Pak Master 75 XL Plus Manual

Air Plasma Cutting
Power Supply
A-02464
Operating Manual
August 23, 1999 Manual No. 0-2746

Read and understand this entire Operating Manual and your
WARNING employer’s safety practices before installing, operating, or
servicing the equipment.
While the information contained in this Operating Manual

WARNING represents our best judgement, Thermal Dynamics Corporation
assumes no liability for its use.
Pak Master® 75XL Plus Air Plasma Cutting Power Supply

Operating Manual Number 0-2746
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 liability
to any party for any loss or damage caused by any error or
omission in the Pak Master® 75XL Plus Air Plasma Cutting
Power Supply Operating Manual, whether such error results
from negligence, accident, or any other cause.
Printed in the United States of America
August 1999
Record Serial Numbers For Warranty Purposes
Purchase Date
Power Supply
Torch
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 ......................................................... 17
3.11 Tip Saver/Drag Cut Sensing Circuit ............................................................. 18
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 ................................................................................................... 24
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

SECTION 1:
GASES AND FUMES
GENERAL INFORMATION
Gases and fumes produced during the plasma cutting
process can be dangerous and hazardous to your health.
1.01 Notes, Cautions and Warnings
• Keep all fumes and gases from the breathing area.
Throughout this manual, notes, cautions, and warnings Keep your head out of the welding fume plume.
are used to highlight important information. These high-
• Use an air-supplied respirator if ventilation is not
lights are categorized as follows:
adequate to remove all fumes and gases.
NOTE • The kinds of fumes and gases from the plasma arc
An operation, procedure, or background informa- depend on the kind of metal being used, coatings
tion which requires additional emphasis or is help- on the metal, and the different processes. You must
ful in efficient operation of the system. be very careful when cutting or welding any met-
als which may contain one or more of the follow-
ing:
CAUTION
Antimony Chromium Mercury
Arsenic Cobalt Nickel
A procedure which, if not properly followed, may
Barium Copper Selenium
cause damage to the equipment.
Beryllium Lead Silver
Cadmium Manganese Vanadium
WARNING • 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
A procedure which, if not properly followed, may regarding the kind and amount of fumes and gases
cause injury to the operator or others in the oper- that may be dangerous to your health.
ating area.
• For information on how to test for fumes and gases
in your workplace, refer to item 1 in Subsection
1.02 Important Safety Precautions 1.03, Publications in this manual.
• Use special equipment, such as water or down draft
cutting tables, to capture fumes and gases.
WARNINGS • Do not use the plasma torch in an area where com-
bustible or explosive gases or materials are located.
OPERATION AND MAINTENANCE OF • Phosgene, a toxic gas, is generated from the vapors
PLASMA ARC EQUIPMENT CAN BE DAN- of chlorinated solvents and cleansers. Remove all
GEROUS AND HAZARDOUS TO YOUR sources of these vapors.
HEALTH.
Plasma arc cutting produces intense electric and ELECTRIC SHOCK
magnetic emissions that may interfere with the
proper function of cardiac pacemakers, hearing Electric Shock can injure or kill. The plasma arc process
aids, or other electronic health equipment. Per- uses and produces high voltage electrical energy. This
sons who work near plasma arc cutting applica- electric energy can cause severe or fatal shock to the op-
tions should consult their medical health profes- erator or others in the workplace.
sional and the manufacturer of the health
equipment to determine whether a hazard exists. • Never touch any parts that are electrically “live” or
“hot.”
To prevent possible injury, read, understand and
follow all warnings, safety precautions and in- • Wear dry gloves and clothing. Insulate yourself from
structions before using the equipment. Call 1-603- the work piece or other parts of the welding cir-
298-5711 or your local distributor if you have any cuit.
questions. • Repair or replace all worn or damaged parts.
• Extra care must be taken when the workplace is
moist or damp.
Date: 6/22/99 1 GENERAL INFORMATION

• Install and maintain equipment according to NEC • To protect your eyes, always wear a welding hel-
code, refer to item 9 in Subsection 1.03, Publica- met or shield. Also always wear safety glasses with
tions. side shields, goggles or other protective eye wear.
• Disconnect power source before performing any ser- • Wear welding gloves and suitable clothing to pro-
vice or repairs. tect your skin from the arc rays and sparks.
• Read and follow all the instructions in the Operat- • Keep helmet and safety glasses in good condition.
ing Manual. Replace lenses when cracked, chipped or dirty.
• Protect others in the work area from the arc rays.
FIRE AND EXPLOSION Use protective booths, screens or shields.
• Use the shade of lens as suggested in the following
Fire and explosion can be caused by hot slag, sparks, or per ANSI/ASC Z49.1:
the plasma arc. Minimum Protective Suggested
Arc Current Shade No. Shade No.
• Be sure there is no combustible or flammable mate- Less Than 300* 8 9
rial in the workplace. Any material that cannot be
300 - 400* 9 12
removed must be protected.
• Ventilate all flammable or explosive vapors from 400 - 800* 10 14
the workplace. * These values apply where the actual arc is clearly
• Do not cut or weld on containers that may have held seen. Experience has shown that lighter filters
combustibles. may be used when the arc is hidden by the work-
piece.
• Provide a fire watch when working in an area where
fire hazards may exist.
1.03 Publications
• Hydrogen gas may be formed and trapped under
aluminum workpieces when they are cut under- Refer to the following standards or their latest revisions
water or while using a water table. DO NOT cut for more information:
aluminum alloys underwater or on a water table
unless the hydrogen gas can be eliminated or dis- 1. OSHA, SAFETY AND HEALTH STANDARDS,
sipated. Trapped hydrogen gas that is ignited will 29CFR 1910, obtainable from the Superintendent of
cause an explosion. Documents, U.S. Government Printing Office, Wash-
ington, D.C. 20402
2. ANSI Standard Z49.1, SAFETY IN WELDING AND
NOISE CUTTING, obtainable from the American Welding
Society, 550 N.W. LeJeune Rd, Miami, FL 33126
Noise can cause permanent hearing loss. Plasma arc pro- 3. NIOSH, SAFETY AND HEALTH IN ARC WELD-
cesses can cause noise levels to exceed safe limits. You ING AND GAS WELDING AND CUTTING, obtain-
must protect your ears from loud noise to prevent per- able from the Superintendent of Documents, U.S.
manent loss of hearing. Government Printing Office, Washington, D.C. 20402
• To protect your hearing from loud noise, wear pro- 4. ANSI Standard Z87.1, SAFE PRACTICES FOR OC-
tective ear plugs and/or ear muffs. Protect others CUPATION AND EDUCATIONAL EYE AND FACE
PROTECTION, obtainable from American National
in the workplace.
Standards Institute, 1430 Broadway, New York, NY
• Noise levels should be measured to be sure the deci- 10018
bels (sound) do not exceed safe levels.
5. ANSI Standard Z41.1, STANDARD FOR MEN’S
• For information on how to test for noise, see item 1 SAFETY-TOE FOOTWEAR, obtainable from the
in Subsection 1.03, Publications, in this manual. American National Standards Institute, 1430 Broad-
way, New York, NY 10018
PLASMA ARC RAYS 6. ANSI Standard Z49.2, FIRE PREVENTION IN THE

USE OF CUTTING AND WELDING PROCESSES,
obtainable from American National Standards Insti-
Plasma Arc Rays can injure your eyes and burn your skin. tute, 1430 Broadway, New York, NY 10018
The plasma arc process produces very bright ultra violet 7. AWS Standard A6.0, WELDING AND CUTTING
and infra red light. These arc rays will damage your CONTAINERS WHICH HAVE HELD COMBUS-
eyes and burn your skin if you are not properly protected. TIBLES, obtainable from American Welding Society,
550 N.W. LeJeune Rd, Miami, FL 33126
GENERAL INFORMATION 2 Date 6/22/99

