A THERMADYNE® Company
R
Air Plasma Cutting
Power Supply
®
The System Includes:
• Pak Master® 50 Power Supply
• PCH/M-35 Smart Torch
• Optional Input Power Cable
• Work Cable with Clamp
Instruction Manual
October 20, 1997
®
with Leads
Manual No. 0-2470
WARNING
Read and understand this entire Instruction Manual and your
employer’s safety practices before installing, operating, or
servicing the equipment.
WARNING
While the information contained in this Instruction Manual
represents our best judgement, Thermal Dynamics Corporation
assumes no liability for its use.
®
Pak Master
50 Air Plasma Cutting Power Supply
Instruction Manual Number 0-2470
Published by:
Thermal Dynamics Corporation
Industrial Park No. 2
West Lebanon, New Hampshire, USA 03784
(603) 298-5711
Copyright 1995 by
Thermal Dynamics Corporation
All rights reserved.
Reproduction of this work, in whole or in part, without written
permission of the publisher is prohibited.
The publisher does not assume and hereby disclaims any liability
to any party for any loss or damage caused by any error or
®
omission in the Pak Master
50 Air Plasma Cutting Power Supply
Instruction Manual, whether such error results from negligence,
accident, or any other cause.
Printed in the United States of America
October 20, 1997
TABLE OF CONTENTS
SECTION 1: GENERAL INFORMATION ......................................................................................1
1.01 Notes, Cautions and Warnings.......................................................................1
1.02 Important Safety Precautions .........................................................................1
1.03 Publications ....................................................................................................2
1.04 Note, Attention et Avertissement.....................................................................3
1.05 Precautions De Securite Importantes.............................................................3
1.06 Documents De Reference ..............................................................................5
1.07 Declaration of Conformity ...............................................................................6
1.08 Statement of Warranty....................................................................................7
SECTION 2: GENERAL DESCRIPTION ......................................................................................9
2.01 SYSTEM DESCRIPTION ...............................................................................9
2.02 SPECIFICATIONS ........................................................................................10
2.03 OPTIONS AND ACCESSORIES ..................................................................12
SECTION 3: INSTALLATION ......................................................................................................13
3.01 UNPACKING..................................................................................................13
3.03 SETTING UP THE TORCH ..........................................................................15
3.04 INSTALLING THE TORCH ...........................................................................17
3.05 REMOTE CONTROL HARNESS INSTALLATION .......................................18
3.06 ELECTRICAL CONNECTIONS ....................................................................20
3.07 WORK CABLE AND GROUND CONNECTIONS.........................................23
3.08 GAS CONNECTIONS ..................................................................................24
SECTION 4: OPERATION ..........................................................................................................27
4.01 OPERATING CONTROLS............................................................................27
4.02 GETTING STARTED ....................................................................................29
4.03 SEQUENCE OF OPERATION......................................................................30
4.04 TORCH PARTS SELECTION.......................................................................31
4.05 CUT QUALITY ..............................................................................................32
4.06 OPERATING THE SYSTEM.........................................................................34
4.07 OPERATING WITH A HAND TORCH...........................................................36
4.08 OPERATING WITH A MACHINE TORCH ....................................................37
4.09 RECOMMENDED CUTTING SPEEDS ........................................................40
4.10 GOUGING ....................................................................................................41
SECTION 5: CUSTOMER/OPERATOR SERVICE.....................................................................43
5.01 GENERAL POWER SUPPLY MAINTENANCE............................................43
5.02 REPLACING CONSUMABLE TORCH PARTS ............................................44
5.03 GENERAL TORCH MAINTENANCE............................................................45
5.04 SERVICING TORCH HEAD COMPONENTS ..............................................47
5.05 SERVICING TORCH LEADS COMPONENTS.............................................53
5.06 TORCH AND LEADS TROUBLESHOOTING...............................................56
5.07 POWER SUPPLY TROUBLESHOOTING ....................................................58
5.08 SERVICE PROCEDURES............................................................................62
TABLE OF CONTENTS (continued)
SECTION 6: PARTS LIST...........................................................................................................69
6.01 ORDERING INFORMATION ........................................................................69
6.02 SYSTEM COMPONENTS AND ACCESSORIES.........................................70
6.03 FRONT PANEL COMPONENTS ..................................................................71
6.04 REGULATOR/SOLENOID ASSEMBLY........................................................72
6.05 BASE PANEL COMPONENTS.....................................................................73
6.06 CHASSIS COMPONENTS ...........................................................................74
6.07 REAR PANEL COMPONENTS ....................................................................76
6.08 REPLACEMENT TORCHES AND LEADS ...................................................77
5.9 TORCH HEADS AND SPLIT HOLDERS........................................................78
5.10 CONSUMABLE TORCH PARTS ..................................................................79
6.11 TORCH OPTIONS AND ACCESSORIES.....................................................80
6.12 TORCH SPARE PARTS KITS ......................................................................82
APPENDIX I: SYSTEM SCHEMATIC .........................................................................................84
SECTION 1:
GENERAL INFORMATION
1.01 Notes, Cautions and Warnings
Throughout this manual, notes, cautions, and warnings
are used to highlight important information. These highlights are categorized as follows:
NOTE
An operation, procedure, or background information which requires additional emphasis or is helpful in efficient operation of the system.
CAUTION
A procedur e which, if not pr operly followed, may
cause damage to the equipment.
WARNING
A procedur e which, if not pr operly followed, may
cause injury to the operator or others in the operating area.
1.02 Important Safety Precautions
• 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 dif ferent processes. You must
be very careful when cutting or welding any metals which may contain one or more of the following:
Antimony Chromium Mercury
Arsenic Cobalt Nickel
Barium Copper Selenium
Beryllium Lead Silver
Cadmium Manganese Vanadium
• Always read the Material Safety Data Sheets (MSDS)
that should be supplied with the material you are
using. These MSDSs will give you the information regarding the kind and amount of fumes and
gases that may be dangerous to your health.
• For information on how to test for fumes and gases
in your workplace, refer to item 1 in Subsection
1.03, Publications in this manual.
• Use special equipment, such as water or down draft
cutting tables, to capture fumes and gases.
• Do not use the plasma torch in an area where combustible or explosive gases or materials are located.
• Phosgene, a toxic gas, is generated from the vapors
of chlorinated solvents and cleansers. Remove all
sources of these vapors.
WARNING
OPERATION AND MAINTENANCE OF
PLASMA ARC EQUIPMENT CAN BE DANGEROUS AND HAZARDOUS TO YOUR
HEALTH.
To prevent possible injury, read, understand and
follow all warnings, safety precautions and instructions before using the equipment. Call 1603-298-5711 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.
ELECTRIC SHOCK
Electric Shock can injure or kill. The plasma arc process
uses and produces high voltage electrical energy. This
electric energy can cause severe or fatal shock to the operator or others in the workplace.
• Never touch any parts that are electrically “live” or
“hot.”
• Wear dry gloves and clothing. Insulate yourself
from the work piece or other parts of the welding
circuit.
• Repair or replace all worn or damaged parts.
• Extra care must be taken when the workplace is
moist or damp.
• Install and maintain equipment according to NEC
code, refer to item 4 in Subsection 1.03, Publications.
• Disconnect power source before performing any service or repairs.
• Read and follow all the instructions in the Operating Manual.
1 GENERAL INFORMATION
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 material 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 underwater or while using a water table. DO NOT cut
aluminum alloys underwater or on a water table
unless the hydrogen gas can be eliminated or dissipated. Trapped hydrogen gas that is ignited will
cause an explosion.
NOISE
Noise can cause permanent hearing loss. Plasma arc processes can cause noise levels to exceed safe limits. Y ou
must protect your ears from loud noise to prevent permanent loss of hearing.
• To protect your hearing from loud noise, wear protective ear plugs and/or ear muffs. Protect others
in the workplace.
• Noise levels should be measured to be sure the decibels (sound) do not exceed safe levels.
• For information on how to test for noise, see item 1
in Subsection 1.03, Publications, in this manual.
PLASMA ARC RAYS
Plasma Arc Rays can injure your eyes and burn your
skin. The plasma arc process produces very bright ultra
violet and infra red light. These arc rays will damage
your eyes and burn your skin if you are not properly
protected.
• To protect your eyes, always wear a welding helmet or shield. Also always wear safety glasses with
side shields, goggles or other protective eye wear.
• Wear welding gloves and suitable clothing to protect your skin from the arc rays and sparks.
• Keep helmet and safety glasses in good condition.
Replace lenses when cracked, chipped or dirty.
• Protect others in the work area from the arc rays.
Use protective booths, screens or shields.
• Use the shade of lens as recommended in Subsection 1.03, item 4.
1.03 Publications
Refer to the following standards or their latest revisions
for more information:
1. OSHA, SAFETY AND HEALTH STANDARDS,
29CFR 1910, obtainable from the Superintendent of
Documents, U.S. Government Printing Office, W ashington, D.C. 20402
2. ANSI Standard Z49.1, SAFETY IN WELDING AND
CUTTING, obtainable from the American Welding
Society, 550 N.W. LeJeune Rd, Miami, FL 33126
3. NIOSH, SAFETY AND HEALTH IN ARC WELDING AND GAS WELDING AND CUTTING, obtainable from the Superintendent of Documents, U.S.
Government Printing Office, W ashington, D.C. 20402
4. ANSI Standard Z87.1, SAFE PRACTICES FOR OCCUP A TION AND EDUCA TIONAL EYE AND F ACE
PROTECTION, obtainable from American National
Standards Institute, 1430 Broadway, New York, NY
10018
5. ANSI Standard Z41.1, STANDARD FOR MEN’S
SAFETY-TOE FOOTWEAR, obtainable from the
American National Standards Institute, 1430 Broadway, New York, NY 10018
6. ANSI Standard Z49.2, FIRE PREVENTION IN THE
USE OF CUTTING AND WELDING PROCESSES,
obtainable from American National Standar ds Institute, 1430 Broadway, New York, NY 10018
7. AWS Standard A6.0, WELDING AND CUTTING
CONTAINERS WHICH HAVE HELD COMBUSTIBLES, obtainable from American Welding Society ,
550 N.W. LeJeune Rd, Miami, FL 33126
8. NFPA Standard 51, OXYGEN-FUEL GAS SYSTEMS
FOR WELDING, CUTTING AND ALLIED PROCESSES, obtainable from the National Fire Protection Association, Batterymarch Park, Quincy, MA
02269
9. NFPA Standard 70, NATIONAL ELECTRICAL
CODE, obtainable from the National Fire Protection
Association, Batterymarch Park, Quincy, MA 02269
10. NFPA Standard 51B, CUTTING AND WELDING
PROCESSES, obtainable from the National Fire Protection Association, Batterymarch Park, Quincy, MA
02269
11. CGA Pamphlet P-1, SAFE HANDLING OF COMPRESSED GASES IN CYLINDERS, obtainable from
the Compressed Gas Association, 1235 Jefferson
Davis Highway, Suite 501, Arlington, VA 22202
GENERAL INFORMATION 2
12. CSA Standard W117.2, CODE FOR SAFETY IN
WELDING AND CUTTING, obtainable from the Canadian Standards Association, Standards Sales, 178
Rexdale Boulevard, Rexdale, Ontario, Canada M9W
1R3
13. NWSA booklet, WELDING SAFETY BIBLIOGRAPHY obtainable from the National Welding Supply
Association, 1900 Arch Street, Philadelphia, PA 19103
14. American W elding Society Standar d A WSF4.1, RECOMMENDED SAFE PRACTICES FOR THE PREP ARATION FOR WELDING AND CUTTING OF CONTAINERS AND PIPING THAT HAVE HELD
HAZARDOUS SUBSTANCES, obtainable from the
American Welding Society, 550 N.W. LeJeune Rd,
Miami, FL 33126
15. ANSI Standard Z88.2, PRACTICE FOR RESPIRATORY PROTECTION, obtainable from American
National Standards Institute, 1430 Broadway, New
York, NY 10018
1.04 Note, Attention et Avertissement
Dans ce manuel, les mots “note,” “attention,” et
“avertissement” sont utilisés pour mettre en relief des
informations à caractère important. Ces mises 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 nonrespect de la procédure en question.
AVERTISSEMENT
Toute procédure pouvant provoquer des blessures
de l’opérateur ou des autres personnes se trouvant
dans la zone de travail en cas de non-respect de la
procédure en question.
1.05 Precautions De Securite Importantes
AVERTISSEMENT
L’OPÉRATION ET LA MAINTENANCE DU
MATÉRIEL DE SOUDAGE À L’ARC AU JET
DE PLASMA PEUVENT PRÉSENTER DES
RISQUES ET DES DANGERS DE SANTÉ.
Il faut communiquer aux opérateurs et au personnel TOUS les dangers possibles. Afin d’éviter les
blessures possibles, lisez, comprenez et suivez tous
les avertissements, toutes les précautions de
sécurité et toutes les consignes avant d’utiliser le
matériel. Composez le + 603-298-5711 ou votre
distributeur local si vous avez des questions.
FUMÉE et GAZ
La fumée et les gaz produits par le procédé de jet de
plasma peuvent présenter des risques et des dangers de
santé.
• Eloignez toute fumée et gaz de votre zone de respiration. Gardez votre tête hors de la plume de fumée
provenant du chalumeau.
• Utilisez un appareil respiratoire à alimentation en
air si l’aération fournie ne permet pas d’éliminer la
fumée et les gaz.
• Les sortes de gaz et de fumée provenant de l’arc de
plasma dépendent du genre de métal utilisé, des
revêtements se trouvant sur le métal et des
différents procédés. V ous devez prendre soin
lorsque vous coupez ou soudez tout métal pouvant
contenir un ou plusieurs des éléments suivants:
antimoine cadmium mercure
argent chrome nickel
arsenic cobalt plomb
baryum cuivre sélénium
béryllium manganèse vanadium
• Lisez toujours les fiches de données sur la sécurité
des matières (sigle américain “MSDS”); celles-ci
devraient être fournies avec le matériel que vous
utilisez. Les MSDS contiennent des renseignements
quant à la quantité et la nature de la fumée et des
gaz pouvant poser des dangers de santé.
• Pour des informations sur la manière de tester la
fumée et les gaz de votre lieu de travail, consultez
l’article 1 et les documents cités à la page 5.
3 GENERAL INFORMATION
• Utilisez un équipement spécial tel que des tables de
coupe à débit d’eau ou à courant descendant pour
capter la fumée et les gaz.
• N’utilisez pas le chalumeau au jet de plasma dans
une zone où se trouvent des matières ou des gaz
combustibles ou explosifs.
• Le phosgène, un gaz toxique, est généré par la fumée
provenant des solvants et des produits de nettoyage
chlorés. Eliminez toute source de telle fumée.
• Prévoyez une veille d’incendie lors de tout travail
dans une zone présentant des dangers d’incendie.
• Le gas hydrogène peut se former ou s’accumuler
sous les pièces de travail en aluminium lorsqu’elles
sont coupées sous l’eau ou sur une table d’eau. NE
PAS couper les alliages en aluminium sous l’eau
ou sur une table d’eau à moins que le gas hydrogène
peut s’échapper ou se dissiper. Le gas hydrogène
accumulé explosera si enflammé.
CHOC ELECTRIQUE
Les chocs électriques peuvent blesser ou même tuer . Le
procédé au jet de plasma requiert et produit de l’énergie
électrique haute tension. Cette énergie électrique peut
produire des chocs graves, voire mortels, pour l’opérateur
et les autres personnes sur le lieu de travail.
