation
Additional filtering is recommended when using air from
a compressor to insure that moisture and debris from the
supply hose does not enter the torch. Although the Pres-
sure Regulator does have its own filter, the optional Dry
Air Filter (or optional Two Stage Air Line Filter) is rec-
ommended for improved filtering. Gas connections to
optional filters are shown in Figures 3-7 and 3-8 below.
A-02607
1/4 NPT to
#4 (6mm)
Hose Fitting
Dry Air Filter
Assembly
#4 (6mm)
Gas Supply
Hose
Hose Clamp
Figure 3-6 Gas Connection to Optional Dry Air
Filter Assembly
Two Stage Filter
Assembly
1/4 NPT to
#4 (6mm) Hose
Fitting
#4 (6mm) Gas
Supply Hose
Hose Clamp
A-01150
Figure 3-7 Gas Connection to Optional Two Stage
Filter Assembly
E. Using High Pressure Gas Cylinders
1. Refer to the following when using high pressure gas
cylinders as the gas supply:
CAUTION
Pressure should be set at 100 psi (6.9 bar) at the
high pressure gas cylinder regulator.
a. Refer to the manufacturer’s specifications for in-
stallation and maintenance procedures for high
pressure gas regulators.
b. Examine the cylinder valves to be sure they are
clean and free of oil, grease or any foreign mate-
rial. Momentarily open each cylinder valve to blow
out any dust which may be present.
c. The cylinder must be equipped with an adjustable
high-pressure regulator capable of outlet pressures
up to 100 psi (6.9 bar) maximum and flows of up
to 200 scfh (94.3 lpm).
2. Slide the gas supply hose over the barbed fitting.
3. Secure the gas supply hose inplace with the adjustable
hose clamp.
SECTION 3: INSTALLATION PROCEDURES 16 Manual 0-2780
NOTE
Supply hose must be at least #4 hose (1/4 in or 6
mm I.D.).
3.09 Connecting Torch Leads
WARNING
Disconnect primary power at the source before as-
sembling or disassembling the power supply, torch
parts, or torch and leads assemblies.
The Torch Leads must be properly installed to the Power
Supply for proper operation. Make all torch connections
to the Torch Bulkhead Panel per the following:
NOTE
Equipment ordered as a system will have the Torch
factory connected to the Power Supply.
1. Turn the screw latch securing the front access panel to
the power supply front panel.
Access
Panel
Screw
Latch
A-02467
Figure 3-8 Front Access Panel
2. Lift up on the access panel to gain access to the torch
bulkhead panel.
CAUTION
This system is designed for use with the PCH/M-
40 torch only. Do not connect any other torch to
this power supply.
3. Remove the Strain Relief Nut from the Strain Relief
supplied on the end of the Torch Leads.
Strain Relief
Nut
Strain Relief
Torch Leads
Assembly
A-02514
Figure 3-9 Torch Strain Relief Nut
4. Feed the end of the torch leads through the hole in the
front panel in the following order:
• Control Cable
• Gas lead
• Pilot Lead
5. Place the Strain Relief Nut over the torch leads and
position it in the hole in the front panel.
6. Hold the Strain Relief Nut in position and tighten the
Strain Relief on the outside of the unit.
7. Connect the torch gas/power lead fitting onto the Gas/
Power Lead Connection.
3.10 Work Cable And Ground
Connections
A. Electromagnetic Interference (EMI)
Pilot arc initiation generates a certain amount of electro-
magnetic interference (EMI), commonly called RF noise.
This RF may interfere with other electronic equipment
such as CNC controllers, etc. To minimize RF interfer-
ence, follow these grounding procedures when install-
ing mechanized systems:
B. Creating an Earth Ground
1. Install a ground wire (not included) between the sys-
tem and a solid earth ground (also called star ground).
To create a solid earth ground, drive a 1/2 in (12 mm)
diameter copper rod at least 6 - 8 ft (1.8 - 2.4 m) into
the earth so that the rod contacts moist soil over most
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