8. NFPA Standard 51, OXYGEN-FUEL GAS SYSTEMS
FOR WELDING, CUTTING AND ALLIED PRO-
CESSES, obtainable from the National Fire Protection AVERTISSEMENT
Association, Batterymarch Park, Quincy, MA 02269
9. NFPA Standard 70, NATIONAL ELECTRICAL CODE, Toute procédure pouvant provoquer des blessures
obtainable from the National Fire Protection Asso- de l’opérateur ou des autres personnes se trouvant
ciation, Batterymarch Park, Quincy, MA 02269 dans la zone de travail en cas de non-respect de la
10. NFPA Standard 51B, CUTTING AND WELDING procédure en question.
PROCESSES, obtainable from the National Fire Pro-
tection Association, Batterymarch Park, Quincy, MA
02269 1.05 Precautions De Securite
11. CGA Pamphlet P-1, SAFE HANDLING OF COM- Importantes
PRESSED GASES IN CYLINDERS, obtainable from
the Compressed Gas Association, 1235 Jefferson
Davis Highway, Suite 501, Arlington, VA 22202 AVERTISSEMENTS
12. CSA Standard W117.2, CODE FOR SAFETY IN
WELDING AND CUTTING, obtainable from the Ca-
nadian Standards Association, Standards Sales, 178 L’OPÉRATION ET LA MAINTENANCE DU
Rexdale Boulevard, Rexdale, Ontario, Canada M9W MATÉRIEL DE SOUDAGE À L’ARC AU JET
1R3 DE PLASMA PEUVENT PRÉSENTER DES
RISQUES ET DES DANGERS DE SANTÉ.
13. NWSA booklet, WELDING SAFETY BIBLIOGRA-
PHY obtainable from the National Welding Supply Coupant à l’arc au jet de plasma produit de l’énergie
Association, 1900 Arch Street, Philadelphia, PA 19103 électrique haute tension et des émissions
14. American Welding Society Standard AWSF4.1, REC- magnétique qui peuvent interférer la fonction
OMMENDED SAFE PRACTICES FOR THE PREPA- propre d’un “pacemaker” cardiaque, les appareils
RATION FOR WELDING AND CUTTING OF CON- auditif, ou autre matériel de santé electronique.
TAINERS AND PIPING THAT HAVE HELD Ceux qui travail près d’une application à l’arc au
HAZARDOUS SUBSTANCES, obtainable from the jet de plasma devrait consulter leur membre
American Welding Society, 550 N.W. LeJeune Rd, professionel de médication et le manufacturier de
Miami, FL 33126 matériel de santé pour déterminer s’il existe des
15. ANSI Standard Z88.2, PRACTICE FOR RESPIRA- risques de santé.
TORY PROTECTION, obtainable from American
Il faut communiquer aux opérateurs et au person-
National Standards Institute, 1430 Broadway, New
nel TOUS les dangers possibles. Afin d’éviter les
York, NY 10018
blessures possibles, lisez, comprenez et suivez tous
1.04 Note, Attention et les avertissements, toutes les précautions de sécurité
et toutes les consignes avant d’utiliser le matériel.
Avertissement Composez le + 603-298-5711 ou votre distributeur
local si vous avez des questions.
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 : FUMÉE et GAZ
NOTE
La fumée et les gaz produits par le procédé de jet de
Toute opération, procédure ou renseignement plasma peuvent présenter des risques et des dangers de
général sur lequel il importe d’insister davantage santé.
ou qui contribue à l’efficacité de fonctionnement
du système. • Eloignez toute fumée et gaz de votre zone de respi-
ration. Gardez votre tête hors de la plume de fumée
ATTENTION provenant du chalumeau.
• Utilisez un appareil respiratoire à alimentation en
Toute procédure pouvant résulter air si l’aération fournie ne permet pas d’éliminer la
l’endommagement du matériel en cas de non- fumée et les gaz.
respect de la procédure en question.

• Les sortes de gaz et de fumée provenant de l’arc de
plasma dépendent du genre de métal utilisé, des
INCENDIE ET EXPLOSION
revêtements se trouvant sur le métal et des différents
procédés. Vous devez prendre soin lorsque vous
coupez ou soudez tout métal pouvant contenir un Les incendies et les explosions peuvent résulter des scories
ou plusieurs des éléments suivants: chaudes, des étincelles ou de l’arc de plasma. Le procédé
antimoine cadmium mercure à l’arc de plasma produit du métal, des étincelles, des
argent chrome nickel scories chaudes pouvant mettre le feu aux matières com-
arsenic cobalt plomb bustibles ou provoquer l’explosion de fumées
baryum cuivre sélénium inflammables.
béryllium manganèse vanadium • Soyez certain qu’aucune matière combustible ou in-
• Lisez toujours les fiches de données sur la sécurité flammable ne se trouve sur le lieu de travail.
des matières (sigle américain “MSDS”); celles-ci Protégez toute telle matière qu’il est impossible de
devraient être fournies avec le matériel que vous retirer de la zone de travail.
utilisez. Les MSDS contiennent des renseignements • Procurez une bonne aération de toutes les fumées
quant à la quantité et la nature de la fumée et des inflammables ou explosives.
gaz pouvant poser des dangers de santé. • Ne coupez pas et ne soudez pas les conteneurs ayant
• Pour des informations sur la manière de tester la pu renfermer des matières combustibles.
fumée et les gaz de votre lieu de travail, consultez • Prévoyez une veille d’incendie lors de tout travail
l’article 1 et les documents cités à la page 5. dans une zone présentant des dangers d’incendie.
• Utilisez un équipement spécial tel que des tables de • Le gas hydrogène peut se former ou s’accumuler
coupe à débit d’eau ou à courant descendant pour sous les pièces de travail en aluminium lorsqu’elles
capter la fumée et les gaz. sont coupées sous l’eau ou sur une table d’eau. NE
• N’utilisez pas le chalumeau au jet de plasma dans PAS couper les alliages en aluminium sous l’eau ou
une zone où se trouvent des matières ou des gaz sur une table d’eau à moins que le gas hydrogène
combustibles ou explosifs. peut s’échapper ou se dissiper. Le gas hydrogène
• Le phosgène, un gaz toxique, est généré par la fumée accumulé explosera si enflammé.
provenant des solvants et des produits de nettoyage
chlorés. Eliminez toute source de telle fumée. RAYONS D’ARC DE PLASMA
CHOC ELECTRIQUE Les rayons provenant de l’arc de plasma peuvent blesser

vos yeux et brûler votre peau. Le procédé à l’arc de plasma
Les chocs électriques peuvent blesser ou même tuer. Le produit une lumière infra-rouge et des rayons ultra-vio-
procédé au jet de plasma requiert et produit de l’énergie lets très forts. Ces rayons d’arc nuiront à vos yeux et
électrique haute tension. Cette énergie électrique peut brûleront votre peau si vous ne vous protégez pas
produire des chocs graves, voire mortels, pour l’opérateur correctement.
et les autres personnes sur le lieu de travail. • Pour protéger vos yeux, portez toujours un casque
• Ne touchez jamais une pièce “sous tension” ou ou un écran de soudeur. Portez toujours des lunettes
“vive”; portez des gants et des vêtements secs. de sécurité munies de parois latérales ou des lu-
Isolez-vous de la pièce de travail ou des autres par- nettes de protection ou une autre sorte de protec-
ties du circuit de soudage. tion oculaire.
• Réparez ou remplacez toute pièce usée ou • Portez des gants de soudeur et un vêtement
endommagée. protecteur approprié pour protéger votre peau
contre les étincelles et les rayons de l’arc.
• Prenez des soins particuliers lorsque la zone de tra-
vail est humide ou moite. • Maintenez votre casque et vos lunettes de protec-
tion en bon état. Remplacez toute lentille sale ou
• Montez et maintenez le matériel conformément au comportant fissure ou rognure.
Code électrique national des Etats-Unis. (Voir la
page 5, article 9.) • Protégez les autres personnes se trouvant sur la zone
de travail contre les rayons de l’arc en fournissant
• Débranchez l’alimentation électrique avant tout tra- des cabines ou des écrans de protection.
vail d’entretien ou de réparation.
• Lisez et respectez toutes les consignes du Manuel
de consignes.