• Ne touchez jamais une pièce “sous tension” ou
“vive”; portez des gants et des vêtements secs.
Isolez-vous de la pièce de travail ou des autres parties du circuit de soudage.
• Réparez ou remplacez toute pièce usée ou
endommagée.
• Prenez des soins particuliers lorsque la zone de travail est humide ou moite.
• Montez et maintenez le matériel conformément au
Code électrique national des Etats-Unis. (V oir la
page 5, article 9.)
• Débranchez l’alimentation électrique avant tout travail d’entretien ou de réparation.
• Lisez et respectez toutes les consignes du Manuel
de consignes.
INCENDIE ET EXPLOSION
RAYONS D’ARC DE PLASMA
Les rayons provenant de l’arc de plasma peuvent blesser
vos yeux et brûler votre peau. Le procédé à l’arc de plasma
produit une lumière infra-rouge et des rayons ultra-violets très forts. Ces rayons d’arc nuiront à vos yeux et
brûleront votre peau si vous ne vous protégez pas
correctement.
• Pour protéger vos yeux, portez toujours un casque
ou un écran de soudeur. Portez toujours des lunettes
de sécurité munies de parois latérales ou des lunettes de protection ou une autre sorte de protection oculaire.
• Portez des gants de soudeur et un vêtement
protecteur approprié pour protéger votre peau
contre les étincelles et les rayons de l’arc.
• Maintenez votre casque et vos lunettes de protection en bon état. Remplacez toute lentille sale ou
comportant fissure ou rognure.
• Protégez les autres personnes se trouvant sur la zone
de travail contre les rayons de l’arc en fournissant
des cabines ou des écrans de protection.
• Respectez le teint de lentille recommandé dans le
article 4, page 5.
Les incendies et les explosions peuvent résulter des
scories chaudes, des étincelles ou de l’arc de plasma. Le
procédé à l’arc de plasma produit du métal, des étincelles,
des scories chaudes pouvant mettre le feu aux matières
combustibles ou provoquer l’explosion de fumées
inflammables.
• Soyez certain qu’aucune matière combustible ou inflammable ne se trouve sur le lieu de travail.
Protégez toute telle matière qu’il est impossible de
retirer de la zone de travail.
• Procurez une bonne aération de toutes les fumées
inflammables ou explosives.
• Ne coupez pas et ne soudez pas les conteneurs ayant
pu renfermer des matières combustibles.
GENERAL INFORMATION 4
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 TRAV AIL ET
DE PROTECTION DE LA SANTÉ, 29CFR 1910,
disponible auprès du Superintendent of Documents, U.S. Government Printing Office, Washington, D.C. 20402
2. Norme ANSI Z49.1, LA SÉCURITÉ DES
OPÉRATIONS DE COUPE ET DE SOUDAGE,
disponible auprès de la Société Américaine de
Soudage (American Welding Society), 550 N.W .
LeJeune Rd., Miami, FL 33126
3. NIOSH, LA SÉCURITÉ ET LA SANTÉ LORS DES
OPÉRATIONS DE COUPE ET DE SOUDAGE À
L’ARC ET AU GAZ, disponible auprès du Superintendent of Documents, U.S. Government Printing Office, Washington, D.C. 20402
4. Norme ANSI Z87.1, PRATIQUES SURES POUR LA
PROTECTION DES YEUX ET DU VISAGE AU
TRAVAIL ET DANS LES ECOLES, disponible de
l’Institut Américain des Normes Nationales (American National Standards Institute), 1430 Broadway,
New York, NY 10018
5. Norme 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 Protection contre les Incendies (NFPA), LES SYSTEMES
À GAZ AVEC ALIMENTATION EN OXYGENE
POUR LE SOUDAGE, LA COUPE ET LES
PROCÉDÉS ASSOCIÉS, disponible auprès de la
National Fire Protection Association, Batterymarch
Park, Quincy, MA 02269
9. Norme 70 de la NFPA, CODE ELECTRIQUE NATIONAL, disponible auprès de la National Fire Protection Association, Batterymarch Park, Quincy, MA
02269
10. Norme 51B de la NFP A, LES PROCÉDÉS DE
COUPE ET DE SOUDAGE, disponible auprès de
la National Fire Protection Association,
Batterymarch Park, Quincy, MA 02269
11. Brochure GCA P-1, LA MANIPULATION SANS
RISQUE DES GAZ COMPRIMÉS EN CYLINDRES,
disponible auprès de l’Association des Gaz
Comprimés (Compressed Gas Association), 1235
Jefferson Davis Highway, Suite 501, Arlington, VA
22202
12. Norme CSA W1 17.2, CODE DE SÉCURITÉ POUR
LE SOUDAGE ET LA COUPE, disponible auprès
de l’Association des Normes Canadiennes, Standards Sales, 178 Rexdale Boulevard, Rexdale,
Ontario, Canada, M9W 1R3
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, P A 19103
14. Norme AWSF4.1 de l’Association Américaine de
Soudage, RECOMMANDATIONS DE PRATIQUES
SURES POUR LA PRÉP ARATION À LA COUPE
ET AU SOUDAGE DE CONTENEURS ET
TUYAUX AYANT RENFERMÉ DES PRODUITS
DANGEREUX , disponible auprès de la American
W elding Society , 550 N.W. LeJeune Rd., Miami, FL
33126
15. Norme ANSI Z88.2, PRATIQUES DE PROTECTION RESPIRATOIRE, disponible auprès de
l’American National Standards Institute, 1430
Broadway, New York, NY 10018
5 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
Directive’ (European Council Directive 73/23/EU, as recently changed in Directive 93/63/EU) and to the National
legislation for the enforcement of this Directive.
Serial numbers are unique with each individual piece of equipment and details description, parts used to 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-M1990 for Arc welding equipment.
* UL (Underwriters Laboratory) rating 94VO flammability testing for all printed-circuit boards used.
* IEC 974-1 (BS 638-PT10) (EN 60 974-1) applicable to welding equipment and associated accessories.
* Extensive product design verification is conducted at the manufacturing facility as part of the routine design and
manufacturing process, to ensure the product is safe and performs as specified. Rigorous testing is incorporated
into the manufacturing process to ensure the manufactured product meets or exceeds all design specifications.
Thermal Dynamics has been manufacturing products that perform in a safe manner for more than 30 years and will
continue to achieve excellence in our area of manufacture.
Manufacturers responsible representative: David Ashworth
Vice President & Managing Director
Thermadyne Europe
Chorley England.
GENERAL INFORMATION 6
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 W ARRANTY IS EXCLUSIVE AND IS IN LIEU OF ANY WARRANTY OF MERCHANTABILITY OR FITNESS FOR A
PARTICULAR PURPOSE.
LIMITA TION 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 expr essly provided her ein, exceed the price of the
goods upon which such liability is based.
THIS W ARRANTY BECOMES INVALID IF REPLACEMENT PAR TS 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 ST AK PAK II): A maximum of three
(3) years from date of sale to an authorized distributor and a maximum of two (2) years from date of sale by such distributor to
the Purchaser, and with the following further limitations on such two (2) year period. The limited warranty period for STAK
PAK II shall be as follows: A maximum of four (4) years from date of sale to an authorized distributor and a maximum of three
(3) years from date of sale by such distributor to the Purchaser, and with the following further limitations on such three (3) year
period:
PARTS
PAK UNITS, POWER SUPPLIES STAK PAK II All OTHERS LABOR
MAIN POWER MAGNETICS ............................................................3 YEARS .............. 2 YEARS ................ 1 YEAR
ORIGINAL MAIN POWER RECTIFIER ...........................................3 YEARS .............. 2 YEARS ................ 1 YEAR
CONTROL PC BOARD .......................................................................3 YEARS .............. 2 YEARS ................ 1 YEAR
ALL OTHER CIRCUITS AND COMPONENTS ............................... 1 YEAR ................ 1 YEAR ................. 1 YEAR
INCLUDING, BUT NOT LIMITED TO, STARTING
CIRCUIT, CONTACTORS, RELAYS, SOLENOIDS, PUMPS,
POWER SWITCHING SEMI-CONDUCTORS
CONSOLES, CONTROL EQUIPMENT, HEAT................................... 1 YEAR ................ 1 YEAR ................ 1 YEAR
EXCHANGES, AND ACCESSORY EQUIPMENT
TORCH AND LEADS............................................................................. 180 DAYS .............180 DAYS............. 180 DAYS
REPAIR/REPLACEMENT PARTS ......................................................... 90 DAYS...............90 DAYS.................NONE
Warranty repairs or replacement claims under this limited warranty must be submitted by an authorized Thermal Arc® repair
facility within thirty (30) days of the repair . No transportation costs of any kind will be paid under this warranty. Transportation
charges to send products to an authorized warranty repair facility shall be the responsibility of the customer. All returned goods
shall be at the customer’s risk and expense. This warranty supersedes all previous Thermal warranties.
Thermal Arc® is a Registered Trademark of Thermal Dynamics.
Effective February 1, 1995
7 GENERAL INFORMATION
GENERAL INFORMATION 8
SECTION 2: GENERAL DESCRIPTION
2.01 SYSTEM DESCRIPTION
The Pak Master® 50
Air Plasma Cutting
System Includes:
• Pak Master® 50 - The power supply provides 35 amp maximum
output and includes all control circuitry, electrical and gas
inputs and outputs, pilot circuitry, and a quick disconnect torch
leads receptacle. The power supply is shipped with a work
cable and clamp attached. A 230V single-phase primary input
power cable with molded 50 amp plug is optional. Machine
torch systems also include a remote hand control and remote
control wire harness.
• PCH/M-35 Torch with Leads (Packaged Separately) - The torch
provides a maximum 1/2 inch (12 mm) cut capacity. Hand
torches are available in 70° and 90° configurations which
include a handle and multi-position switch assembly. Machine
torches include a rack and pinion mounting assembly. A
phenolic (plastic) pinch block mounting assembly is optional.
Torch leads are available in 12.5, 25, or 50 ft (3.8, 7.6, or 15.2 m)
lengths with a quick disconnect torch leads fitting for simple
installation. The PCH/M-35 includes a spare parts kit which
provides an assortment of replacement consumable torch parts.
• See page 12 for a list of other system options and accessories.
Work Cable
with Clamp
A-00750
Pak Master 50
Power Supply
CSD
CURR
PILOT
DC
GAS
PIP
RUN
TEMP
ON
AC
SET
OFF
GAS PRESSURE
TORCH
WORK
Figure 2-A System Components
with Leads
Torch
Manual 0-2470 9 GENERAL DESCRIPTION
2.02 SPECIFICATIONS
Controls
Panel Indicators
Input Power
Output Power
Cut Capacity
Pilot Circuitry
CNC Capability
Weight
Dimensions
ON/OFF Switch
RUN/SET Switch
Output Current Control
Corner Slowdown Control
Pressure Regulator Control
LED Indicators:
AC Power, TEMP, PIP (Parts-In-Place), GAS, DC Power, PILOT
Pressure Gauge
200 to 460 VAC (±10%), 50 or 60 Hz, Single or Three-Phase
575V Requires Additional Transformer (Catalog No. 9-6211)
Continuously variable from 15 to 35 Amps maximum
70% Duty Cycle
1/2 in (12.7 mm) at 10 ipm
High Frequency (HF), Constant DC
Remote Start/Stop, OK-to-Move, and Corner Slowdown (CSD)
69.8 lbs (31.7 kg)
18.5" High x 11.1" Wide x 21.7" Long
(470 x 282 x 551 mm)
Table 2-A Power Supply Specifications
Configurations
Current Rating
Duty Cycle
Cutting Range
Pierce Rating
Transfer Distance
Consumable Parts
Gases
Pressure Requirements
Flow Requirements
Available Leads Lengths
70° or 90° Hand Torch, 180° Machine Torch
35 amps Maximum, DC Straight Polarity
100% @ 35 amps
Most materials up to 1/2 in (12.7 mm)
1/4 in (6.3 mm)
3/8 in (9.5 mm)
Gas Distributor, Electrode, Tip, Shield Cup
Compressed Air, Nitrogen (N2)
70 psi (4.8 BAR)
Cutting - 200 scfh (94.4 lpm)
Gouging - 230 scfh (108.5 lpm)
12.5 ft (3.8 m), 25 ft (7.2 m), or 50 ft (15.2 m)
Extendable to 150 ft (45.6 m)
Table 2-B Torch Specifications
GENERAL IDESCRIPTION 10 Manual 0-2470
2.02 SPECIFICATIONS (continued)
PCH-35 70 ° Hand Torch
PCH-35 90 ° Hand Torch
PCM-35 Machine Torch
with Rack and Pinion
Mounting Assembly
1.38 in
(35 mm)
9.59 in
(244 mm)
8.95 in
(227 mm)
1.06 in
(27 mm)
1.06 in
(27 mm)
6.21 in (158 mm) Min.
14.72 in (374 mm) Max.
0.20 in (5 mm)
16.60 in (422 mm)
2.95 in
(75 mm)
3.09 in
(78 mm)
1.06 in
(27 mm)
A-00009
Figure 2-B PCH/M-35 Torch Dimensions
Manual 0-2470 11 GENERAL DESCRIPTION
2.03 OPTIONS AND ACCESSORIES
Pak Master 50
System Options and
Accessories
• Remote Control (RC) Wire Harness ......................Cat. No. 9-6210
For converting a hand cutting system to mechanized use with a
remote hand pendant control or computer control (CNC) cable.
• Remote Hand Pendant Control ..............................Cat. No. 7-3114
Hand-held remote ON/OFF control device for systems with
remote wire harness installed. Includes a 25 ft (7.6 m) cable.
• Computer (CNC) Interface Cable - 25 ft (7.6 m) .. Cat. No. 8-5557
Computer (CNC) Interface Cable - 50 ft (15.2 m) Cat. No. 8-5558
For interfacing the power supply with a computer or auxiliary
control device. Provides ON/OFF, OK-to-move, and corner
slowdown signals. (Remote wire harness must be installed.)
• High Pressure Regulator - Air ................................Cat. No. 9-3022
High Pressure Regulator - Nitrogen (N
• Running Gear............................................................ Cat. No. 7-3201
For transporting the system with torch and leads storage.
• Air Line Filter - Single Stage ...................................Cat. No. 7-3265
Air Line Filter - Two Stage...................................... Cat. No. 7-3340
Remove damaging moisture and contaminants from the air
stream when using compressed air.
• 575V Transformer Unit............................................Cat. No. 9-6211
For operating standard systems with 575V three-phase input.
2) .............Cat. No. 9-2722
Torch Options
and Accessories
NOTE
• Spare Parts Kit - MaximumLife™..........................Cat. No. 5-6001
Spare Parts Kit - Gouging .......................................Cat. No. 5-6015
Kits contain replacement front-end torch parts (see detailed
description of spare parts kit contents on page 80).
• Leads Extension Kit - PCH-35, 25 ft (7.6 m) .........Cat. No. 4-6007
Leads Extension Kit - PCH-35, 50 ft (15.2 m) .......Cat. No. 4-6008
Leads Extension Kit - PCM-35, 25 ft (7.6 m) .........Cat. No. 4-6009
Leads Extension Kit - PCM-35, 50 ft (15.2 m) .......Cat. No. 4-6010
For extending torch leads up to 150 ft (45.7 m).