• Utilisez la nuance de lentille qui est suggèrée dans 4. Norme ANSI Z87.1, PRATIQUES SURES POUR LA
le recommendation qui suivent ANSI/ASC Z49.1: PROTECTION DES YEUX ET DU VISAGE AU
Nuance Minimum Nuance Suggerée TRAVAIL ET DANS LES ECOLES, disponible de
Courant Arc Protective Numéro Numéro l’Institut Américain des Normes Nationales (Ameri-
Moins de 300* 8 9 can National Standards Institute), 1430 Broadway,
New York, NY 10018
300 - 400* 9 12
5. Norme ANSI Z41.1, NORMES POUR LES
400 - 800* 10 14
CHAUSSURES PROTECTRICES, disponible auprès
* Ces valeurs s’appliquent ou l’arc actuel est observé de l’American National Standards Institute, 1430
clairement. L’experience a démontrer que les filtres Broadway, New York, NY 10018
moins foncés peuvent être utilisés quand l’arc est 6. Norme ANSI Z49.2, PRÉVENTION DES
caché par moiceau de travail. INCENDIES LORS DE L’EMPLOI DE PROCÉDÉS
DE COUPE ET DE SOUDAGE, disponible auprès
de l’American National Standards Institute, 1430
BRUIT Broadway, New York, NY 10018
7. Norme A6.0 de l’Association Américaine du
Le bruit peut provoquer une perte permanente de l’ouïe. Soudage (AWS), LE SOUDAGE ET LA COUPE DE
Les procédés de soudage à l’arc de plasma peuvent CONTENEURS AYANT RENFERMÉ DES
provoquer des niveaux sonores supérieurs aux limites PRODUITS COMBUSTIBLES, disponible auprès de
normalement acceptables. Vous dú4ez vous protéger les la American Welding Society, 550 N.W. LeJeune Rd.,
oreilles contre les bruits forts afin d’éviter une perte Miami, FL 33126
permanente de l’ouïe.
8. Norme 51 de l’Association Américaine pour la Pro-
• Pour protéger votre ouïe contre les bruits forts, portez tection contre les Incendies (NFPA), LES SYSTEMES
des tampons protecteurs et/ou des protections À GAZ AVEC ALIMENTATION EN OXYGENE
auriculaires. Protégez également les autres POUR LE SOUDAGE, LA COUPE ET LES
personnes se trouvant sur le lieu de travail. PROCÉDÉS ASSOCIÉS, disponible auprès de la
National Fire Protection Association, Batterymarch
• Il faut mesurer les niveaux sonores afin d’assurer
Park, Quincy, MA 02269
que les décibels (le bruit) ne dépassent pas les
niveaux sûrs. 9. Norme 70 de la NFPA, CODE ELECTRIQUE NA-
TIONAL, disponible auprès de la National Fire Pro-
• Pour des renseignements sur la manière de tester le
tection Association, Batterymarch Park, Quincy, MA
bruit, consultez l’article 1, page 5.
02269
1.06 Documents De Reference 10. Norme 51B de la NFPA, LES PROCÉDÉS DE
COUPE ET DE SOUDAGE, disponible auprès de
Consultez les normes suivantes ou les révisions les plus la National Fire Protection Association,
récentes ayant été faites à celles-ci pour de plus amples Batterymarch Park, Quincy, MA 02269
renseignements :
11. Brochure GCA P-1, LA MANIPULATION SANS
1. OSHA, NORMES DE SÉCURITÉ DU TRAVAIL ET RISQUE DES GAZ COMPRIMÉS EN CYLINDRES,
DE PROTECTION DE LA SANTÉ, 29CFR 1910, disponible auprès de l’Association des Gaz
disponible auprès du Superintendent of Docu- Comprimés (Compressed Gas Association), 1235
ments, U.S. Government Printing Office, Washing- Jefferson Davis Highway, Suite 501, Arlington, VA
ton, D.C. 20402 22202
2. Norme ANSI Z49.1, LA SÉCURITÉ DES 12. Norme CSA W117.2, CODE DE SÉCURITÉ POUR
OPÉRATIONS DE COUPE ET DE SOUDAGE, LE SOUDAGE ET LA COUPE, disponible auprès
disponible auprès de la Société Américaine de de l’Association des Normes Canadiennes, Stan-
Soudage (American Welding Society), 550 N.W. dards Sales, 178 Rexdale Boulevard, Rexdale,
LeJeune Rd., Miami, FL 33126 Ontario, Canada, M9W 1R3
3. NIOSH, LA SÉCURITÉ ET LA SANTÉ LORS DES 13. ivret NWSA, BIBLIOGRAPHIE SUR LA SÉCURITÉ
OPÉRATIONS DE COUPE ET DE SOUDAGE À DU SOUDAGE, disponible auprès de l’Association
L’ARC ET AU GAZ, disponible auprès du Superin- Nationale de Fournitures de Soudage (National
tendent of Documents, U.S. Government Printing Welding Supply Association), 1900 Arch Street,
Office, Washington, D.C. 20402 Philadelphia, PA 19103

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

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.
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.
* 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

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

available in 25 ft (7.6 m), or 50 ft (15.2 m) lengths with
SECTION 2: fittings for simple installation. Spare Parts Kits are avail-
INTRODUCTION able for the torches which provide an assortment of re-
placement torch parts.
NOTE
2.01 Scope of Manual
Refer to Section 2.04 for list of power supply op-
This manual contains descriptions, operating instructions tions and accessories.
and basic maintenance procedures for the PAK Master®
75XL Plus Air Plasma Cutting Power Supply. Service of 2.03 Specifications/Design Features
this equipment is restricted to Thermal Dynamics trained
personnel; unqualified personnel are strictly cautioned A. Power Supply Technical Specifications
against attempting repairs or adjustments not covered in
The following specifications apply to the Power Supply
this manual, at the risk of voiding the Warranty.
only:
Read this manual thoroughly. A complete understand-
ing of the characteristics and capabilities of this equip- 1. Front Panel Controls
ment will assure the dependable operation for which it ON/OFF Switch, RUN/SET/LATCH Switch and
was designed. Output Current Control
2.02 General Description of System 2. Front Panel LED Indicators
The 75XL PLUS System includes a power supply, PCH/ AC, TEMP, GAS, DC
M-60 torch & leads and work cable & clamp. 3. Rear Panel
The Power Supply provides 60 amp maximum output Input Power Cable Strain Relief*, Gas Connection, Gas
and includes all control circuitry, electrical and gas in- Regulator/Filter Assembly
puts and outputs, pilot circuitry, torch leads receptacle
and a work cable with clamp. *208/230/240 units include input power cable
NOTE 4. Input Power
The power supply can be ordered in various con- Can be configured for the following:
figurations with various options factory installed.
208/230/240 VAC (±10%), 50/60 Hz, Single or Three-
Phase
XL PLUS Power Supply

380/415 VAC (±10%), 50/60 Hz, Three-Phase
460 VAC (±10%), 50/60 Hz, Single or Three-Phase
5. Output Power
Continuously variable from 15 to 60 Amps maximum
6. Duty Cycle
65% Duty Cycle at an output of 104VDC/60 Amps
100% Duty Cycle at an output of 104 VDC/50 Amps
A-02462
Torch and Leads
7. Cut Capacity (Mild Steel)
Work Cable and Clamp 3/4 inch (19.1 mm); 1 inch (25.4 mm) severance
8. Pilot Circuitry
Figure 2-1 Pak Master 75XL Plus System
Capacitive Discharge (CD), Pulsed DC
The PCH/M-60 torch provides a maximum 1 inch (25.4 9. Weight
mm) cut capacity. Hand torches are available in a 70°
and 90° torch head configuration, a machine torch is avail- 64 lbs (29 kg) w/work lead
able in a 180° torch head configuration. Torch leads are
71 lbs (32 kg) w/work lead and 25' Torch & Lead
Manual 0-2746 9 SECTION 2: INTRODUCTION

10. Overall Dimensions D. Smart Cart
19" (482 mm) High x 13" (330 mm) Wide x 24.8" (630 Steel cart on easy rolling 10" pneumatic tires to pro-
mm)Long vide maximum mobility for the power supply. Handle
is 3/4" tubing with hooks for storage of torch leads.
Overall dimensions are with Handle, Lead Wrap
A tie down strap is also included.
Bracket, and Gas Requlator/Filter Assembly installed.
E. 575V Transformer
B. Gas Regulator/Filter Assembly
Specifications This step-down transformer allows the power sup-
ply to operate with 575 VAC three-phase input power.
The following specifications apply to the Gas Regulator/
Filter Assembly only: F. Computer Control Cable (CNC)
1. Gas regulator maximum gauge pressure NOTE
160 psi (11 bar) This accessory can be used only with the PCM-60
Torches.
2. Maximum input gas pressure
The interface cable is available in two lengths, 25 ft
125 psi (8.6 bar) (7.6 m) and 50 ft (15.2 m). The cable is used to inter-
3. Filter face the power supply with an auxiliary control de-
vice to provide OK-To-Move and ON/OFF signals.
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 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. Filters moisture and contaminants to 5 mi-
crons. This filter assembly is pre-assembled at the fac-
tory 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 options A
or B above.
SECTION 2: INTRODUCTION 10 Manual 0-2746

least 6 inches (0.2 m) on each side for clearance . Provide
SECTION 3: sufficient clearance in front of the unit to allow access to
the front panel controls (minimum 6 inches or 0.2 m).
INSTALLATION
PROCEDURES CAUTION
Operation without proper air flow will inhibit

3.01 Introduction proper cooling and reduce duty cycle.
NOTE 3.03 Unpacking

Depending on how the system was ordered, some
Each component of the system is packaged and protected
Power Supply Options may already be installed.
with a carton and packing material to prevent damage
If option(s) have been factory installed some of the during shipping.
instructions may not apply. It is recommended
l. Unpack each item and remove all packing material.
that all subsections be read for general informa-
tion., NOTE
This section describes installation of the Power Supply The Cutting Spare Parts Kit is shipped in the Torch
and connecting the Torch. Leads Storage Area on the side of the Power Sup-
ply.
These instructions apply to the Power Supply only; in-
stallation procedures for the Torch, Options, and Acces- 2. Locate the packing list(s) and use the list to identify
sories are given in Manuals specifically provided for those and account for each item.
units.
3. Inspect each item for possible shipping damage. If
The complete installation consists of: damage is evident, contact your distributor and/or
shipping company before proceeding with system in-
1. Site selection
stallation.
2. Unpacking
3. Connections to Power Supply
3.04 Lifting Options
a. Input power
b. Gas WARNINGS
c. Work cable
Do not touch live electrical parts.
d. Torch Leads
Disconnect input power conductors from de-ener-
4. Grounding gized supply line before moving unit.
5. Operator training
This unit is equipped with one handle mounted onto the
3.02 Site Selection top of the enclosure for hand carrying purposes.
Select a clean, dry location with good ventilation and ad-

equate working space around all components. WARNING
NOTE
Review Important Safety Precautions (page 1) to FALLING EQUIPMENT can cause serious per-
be sure that the selected location meets all safety sonal injury and equipment damage.
requirements.
• Lift unit with the handle on top of the enclosure.
The power supply is fan cooled by air flow through the
front panel to the rear panel. Air flow must not be ob- • Persons only of adequate physical strength should
structed. Provide at least 2 feet (0.61 m) in the rear and at lift the unit.
• Use hand cart or similar device of adequate capac-
ity.
Manual 0-2746 11 SECTION 3: INSTALLATION PROCEDURES

• 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 Left Side
transported safely and securely. Panel
WARNING
HANDLE is not for mechanical lifting.
A-00910
3.05 Input Power Connections
The Power Supply accepts input voltages from 208V to
Ground Wire
460V. Input can be 50 or 60 Hz, single-phase or three-
Screws
phase.
(5 Places)
The Power Supply is factory-wired for 230V single-phase
or 460V three-phase input depending on the order. For
any other input voltage, the Power Supply must be Figure 3-1 Removing Left Side Panel
changed using the procedure in Sections 3.06.
NOTE
A. Electrical Connections
There is a ground wire connection to the Left Side
The power source must conform to local and national elec- Panel on the inside of the unit.
tric codes. Recommended circuit protection and wiring
requirements are shown in Appendix I. 2. Carefully pull the Left Side Panel up and away from
the unit to gain access to the inside of the unit.
B. Opening Power Supply Enclosure
The left side panel of the Power Supply must be removed 3.06 Input Voltage Selection
to gain access to the input power connections and the
input voltage selection. NOTE
For power supplies to use 575 VAC input power,
the unit must be setup for 460V three-phase op-
WARNING eration and the 575V Transformer Accessory must
be installed.
Disconnect primary power at the source before as- The Power Supply has three voltage settings; 208/230/
sembling or disassembling the Power Supply, torch 240VAC, 380/415VAC, or 460VAC. Power Supplies are
parts, or torch and leads assemblies. factory-wired for 230V single-phase or 460VAC three-
phase input depending on the order. Input voltage selec-
1. Using a phillips head screw driver remove the five tion is accomplished by switching a wire harness con-
screws which secure the left side panel (viewed from nector inside the Power Supply. Also, a jumper wire must
front of unit) to the frame assembly. be properly installed depending on the input used.
WARNING
Disconnect primary power at the source before as-

sembling or disassembling the power supply, torch
parts, or torch and leads assemblies.
1. Move the power selection plug to the desired input

connection for 208/230/240V, 380/415V, or 460V op-
eration per the label attached to the panel.
SECTION 3: INSTALLATION PROCEDURES 12 Manual 0-2746

2. Connect the input cable inside the Power Supply for
the type of operation per the following:
Voltage Selection
Label Three-Phase Operation
460 Volts Three-phase operation requires a 3-conductor cable
380/415 Volts with ground.
208/230/240 Volts
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.
Voltage Selection A-00911
Connector
NOTE
The jumper wire from L1 to L4 must not be re-
moved.
Figure 3-2 Input Voltage Selection
2. For three-phase 460VAC input, the jumper wire be- Input L3

tween L2 and L2 (storage) must be left in this storage Contactor L2
connection.
L1
For single-phase operation the jumper wire must be
installed on the contactor as described in Section 3.07
for single-phase input voltage.
3.07 Primary Input Power Cable

Connections
A-02670
Units ordered as 230V, single-phase, will have a six foot
power input cable and plug factory installed. For all other
units, a cable must be provided by the end user. Recom- Unused Jumper
mended cable sizes are specified in Appendix I. AC Input L3 to L3 (storage)
Power Cable
1. Route the primary power cable through the strain re- GND
lief fitting in the rear panel of the Power Supply and
tighten strain relief screws.
Figure 3-4 Primary Power Cable Connections -
Three-Phase Operation
AC Input Power
Cable Strain Relief
AC Input
A-00912 Power Cable
Figure 3-3 AC Input Power Cable Strain Relief

Single-Phase Operation
Single-phase operation requires a 2-conductor cable Input Contactor
with ground. L2
L1
a. Locate the single-phase jumper wire connected
between the two L3 terminal lugs on the input
contactor.
b. Move one end of the jumper wire from termi-
nal lug L3 to L2 at the contactor.
NOTE
The jumper wire from L1 to L4 must not be re- A-00915
moved.
L3 GND
Input Contactor AC Input
L2
Power Cable
Figure 3-6 Primary Power Cable Connections -

Single-Phase Operation
3.08 Gas Connections

A. Gas Requirements
A-00914 Single Phase

Jumper Wire
WARNING
(L2 to L3)
Figure 3-5 Single Phase Jumper Wire Installation
This unit not to be used with oxygen (O2).
c. Locate the ground stud and remove the top nut

Gases: Compressed Air or Nitrogen (N2) Only
and washer.
Pressure: 60 psi (4.1 bar)
d. Install a lug terminal on the ground wire.
e. Place the ground wire onto the ground stud CAUTION
and secure with the nut and washer.
f. Insert the other two wires into the L1 and L2 Maximum input gas pressure must not exceed 125
terminals on the contactor. psi (8.6 bar)
g. Tighten all set screws. Flow: Cutting - 300 scfh (142 lpm)
Gouging - 300 scfh (142 lpm)

B. Checking Air Quality D. Optional Air Line Filter Installation
To test the quality of air, place the RUN/SET/LATCH Filtering is required when using air from a compressor to
switch to SET position, place a welding filter lens in front insure that moisture and debris from the supply hose does
of the torch and turn on the gas. Any oil or moisture in not enter the torch. Although the Regulator does have its
the air will be visible on the lens. Do not initiate an arc! own filter, it is recommended the optional Dry Air Filter
or optional Two Stage Air Line Filter be installed for im-
CAUTION proved filtering. Gas connections to optional filters are
shown in Figures 3-8 and 3-9 below.
The air supply must be free of oil, moisture, and
other contaminants. Excessive oil and moisture
may cause double-arcing, rapid tip wear, or even
complete torch failure. Contaminants may cause
poor cutting 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-
Dry Air Filter
nection is the same for compressed air or high pressure Assembly
gas cylinders.
Connect the gas supply as follows: 1/4 NPT to
#4 (6mm)
1. Locate the 1/4 NPT to #4 (6mm) hose barbed fitting Hose Fitting
shipped inside the Torch Spare Parts Kit. Hose Clamp

A-02469
#4 (6mm)
2. If an optional air line filter is to be installed, refer to Gas Supply
subsection D. Hose
3. Install the barbed fitting as shown below.

4. Tighten the barbed fitting Figure 3-8 Gas Connection to Optional Dry Air
Filter Assembly
5. Place an adjustable hose clamp(customer supplied),
1/4" (6.5mm) to 5/8" (15.9mm)) over the gas supply
hose.
A-00917
1/4 NPT to #4 (6mm)

Hose Fitting
Regulator/Filter
Hose Clamp
Assembly
1/4 NPT to
#4 (6mm) Hose
Fitting
Hose Clamp
#4 (6mm) Gas Two Stage Filter

Supply Hose Assembly
A-00916
#4 (6mm) Gas
Supply Hose
Figure 3-9 Gas Connection To Optional Two Stage
Filter Assembly
Figure 3-7 Gas Connection To Regulator/Filter
Assembly

E. Using High Pressure Gas Cylinders
1. Refer to the following when using high pressure gas
cylinders as the gas supply:
Access
Panel
CAUTION
Pressure should be set at 100 psi (6.9 bar) at the

high pressure gas cylinder regulator.
Screw
a. Refer to the manufacturer’s specifications for in- Latch
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 A-02467
high-pressure regulator capable of outlet pressures
up to 100 psi (6.9 bar) maximum and flows of up
to 300 scfh (141.5 lpm). Figure 3-10 Front Access Panel
2. Slide the gas supply hose over the barb fitting.
2. Lift up on the access panel to gain access to the torch
3. Secure the gas supply hose in place with the adjust- bulkhead panel.
able hose clamp.
NOTE CAUTION
Supply hose must be at least #4 hose (1/4 in or 6
mm I.D.). This system is designed for use with the PCH/M-
60 torch only. Do not connect any other torch to
3.09 Connecting Torch Leads this power supply.
3. Remove the Strain Relief Nut from the Strain Relief
supplied on the end of the Torch Leads.
WARNING
Disconnect primary power at the source before as- Torch Leads

sembling or disassembling the power supply, torch Assembly
Strain Relief
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
Strain Relief
factory connected to the Power Supply. Nut
1. Turn the screw latch securing the front access panel to
the power supply front panel. A-02514
Figure 3-11 Torch Strain Relief Nut