• Phenolic Mounting Tube......................................... Cat. No. 7-3251
Phenolic Pinch Block Mounting Assembly ..........Cat. No. 7-3252
For machine mounted torch applications where a non-metal
mounting assembly is desired.
• Switch Lever Kit .......................................................Cat. No. 8-5170
Provides a lever for activating the hand torch control switch.
See System Components and Accessories (page 70) or Torch
Options and Accessories (page 80) for more information.
GENERAL IDESCRIPTION 12 Manual 0-2470
SECTION 3: INSTALLATION
3.01 UNPACKING
Each component of the system is packaged separately and protected with a carton and packing material to prevent damage
during shipping.
What's Included with
the Power Supply
What's Included
with the Torch
Included with each power supply is:
(1) Work Cable with Clamp (Attached)
(1) 230V Single-Phase Input Power Cable with Plug (Optional)
(1) Air Q/D Coupling - 1/4 NPT to #6 Barb .......... Cat. No. 9-6258
(1) Fuse - 2 Amp, 600V ...............................................Cat. No. 9-3861
(1) Spare Parts Container (without Parts) ...............Cat. No. 8-3213
(1) Pak Master 50 Instruction Manual .....................Cat. No. 0-2470
Included with each machine torch system is:
(1) Remote Control Hand Pendant .......................... Cat. No. 7-3114
(1) Remote Control Interface Wire Harness ...........Cat. No. 9-6210
Torches are packaged separately. Included with each torch is:
(1) PCH/M-35 Torch (with Shield Cup, Tip, Electrode, and Gas
Distributor Installed)
(1) Torch Leads with Quick Disconnect (Attached)
(1) Torch Handle Assembly (For Hand Torches), or
(1) Machine Torch Mounting Assembly (For Machine Torches)
(1) MaximumLife™ Cutting Spare Parts Kit - Includes:
(1) Shield Cup Attachment .................................Cat. No. 9-6503
(5) Tips (Standoff Cutting) .................................Cat. No. 9-6500
(3) Tips (Drag Cutting)........................................ Cat. No. 9-6501
(5) Electrodes ........................................................ Cat. No. 9-6506
(1) Gas Distributor ...............................................Cat. No. 9-6507
Other accessories are packaged separately.
Unpacking Procedure
Manual 0-2470 13 INSTALLATION
1. Unpack each item and remove all packing material.
2. Locate the packing list(s) and use the list to identify and
account for each item.
3. Inspect each item for possible shipping damage. If damage is
evident, contact your distributor and/or shipping company
before proceeding with system installation.
3.02 CHOOSING A LOCATION
Choosing a Location
CAUTION
NOTE
Select a clean, dry location with good ventilation and adequate
working space around all components.
The power supply is cooled by air flow through the rear panel.
Air flow must not be obstructed. Provide at least 2 feet (0.61 m) of
clearance in the rear. Provide at least 6 inches (0.15 m) clearance
on each side. Provide sufficient clearance in front of the unit to
allow access to front panel controls (minimum 6 in or 0.15 m).
Operation without proper air flow will inhibit proper cooling and
reduce duty cycle.
Review Important Safety Precautions at the front of this Manual
to be sure that the selected location meets all safety requirements.
INSTALLA TION 14 Manual 0-2470
3.03 SETTING UP THE TORCH
WARNING
Hand Torch Set-Up
Disconnect primary power at the source before disassembling
the power supply, torch, or torch leads.
The torch parts (shield cup, tip, electrode, and gas distributor)
must correspond with the type of operation (drag cutting, standoff cutting, or gouging). Refer to Torch Parts Selection (page 31).
The torch is factory assembled with the control switch in the top
front position (see Figure 3-A below). To position the control
switch on the bottom (underside) of the handle, pull the handle
back approximately 2 inches (51 mm) and rotate the handle
assembly 180° (do not rotate beyond 180°). To position the
control switch in the rear position:
1. Locate the tab on the back of the switch track closure. Gently
press in on the tab and carefully pry the closure upward.
2. Remove the switch track insert and the torch control switch.
3. Reinstall the switch track insert, then the switch, then the
switch track closure.
The optional switch lever kit provides a lever for activating the
torch control switch. Refer to Torch Options and Accessories
(page 80) for ordering information.
Reverse view of
closure - press
tab to remove
Bottom mounted
torch switch (shown
with optional switch lever)
Switch Track Closure
Switch Track Insert
Switch Assembly
Switch Track
Switch Lever
with Mounting
Brackets
(Optional)
Figure 3-A Hand Torch Switch Options
Manual 0-2470 15 INSTALLATION
3.03 SETTING UP THE TORCH (continued)
WARNING
Machine Torch Set-Up
Disconnect primary power at the source before disassembling
the power supply, torch, or torch leads.
The torch parts (shield cup, tip, electrode, and gas distributor)
must correspond with the type of operation (drag cutting, standoff cutting, or gouging). Refer to Torch Parts Selection (page 23).
Metal mounting tubes with rack and pinion assemblies are
standard for machine torches. Phenolic (plastic) mounting tubes
with pinch blocks are optional (see Torch Options and Accessories, page 80).
1. Mount the torch assembly on the cutting table.
Refer to Figure 3-B and:
2. To obtain a clean vertical cut, use a square to align the torch
perpendicular to the surface of the workpiece.
Shown wth
Phenolic Pinch
Block Mounting
Assembly
Use a square to align
the torch assembly
perpendicular to the surface
of the workpiece
Figure 3-B Machine Torch Set-Up
Shown with
Rack and Pinion
Mounting Assembly
A-00057
INSTALLA TION 16 Manual 0-2470
3.04 INSTALLING THE TORCH
WARNING
CAUTION
Installing the Torch
Disconnect primary power at the source before disassembling
the power supply, torch, or torch leads.
This system is designed for use with the PCH/M-35 torch only.
Do not connect any other torch to this power supply.
1. Check the torch for proper assembly (refer to Torch Parts
Selection, page 31).
2. Connect the torch leads fitting onto the receptacle marked
TORCH on the front panel of the power supply.
CSD
CURR
PILOT
DC
GAS
PIP
RUN
TEMP
ON
AC
SET
OFF
GAS PRESSURE
TORCH
Torch Leads
Connector
WORK
Quick Disconnect
A-00751
Fitting
Figure 3-C Torch Connections
Manual 0-2470 17 INSTALLATION
3.05 REMOTE CONTROL HARNESS INSTALLATION
RC Wire Harness
WARNING
Remove the Hole Plug
Open the Enclosure
Installation of the remote control (RC) wire harness is required
for machine torch systems. Installation requires four #6-32 screws
with locknuts.
Disconnect primary power at the source before assembling or
disassembling the power supply, torch parts, or torch and leads
assemblies.
Refer to Figure 3-D and:
1. Remove the hole plug from the hole marked “REMOTE
CONTROL” on the upper left rear panel of the power supply.
2. Locate the eight screws which hold together the two halves of
the power supply enclosure. Lay the power supply on its side
with the screw heads facing UP. Remove all eight mounting
screws and carefully lift the upper half of the enclosure from
the unit. Lift the unit from the lower half of the enclosure and
set the unit in upright position on a secure working surface.
(continued on next page)
J6 Connector
Remote Control
Wire Harness
Hole Marked
“REMOTE
CONTROL”
Pak Master
Rear Panel
Ground Stud
(Inside Rear Panel)
J7 Connector
Ground Wire
A-00752
Figure 3-D Installing the RC Wire Harness
INSTALLA TION 18 Manual 0-2470
3.05 REMOTE CONTROL HARNESS INSTALLATION (continued)
Install the Wire Harness
CAUTION
Reassemble the
Enclosure
3. Inside the power supply, locate the white 6-pin connector J7
on the top panel, close to the “REMOTE CONTROL” hole
location.
4. Connect the 6-pin plug on the remote control wire harness to
the 6-pin connector J7.
5. Locate the ground stud on the RIGHT side of the rear panel,
inside the panel, at approximate center height. Connect the
ground wire of the remote control wire harness to the ground
stud.
Do not ground the remote control wire harness to the system
ground stud, which is visible on the top panel of the power
supply.
6. Using the four #6-32 screws with locknuts, install the remote
control receptacle (J24) in the rear panel (position the receptacle in the hole from INSIDE the unit).
7. Before reassembling the power supply enclosure, check that
all wire harnesses and ribbon cables are properly located in
the notches of the top and middle panels.
8. Position the unit in an upright position. Tip the unit and slide
one of the case halves onto the chassis. Then lift the unit and
set it down on its side with the case half down.
9. Before installing the other case half, make sure the edges of
the bottom, middle, and top chassis panels are fully inserted
into the slots in the case. Look for gaps between the front and
rear panels and the edge of the case. Look into the case to see
that the notches in the top corners of the front and rear panels
are flush against the plastic stops of the case. Some lifting and
re-settling of the chassis may be required to get all components aligned correctly.
10. Gently lower the other half of the enclosure onto the other
side of the chassis by tipping it slightly so that the top is
slightly lower than the bottom. Then push and gently tap
down until the two case halves are within l/16 inch. (If you
have trouble getting the case halves close enough, remove the
top half and check to see that the bottom half is fully engaged
and that there are no wires out of place on the top and middle
panels.
11. Install the eight screws, lockwashers and nuts to complete the
assembly.
Manual 0-2470 19 INSTALLATION
3.06 ELECTRICAL CONNECTIONS
Primary Input Voltages
CAUTION
WARNING
Input Voltage
Changeover
REMOTE
CONTROL
The unit can accept any input voltage from 200V to 460V (± 10%),
single or three phase, 50 or 60 Hz. 575V input requires an additional step-down transformer (Catalog No. 9-6211).
Input voltage settings must be verified before applying power to
the unit. Refer to Figure 3-E, below.
Disconnect primary power at the source before disassembling
the power supply, torch, or torch leads.
1. Remove the voltage selection access panel.
2. Connect the 9-circuit plug on the rear panel to the receptacle
which corresponds with the actual primary input voltage
(HIGH for 380/415/460V or LOW for 200/220V).
3. Connect the single-circuit plug on the rear panel to the
receptacle which corresponds to the actual primary input
voltage (460V, 380/415V, or 200/220V).
4. Replace the voltage selection access panel.
460V
HIGH
380/415V
LOW
200/220V
A-00753
200-240
VAC
Access Panel
Access Panel
380/415/460
VAC
REMOTE
CONTROL
Detail of Voltage Connection Panel
LOW
380-
HIGH
200-240
VAC
200-
380-460
VAC
200/220
VAC
Screws
Nine-Circuit Plug
A-00754
Single-Circuit Plug
Figure 3-E Input Voltage Selection
INSTALLA TION 20 Manual 0-2470
3.06 ELECTRICAL CONNECTIONS (continued)
CAUTION
Input Power Cable
Connections
WARNING
NOTE
CAUTION
Both input voltage settings on the power supply must correspond
to the actual primary input voltage.
Systems ordered for 230V operation come supplied with a 230V
single-phase input power cable attached. For any other input
voltage, the 230V input power cable must be removed and
replaced with an appropriate power cable.
Disconnect primary power at the source before disassembling
the power supply, torch, or torch leads.
Refer to Figure 3-F (page 22) and:
1. Remove the access panel on the rear panel of the unit and
disconnect the factory-installed 230V input power cable.
Loosen the strain relief and remove the cable.
Input power connections can be made directly to a properly
fused disconnect or by using a plug which conforms to the
recommended ratings.
The primary power source, power cable, and plug all must
conform to local electric code and the recommended circuit
protection and wiring requirements (see Table 3-A, page 22).
WARNING
2. Before connecting the replacement input power cable, strip
back the outer covering approximately 3 inches (76 mm) to
expose the individual wires. Then cut back the insulation on
the individual wires approximately 1/8 - 3/16 inch (3-5 mm).
3. Install a #10 ring terminal on the ground (GND) wire of the
input power cable.
Make sure the ground wire is designated as GND on the other
end of the cable. Electric shock and damage to the unit could
occur if power is applied to the GND terminal.
4. Connect the input power cable according to Figure 3-F.
Terminal L3 is not used for single-phase connections.
Manual 0-2470 21 INSTALLATION
3.06 ELECTRICAL CONNECTIONS (continued)
Ground Wire
Input Power
Cable
A-00756
REMOTE
CONTROL
Input Power Cable Connections
ø
Single-Phase (1
L1
) Three-Phase (3ø)
GND
L1
GND
L2
L3
L2
L3
Figure 3-F Input Power Cable Connections
Input Power Input Current Freq. Recommended Sizes
Voltage 1-Ph 3-Ph 1-Ph 3-Ph Fuse (Amps) Wire (AWG) Wire (Canada)
(Volts) (kVA) (kVA) (Amps) (Amps) (Hz) 1-Ph 3-Ph 1-Ph 3-Ph 1-Ph 3-Ph
180 7 5 37 17 50/60 45 20 10 14 8 10
200 7 5 33 15 50/60 40 20 10 16 8 12
220 7 5 30 14 50/60 35 20 10 16 8 12
240 7 5 28 13 50/60 35 15 12 12 8 12
380 7 5 18 8 50/60 25 10 14 18 10 12
460 7 5 14 7 50/60 20 10 16 18 10 12
506 7 5 13 6 50/60 15 8 16 18 12 12
Table 3-A Line Voltages with Recommended Circuit Protection and Wire Sizes
(Based on Table 310-16, 1987 National Electric Code) and Table 4, Canadian
Electrical Code.
INSTALLA TION 22 Manual 0-2470
3.07 WORK CABLE AND GROUND CONNECTIONS
Electromagnetic
Interference (EMI)
Creating an Earth
Ground
High frequency pilot arc initiation generates electromagnetic
interference (EMI), commonly called RF noise. EMI may interfere
with nearby electronic equipment such as CNC controllers, etc.
Torch leads are shielded to help prevent this problem. To further
minimize RF interference, follow these grounding procedures
when installing mechanized systems:
1. Install a ground wire (not included) between the internal
ground stud in the power supply and a solid earth ground (or
star ground). To create a solid earth ground, drive a 1/2 in
(12 mm) copper rod approximately 6-8 ft (1.8-2.4 m) into the
earth so that the rod contacts moist soil over most of its
length. The depth required will vary depending on location.
Locate the rod as close as possible to the power supply. The
work table should be connected to the same earth ground.
2. Connect the control device (CNC) to a separate earth ground.
The ground cable should be at least 12 gauge wire.
3. To minimize RF interference, position torch leads as far as
possible (at least 1 ft or 0.3 m) from any CNC components,
control cables, or primary power lines.
4. Keep torch leads clean. Dirt and metal particles bleed off
energy, which causes difficult starting and increased chance
of RF interference.
Work Cable Connection
Refer to Figure 3-G and:
5. Make sure the work cable is properly connected to the
workpiece before operating the system.
GAS
RUN
TEMP PIP
ON
AC
SET
OFF
GAS PRESSURE
TORCH
WO
Make a solid work cable
connection to the workpiece or cutting table
Figure 3-G Work Cable Connection
A-00757
Manual 0-2470 23 INSTALLATION
3.08 GAS CONNECTIONS
Gases
Pressure
Flow
CAUTION
CAUTION
Checking Air Quality
Filtering
Gas Connections
Compressed Air or Nitrogen (N2) Only
70 psi (4.8 BAR)
Cutting - 200 scfh (94.4 lpm)
Gouging - 230 scfh (108.5 lpm)
Max input pressure must not exceed 125 psi (8.6 BAR/860kPa)
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.