4. Feed the end of the torch leads through the hole in the B. Creating an Earth Ground
front panel in the following order:
1. Install a ground wire (not included) between the sys-
• Control Cable tem and a solid earth ground (also called star ground).
• Gas lead 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
• Pilot Lead the earth so that the rod contacts moist soil over most
5. Place the Strain Relief Nut over the torch leads and of its length. The required depth will vary depend-
position it in the hole in the front panel. ing on location (see NOTE). Locate the rod as close as
possible to the power supply. The work table should
6. Hold the Strain Relief Nut in position and tighten the
be connected to the same earth ground as the power
Strain Relief on the outside of the unit.
supply.
7. Connect the torch gas/power lead fitting onto the Gas/
NOTE
Power Lead Connection.
A properly installed ground rod will have a resis-
tance of one ohm or less.
Pilot Lead Stud
Control Cable 2. Connect the control device (CNC) to a separate earth
Connector ground similar to the ground rod described above.
The ground cable should be at least 12 gauge (4 mm2)
wire.
Control Cable
3. To minimize RF interference, position torch leads as
Pilot Lead far as possible (at least 1 ft or 0.3 m) from any CNC
components, drive motors, control cables, or primary
power lines.
Gas/Power Lead 4. Keep torch leads clean. Dirt and metal particles bleed
Gas/Power Connection off energy, which causes difficult starting and in-
Lead
creased chance of RF interference.
Torch Lead
Assembly
A-00929 5. Make sure work cable and ground cables are properly
connected. The work cable must have a solid connec-
tion to the workpiece or cutting table. The connec-
Figure 3-12 Torch Leads Connections tion must be free from dirt, grease, oil and paint
7. Connect the Torch Control Cable to the Torch Control

Connection.
8. Remove the top nut and washer from the Pilot Stud.
9. Place the lug on the Pilot Control Wire onto the stud
and secure with the nut and washer removed in Step
8.
10. Close the access panel and turn the latching screw .
3.10 Work Cable And Ground A-02459

Connections
A. Electromagnetic Interference (EMI) Work Cable
And Clamp
Pilot arc initiation generates a certain amount of electro-
magnetic interference (EMI), commonly called RF noise.
This RF may interfere with other electronic equipment Make a solid work cable
connection to the work-
such as CNC controllers, etc. To minimize RF interfer- piece or cutting table
ence, follow these grounding procedures when install-
ing mechanized systems:
Figure 3-13 Power Supply Work Cable Connection

3.11 Tip Saver/Drag Cut Sensing
Circuit
This power supply is equipped with a Tip Saver/Drag
Cut Sensing Circuit which cuts current back to 35 amps if
the tip touches the workpiece. The purpose of this is to
prolong the life of the tip.
If the user does not want the current to be decreasedwhen
the tip touches the workpiece, the sensing circuit can be
defeated by closing switch SW1-1 on the Gate/Logic PC
Board. Slide top white toggle on SW1-1 to the right to
close circuit.
SW1
ON
1
2
Gate/Logic PC Board
A-02569
Figure - SW1 Switch Location
WARNING
Tip life will be considerably shortened if tip is re-

peatedly touched to the workpiece without the Tip
Saver/Drag Sensing Circuit feature active.

3. Torch Leads Input
SECTION 4:
Hole in the front panel to feed the torch leads through
OPERATION to the internal bulkhead connections.
4. Work Cable and Clamp

4.01 Introduction Work cable with clamp (factory installed).
This Section provides a description of the Power Supply 5. Torch Leads and Spare Parts Kit Storage Area
operating controls and procedures. Identification of the
Front and Rear Panel components is followed by operat- Bracket connected to the side panel of the unit for use
ing procedures. in storing the torch, torch leads, work cable, and spare
parts kit when not in use. The spare parts kit fits into
4.02 Functional Overview the opening on the top of the bracket. The torch leads
and work cable wrap around the bracket for easy stor-
The PAKMaster 75XL PLUS provides a degree of operat- age.
ing flexibility and the use of simple controls.
B. Control Panel
4.03 Operating Controls
4 5 6 7
This subsection provides specfic functional descriptions
of the Power Supply operating controls and indicators.
CURRENT
35 40 45 AC
A. Front and Side Panel 30
50 TEMP
25
1
1. Control Panel 20
55
GAS
15 60
DC
All operator controls, except gas pressure adjustment, A
are located on this panel. Power ON/OFF and RUN/ ON RUN
SET/LATCH switches; CURRENT control; LED indi-

SET
cators for AC Power, TEMP, GAS, and DC. 2
OFF LATCH
1 A-02456
3
2 Figure 4-2 Operating Controls
1. Current Control
3
Adjustment to set the desired output current between
5
15-60 amps. For drag cutting applications set the con-
trol between 15 - 35 amps. The unit has an automatic
fold-back circuit that limits current to 35 amps dur-
ing drag cutting.
A-02458
2. ON/OFF Power Switch
4 ON position supplies AC power to activate all sys-
tem control circuits. OFF position deactivates control
circuits.
Figure 4-1 Front and Side Panel Connections
3. RUN/SET/LATCH Switch
2. Access Panel RUN position is used for torch operation. SET posi-
tion used for setting gas pressure and purging lines.
A panel to gain access to the bulkhead area contain- LATCH position is used for specific applications (torch
ing the torch connections. switch can be released after main arc transfer).
Manual 0-2746 19 SECTION 4: OPERATION

4. AC Power Indicator 3. Gas/Power Lead Connection
Green LED indicator will blink ON then OFF for ap- Connects the torch gas/negative lead to the unit.
proximately eight seconds and then stay ON after the
ON/OFF power switch is set to ON. Indicates oper- D. Rear Panel
ating power is present in the unit. 1. Gas Input
5. TEMP Indicator Input connection for air or nitrogen (N2) input.
Normally OFF. Yellow LED indicator will come ON
when the internal temperature senors detect tempera-
tures above normal limits. The unit should be allowed WARNING
to cool before continuing operation.
6. GAS Indicator This unit not to be used with oxygen (O2).
Green LED indicator will come ON when the input

gas pressure is set to 35 psi (2.4 bar) or higher. Indica-
tor will be OFF when the pressure falls below 35 psi
(2.4 bar).
7. DC Indicator
Green LED indicator will come ON while the torch
switch is pressed.
C. Torch Panel Bulkhead
1
The torch panel bulkhead is located under the access
panel.
3
1. Pilot Lead Stud
Connects the pilot control wire on the torch to the unit.
1
2
A-00928
Figure 4-4 Rear Panel
3 2. Primary Input Power Cable Strain Relief

NOTE
A-00923
Input power cable is supplied on units when or-

Figure 4-3 Torch Panel Connections dered for 230V single-phase operation.
Primary input power cable strain relief for the pri-
2. Control Cable Connector mary power cable (see Note above) capable of han-
dling the input voltage designed for this unit.
Connects the torch switch to the unit. In machine torch
applications connects the torch switch on the pendant
to the unit.
SECTION 4: OPERATION 20 Manual 0-2746

3. Gas Pressure Regulator/Filter Assembly
Pressure regulator to adjust the input gas pressure to
the Power Supply. An air line filter is supplied as part 1
of the pressure regulator.
4. Optional Filters
a. Dry Air Filter Assembly
This optional in-line filter removes moisture and con-
taminants from the air stream when using compressed
air. The filter is capable of filtering to at least .85 mi-
crons.
3
4
2
A-00924
3
4
Figure 4-6 Rear Panel Showing Optional Two Stage
Air Filter
A-02460
4.04 Sequence of Operation

2 1 The following is a typical sequence of operation for this
cutting system. Refer to Appendix II for a block diagram.
1. Close main power source disconnect.
a. AC power is available at the Power Supply.
Figure 4-5 Rear Panel Showing Optional Dry Air 2. Place RUN/SET/LATCH switch to RUN mode.
Filter
3. Place the ON/OFF power switch on the front panel
of the Power Supply to ON.
b. Two Stage Air Line Filter
a. AC Power indicator LED blinks ON and OFF
An alternative to the Dry Air Filter, this optional filter
for eight seconds then stays ON.
will also remove moisture and contaminants from the
air stream when using compressed air. Filters to 5 b. Fans turn on.
microns.
4. Place RUN/SET/LATCH switch to SET mode.
a. Gas solenoid opens and gas flows to set pres-
sure.
b. GAS indicator turns ON.