To test the quality of air, 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!
An air line filter (not included) is required when using air from a
compressor to insure that moisture and debris from the supply
hose does not enter the torch. The filter must be capable of
filtering to at least 5 microns, For highly automated applications,
a refrigerated drier may be used.
The rear panel of the power supply is equipped with a 1/4 NPT
gas input fitting. A quick disconnect coupling (1/4 NPT to #6
barb) is supplied with the unit.
Using High Pressure
Gas Cylinders
Refer to the manufacturer's specifications for installation and
maintenance procedures for high pressure gas regulators. Do not
use an air line filter with high pressure gas cylinders. To use air
or nitrogen from a high pressure gas cylinder:
1. Examine the cylinder valves to be sure they are clean and free
of oil, grease or any foreign material. Momentarily open each
cylinder valve to blow out any dust which may be present.
2. Each cylinder must be equipped with an adjustable highpressure regulator capable of pressures up to 125 psi (8.6
BAR) maximum and flows of up to 700 scfh (328 lpm).
Refer to Figure 3-H (page 25) and:
3. Connect the 1/4 NPT adaptor fitting to the gas input fitting
on the rear panel of the power supply.
4. Connect the 1/4 NPT male side of the quick disconnect
coupling to the adaptor fitting.
5. Connect the supply hose from the high pressure regulator to
the barb side of the quick disconnect coupling.
6. Connect the quick disconnect coupling.
INSTALLA TION 24 Manual 0-2470
3.08 GAS CONNECTIONS (continued)
7. Set the high pressure regulator to 100 psi and adjust the unit
regulator for the desired 70 psi.
CAUTION
Using Shop Air
Always open the high pressure cylinder valve slowly to prevent
damage to the unit gas regulator.
An air line filter (ordered separately) is required when using air
from a compressor to insure that moisture and debris from the
supply hose does not enter the torch.
The LeMan two stage air line filter kit is recommended for most
applications. Follow the installation instructions for this kit on
page 18.
Air Line Filter Kit - Two Stage...................................Cat. No. 7-3340
A-00758
Quick Disconnect
Fitting (1/4 NPT)
Quick Disconnect
Coupling (1/4 NPT
to #6 Hose)
Rear Panel Fitting
(1/4 NPT)
Supply Hose from
Source (#6 Hose)
Figure 3-H Gas Connections
Manual 0-2470 25 INSTALLATION
3.08 GAS CONNECTIONS (continued)
Installing
Air Line Filter
NOTE
Refer to Figure 3-I and:.
1. Press fit the nylon screw receptacles into the rear panel
openings as shown.
2. Secure the air filter with bracket to the power supply with the
1/2 in pan head screws.
3. Connect the 1/4 NPT male coupling of the gas hose assembly
to the power supply first, then connect the female JIC fitting
to the air filter . Tighten both fittings with a 9/16 in wrench.
Supply hoses must be at least #6 hose (3/8 in or 9.5 mm I.D.).
Nylon Screw
Receptacles
Air Filter
Assembly
Female
JIC
Male
1/4 NPT
A-00759
Rear Panel Fitting
(1/4 NPT)
Figure 3-I Gas Connections Using Optional Air Line Filter
INSTALLA TION 26 Manual 0-2470
SECTION 4: OPERATION
4.01 OPERATING CONTROLS
PIP (Parts-In-Place) Indicator
TEMP Indicator
AC Indicator
RUN/SET Switch
ON/OFF Switch
ON
OFF
RUN
SET
AC TEMP PIP GAS DC PILOT
GAS Indicator
DC Indicator
PILOT Indicator
CSD Control
Current Control
CSD
CURRENT
TORCH Receptacle
WORK Cable
60
40
34
80
2
5
20
1
TORCH
GAS PRESSURE
WORK
6
bar
psi
100
Figure 4-A Operating Controls (See Table 4-A, page 28)
Gas Pressure Gauge
Gas Pressure Control
Manual 0-2470 27 OPERATION
4.01 OPERATING CONTROLS (continued)
INDICATOR
1. ON/OFF Switch
2. RUN/SET Switch
3. AC Indicator
4. TEMP Indicator
5. PIP (Parts-In-Place)
Indicator
6. GAS Indicator
7. DC Indicator
8. PILOT Indicator
FUNCTION
ON position supplies AC power to activate all system control circuits. OFF
position deactivates control circuits.
RUN position is used for torch operation. SET position is used for setting gas
pressure and purging lines.
Green LED light indicates AC input power is present in the system when the
ON/OFF switch is in ON position.
Green LED light indicates proper operating temperature range. Red light
indicates overheating; unit must be allowed to cool.
Yellow LED light indicates proper torch assembly. Light goes out if the shield
cup is not fully seated against the PIP pins in the torch body.
Yellow LED light (with RUN/SET switch in SET position) indicates gas pressure
is above the minimum (42 psi or 2.9 BAR) to the torch. Light goes out in RUN
position until torch is activated.
Yellow LED light indicates adequate DC power output for main arc when the
torch is activated.
Yellow LED light indicates pilot arc circuit is activated. Light goes out when
main arc is established and comes back on if the main arc is interrupted and
pilot arc restarts.
9. Corner Slowdown
Adjustment
10. Current Control
11. Pressure Gauge
12. Pressure Control
Sets corner slowdown (CSD) output to a percentage of main output. Minimum
output during CSD is 15 amps. Turn fully clockwise for maximum output (100%
of main current) during CSD. See Corner Slowdown Operation, page 29.
Selects output current.
Displays input pressure to the torch.
Adjusts pressure from the regulator. Pull knob out and turn clockwise to
increase pressure to desired level.
Table 4-A Operating Controls
OPERATION 28 Manual 0-2470
4.02 GETTING STARTED
WARNING
Check Torch Parts
Check Input Power
Connect Work Cable
Check Gas Supply
Purge the System
(Gas Pre-Flow)
Disconnect primary power at the source before disassembling
the power supply, torch, or torch leads.
Follow this set-up procedure each time the system is operated:
1. Check the torch for proper assembly and appropriate front
end torch parts (see Torch Parts Selection, page 31 and
Replacing Consumable Torch Parts, page 44).
2. Check primary power source as follows:
a. Check the power source for proper input voltage. Make
sure the power source meets circuit protection and wiring
requirements (see Table 3-A, page 22).
b. Make sure that the power supply is set for the proper
voltage (see Electrical Connections, page 20).
c. Connect the input power cable (or close the main discon-
nect switch) to supply power to the system.
3. Check for a solid work cable connection to the workpiece.
4. Select desired gas (air or nitrogen). Make sure gas sources
meet pressure and flow requirements (see Gas Connections,
page 16). Check connections and turn gas supply on.
5. Move the ON/OFF switch to ON position. When the unit is
switched on, an automatic 20-second pre-flow gas purge will
remove any moisture that may have accumulated in the torch
and leads while the system was shut down. The torch cannot
be activated during pre-flow. After 20 seconds, if the RUN/
SET switch is in SET position, gases will flow. If the RUN/
SET switch is in RUN position, there will be no gas flow.
Select Output Current
Set Operating Pressure
Manual 0-2470 29 OPERATION
6. Select the desired current output level (15 to 35 amps).
7. Move the RUN/SET switch to SET position. Adjust the gas
pressure to 70 psi (4.8 BAR).
8. Set the RUN/SET switch to RUN position.
The system is now ready for operation.
4.03 SEQUENCE OF OPERATION
ACTION
Close external
disconnect switch.
RESULT
Power to system.
ACTION
Protect eyes and
activate torch.
RESULT
Gas flows.
GAS indicator on.
After gas pre-flow:
DC indicator on.
Power supply enabled.
HF relay closes.
Pilot arc established.
PILOT indicator on.
ACTION
Torch deactivated (by torch switch
release or by remote device).
RESULT
Main arc stops. Pilot stops.
(Power supply enable signal removed.)
DC indicator off.
PILOT indicator off.
NOTE - If torch is activated during
post-flow, pilot arc will immediately restart.
If torch is within transfer distance (3/8 in) of
workpiece, main arc will transfer.
After post-flow:
Gas solenoid closes, gas flow stops.
GAS indicator off.
ACTION
ON/OFF switch
to ON.
RESULT
AC, TEMP, PIP
indicators on.
Fan on.
Pilot disabled during
20 second pre-flow.
RUN/SET switch
Gas solenoid open,
GAS indicator on.
PILOT ARC
All indicators off.
ACTION
to SET.
RESULT
gas flows to set
pressure.
ACTION
ON/OFF switch
to OFF.
RESULT
Power supply
fan off.
ACTION
RUN/SET switch
to RUN.
RESULT
Gas flow stops.
GAS indicator off.
Power circuit ready.
ACTION
Torch moved away
from work (while
still activated).
RESULT
Main arc stops.
Pilot arc auto-
matically restarts.
PILOT indicator on.
ACTION
Torch moved within
transfer distance of
workpiece.
RESULT
Main arc transfer.
Pilot arc off.
PILOT indicator off.
DC indicator still on.
ACTION
Open external
disconnect.
RESULT
No power to system.
Figure 4-B Sequence of Operation
OPERATION 30 Manual 0-2470
4.04 TORCH PARTS SELECTION
Torch Parts Selection
MaximumLife™ Parts
CAUTION
The torch parts (shield cup, tip, electrode, and gas distributor)
must correspond with the type of operation (drag cutting, standoff cutting, or gouging).
Standard Shield Cup (For Standoff Cutting) ..........................9-6003
Crown Shield Cup Standoff (For Drag Cutting) ....................9-6004
Tip - Standoff Cutting ................................................................9-6000
Tip - Drag Cutting ......................................................................9-6001
Tip - Drag Cutting (Heavy Duty) ............................................ 9-6120
Tip - Gouging ..............................................................................9-6002
Electrode ......................................................................................9-6006
Gas Distributor............................................................................9-6007
Shield Cup Attachment, MaximimLife™ .............................. 9-6503
Tip - Standoff, MaximimLife™................................................ 9-6500
Tip - Drag, MaximimLife™ ...................................................... 9-6501
Electrode, MaximimLife™ ........................................................9-6506
Gas Distributor, MaximimLife™..............................................9-6507
Do not use MaximimLife™ parts with standard parts.
MaximimLife™ shield cup attachment (No. 9-6503) must be
installed over the standard shield cup.
Standard Shield Cup
Catalog No. 9-6003
Standoff Cutting Tip
(.031 in)
Catalog No. 9-6000
Heavy Duty Drag Tip
(.036 in)
Catalog No. 9-6120
Electrode
Catalog No. 9-6006
Crown Shield Cup
Catalog No. 9-6004
Drag Cutting Tip
(.031 in)
Catalog No. 9-6001
Gouging Tip
(.046)
Catalog No. 9-6002
Gas Distributor
Catalog No. 9-6007
A-00017
Figure 4-C Torch Parts Selection
MaximumLife™ Parts
Shield Cup
Catalog No. 9-6503
Standoff
Cutting Tip (.031 in)
Catalog No. 9-6500
Electrode
Catalog No. 9-6506
Drag
Cutting Tip (.031 in)
Catalog No. 9-6501
Gas Distributor
Catalog No. 9-6507
A-00318
Manual 0-2470 31 OPERATION
4.05 CUT QUALITY
Cut quality requirements differ depending on application. For
instance, nitride build-up and bevel angle may be major factors
when the surface will be welded after cutting. Dross-free cutting
is important when finish cut quality is desired to avoid a secondary cleaning operation. The following cut quality characteristics
are illustrated in Figure 4-D below:
Cut Surface
Bevel Angle
Top-Edge Rounding
Dross Build-up
and Top Spatter
Kerf Width
Nitride Build-up
• The condition (smooth or rough) of the face of the cut.
• The angle between the surface of the cut edge and a plane
perpendicular to the surface of the plate. A perfectly perpendicular cut would result in a 0° bevel angle.
• Rounding on the top edge of a cut due to wearing from the
initial contact of the plasma arc on the workpiece.
• Dross is molten material which is not blown out of the cut area
and re-solidifies on the plate. Top spatter is dross which accumulates on the top surface of the workpiece. Excessive dross
may require secondary clean-up operations after cutting.
• The width of material removed during the cut.
• Nitride deposits which may remain on the surface of the cut
when nitrogen is present in the plasma gas stream. Nitride
buildups may create difficulties if the material is welded after
the cutting process.
Kerf Width
Cut Surface
Bevel Angle
Top
Spatter
Top Edge
Rounding
Dross
Build-Up
Cut Surface
Drag Lines
A-00007
Figure 3-D Cut Quality Characteristics
OPERATION 32 Manual 0-2470
4.05 CUT QUALITY (continued)
GAS
Air
Nitrogen
Gage to 1/2 in.
Table 4-B Cut Quality on Various Materials and Material Thicknesses
Description of Cut
Characteristics
NOTE
MATERIAL
THICKNESS
Excellent - Minimum bevel (0 - 4°), minimum kerf (2 x tip orifice
diameter), little or no dross, smooth cut surface.
Good - Slight bevel (0 - 10°), slightly wider kerf (2-1/2 x tip
orifice diameter), some dross (easily removed), medium-smooth
cut surface, slight top 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.
Cut quality depends heavily on set-up and parameters such as
torch standoff, alignment with the workpiece, cutting speed, gas
pressures, and operator ability.
Carbon Steel
Good - Excellent
Good
TYPE OF MATERIAL
Stainless Steel
Good - Excellent
Good
Aluminum
Good - Excellent
Good
Manual 0-2470 33 OPERATION
4.06 OPERATING THE SYSTEM
WARNING
WARNING
CAUTION
NOTE
Piloting
Torch Standoff
Disconnect primary power at the source before disassembling
the power supply, torch, or torch leads.
Frequently review the Important Safety Precautions at the front
of this Manual. Be sure the operator is equipped with proper
gloves, clothing, eye and ear protection. Make sure no part of the
operator’s body comes into contact with the workpiece while the
torch is activated.
Sparks from the cutting process can cause damage to coated,
painted, and other surfaces such as glass, plastic and metal.
Handle torch leads with care and protect them from damage.
Piloting is harder on parts life than actual cutting because the
pilot arc is directed from the electrode to the tip rather than to a
workpiece. Whenever possible, avoid excessive pilot arc time to
improve parts life.
Improper standoff (the distance between the torch tip and
workpiece) can adversely affect tip life as well as shield cup life.
Standoff may also significantly affect the bevel angle. Reducing
standoff generally results in a more square cut. A specially
designed shield cup attachment is available for drag cutting,
which allows the operator to keep the torch in contact with the
workpiece during operation. Drag cutting also requires special
cutting tips.
Edge Starting
Direction of Cut
Dross
OPERATION 34 Manual 0-2470
For edge starts, hold the torch perpendicular to the workpiece
with the front of the tip on the edge of the workpiece at the point
where the cut is to start. When starting at the edge of the plate, do
not pause at the edge and force the arc to "reach" for the edge of
the metal. Establish the cutting arc as quickly as possible.
In the PCH/M-35 torch, the plasma gas stream swirls as it leaves
the torch. The purpose of the swirl is to maintain a smooth
column of gas. The swirl effect results in one side of a cut being
more square than the other. Viewed along the direction of travel,
the right side of the cut is more square than the left.
If dross is present on carbon steel, it is commonly referred to as
either “high speed, slow speed, or top dross”. Dross present on
top of the plate is normally caused by too great a torch to plate
distance. Top dross is normally very easy to remove and can
often be wiped off with a welding glove. Slow speed dross is
normally present on the bottom edge of the plate. It can vary
from a light to heavy bead, but does not adhere tightly to the cut
edge, and can be easily scraped off.
4.06 OPERATING THE SYSTEM (continued)
(continued)
Problem
Insufficient
Penetration
Main Arc
Extinguishes
Dross
High speed dross usually forms a narrow bead along the bottom
of the cut edge and is very difficult to remove. When cutting a
troublesome steel, it is sometimes useful to reduce the cutting
speed to produce slow speed dross. Any resultant cleanup can be
accomplished by scraping, not grinding.
Common Cutting Faults
Possible Cause
1. Cutting speed too fast
2. Torch tilted too much
3. Metal too thick
4. Worn torch parts
5. Cutting current too low
1. Cutting speed too slow
2. Torch standoff too high from workpiece
3. AC line too low - reduce output current
4. Work cable disconnected
5. Worn torch parts
Excessive
Dross Formation
Short Torch
Parts Life
1. Cutting speed too slow (bottom dross) Easily removed
2. Cutting speed too fast (bottom dross) Tight bead, Difficult to remove
3. Torch standoff too high from workpiece (top dross) Easily removed
4. Worn torch parts
5. Improper cutting current
1. Oil or moisture in air source
2. Exceeding system capability (material too thick)
3. Excessive pilot arc time
4. Air flow too low (incorrect pressure)
5. Improperly assembled torch
Table 4-C Common Causes of Operating Problems
Manual 0-2470 35 OPERATION
4.07 OPERATING WITH A HAND TORCH
Cutting with a
Hand Torch
1. The torch can be comfortably held in one hand or steadied
with two hands. Choose the technique that feels most comfortable and allows good control and movement. Position the
index finger or thumb to press the control switch on the torch
handle.
2. For edge starts, hold the torch perpendicular to the workpiece
with the front of the tip on the edge of the workpiece at the
point where the cut is to start. For piercing, angle the torch
slightly to direct sparks away from the torch until the pierce
is complete.
3. For drag cutting, keep the torch in contact with the
workpiece. Drag cutting requires special torch parts. Drag
cutting is not recommended on materials over 3/16 in (5 mm)
thick. For standoff cutting, hold the torch approximately 1/8
inch (3 mm) from the work.
4. With the torch in starting position, press and hold the control
switch. After an initial two-second gas purge, the pilot arc
will come on and remain on until the cutting arc starts.
5. Once on, the main arc remains on as long as the control
switch is held down, unless the torch is withdrawn from the
work or torch motion is too slow. If the cutting arc is interrupted, the pilot arc comes back on automatically.
Piercing with a
Hand Torch
6. To shut off the torch simply release the control switch. When
the switch is released a ten second post-flow will occur. If the
torch switch is closed during the post-flow, the cutting arc
will restart immediately when the torch is brought within
range of the workpiece.
1. When piercing with a hand torch, tip the torch slightly so that
blowback particles blow away from the torch tip (and operator) rather than directly back into it.
2. Complete the pierce off the cutting line and then continue the
cut onto the line. Hold the torch perpendicular to the
workpiece after the pierce is complete.
3. Clean spatter and scale from the shield cup and the tip as
soon as possible. Spraying or dipping the shield cup in antispatter compound will minimize the amount of scale which
adheres to it.
OPERATION 36 Manual 0-2470
4.08 OPERATING WITH A MACHINE TORCH
WARNING
NOTE
Using Corner Slowdown
for Mechanized Cutting
Tools Required
Setting CSD Output
Disconnect primary power at the source before disassembling
the power supply, torch, or torch leads.
Frequently review the Important Safety Precautions beginning on
page iii of this manual.
The corner slowdown (CSD) function provides a reduction in
output current which corresponds with the reduced travel speed
of a mechanized torch as it changes direction at a sharp corner.
When activated (by CNC or other control device) corner slowdown eliminates excessive metal removal in corners.
Normally open (NO) contacts (supplied by the control device)
close when the torch travel speed decreases through a corner.
When the contacts close, power supply output drops to a preset
current level.
Small Standard (Slotted Head) Screwdriver
The corner slowdown adjustment is located on the upper front
panel (see Figure 4-A, page 27). CSD output is a percentage of the
main output setting. Minimum output is 15 amps during CSD.
Turn the control clockwise to increase CSD output. Maximum
CSD output is 100% of the main output level. Typically, CSD
output should not be set lower than 70% of the main current level
to insure full arc penetration during corner slowdown. When
adjusting output current level, corner slowdown output should
be adjusted accordingly.
Manual 0-2470 37 OPERATION
4.08 OPERATING WITH A MACHINE TORCH (continued)
Cutting with a
Machine Torch
The machine torch can be activated by remote control pendant or
by a remote interface device such as CNC.
Refer to Figure 4-E below and:
1. Use a square to align the torch perpendicular to the workpiece to obtain a clean, vertical cut (see Setting Up the Torch,
page 20).
2. To start a cut at the plate edge, position the center of the torch
along the edge of the plate
Shown with
Optional Rack and Pinion
Mounting Assembly
Direction of Torch Travel
Standoff Distance
Straight Arc
Trailing Arc
A-00008
Leading Arc
Figure 4-E Machine Torch Set-up and Operation
OPERATION 38 Manual 0-2470
4.08 OPERATING WITH A MACHINE TORCH (continued)
Standoff Distance
Travel Speed
Piercing with a
Machine Torch
Proper tip-to-work (standoff) distance is critical to ensure accuracy, optimum cut quality, and maximum consumable parts life
in mechanical systems. The recommended standoff distance for
mechanized systems is 3/16 in (5 mm).
Proper travel speed is indicated by the trail of the arc which is
seen below the plate (see Figure 4-E, page 38). A straight arc is
generally recommended for the best cut using air plasma on
stainless or aluminum. For air plasma on mild steel, a five degree
leading arc is recommended.
For optimum smooth surface quality, the travel speed should be
adjusted so that only the leading edge of the arc column produces
the cut. If the travel speed is too slow, a rough cut will be produced as the arc moves from side to side in search of metal for
transfer.
Travel speed also affects the bevel angle of a cut. When cutting in
a circle or around a corner, slowing down the travel speed will
result in a squarer cut. The power supply has a corner slowdown
feature which reduces output for this purpose (see Corner Slowdown Operation, page 37).
To pierce with a machine torch, the arc should be started with the
torch positioned as high as possible above the plate while allowing the arc to transfer and pierce. This standoff helps avoid
having molten metal blow back onto the front end of the torch.
When operating with a cutting machine, a pierce or dwell time is
required. Torch travel should not be enabled until the arc penetrates the bottom of the plate. As motion begins, torch standoff
should be reduced to the recommended 1/8 - 3/8 inch (3 - 9 mm)
distance for optimum speed and cut quality. Clean spatter and
scale from the shield cup and the tip as soon as possible. Spraying
or dipping the shield cup in anti-spatter compound will minimize
the amount of scale which adheres to it.
Manual 0-2470 39 OPERATION
4.09 RECOMMENDED CUTTING SPEEDS
Recommended
Cutting Speeds
Cutting speed depends on material, thickness, and the operator’s
ability to accurately follow the desired cut line. The following
factors may have an impact on system performance:
• Torch parts wear
• Air quality
• Line voltage fluctuations
• Torch standoff height
• Proper work cable connection
NOTE
This information represents realistic expectations using recommended practices and well-maintained systems. Actual speeds
may vary up to 50% from those shown.
Thickness Tip Gas(es) Voltage Amperage Speed (Per Minute) Standoff
(Inches) (Cat. No.) (Volts) (Amps) (Inches) (Meters) (Inches)
1/16 9-6000 Air 97 35 260 6.6 1/8
1/8 9-6000 Air 102 35 75 1.9 1/8
1/4 9-6000 Air 108 35 45 1.1 1/8
3/8 9-6000 Air 115 35 22 0.6 1/8
1/2 9-6000 Air 120 35 12 0.3 1/8
Table 4-D PCM-35 Cutting Speeds - Air Plasma on Mild Steel
Thickness Tip Gas(es) Voltage Amperage Speed (Per Minute) Standoff
(Inches) (Cat. No.) (Volts) (Amps) (Inches) (Meters) (Inches)
1/16 9-6000 Air 100 35 250 6.3 1/8
1/8 9-6000 Air 118 35 100 2.5 1/8
1/4 9-6000 Air 124 35 25 0.6 1/8
3/8 9-6000 Air 130 35 15 0.4 1/8
1/2 9-6000 Air 136 35 5 0.1 1/8
Table 4-E PCM-35 Cutting Speeds - Air Plasma on Aluminum
Thickness Tip Gas(es) Voltage Amperage Speed (Per Minute) Standoff
(Inches) (Cat. No.) (Volts) (Amps) (Inches) (Meters) (Inches)
1/16 9-6000 Air 110 35 250 6.3 1/8
1/8 9-6000 Air 112 35 75 1.9 1/8
1/4 9-6000 Air 114 35 20 0.5 1/8
3/8 9-6000 Air 117 35 10 0.3 1/8
1/2 9-6000 Air 124 35 7 0.2 1/8
Table 4-F PCM-35 Cutting Speeds - Air Plasma on Stainless Steel
OPERATION 40 Manual 0-2470
4.10 GOUGING
WARNING
Be sure the operator is equipped with proper gloves, clothing,
eye and ear protection and that all safety precautions at the front
of this manual have been followed. Make sure no part of the
operator’s body comes in contact with the workpiece when the
torch is activated.
CAUTION
CAUTION
WARNING
Gouging Parameters
Torch Travel Speed
Current Setting
Sparks from plasma gouging can cause damage to coated,
painted or other surfaces such as glass, plastic, and metal.
Check torch parts. The torch parts (shield cup, tip, electrode, and
gas distributor) must correspond with the type of operation (drag
cutting, standoff cutting, or gouging). Refer to Torch Parts Selection (page 31).
Disconnect primary power to the system before disassembling
the torch, leads, or power supply.
Gouging performance depends on parameters such as torch
travel speed, current level, lead angle (the angle between the
torch and workpiece), and the distance between the torch tip and
workpiece (standoff).
Optimum torch travel speed for gouging is between 20 and 120
inches per minute (0.5 and 3.0 meters per minute). Travel speed is
dependent on current setting, lead angle, and mode of operation
(hand or machine torch).
Current settings depend on torch travel speed, mode of operation
(hand or machine torch), and the amount of material to be removed.
Lead Angle
Manual 0-2470 41 OPERATION
The angle between the torch and workpiece depends on the
current setting and torch travel speed. At 35 amps, the recommended lead angle is 35°. An angle greater than 45° may result in
inconsistent metal removal. If the lead angle is too small (less
than 35°), less material may be removed, requiring more passes.
In some applications, such as removing welds or working with
light metal, this may be desirable.
4.10 GOUGING (continued)
Standoff Distance
Slag Build-up
The tip to work distance affects gouge quality and depth. A
standoff of 1/8 - 1/4 in (3 - 6 mm) allows smooth, consistent
metal removal. A smaller standoff may result in a severance cut
rather than a gouge. A standoff greater than 1/4 in (6 mm) may
result in minimal metal removal or loss of transferred main arc.
Slag generated by gouging on materials such as carbon and
stainlesss steels, nickels, and alloyed steels, can be removed easily
in most cases. Slag does not obstruct the gouging process if it
accumulates to the side of the gouge path. However, slag buildup can cause inconsistencies and irregular metal removal if large
amounts of material build up in front of the arc. The build-up is
most often a result of improper travel speed, lead angle, or
standoff height.
OPERATION 42 Manual 0-2470
SECTION 5: CUSTOMER/OPERATOR SERVICE
5.01 GENERAL POWER SUPPLY MAINTENANCE
Routine Maintenance
WARNING
CAUTION
The only routine maintenance required for the power supply is a
thorough cleaning and inspection, with the frequency depending
on the usage and the operating environment.
Disconnect primary power to the system before disassembling
the torch, leads, or power supply.
Do not blow air into the power supply during cleaning. Blowing
air into the unit can cause metal particles to interfere with sensitive electrical components and cause damage to the unit.
To clean the unit, open the enclosure (see Service Procedures.
page 62) and use a vacuum cleaner to remove any accumulated
dirt and dust. The unit should also be wiped clean. If necessary,
solvents that are recommended for cleaning electrical apparatus
may be used.
Manual 0-2470 43 CUSTOMER/OPERATOR SERVICE
5.02 REPLACING CONSUMABLE TORCH PARTS
WARNING
WARNING
NOTE
Disconnect primary power to the system before disassembling
the torch, leads, or power supply.
DO NOT TOUCH internal torch parts while the AC indicator on
the front panel of the power supply is lit.
The tip, gas distributor, and electrode are held in place by the
shield cup. Position the torch with the shield cup facing upward
to prevent these parts from falling out when the cup is removed.
Refer to Figure 5-A and:
1. Unscrew and remove the shield cup from the torch. Inspect
the cup for damage. Wipe it clean or replace if damaged.
2. Remove the tip. Check for excessive wear (indicated by an
elongated or oversized orifice). Clean and replace the tip if
necessary.
3. Remove the gas distributor and check for excessive wear,
plugged gas holes, or discoloration. Replace if necessary.
Torch Head Assembly
(70° Hand Torch Shown)
Gas
Distributor
Electrode
A-00016
Figure 5-A PCH/M-35 Consumable Parts
Tip
Standard
Shield Cup
Crown (Castle)
Shield Cup
Extension
CUSTOMER/OPERATOR SERVICE 44 Manual 0-2470
5.02 REPLACING CONSUMABLE TORCH PARTS (continued)
4. Remove the electrode. The face of the electrode should not be
recessed more than 0.10 inch (2.5 mm). If it is worn beyond
this point it must be replaced.
5. Reinstall the parts and shield cup on the torch as shown.
Hand tighten the shield cup until it is seated on the torch
head. If resistance is felt when installing the cup, check the
threads before proceeding with installation.
5.03 GENERAL TORCH MAINTENANCE
Cleaning the Torch
WARNING
WARNING
CAUTION
Even if precautions are taken to use only clean air with a torch,
eventually the inside of the torch becomes coated with residue.
This buildup can affect the pilot arc initiation and the overall cut
quality of the torch.
Disconnect primary power to the system before disassembling
the torch, leads, or power supply.
DO NOT touch any internal torch parts while the AC indicator
light on the front panel of the power supply is lit.
The inside of the torch should be cleaned with electrical contact
cleaner using a cotton swab or soft wet rag. In severe cases, the
torch can be removed from the leads (see Servicing the Torch,
page 47) and cleaned more thoroughly by pouring electrical
contact cleaner into the torch and blowing it through with compressed air.
Dry the torch thoroughly before reinstalling.
Manual 0-2470 45 CUSTOMER/OPERATOR SERVICE
5.03 GENERAL TORCH MAINTENANCE (continued)
Checking the
Center Insulator
WARNING
WARNING
The center insulator separates the negative and positive charged
sections of the torch. If the center insulator does not provide
adequate resistance, current which is intended for the pilot arc
may be dissipated into the torch head, resulting in torch failure.