NOTE If torch is within 3/8 in (9.5mm) transfer distance
of workpiece, main arc will transfer.
GAS indicator will not come ON if the gas pres-
sure is set below 35 psi (2.4 bar) at the Regulator/ 13. Gas will flow for 15 seconds (post-flow).
Filter Assembly.
a. Gas solenoid closes
5. Place RUN/SET/LATCH switch to RUN mode.
b. Gas flow stops.
a. Gas flow stops.
c. GAS indicator turns OFF.
b. GAS indicator turns OFF.
14. Place the ON/OFF power switch on the front panel
6. Protect eyes and press or activate torch switch of the unit to OFF
a. Gas pre-flows starts. a. AC Power indicator turns OFF.
b. GAS indicator turns ON. b. Fans turn OFF.
7. After gas pre-flow (approximately 2 seconds) 15. Place the main power disconnect to open.
a. Power supply enabled. a. Main AC power is removed from the system.
b. DC indicator turns ON.
4.05 Preparations for Operating
c. Pilot relay closes.
Follow this set-up procedure each time the system is op-
8. Pilot arc is established erated:
9. Move Torch within transfer distance of workpiece.
a. Main arc transfer. WARNING
b. Pilot arc OFF.
10. Optional - Place RUN/SET/LATCH to LATCH Disconnect primary power at the source before dis-
mode. assembling the power supply, torch, or torch leads.
NOTE
A. Torch Parts Selection
For general cutting, use the RUN position which
Check the torch for proper assembly and appropriate front
provides normal touch operation where the torch
end torch parts. The torch parts (shield cup, tip and elec-
switch must be held throughout the main arc trans-
trode) must correspond with the type of operation (cut-
fer.
ting or gouging).
For specific applications, use the LATCH position
where the torch switch can be released after the main
arc transfer. The torch remains activated until the
main arc breaks from the workpiece.
11. Complete cutting operation.
NOTE
If the torch is lifted from the workpiece, while still
having torch swicth activated, the main arc will
stop and the pilot arc will automatically restart.
12. Release or deactivate the torch switch.
a. Main arc stops.
b. Pilot arc stops (power supply enable signal re-
moved).
NOTE
If torch is activated during post-flow, pilot arc will
immediately restart.

Make a solid work cable
connection to the work-
piece or cutting table
Copper Shield Cup
Catalog No. 8-7496
Standard Shield Cup Crown Shield Cup

Catalog No. 8-7500 Catalog No. 8-7507
Standoff Cutting Tip A-00925

Air/N2, 60 Amp Electrode
Figure 4-8 Work Cable Connection To Workpiece
Drag Cutting Tip E. Torch Connection

Air/N2, 35 Amp Gouging Tip, Air
Catalog No. 8-7503 Catalog No. 8-7506 Check that the torch is properly connected.
F. Power Supply On
Gas Distributor Gouging Gas Distributor Move the ON/OFF switch to ON position.
G. Select Output Current
A-02473
Figure 4-7 Parts Selection (PCH-60) Select the desired current output level for the operation:
• 15 to 60 amps for standoff cutting and gouging
B. Check primary power source as follows: • 15 to 35 amps for drag cutting
1. Check the power source for proper input voltage. Make
H. Set Operating Pressure
sure the input power source meets the power require-
ments for the unit per Section 2.03-A-4, Specifications/ Move the RUN/SET/LATCH switch to SET position. Ad-
Design Features. just the gas pressure to 60 psi (4.1 bar).
2. Connect the input power cable (or close the main dis- I. RUN/SET Switch
connect switch) to supply power to the system.
Set the RUN/SET/LATCH switch to RUN position.
C. Gas Selection
The system is now ready for operation.
Select desired gas (air or nitrogen). Make sure gas source
meets pressure and flow requirements (refer to Section NOTE
3.08, Gas Connections). Check connection and turn gas For general cutting, use the RUN position which
supply on. provides normal touch operation where the torch
D. Work Cable Connection switch must be held throughout the main arc trans-
fer.
Check for a solid and clean work cable connection to the
workpiece. The area must be free from paint and rust. For specific applications, use the LATCH position
where the torch switch can be released after the main
arc transfer. The torch remains activated until the
main arc breaks from the workpiece.

4.06 Cut Quality
Kerf Width
Cut quality requirements differ depending on applica- Cut Surface
tion. For instance, nitride build-up and bevel angle may Bevel Angle
be major factors when the surface will be welded after
cutting. Dross-free cutting is important when finish cut Top
Spatter
quality is desired to avoid a secondary cleaning opera-
tion.
The following cut quality characteristics are illustrated Top Edge
Rounding
in Figure 4-9 below:
Cut Surface Dross

Build-Up
The condition (smooth or rough) of the face of the cut. Cut Surface A-00007
Drag Lines
Bevel Angle
The angle between the surface of the cut edge and a plane Figure 4-9 Cut Quality Characteristics
perpendicular to the surface of the plate. A perfectly per-
pendicular cut would result in a 0° bevel angle. Cut quality will vary on different types of and material
Top-Edge Rounding thicknesses.
Rounding on the top edge of a cut due to wearing from The following table shows the cut quality that can be ex-
the initial contact of the plasma arc on the workpiece. pected from this equipment for materials with a thick-
ness from gauge to 3/4 inch (19.1mm):
Dross Build-up and Top Spatter
T yp e o f M ater ial
Dross is molten material which is not blown out of the C ar b o n S t ain less
cut area and re-solidifies on the plate. Top spatter is dross G as A lu m in u m
S t eel S t eel
which accumulates on the top surface of the workpiece. G ood - G ood - G ood -
A ir
Excessive dross may require secondary clean-up opera- E x c ellent E x c ellent E x c ellent
tions after cutting. N i trogen G ood G ood G ood
Kerf Width Description of Cut Characteristics

The width of material removed during the cut. Excellent - Minimum bevel (0 - 4°), minimum kerf (2 x
tip orifice diameter), little or no dross, smooth
Nitride Build-up
cut surface.
Nitride deposits which may remain on the surface of the
Good - Slight bevel (0 - 10°), slightly wider kerf (2-1/2 x
cut when nitrogen is present in the plasma gas stream.
tip orifice diameter), some dross (easily re-
Nitride buildups may create difficulties if the material is
moved), medium-smooth cut surface, slight top
welded after the cutting process.
edge rounding.
Fair - Excessive bevel (over 10°), wide kerf (over 2-1/2 x
tip orifice diameter), medium to heavy dross, rough
cut surface, top edge rounding.
NOTES
Cut quality depends heavily on set-up and param-
eters such as torch standoff, alignment with the
workpiece, cutting speed, gas pressures, and op-
erator ability.

Weekly or Every 30 Cutting Hours:
SECTION 5:
1. Check fan for proper operation and adequate air
CUSTOMER/OPERATOR flow.
SERVICE 2. Vacuum dust and dirt out of the entire machine.
CAUTION
5.01 Introduction
This section describes basic maintenance procedures per- Do not blow air into the power supply during clean-
formable by operating personnel. No other adjustments ing. Blowing air into the unit can cause metal par-
or repairs are to be attempted by other than Thermal ticles to interfere with sensitive electrical compo-
Dynamics Trained personnel. nents and cause damage to the unit.
For major troubleshooting and parts replacement pro- Six Months or Every 720 Cutting Hours:
cedures refer to PAK Master 75XL Plus Power Supply 1. Check the in-line air filter(s), clean or replace as
Service Manual 0-2747. required
5.02 General Maintenance 2. Check cables and hoses for leaks or cracks, replace
if necessary.
3. Check all contactor points for severe arcing or pits,
WARNING replace if necessary.
B. Optional Dry Air Filter Element
Disconnect primary power to the system before dis- Replacement
assembling the torch, leads, or power supply.
NOTE
To clean the unit, open the enclosure (refer to Section 5.05- The XL PLUS Power Supply shuts down automati-
A, Opening Enclosure) and use a vacuum cleaner to re- cally when the Filter Element becomes completely
move any accumulated dirt and dust. The unit should saturated. The Filter Element can be removed from
also be wiped clean. If necessary, solvents that are rec- its housing, dried out, and reused. Allow 24 hours
ommended for cleaning electrical apparatus may be used. for Element to dry.
This schedule applies to all types of non-liquid cooled 1. Remove power from power supply.
plasma cutting systems. Some systems will not have all
2. Shut off air supply and bleed down system before
the parts listed and those checks need not be performed.
disassembly to change Filter Element.
NOTE
The actual frequency of maintenance may need to be ad-
justed according to the operating environment.
A. Maintenance Schedule
Daily Operational Checks or Every Six Cutting Hours:
1. Check torch consumable parts, replace if damaged
or worn.
2. Inspect torch for any cracks or exposed wires, re-
place if necessary.
3. Check plasma and secondary supply and pressure/
flow.
4. Purge plasma gas line to remove any moisture
build-up.
5. Inspect input power cable for damage or exposed
wires, replace if necessary.
Manual 0-2746 25 SECTION 5: SERVICE

Make sure no part of the operator’s body comes into
contact with the workpiece while the torch is acti-
vated.
Housing
CAUTION
Sparks from the cutting process can cause damage