Disconnect primary power to the system before disassembling
the torch, leads, or power supply.
DO NOT touch any internal torch parts while the AC indicator
light on the front panel of the power supply is lit.
Refer to Figure 5-A (page 44) and:
1. Remove the shield cup, tip, gas distributor, and electrode
from the torch. Disconnect the torch leads from the power
supply to isolate the torch from power supply circuits.
2. Using an ohmmeter (set to 10K or higher), check for continuity between the positive and negative torch quick disconnect
fittings. Infinite resistance (no continuity) should be found. If
continuity is found, refer to Torch and Leads Troubleshooting
(page 56).
CUSTOMER/OPERATOR SERVICE 46 Manual 0-2470
5.04 SERVICING TORCH HEAD COMPONENTS
WARNING
WARNING
Tools Required
Removing a Machine
Torch Head
Disconnect primary power to the system before disassembling
the torch, leads, or power supply.
NEVER touch any internal torch parts while the AC indicator
light on the front panel of the control module is lit.
(1) No. 1 Phillips Head Screwdriver
(2) 1/4 in Open End Wrenches
Refer to Figure 5-B and:
1. Unscrew the retaining nut from the mounting tube and slide
the mounting assembly up over the leads.
2. Pull the mounting adaptor from the torch head assembly.
Slide the mounting assembly back over the leads to expose
the negative/plasma lead connection, pilot lead connection,
and two PIP (parts-in-place circuit) connectors.
3. Disconnect the negative/plasma and pilot leads and the PIP
connectors to allow removal of the torch head.
Pinion Assembly
Positioning TubeBushing
Mounting Adaptor
Retaining Nut
Negative/Plasma Lead Connection
PIP Connectors
Pilot Lead Connection
Machine Torch Head
Figure 5-B Torch Mounting Assembly (PCM-35 Machine Torch)
Manual 0-2470 47 CUSTOMER/OPERATOR SERVICE
5.04 SERVICING TORCH HEAD COMPONENTS (continued)
WARNING
Tools Required
Removing a Hand Torch
Control Switch
NOTE
Disconnect primary power to the system before disassembling
the torch, leads, or power supply.
(1) No. 1 Phillips Head Screwdriver
(1) No. 1 Slotted Head Screwdriver
(2) 1/4 inch Open End Wrench
(1) Pin Removal Tool (Catalog No. 9-5847)
Refer to Figure 5-C and:
1. Pull the protective boot from the end of the torch handle and
slide it back over the leads to expose the two torch switch
connectors. Disconnect both torch switch connectors. It is not
necessary to disconnect the PIP connectors.
2. Remove the switch closure from the torch handle by carefully
pressing in on the switch closure tab and gently prying the
closure upward. Remove the switch insert. Slide the switch
out of the track on the torch handle.
3. Push the torch switch connectors through the end of the torch
handle to allow removal of the torch switch.
It may be necessary to remove the connectors from the switch
leads before removing or reinstalling the switch assembly.
Slide protective
boot back
Disconnect
torch switch
connectors
Press tab
to remove
closure
PIP
Connectors
Torch Handle
Reverse view
of closure
Remove switch
closure from
torch handle
Switch
Insert
Torch
Switch
Figure 5-C Removing the Torch Control Switch (PCH-35 Hand Torch)
CUSTOMER/OPERATOR SERVICE 48 Manual 0-2470
5.04 SERVICING TORCH HEAD COMPONENTS (continued)
WARNING
Removing a Hand
Torch Head
Disassembling a
Torch Head Assembly
Disconnect primary power to the system before disassembling
the torch, leads, or power supply.
Refer to Figure 5-D and:
1. Slide the torch handle back over the leads to expose the
negative/plasma lead connection, the pilot lead connection,
and the two PIP (parts-in-place circuit) connectors.
2. Disconnect the negative/plasma and pilot leads and the PIP
connectors to allow removal of the torch head.
Refer to Figure 5-E (page 50) and:
1. Remove the two O-rings from the back of the torch head
assembly.
2. Remove the shield cup, tip, gas distributor and electrode if
necessary (see Figure 5-A, page 44).
3. Remove the two assembly screws which secure the split
holder and separate the two halves of the holder to allow
removal of the torch head and PIP assemblies.
Negative/Plasma
Lead Connection
Slide torch handle
back over leads
A-00011
PIP Connectors
Pilot Lead Connection
Remove consumables from front end
and remove screws to allow disassembly
Torch Handle
O-Rings
Figure 5-D Removing the Torch Head (PCH-35 Hand Torch)
Manual 0-2470 49 CUSTOMER/OPERATOR SERVICE
5.04 SERVICING TORCH HEAD COMPONENTS (continued)
Handle
O-Rings
Torch Head
Mounting Screws
A-00157
WARNING
Replacing the
PIP Assembly
CAUTION
PIP Pin Assemblies
Figure 5-E Disassembling the Split Holder
Disconnect primary power to the system before disassembling
the torch, leads, or power supply.
Refer to Figure 5-F (page 51) and:
1. Carefully remove the PIP wires from the strain relief bosses
inside the split holder.
2. Slide the PIP pin receptacles forward out of the retention
slots.
Do not lift the PIP pin receptacles out of the split holder to avoid
damage to holder and/or PIP pin receptacles may occur.
3. Install replacement PIP pin assemblies by positioning the
square solder post of the PIP pin receptacle in the retention
slot in the split holder and sliding the assembly up into place.
Position the flange on the PIP pin receptacle flush with the
front face of the split holder.
4. Route the PIP wires around the strain relief bosses as shown.
Push the teflon insulation covering both PIP wires up to the
strain relief boss closest to the back of the split holder for
voltage insulation from the brass pilot lead connector.
CUSTOMER/OPERATOR SERVICE 50 Manual 0-2470
5.04 SERVICING TORCH HEAD COMPONENTS (continued)
Replacing the
PIP Assembly
(continued)
CAUTION
Reassembling
the Torch Head
5. Position both PIP leads through the notch where the negative/plasma lead exits the holder.
6. Position the torch head inside the holder. Align the notch on
the pilot lead with the corresponding tab on the split holder.
Make sure the negative/plasma fitting is securely inserted in
the groove in the holder. Make sure the crescent on the torch
head is inserted into the mating groove in the holder.
7. Place the second half of the holder over the torch head.
Confirm that the PIP pin assemblies, PIP leads, and the
negative/plasma and pilot leads are properly positioned.
Do not force the holder together. Damage to the insulation on the
leads will cause torch head failure. The PIP leads must be positioned correctly to allow reassembly of the torch head.
Refer to Figure 5-E (page 50) and:
1. Install the two assembly screws to secure the split holder and
reinstall the O-rings on the back of the torch head assembly.
Refer to Figure 5-A (page 44) and:
2. Install the front end torch parts.
Position PIP wires through
strain relief bosses as shown
Teflon sleeve must cover
wires up to strain relief area
Figure 5-F Installing a Replacement PIP Assembly
A-00158
Bend wires to
fit grooves
Flange flush
with split holder
surface
AB
Split Holder
Install wire A first,
then wire B.
A-00159
Manual 0-2470 51 CUSTOMER/OPERATOR SERVICE
5.04 SERVICING TORCH HEAD COMPONENTS (continued)
WARNING
Reassembling the
Hand Torch Handle and
Switch Assembly
NOTE
Reassembling the
Machine Torch
Mounting Assembly
Disconnect primary power to the system before disassembling
the torch, leads, or power supply.
Refer to Figure 5-D (page 49) and:
1. Connect the two PIP lead connectors and the negative/
plasma and pilot leads. Use electrical tape to secure the PIP
leads to the torch leads covering.
2. Slide the torch handle securely onto the torch head.
Refer to Figure 5-C (page 48) and:
3. Install the torch switch by pushing the torch switch connectors through the end of the handle and inserting the switch
into the track on the torch handle.
It may be necessary to remove the connectors from the switch
leads before removing or reinstalling the switch assembly.
4. Install the switch insert and switch closure.
5. Reattach the torch switch leads connectors if necessary and
connect the torch switch leads. Slide the protective boot
forward to cover the end of the handle.
Refer to Figure 5-B (page 47) and:
1. Connect the two PIP lead connectors and the negative/
plasma and pilot leads.
NOTE
CUSTOMER/OPERATOR SERVICE 52 Manual 0-2470
On a machine torch, the control leads are not used. The two
connectors are taped to the leads covering. Do not confuse the
control leads (green/white) with the PIP leads (black/red).
2. Slide the mounting adaptor and retaining nut down and push
the adaptor securely onto the back of the torch head.
3. Slide the positioning tube and pinion assembly down and
thread the retaining nut onto the positioning tube.
5.05 SERVICING TORCH LEADS COMPONENTS
WARNING
Tools Required
Loosening the Set
Screws
Disassembling the
Quick Disconnect Fitting
Disconnect primary power to the system before disassembling
the torch, leads, or power supply.
(1) 3/32 inch Allen Wrench
(1) 15/16 inch (or Adjustable) Open End Wrench
(1) 11/16 inch (or Adjustable) Open End Wrench
(1) No. 1 Slotted Head Screwdriver
(1) Sharp Probe or O-Ring Tool
Refer to Figure 5-G (page 54) and:
1. Disconnect the torch leads from the power supply.
2. Turn the outer retaining nut until one of the three set screws
in the inner retaining ring is visible through one of the slots in
the nut.
3. Partially loosen each of the set screws which secure the inner
retaining ring and boot onto the quick disconnect body. If the
set screws are turned too far out, the outer retaining nut will
not turn properly.
4. Pull the protective boot and inner retaining ring from the
quick disconnect body and slide them back over the torch
leads to expose the leads connections.
5. Slide the outer retaining nut back over the leads.
Disconnecting the Leads
from the Fitting
Reassembling the
Quick Disconnect Fitting
6. Remove the locking tabs from the signal connector plug.
7. Gently push the tabs in (toward the center) on the front of the
signal connector plug. Carefully push the connector out
through the back of the quick disconnect body.
8. Disconnect the negative/plasma and pilot lead fittings.
9. Remove the inner retaining ring from the boot. Remove both
the outer retaining nut and inner retaining ring from the
leads. The boot cannot fit over the signal connector plug.
1. Slide the inner retaining ring and outer retaining nut onto the
torch leads. Attach the inner retaining ring to the boot.
2. Connect the negative/plasma and pilot fittings to the quick
disconnect body.
3. Insert the signal connector plug in the quick disconnect body
and install locking tabs on both sides. Install the locking tabs
with the beveled edge toward the signal connector.
4. Slide the outer retaining nut, boot, and inner retaining ring
down onto the quick disconnect body.
5. Tighten the three set screws to secure the inner retaining ring
onto the quick disconnect body.
Manual 0-2470 53 CUSTOMER/OPERATOR SERVICE
5.05 SERVICING TORCH LEADS COMPONENTS (continued)
NOTE - PCH/M-35 Quick Disconnect Replacement Kit
(Catalog No. 9-5836) includes all quick disconnect items.
Outer Retaining
Nut
Set Screw
(Three)
Signal Pin
Connector
Quick Disconnect
Body (Torch End)
Rotate outer retaining
ring to access all
three set screws
Gently press tabs inward
and remove connector
(Reverse View)
Signal Pin Connector
Slide boot and retaining
ring back over leads to
expose leads connections
Outer Retaining Nut
Inner Retaining Ring
Pilot Lead
Connection
Negative/Plasma
Lead Connection
A-00013
Figure 5-G Disassembling the Quick Disconnect Fitting
CUSTOMER/OPERATOR SERVICE 54 Manual 0-2470
5.05 SERVICING TORCH LEADS COMPONENTS (continued)
AB
10
11
12 13 14
6
789
12
345
A-00018
Pins
3, 4
1, 6
13, 14
A
B
Description
Torch Switch
Parts-In-Place (PIP)
Shield (GND)
Pilot Return - Positive
Negative - Gas
Figure 5-H Torch Quick Disconnect Fitting - Front End View
Manual 0-2470 55 CUSTOMER/OPERATOR SERVICE
5.06 TORCH AND LEADS TROUBLESHOOTING
WARNING
WARNING
Checking the
Center Insulator
Checking the Torch
Head Connections
Checking the
Torch Head
Disconnect primary power to the system before disassembling
the torch, leads, or power supply.
DO NOT touch any internal torch parts while the AC indicator
light on the front panel of the power supply is lit.
1. Remove the shield cup, tip, gas distributor, and electrode
from the torch. Disconnect the torch leads from the power
supply to isolate the torch from power supply circuits.
2. Using an ohmmeter (set to 10K or higher), check for continuity between the positive and negative torch quick disconnect
fittings. Infinite resistance (no continuity) should be found.
3. If there is continuity between the two torch quick disconnect
fittings, remove the torch head from the leads (see Servicing
Torch Head Components, page 47). Visually check that the
PIP wires, torch switch wires, pilot lead connection, and
negative/plasma lead connections are properly connected
and in good condition (no shorts or arcing). If problems are
evident, repair or replace as required.
4. With the torch head disconnected from the leads, measure the
resistance between negative cathode body of the torch head
(where the electrode seats) and the positive anode body of the
torch head (the outer threads where the shield cup seats).
Infinite resistance (no continuity) should be measured between negative and positive sections of the torch head. If any
current can flow through the center insulator, the torch head
is faulty and must be replaced. If the torch head is okay, the
problem is in the leads or quick disconnect assembly.
Checking the Torch
Quick Disconnect
Assembly
CUSTOMER/OPERATOR SERVICE 56 Manual 0-2470
5. Slide the quick disconnect body, boot, and retaining ring back
(see Servicing Torch Leads Components, page 53). Visually
inspect the quick disconnect components to verify that there
is no contact between the positive and negative sections. If
contact is evident, repair or replace as required. If no problems are evident, remove the quick disconnect assembly from
the torch leads and check for continuity between the positive
and negative torch quick disconnect fittings. If there is no
continuity, the quick disconnect assembly is okay. If continuity is found, replace the torch quick disconnect assembly.
5.06 TORCH AND LEADS TROUBLESHOOTING (continued)
Checking the
Torch Leads
Reassembling the
Torch and Leads
6. If the torch quick disconnect assembly is okay, check the
torch leads by measuring the resistance between the positive
pilot lead connector and the negative/plasma lead fitting. If
continuity is found, replace the torch leads. If no continuity is
found, the torch leads are okay.
7. Recheck the torch head, leads, and quick disconnect assembly
to confirm proper measurements. If each component is found
to be okay, there is an assembly problem. Carefully reassemble the torch, leads, and quick disconnect and return to
step 2.
Manual 0-2470 57 CUSTOMER/OPERATOR SERVICE
5.07 POWER SUPPLY TROUBLESHOOTING
Troubleshooting and repairing the Pak Master 50 power supply
is a process which should be undertaken only by those familiar
with high voltage high power electronic equipment.
There are extremely dangerous voltage and power levels present
WARNING
inside this unit. Do not attempt to diagnose or repair unless you
have had training in power electronics measurement and
troubleshooting techniques.
Basic and Advanced
Troubleshooting
NOTE
Two levels of troubleshooting are covered in the troubleshooting
guide. The first (basic) level of troubleshooting are those which
can be performed without special equipment or knowledge, and
without removing the plastic enclosure from the unit. The second
(advanced) level of troubleshooting provides procedures for
replacing components and subassemblies which will allow the
technician with a few common tools to remove the plastic
enclosure and analyze some failures.
Advanced troubleshooting steps are marked with an asterisk (*).
If major complex subassemblies are faulty, the unit must be
returned to an authorized service center for repair.
CUSTOMER/OPERATOR SERVICE 58 Manual 0-2470
5.07 POWER SUPPLY TROUBLESHOOTING (continued)
SYMPTOM POSSIBLE CAUSE REMEDY
A. AC indicator not lit.
B.AC indicator lit. TEMP
indicator red
1.Input power not properly
connected to input panel
2.Input power selection does
not correspond to actual
input voltage
3.Input fuse blown
4.Faulty LDD PC board*
1.Unit is overheated
2. Fan not running (or
airflow obstructed)
1.Check that input power is
present and properly
connected (see Electrical
Connections, page 20)
2.Check actual line voltage
vs. voltage selection on
rear panel (see Electrical
Connections, page 20)
3.Check fuse on inside of
rear panel. If blown,
doublecheck voltage
selection and replace fuse.
If fuse blows again, return
unit to a service station
4.Check and replace if
necessary (see Service
Procedures, page 66)
1.Make sure the unit has not
been operated beyond 70%
duty cycle limit
2.Check for obstructed air
flow (see Service Procedures, page 67)
3.Faulty LDD board*
C. AC indicator lit, TEMP
indicator green, PIP
indicator not lit
Manual 0-2470 59 CUSTOMER/OPERATOR SERVICE
1.Torch not properly connected to power supply
2.Shield cup not properly
installed on torch
3.Faulty PIP assembly in
torch holder
4.Faulty pins inside torch
quick disconnect
3.Check and replace if
necessary (see Service
Procedures, page 66)
1.Check that quick disconnect is properly attached
2.Check that shield cup is
fully seated against torch
head (do not overtighten)
3.Check PIP assembly (see
Servicing Torch Head
Components, page 44)
4.Check for continuity
between pins 1 and 6.
Check that pins in either
half of quick disconnect
are not pushed back. See
Figure 5-H (page 55)
5.07 POWER SUPPLY TROUBLESHOOTING (continued)
SYMPTOM POSSIBLE CAUSE REMEDY
C. (continued)
D.AC indicator lit, TEMP
indicator green, PIP
indicator lit, GAS indicator
not lit
E.When power is applied to
unit, GAS indicator
remains lit for more than
20 seconds
5.Faulty LDD board*
1.Gas not connected or
pressure too low
2.Faulty pressure switch*
3.Faulty regulator*
4.Faulty LDD board*
1.RUN/SET switch in SET
position
2.Faulty LDD board*
3.Faulty solenoid*
5.Check and replace if
necessary. See Service
Procedures (page 66)
1.Check source for at least
70 psi (4.8 BAR). In SET
position, adjust gas pressure to 70 psi
2.Check and replace if
necessary. See Service
Procedures (page 65)
3.Check and replace if
necessary. See Service
Procedures (page 65)
4.Check and replace if
necessary. See Service
Procedures (page 65)
1.Set switch to RUN position
2.Check and replace if
necessary. See Service
Procedures (page 65)
3.Check and replace if
necessary. See Service
Procedures (page 65)
F.Torch will not pilot when
torch switch is activated
CUSTOMER/OPERATOR SERVICE 60 Manual 0-2470
1.Switch activated during 20
second pre-flow
2.Faulty torch parts
3.Gas pressure too high
4.Faulty high frequency
trigger circuit*
1.Release switch and wait at
least 20 seconds before
activating switch again
2.Inspect torch parts and
replace if necessary (see
Replacing Consumable
Torch Parts, page 44)
3.Set pressure to 70 psi (4.8
BAR)
4.Check spark gap assembly
(see Service Procedures,
page 65)
5.07 POWER SUPPLY TROUBLESHOOTING (continued)
SYMPTOM POSSIBLE CAUSE REMEDY
G.DC indicator not lit when
torch switch is activated
H.Torch pilots but does not
cut
I.Torch cuts but not ad-
equately
1.Switch activated during 20
second pre-flow
2.DC output not present*
1.Torch too far from
workpiece
2.Work lead not connected
3.Power supply not sensing
transfer current*
1.Current set too low
2.Torch is being moved too
fast across workpiece
3.Excessive oil or moisture
in torch
1.Release switch and wait at
least 20 seconds before
activating switch again
2.Check DC output (see
Section 5.08, page 68)
1.Hold torch 1/8 inch (3
mm) from workpiece
2.Make sure work lead is
connected securely (check
continuity if necessary)
3.Check D23 indicator on
LDD board. If not lit, send
unit to an authorized
service center
1.Increase current setting
2.Reduce cutting speed (see
Cutting Speeds, page 40)
3.Hold torch 1/8 inch (3
mm) from clean surface
while purging and observe
oil or moisture buildup
(do not activate torch)
Manual 0-2470 61 CUSTOMER/OPERATOR SERVICE
5.08 SERVICE PROCEDURES
This section explains how to remove and replace any of the
replaceable subassemblies listed in the Troubleshooting Guide.
WARNING
Opening the Enclosure
Main Transformer (T3)
Disconnect primary power to the system before disassembling
the torch, leads, or power supply.
There are eight mounting screws with nuts which secure the
enclosure. Lay the power supply on its side with the mounting
screw heads facing up. Remove the mounting screws and carefully lift the upper enclosure half from the chassis.
The only reason the main transformer should be replaced is if the
cores are cracked due to shipping damage or the unit being
dropped. Minor chips are normal. If any burning or arcing is
visible on the main transformer, return the unit to an authorized
service center.
To remove the transformer:
1. Remove the two mounting nuts on the FET board and the
four mounting nuts on the pilot board which fasten the
transformer leads to the PC boards.
2. Remove current sensor plugs from pilot and LDD PC boards.
3. Remove the four screws which hold the mounting plate to the
bottom chassis.
4. Carefully remove the transformer from the unit.
5. Install the replacement transformer by reversing the above
procedure. While tightening the nuts on the leads, make sure
the leads do not twist so that one could short against another.
CUSTOMER/OPERATOR SERVICE 62 Manual 0-2470
5.08 SERVICE PROCEDURES (continued)
Pilot Inductor (L4)
The only reason the pilot inductor should be replaced is if the
cores are cracked due to shipping damage or the unit being
dropped. Minor chips are normal. If any burning or arcing is
visible on the pilot inductor, return the unit to an authorized
service center.
To remove the pilot inductor:
1. Disconnect the wire from one lead of the pilot inductor and
the connecting copper link from the other lead.
2. Turn the unit on its side to access the two mounting nuts and
lockwashers which attach it to the chassis. Remove the
inductor from the unit.
3. Install the replacement inductor by reversing the above
procedure. To avoid damaging the core of the replacement
inductor, do not force it into place.
Fan Assembly
Work Lead Inductor (L7)
HF Core Inductor (L5)
Regulator/Solenoid/
Gauge Assembly
Inductor Assembly (L6)
Main Transformer (T3)
Pilot Inductor (L4)
High Frequency Transformer (T2)
Spark Gap Assembly
A-00762
Figure 5-I Base Panel Component Locations
Fuse 1FU
Auxiliary Transformer (T1)
Manual 0-2470 63 CUSTOMER/OPERATOR SERVICE
5.08 SERVICE PROCEDURES (continued)
Work Lead Inductor (L7)
Main Output Inductor
(L6)
Auxiliary Transformer
(T1)
The work lead inductor has a core of steel laminations and
should never need replacing. If any burning or arcing is visible
on the work lead inductor, return the unit to an authorized
service center.
The only reason the main output choke should be replaced is if
the cores are cracked due to shipping damage or the unit being
dropped. Minor chips are normal. If any burning or arcing is
visible on the pilot inductor, return the unit to an authorized
service center.
To remove the main output choke :
1. Remove the hardware which connects the lead wire on one
terminal and the copper link on the other terminal.
2. Turn the unit on its side and remove the two mounting nuts
and lockwashers which secure the main output choke to the
bottom chassis. Remove the component from the unit.
3. Install the replacement main output choke by reattaching the
mounting and terminal hardware.
To replace the auxiliary transformer:
1. Disconnect the single pin connector on the white wire coming
from the auxiliary transformer.
2. Using a pin removal tool, remove the pins from connectors
J14-A, J14-B, and J14-C on the voltage selection panel.
3. Disconnect the secondary wires by unplugging the J15
connector from the auxiliary transformer.
4. Removing the four mounting screws and washers and remove the auxiliary transformer from the unit.
5. Install the replacement transformer on the bottom chassis
panel. Reattach the J15 connector. Connect the brown wire to
the top connector on the voltage selection panel, connect the
orange wire to the middle connector, and connect the black
wire to the lower connector. Connect the white wire to the
free hanging single pin connector.
CUSTOMER/OPERATOR SERVICE 64 Manual 0-2470
5.08 SERVICE PROCEDURES (continued)
High Frequency
Transformer (T2)
Spark Gap Assembly
HF Inductor (L5)
To replace the high frequency transformer:
1. Disconnect the two high voltage leads from the spark gap
assembly.
2. Unplug the J18 connector.
3. Remove the four mounting screws.
4. Install the replacement HF transformer on the bottom chassis.
Plug in the J18 connector and replace the high voltage leads
to the spark gap assembly.
To replace the spark gap assembly:
1. Disconnect wires and remove the two mounting screws.
Remove the spark gap assembly from the unit.
2. Install the replacement spark gap assembly.
3. Connect the wiring.
4. With a feeler gauge, check the gap between the two electrodes. The gap should be .035 inches. Adjust if necessary and
tighten set screws.
There should be no reason to replace the HF inductor unless it
somehow gets bent so it interferes with other components or the
chassis. To replace the HF inductor:
Solenoid/Regulator/
Switch/Gauge Assembly
1. Disconnect the HF inductor from the spark gap assembly and
the torch connecting lug. Keep it away from other components and sheet metal as it has very high voltages on it, and it
can emit electrical interference into critical circuitry.
2. Install a replacement HF inductor and connect.
To check the solenoid, measure for 115 VAC between wires 18
and 21. If 115 VAC is present, replace the solenoid:
1. Disconnect the two connecting hoses by pushing the slip ring
at the end of each quick disconnect fitting toward the fitting
and holding while pulling on the hose.
2. Disconnect the four wires from the pressure switch and
solenoid.
3. If present, remove the two mounting screws through the front
panel and the regulator nut and remove the assembly.
4. Install a new assembly on the front panel and reattach the
hoses by pushing the hose into the fitting until it stops (about
3/8 inch penetration). Secure nut on the regulator with gauge
properly located in flanged hole.
5. Reconnect the wires to the pressure switch and solenoid.
Manual 0-2470 65 CUSTOMER/OPERATOR SERVICE
5.08 SERVICE PROCEDURES (continued)
Checking the
LDD Board
Replacing the
LDD Board
To check the Log/Gate Drive/Display (LDD) PC board assembly,
measure for 15-18 VAC from J1-9 to J1-7 and from J1-9 to J1-6. If
15-18 VAC is not present, replace the LDD board.
Since the LDD board contains no high power circuitry, but does
contain all the controlling logic for the unit, many problems could
be caused by a faulty board. Never replace the LDD board to try
to fix a problem if there is any evidence of burning or arcing
anywhere in the unit. When disconnecting or connecting any of
the connectors from the board, support the board under the
connector to keep from putting too much stress on the board.
To replace the LDD board assembly:
1. Disconnect Jl, J2, J4, J5, and J16 from the LDD board, gently
folding back the harness and ribbon cables out of the way.
2. Remove the mounting screw near the middle of the board.
3. With a small screwdriver loosen the locking screw in the
current adjust knob and remove the knob.
4. Gently squeeze the top of the two rear plastic mounting
standoffs to release the board. Lift the rear end of the board
just enough to clear the locking tabs.
5. Squeeze the tops of the two front standoffs and lift the board
enough to clear the locking tabs. By lifting the rear of the
board, gently remove it, taking care not to get it caught on the
front panel holes for the switches or current control pot.
6. Install new board by tipping the front end of the board down
and putting the switches, LED and current control pot
through the front panel openings, and moving the board until
the two front mounting holes are over the standoffs.
7. Lower the board onto the four standoffs and screw in the
board mounting screw.
8. Reconnect J1, J2, J4, J5, and J16. The connectors all go in one
way only except Jl. Make sure J1 is connected so both ends of
the cable half of the connector line up with the ends of the
board mounted connector.
9. Turn the shaft of the pot all the way clockwise and reattach
the knob by tightening the screw with the line on the knob at
the straight down position.
CUSTOMER/OPERATOR SERVICE 66 Manual 0-2470
5.08 SERVICE PROCEDURES (continued)
Fan Assembly
The fan assembly consists of a rotary fan, an attached spacer
plate, and a foam seal. To replace the fan assembly:
1. Remove the LDD board to expose the top panel.
2. Remove the two nuts which hold the input connection block
from the top panel. Move the input block and its mounting
panel up out of the way.
3. Remove the four nuts which hold the top panel to the front
and rear panel and lift the top panel to allow the fan assembly
to be removed by lifting it out.
4. Remove the old fan by removing the two wires from the fan
terminals and removing the four mounting screws from the
rear panel. A small socket wrench or needlenose pliers may
be necessary to hold the nuts while removing the screws.
5. Replace with a new fan assembly. Slide the assembly in
gently so that the foam seal doesn’t catch and seals tightly
against the heatsinks.
6. Place the fan guard on the outside of the unit and reinstall the
four fan mounting screws and nuts.
7. Connect the two wires back onto the fan terminals (polarity
doesn’t matter).
8. Put the top panel onto its mounting studs and make sure the
studs on the bottom of the panel enter the holes in the top of
the heatsinks. Some slight wiggling of the heatsinks may help
this alignment. Tighten the panel mounting nuts to just short
of fully tight and measure the distance between the middle
and top panels. Move the panel slightly until this distance is
4 1/16 inches from the top of the middle panel to the top of
the top panel. Tighten the mounting screws the rest of the
way. Check this measurement again, because if it is off, you
will have difficulty reassembling the enclosure.
9. Install the LDD board and remount the input block to the top
panel.
Manual 0-2470 67 CUSTOMER/OPERATOR SERVICE
5.08 SERVICE PROCEDURES (continued)
DC Output Check
Reassembling the
Enclosure
Disconnect the primary coil (J18 ) of the HF transformer and
check for approximately 300VDC on the output connector to the
torch (positive and negative). If 300VDC is present, check torch
and leads for open. If not, then send unit to an authorized service
station.
Before reassembling the power supply enclosure, check that all
wire harnesses and ribbon cables fit into the notches in the edge
of the top and middle panels so that wires don’t get pinched.
1. With the unit in an upright position, tip the unit so that one of
the case halves may be slid onto the chassis. Then lift the unit
and set it down on the side with the case half down.
2. Before installing the other case half, make sure the edges of
the bottom, middle, and top chassis panels are fully inserted
into the slots in the case. Look for gaps between the front and
rear panels and the edge of the case, and look into the case to
see that the notches in the top corners of the front and rear
panels are flush against the plastic stops of the case. It may
take some lifting and re-settling of the chassis to get this all
lined up.
3. Once the chassis is properly aligned in one case half, gently
lower the other half onto the other side of the chassis by
tipping it slightly so that the top is slightly lower than the
bottom. Then push and gently tap down until the two case
halves are within l/16 inch. (If you have trouble getting the
case halves close enough, remove the top half and check to
see that the bottom half is fully engaged and that there are no
wires out of place on the top and middle panels.