Filter to coated, painted, and other surfaces such as glass,
Element plastic and metal.
NOTE
Spring
Handle torch leads with care and protect them from
damage.
Assembled Filter
Cover
A. Piloting
Piloting is harder on parts life than actual cutting because
Barbed the pilot arc is directed from the electrode to the tip rather
Fitting than to a workpiece. Whenever possible, avoid excessive
A-02476
pilot arc time to improve parts life.
B. Torch Standoff
Figure 5-1 Optional Dry Air Filter Replacement
Improper standoff (the distance between the torch tip and
workpiece) can adversely affect tip life as well as shield
3. Disconnect gas supply hose from barbed fitting.
cup life. Standoff may also significantly affect the bevel
4. Turn the Cover counterclockwise and remove it angle. Reducing standoff will generally result in a more
from the Filter Housing. The Filter Element is lo- square cut.
cated inside the housing.
C. Edge Starting
5. Remove the Filter Element from the Housing and
set Element aside to dry. For edge starts, hold the torch perpendicular to the work-
piece with the front of the tip at the edge of the work-
6. Wipe inside of housing clean, then insert the re- piece at the point where the cut is to start. When starting
placement Filter Element cup side first, as shown at the edge of the plate, do not pause at the edge and
below. force the arc to "reach" for the edge of the metal. Estab-
lish the cutting arc as quickly as possible.
7. Replace Housing on Cover.
8. Reattach gas supply hose to barbed fitting.
D. Direction of Cut
NOTE In the PCH/M-60 torches, the plasma gas stream swirls

as it leaves the torch to maintain a smooth column of gas.
If unit leaks between housing and cover, inspect This swirl effect results in one side of a cut being more
the "O" Ring for cuts or other damage. square than the other. Viewed along the direction of travel,
the right side of the cut is more square than the left (Refer
5.03 Common Operating Problems to Figure 5-2). To make a square-edged cut along an in-
side diameter of a circle, the torch should move counter-
clockwise around the circle. To keep the square edge along
WARNINGS an outside diameter cut, the torch should travel in a clock-
wise direction.
Disconnect primary power at the source before dis-

assembling the power supply, torch, or torch leads.
Frequently review the Important Safety Precau-
tions (page 1). Be sure the operator is equipped with
proper gloves, clothing, eye and ear protection.
SECTION 5: SERVICE 26 Manual 0-2746

b. Torch standoff too high from workpiece
Left Side
Cut Angle c. Worn torch parts
Right Side
Cut Angle d. Improper cutting current
4. Short Torch Parts Life
a. Oil or moisture in air source
b. Exceeding system capability (material too thick)
c. Excessive pilot arc time
A-00512
d. Air flow too low (incorrect pressure)
Figure 5-2 Side Characteristics Of Cut e. Improperly assembled torch
E. Dross 5.04 Troubleshooting Guide

Generally when dross is present on carbon steel, it is re-
A. General
ferred to as either "high speed or slow speed dross".
Troubleshooting and repairing this unit is a process which
"High speed dross" usually forms a narrow bead along
should be undertaken only by those familiar with high
the bottom of the cut edge and is very difficult to remove.
voltage high power electronic equipment.
"Slow speed dross" will be in larger quantities but does
not adhere tightly to the cut edge and can be easily re-
moved.
WARNING
When cutting a troublesome steel, it is suggested that the
torch travel speed be reduced to produce "slow speed
dross". Any required cleanup can then be done by scrap- There are extremely dangerous voltage and power
ping, not grinding. levels present inside this unit. Do not attempt to
diagnose or repair unless you have had training in
Dross present on top of the plate (top spatter), is normally power electronics measurement and troubleshoot-
caused by a slow torch travel speed or too high of a torch ing techniques.
standoff distance.
F. Common Cutting Faults B. Basic Troubleshooting
1. Insufficient Penetration This manual covers a basic level of troubleshooting that
requires limited dissasembly and measurements. It is
a. Cutting speed too fast helpful for solving many of the common problems that
b. Torch tilted too much can arise with this system.
c. Metal too thick If major complex subassemblies are faulty, the unit must
be returned to an authorized service center for repair.
d. Worn torch parts
Follow all instructions as listed and complete each sec-
e. Cutting current too low tion in the order presented.
2. Main Arc Extinguishes For major troubleshooting and parts replacement pro-
a. Cutting speed too slow cedures refer to PAK Master 75XL PLUS Power Supply
Service Manual 0-2747.
b. Torch standoff too high from workpiece
C. How to use this Guide
c. Cutting current too high
The following information is a guide to help the Cus-
d. Work cable disconnected tomer/Operator determine the most likely causes for
e. Worn torch parts various symptoms.
3. Excessive Dross Formation This guide is set up in the following manner:
a. Cutting speed too slow X. Symptom (Bold Type)

Any Special Instructions (Text Type)

1. Cause (Italic Type) a. Check and connect to proper input power line
a. Check/Remedy (Text Type) 5. Faulty components in unit
Locate your symptom, check the causes (easiest listed first) a. Return for repair or have qualified technician
then remedies. Repair as needed being sure to verify that repair per Service Manual.
unit is fully operational after any repairs.
C. Torch will not pilot when torch switch is activated
A. AC Power indicator OFF
1. RUN/SET/LATCH switch in SET position
1. Switch at customer's main power panel in OFF posi-
a. Move switch to RUN position.
tion.
a. Close main power panel switch 2. Faulty torch parts
a. Inspect torch parts and replace if necessary (re-
2. Input power not properly connected to customer's main
fer to Instruction Manual supplied with torch).
power panel
3. Gas pressure too high or too low
a. Check that input power is present and unit is
properly connected (refer to Section 3.05, Input a. Set pressure to 60 psi (4.1 bar).
Power Connections.)
4. Faulty components in unit
3. Customer's main power line fuse(s) blown
a. Return for repair or have qualified technician
a. Check main power panel fuse(s) and replace as repair per Service Manual.
required.
D. AC Power indicator ON; Fans operating; No
4. Actual input voltage does not correspond to voltage cutting output
selection inside unit
1. Torch not properly connected to power supply
a. Check actual line voltage vs. voltage selection
(inside of unit). a. Check that torch leads are properly attached to
power supply.
5. Unit internal fuse blown or loose
2. Shield cup not properly installed on torch
a. If blown, double check input voltage vs. volt-
age selection (inside of unit) and replace fuse a. Check that shield cup is fully seated against
per Section 5.05-B. If fuse blows again, compo- torch head (do not overtighten if screwed on).
nents inside the unit may be faulty. 3. Faulty components in unit
6. Faulty components in unit a. Return for repair or have qualified technician
a. Return unit to an authorized service center for repair per Service Manual.
repair or have qualified technician repair per 4. Faulty Torch
Service Manual.
B. AC Power indicator ON; TEMP indicator ON repair per Torch Service Manual (0-2752).
1. Airflow obstructed E. Low cutting output with no control
a. Check for obstructed air flow and correct con- 1. Incorrect setting of CURRENT control
dition.
a. Check and adjusted to proper setting.
2. Fan blocked
2. Faulty components in unit
a. Check and correct condition
3. Unit is overheated repair per Service Manual.
a. Allow unit to cool down for about 5 minutes. F. Limited output with no control
Make sure the unit has not been operated be-
yond duty cycle limit. 1. Poor input or output connections
4. Input line voltage is below 75% of rated level a. Check all input and output connections.
2. Incorrect setting of CURRENT control

a. Check and adjusted to proper setting. 5.05 Power Supply Parts
3. Faulty components in unit Replacement
repair per Service Manual.
WARNING
G. Erractic or improper cutting output
1. Poor input or output connections
Disconnect primary power to the system before dis-
a. Check all input and output connections. assembling the torch, leads, or power supply.
2. Incorrect type and size cable on input or output
A. Left Side Panel Removal
a. Use proper type and size cables.
1. Using a phillips head screw driver remove the five
H. AC Power indicator ON; Cutting output avail- screws which secure the left side panel (viewed
able; Fans not operating, from front of unit) to the frame assembly.
1. Fan blades blocked
a. Check and clear blades.
2. Faulty components in unit Left Side
Panel
repair per Service Manual.
I. AC POWER indicator ON; Fans operate; No gas
flow
1. Gas not connected or pressure too low
a. Check source for at least 70 psi (4.8 bar).
A-02468
2. Gas supply pressure too high
a. Maximum of 125 PSI inlet pressure
3. Faulty components in unit Ground
Screws Wire
repair per Service Manual. (5 places)
J. Torch cuts but not adequately

Figure 5-1 Left Side Panel Removal
1. Drag circuit active
a. Lift tip from work piece. NOTE
2. Current set too low There is a ground wire connection to the Left Side
Panel on the inside of the unit. There is no need to
a. Increase current setting.
disconnect the ground wire.
3. Torch is being moved too fast across workpiece
2. Carefully pull the Left Side Panel up and away
a. Reduce cutting speed (refer to Instruction from the unit to gain access to the inside of the
Manual supplied with torch. unit.
4. Excessive oil or moisture in torch 3. To reinstall the left side panel do the following:
a. Hold torch 1/8 inch (3 mm) from clean surface a. Place the left side panel onto the frame and
while purging and observe oil or moisture slide the top edge under the lip on the top of
buildup (do not activate torch). the right side panel.
b. Reinstall all the screws to secure the left side
panel.

B. Fuse Replacement
1. Remove the left side panel per paragraph "A"
above.
2. Locate the internal fuse above the input power con-
tactor on the left side of the unit.
3. Replace the fuse (0.8 amp, 600V).
4. Reinstall the left side panel per paragraph "A"
above.
Internal Fuse A-00919

0.8 Amps, 600V
Figure 5-2 Internal Fuse Location

SECTION 6:
PARTS LISTS
6.01 Introduction
A. Parts List Breakdown
The parts list provide a breakdown of all replaceable com-
ponents. The parts lists are arranged as follows:
Section 6.03 Complete Power Supply Replacement
Section 6.04 Replacement Parts
Section 6.05 Options and Accessories
NOTE
Parts listed without item numbers are not shown,
but may be ordered by the catalog number shown.
B. Returns
If a Thermal Dynamics product must be returned for ser-
vice, contact your Thermal Dynamics distributor. Mate-
rials returned to Thermal Dynamics without proper au-
thorization will not be accepted.
6.02 Ordering Information

Order replacement parts by catalog number and complete
description of the part or assembly, as listed in the parts
list for each type item. Also include the model and serial
number of the torch. Address all inquiries to your autho-
rized Thermal Dynamics distributor.
Manual 0-2746 31 SECTION 6: PARTS LISTS

6.03 Complete Power Supply Replacement
Power supply includes: Work cable and clamp, pressure regulator/air filter, and operating manual.
Description Qty Catalog #
PAK MASTER 75XL PLUS Power Supply

208/230VAC, Single-Phase With 50 Amp Input Plug and Cable 1 3-7556-1
460VAC, Three-Phase Without Input Plug and Cable 1 3-7556-2
6.04 Replacement Parts

Qty Description Catalog #
1 Fuse (0.8 amp, 600V) 9-7526
1 220V Single-Phase Input Power Cable 9-7512
6.05 Options and Accessories

Qty Description Catalog #
1 Smart Cart 7-7777
1 575V Transformer 9-7500
1 Filter Kit “Dry Air” – Includes Filter And Hose - Optional 7-7507
1 Replacement Filter Body “Dry Air” 9-7740
2 Replacement Filter Element “Dry Air” 9-7741
1 Replacement Filter Hose “Dry Air” 9-7742
1 Bracket, Laman Filter Mounting - Optional 9-7535
1 Two Stage Air Line Filter Kit - Optional 7-7500
1 Dual Stage Air Filter Assembly 9-7527
1 Replacement First Stage Filter 9-1021
1 Replacement Second Stage Filter 9-1022
Computer Control Cable (CNC)
1 25 Foot (7.6 M) 8-5557
1 50 Foot (15.2 M) 8-5558
Housing
Filter
Element
Spring
Assembled Filter
Cover
Barbed
Fitting
A-02476
Optional Dry Air Filter Kit
SECTION 6: PARTS LISTS 32 Manual 0-2746

APPENDIX I: INPUT WIRING REQUIREMENTS
Input P ower Input Current Input Recommended S izes (See Notes)

V oltage Freq. 1-Ph 3-Ph 1-Ph 3-Ph Fuse (Amps) W ire (AW G) W ire (Canada)
(V olts) (Hz) (kVA) (kVA) (Amps) (Amps) 1-Ph 3-Ph 1-Ph 3-Ph 1-Ph 3-Ph
208 50/60 12.5 11.2 60 31.1 70 40 4 8 4 8
230 50/60 12.5 11.3 54.1 28.3 70 35 4 8 4 8
240 50/60 12.6 11.4 52.3 27.5 60 35 6 8 6 8
380 50/60 13.9 12.4 36.5 18.9 45 25 8 10 8 10
415 50/60 13.9 12.6 33.4 17.5 40 25 8 12 8 12
460 50/60 13.9 12.7 30.1 16 35 25 8 12 8 12
575 Requires Transform er M odule
Line V oltages with Recom m ended Circuit P rotection and W ire S izes
(B ased on Table 310-16, 1987 National Electric Code) and Table 4, Canadian Electrical Code.
NOTES
The table above is based on the following output current and voltage: 130VDC @ 60A
An energy limiting fuse UL Class RK-1 (examples: BUSS LPS/LPN-RK or Gould-Shawmut AZK-A6K) should be
used to minimize damage to Plasma Cutting, Welding or power distribution equipment.
NEVER use replaceable element fuses like UL Class H, or "one-time" fuses like UL Class K5.
Primary input power cable must have an outside diameter of 0.69 inches (17.5 mm) or greater.
Manual 0-2746 33 APPENDIX

APPENDIX II: SEQUENCE OF OPERATION
(BLOCK DIAGRAM)
LATCH
ACTION ACTION ACTION ACTION

Close external ON/OFF switch RUN/SET/LATCH switch RUN/SET/LATCH
disconnect switch. to ON. to SET. switch to RUN.
RESULT RESULT RESULT RESULT
Power to system. AC indicator blinks for 8 Gas solenoid open, Gas flow stops.
seconds then steady on. gas flows to set pressure. GAS indicator off.
Fans on. GAS indicator on.
Power circuit ready.
ACTION
ACTION
Torch moved away
Protect eyes and from work (while
activate torch still activated).
RESULT RESULT
Gas flows (2 seconds). Main arc stops.
PILOT ARC Pilot arc automatically
restarts.
After gas pre-flow:
DC indicator on.
Pilot relay closes.
Pilot arc established
ACTION
Torch moved within
transfer distance of workpiece.
ACTION
RESULT Torch Switch
ACTION can be released.
Main arc transfer.
Torch deactivated (by torch switch Pilot arc off.
release or by remote device). RESULT
Transfer will continue
RESULT until torch is removed
from workpiece.
Main arc stops.
(Power supply enable signal removed.)
Gas flows (15 seconds)
NOTE - If torch is activated during
post-flow, pilot arc will immediately restart.
If torch is within transfer distance (3/8 in) of ACTION
ACTION
workpiece, main arc will transfer.
ON/OFF switch
to OFF Open external
After post-flow: disconnect.
Gas solenoid closes, gas flow stops. RESULT
RESULT
GAS indicator off.
All indicators off.
Power supply fans off. No power to system.
A-02461
APPENDIX 34 Manual 0-2746

This Page Left Blank

APPENDIX III: SYSTEM SCHEMATIC
INRUSH
GAS
GAS
SOL
13 16
INRUSH
J21 J20 J19
A-02503

OK TO
MOVE
OK
8/11/99
A-02503


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Air Plasma Cutting

August 23, 1999 Manual No. 0-2746

While the information contained in this Operating Manual

Pak Master® 75XL Plus Air Plasma Cutting Power Supply

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

PLASMA ARC RAYS 6. ANSI Standard Z49.2, FIRE PREVENTION IN THE

GENERAL INFORMATION 2 Date 6/22/99

Date: 6/22/99 3 GENERAL INFORMATION

CHOC ELECTRIQUE Les rayons provenant de l’arc de plasma peuvent blesser

GENERAL INFORMATION 4 Date 6/22/99

Date: 6/22/99 5 GENERAL INFORMATION

GENERAL INFORMATION 6 Date 6/22/99

National Standard and Technical Specifications

Manufacturers responsible representative: Steve Ward

Date: 6/22/99 7 GENERAL INFORMATION

THIS WARRANTY IS INVALID IF THE PRODUCT IS SOLD BY NON-AUTHORIZED PERSONS.

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

Torch And Leads

Maximizer 300 Torch 1 Year 1 Year

Repair/Replacement Parts 90 Days 90 Days 90 Days None

Effective May 6, 1999

GENERAL INFORMATION 8 Date 6/22/99

2.02 General Description of System 2. Front Panel LED Indicators

XL PLUS Power Supply

Manual 0-2746 9 SECTION 2: INTRODUCTION

2.04 Power Supply Options and

SECTION 2: INTRODUCTION 10 Manual 0-2746

Operation without proper air flow will inhibit

NOTE 3.03 Unpacking

Select a clean, dry location with good ventilation and ad-

Manual 0-2746 11 SECTION 3: INSTALLATION PROCEDURES

HANDLE is not for mechanical lifting.

Disconnect primary power at the source before as-

1. Move the power selection plug to the desired input

SECTION 3: INSTALLATION PROCEDURES 12 Manual 0-2746

2. For three-phase 460VAC input, the jumper wire be- Input L3

3.07 Primary Input Power Cable

Figure 3-3 AC Input Power Cable Strain Relief

Manual 0-2746 13 SECTION 3: INSTALLATION PROCEDURES

Figure 3-6 Primary Power Cable Connections -

3.08 Gas Connections

A-00914 Single Phase

c. Locate the ground stud and remove the top nut

SECTION 3: INSTALLATION PROCEDURES 14 Manual 0-2746

shipped inside the Torch Spare Parts Kit. Hose Clamp

3. Install the barbed fitting as shown below.

1/4 NPT to #4 (6mm)

#4 (6mm) Gas Two Stage Filter

Manual 0-2746 15 SECTION 3: INSTALLATION PROCEDURES

Pressure should be set at 100 psi (6.9 bar) at the

Disconnect primary power at the source before as- Torch Leads

The Torch Leads must be properly installed to the Power

Figure 3-11 Torch Strain Relief Nut

SECTION 3: INSTALLATION PROCEDURES 16 Manual 0-2746