4. Install the eight screws, lockwashers and nuts to finish the
assembly.
CUSTOMER/OPERATOR SERVICE 68 Manual 0-2470
SECTION 6: PARTS LIST
6.01 ORDERING INFORMATION
Parts listed without item numbers are not shown, but may be
ordered by the catalog number shown.
Order replacement parts by catalog number and complete description of the part or assembly, as listed in the description
column of the Parts List. Also include the model and serial
number of the torch. Address all inquiries to your authorized
Thermal Dynamics distributor.
If a Thermal Dynamics product must be returned for service,
contact your Thermal Dymanics distributor. Materials returned
to Thermal Dynamics without proper authorization will not be
accepted.
Manual 0-2470 69 P ARTS LIST
6.02 SYSTEM COMPONENTS AND ACCESSORIES
Qty. Catalog Description
Number
Complete systems include power supply with 230V primary power cable, work lead, PCH/M-35
torch with leads, and torch spare parts kit. Machine torch systems include metal mounting tube
and pinion assembly and remote pendant control with ON/OFF switch:
1 1-6249 Pak Master 50 with PCH-35 70° Torch and 12.5 ft (3.8 m) Leads
1 1-6250 Pak Master 50 with PCH-35 70° Torch and 25 ft (7.6 m) Leads
1 1-6251 Pak Master 50 with PCH-35 70° Torch and 50 ft (15.2 m) Leads
1 1-6252 Pak Master 50 with PCH-35 90° Torch and 12.5 ft (3.8 m) Leads
1 1-6253 Pak Master 50 with PCH-35 90° Torch and 25 ft (7.6 m) Leads
1 1-6254 Pak Master 50 with PCH-35 90° Torch and 50 ft (15.2 m) Leads
1 1-6255 Pak Master 50 with PCM-35 Machine Torch and 12.5 ft (3.8 m) Leads
1 1-6256 Pak Master 50 with PCM-35 Machine Torch and 25 ft (7.6 m) Leads
1 1-6257 Pak Master 50 with PCM-35 Machine Torch and 50 ft (15.2 m) Leads
Complete 575V Systems Only:
Complete 575V systems include power supply with work lead, 575 VAC transformer assembly,
PCH/M-35 torch with leads, and torch spare parts kit. Machine torch systems include metal
mounting tube and pinion assembly and remote pendant control with ON/OFF switch:
1 1-6260 Pak Master 50(575V) with PCH-35 70° Torch and 12.5 ft Leads
1 1-6261 Pak Master 50(575V) with PCH-35 70° Torch and 25 ft Leads
1 1-6262 Pak Master 50(575V) with PCH-35 70° Torch and 50 ft Leads
1 1-6263 Pak Master 50(575V) with PCH-35 90° Torch and 12.5 ft Leads
1 1-6264 Pak Master 50(575V) with PCH-35 90° Torch and 25 ft Leads
1 1-6265 Pak Master 50(575V) with PCH-35 90° Torch and 50 ft Leads
1 1-6266 Pak Master 50(575V) with PCM-35 Machine Torch and 12.5 ft Leads
1 1-6267 Pak Master 50(575V) with PCM-35 Machine Torch and 25 ft Leads
1 1-6268 Pak Master 50(575V) with PCM-35 Machine Torch and 50 ft Leads
PARTS LIST 70 Manual0-2470
6.03 FRONT PANEL COMPONENTS
Item Qty. Catalog Description Reference
No. Number Designator
1 1 9-6236 Front Panel
2 1 9-6207 Regulator/Solenoid Assembly (see page 62)
1 9-5834 Quick Disconnect Replacement Kit - Includes Items 3-6:
3 1 Quick Disconnect Body
4 1 Quick Disconnect Retaining Ring Clip
5 1 Quick Disconnect Body Wave Spring Washer
6 2 9-4488 Socket Retaining Ring Clip
7 1 9-6237 RF Filter PC Board Assembly PCB
8 1 9-6221 Socket Assembly - Plasma
9 1 8-6332 Socket Assembly - Secondary
10 2 8-7071 Hole Plug - 1/4
11 2 9-6240 Bumper, Locking Tab, Signal Connector
12 1 8-4249 Strain Relief (Work Cable)
13 1 8-4247 Work Cable with Clamp - 10 ft
1 8-5560 Work Cable Clamp
1 8-4243 Ground Tag (Not Shown)
5
9
4
11
1
8
3
6
2
10
12
13
2
7
A-00763
Manual 0-2470 71 P ARTS LIST
6.04 REGULATOR/SOLENOID ASSEMBLY
Item Qty. Catalog Description Reference
No. Number Designator
1 9-6207 Regulator/Solenoid Assembly - Includes:
1 1 8-4382 Regulator
2 1 8-3370 Solenoid Valve, 1/8 NPT SOL
3 1 8-5533 Pressure Switch, 42 psi PS
4 1 8-0354 Fitting - 1/8 NPT Close Nipple
5 1 8-3369 Reducer Bushing
6 1 9-6220 Gauge - 0-100 PSI/BAR
7 1 9-6230 Fitting - 1/4 NPT x 3/8 Tube, Straight
8 1 9-2023 Fitting - 1/4 - 1/8 NPT Reducer
6
5
1
1
8
4
7
3
A-00764
2
5
PARTS LIST 72 Manual0-2470
6.05 BASE PANEL COMPONENTS
Item Qty. Catalog Description Reference
No. Number Designator
1 1 8-2192 Auxiliary Transformer - IEC Models T1
2 1 9-6202 Work Lead Inductor L7
3 1 9-6203 Output Inductor Assembly L6
4 1 9-5528 High Frequency Transformer Assembly T2
5 1 9-6205 Spark Gap Assembly
6 1 9-6229 Single Circuit Receptacle
7 1 9-6200 Main Transformer T3
8 1 9-6201 Pilot Inductor Assembly L4
9 1 9-6213 Base Panel
10 2 9-3133 Fiber Washer
11 1 9-6214 Resistor - 10 ohm, 12 watt R
12 1 8-4243 Ground Tag
13 1 8-4281 Male Adaptor
14 1 9-5770 Disc Capacitor C
15 1 9-6239 Bracket, Inductor Lead Connection
16 1 9-6203 HF Inductor Coil
2
10 11
A-00774
8
3
9
7
12
6
1
4
16
15
14
13
5
Manual 0-2470 73 P ARTS LIST
6.06 CHASSIS COMPONENTS
-Item Qty. Catalog Description
No. Number
1 1 9-6241 Input Voltage Connection Panel
2 1 9-6242 Terminal Block
3 1 9-6217 Pilot PC Board/Heatsink Assembly
4 1 9-6243 Insulator - Input Voltage Block
5 1 9-4146 Current Control Knob
6 1 9-6215 FET PC Board/Heatsink Assembly
7 1 9-6244 Dust Shield - Pilot PC Board
8 1 9-6245 Dust Shield - FET PC Board
9 1 9-6208 LDD (Log/Gate Drive/Display) PC Board Assembly
10 1 9-6224 Middle Chassis Panel
11 2 9-6225 Resistor, 50 ohm, 50 watt
12 2 9-6226 Resistor, 6k ohm, 50 watt
13 8 9-6227 Resistor Mounting Clip
14 1 9-6222 Top Chassis Panel
15 4 9-6223 PC Board Support
16 1 8-4243 Ground Tag
17 1 9-6276 Input OVP Board
The following parts sre not shown:
4 8-0381 Rubber Feet
1 9-6248 Ribbon Cable Assembly - 34 Circuit
1 9-6249 Ribbon Cable Assembly - Dual 10-20 Circuit
1 9-6250 Access Panel - Input Voltage Connection
1 9-6251 Access Panel - Voltage Changeover
1 9-6252 Vinyl Cap - Torch Quick Disconnect
1 9-6253 Voltage Tag
2 9-6254 Upper Side Panel Overlay “Pak Master 50”
2 9-6255 Lower Side Panel Overlay “TDC”
1 9-6256 Input Power Connection Label
1 8-3216 USA Label
1 8-5544 Warning Label
2 9-6257 Enclosure Half
1 8-4384 Input Power Cable Assembly, 220V
PARTS LIST 74 Manual0-2470
2
1
8
16
15
13
14
6
3
5
10
9
7
12
11
A-00775
Manual 0-2470 75 P ARTS LIST
6.07 REAR PANEL COMPONENTS
Item Qty. Catalog Description
No. Number
1 1 9-6228 Rear Panel
2 1 9-6209 Fan Assembly
3 3 9-6229 Single Circuit Receptacle
4 1 9-6230 Fitting - 1/4 NPT x 3/8 Tube
5 1 8-4289 Flex Connector
6 1 8-4251 Finger Guard
7 2 9-6231 Nine Circuit Receptacle
8 1 9-3861 Fuse - 2 amp, 600V
9 3 Retaining Ring (.300 inch I.D.)
10 1 9-5562 Fuse Holder (IEC Internal Style Only)
11 1 9-6232 Adaptor - Inert B to 1/4 NPT Female
12 1 9-6233 Retaining Ring (.75 inch I.D.)
13 1 9-6234 Hole Plug
14 1 8-6214 Amber Lamp
15 1 9-6247 Adaptor - Rear Panel Fitting
16 1 9-6235 Fan/Heatsink Gasket
The follwing part is not shown:
1 8-4243 Label, Ground
16
2
(5)
5
13
10
14
4
8
6
3
7
11
9
15
12
1
A-00776
PARTS LIST 76 Manual0-2470
6.08 REPLACEMENT TORCHES AND LEADS
Qty. Catalog Description
Number
Replacement Hand Torches with Leads and Spare Parts Kit:
1 2-6001 PCH-35 70° Hand Torch, 12.5 ft (3.8 m) Leads, Spare Parts Kit
1 2-6002 PCH-35 70° Hand Torch, 25 ft (7.6 m) Leads, Spare Parts Kit
1 2-6003 PCH-35 70° Hand Torch, 50 ft (15.2 m) Leads, Spare Parts Kit
1 2-6004 PCH-35 90° Hand Torch, 12.5 ft (3.8 m) Leads, Spare Parts Kit
1 2-6005 PCH-35 90° Hand Torch, 25 ft (7.6 m) Leads, Spare Parts Kit
1 2-6006 PCH-35 90° Hand Torch, 50 ft (15.2 m) Leads, Spare Parts Kit
Replacement Machine Torches with Leads, Mounting Assembly, and Spare Parts Kit
1 2-6083 PCM-35 Machine Torch, 12.5 ft (3.8 m) Leads, Spare Parts Kit
1 2-6084 PCM-35 Machine Torch, 25 ft (7.6 m) Leads, Spare Parts Kit
1 2-6085 PCM-35 Machine Torch, 50 ft (15.2 m) Leads, Spare Parts Kit
Replacement Machine Torches with Leads, Phenolic Mtg Tube w/Pinch Block, Spare Parts Kit:
1 2-6007 PCM-35 Machine Torch, 12.5 ft (3.8 m) Leads, Spare Parts Kit
1 2-6008 PCM-35 Machine Torch, 25 ft (7.6 m) Leads, Spare Parts Kit
1 2-6009 PCM-35 Machine Torch, 50 ft (15.2 m) Leads, Spare Parts Kit
Replacement Torches with Leads Only:
1 2-6052 PCH-35 70° Hand Torch, 12.5 ft (3.8 m) Leads
1 2-6053 PCH-35 70° Hand Torch, 25 ft (7.6 m) Leads
1 2-6054 PCH-35 70° Hand Torch, 50 ft (15.2 m) Leads
1 2-6055 PCH-35 90° Hand Torch, 12.5 ft (3.8 m) Leads
1 2-6056 PCH-35 90° Hand Torch, 25 ft (7.6 m) Leads
1 2-6057 PCH-35 90° Hand Torch, 50 ft (15.2 m) Leads
1 2-6100 PCM-35 Machine Torch, Metal Mtg. Assy, 12.5 ft (3.8 m) Leads
1 2-6101 PCM-35 Machine Torch, Metal Mtg. Assy, 25 ft (7.6 m) Leads
1 2-6102 PCM-35 Machine Torch, Metal Mtg. Assy, 50 ft (15.2 m) Leads
1 2-6058 PCM-35 Machine Torch, Pinch Block Assy, 12.5 ft (3.8 m) Leads
1 2-6059 PCM-35 Machine Torch, Pinch Block Assy, 25 ft (7.6 m) Leads
1 2-6060 PCM-35 Machine Torch, Pinch Block Assy, 50 ft (15.2 m) Leads
Replacement Torch Leads with Quick Disconnect Assembly:
1 4-6023 Replacement Leads - 12.5 ft (3.8 m)
1 4-6024 Replacement Leads - 25 ft (7.6 m)
1 4-6025 Replacement Leads - 50 ft (15.2 m)
Replacement Torch Leads without Quick Disconnect Assembly:
1 4-6033 Replacement Leads - 12.5 ft (3.8 m)
1 4-6034 Replacement Leads - 25 ft (7.6 m)
1 4-6035 Replacement Leads - 50 ft (15.2 m)
Manual 0-2470 77 P ARTS LIST
5.9 TORCH HEADS AND SPLIT HOLDERS
Item Qty. Catalog Description
No. Number
1 1 9-5807 Basic Internal Head - PCH-35 70° Hand Torch
2 1 9-5808 Basic Internal Head - PCH-35 90° Hand Torch
3 1 9-5809 Basic Internal Head - PCM-35 Machine Torch
4 1 9-6259 Split Holder (Two Parts) - PCH-35 70° Hand Torch
1 9-5856 Split Holder (Two Parts) with PIP Parts - PCH-35 70° Hand Torch
5 1 9-6260 Split Holder (Two Parts) - PCH-35 90° Hand Torch
1 9-5857 Split Holder (Two Parts) with PIP Parts - PCH-35 90° Hand Torch
6 1 9-6261 Split Holder (Two Parts) - PCM-35 Machine Torch
1 9-5858 Split Holder (Two Parts) with PIP Parts - PCM-35 Machine Torch
7 1 9-6103 PIP Pin Wire Assembly
8 2 8-0533 O-Ring
4
8
12
6
7
5
8
3
PARTS LIST 78 Manual0-2470
8
5.10 CONSUMABLE TORCH PARTS
Qty. Catalog Description
Number
1 9-6003 Standard Shield Cup (For Standoff Cutting)
1 9-6004 Shield Cup Standoff Attachment (for Drag Cutting)
1 9-6000 Tip - Standoff Cutting
1 9-6001 Tip - Drag Cutting
1 9-6120 Tip - Drag Cutting (Heavy Duty)
1 9-6002 Tip - Gouging
1 9-6006 Electrode
1 9-6007 Gas Distributor
MaximumLife™ Parts
1 9-6503 MaximimLife™ Shield Cup Attachment (Install Over Standard Cup)
1 9-6500 MaximimLife™ Standoff Cutting Tip
1 9-6501 MaximimLife™ Drag Cutting Tip
1 9-6506 MaximimLife™ Electrode
1 9-6507 MaximimLife™ Gas Distributor
Standard Shield Cup
Catalog No. 9-6003
Standoff Cutting Tip
(.031 in)
Catalog No. 9-6000
Heavy Duty Drag Tip
(.036 in)
Catalog No. 9-6120
Electrode
Catalog No. 9-6006
Crown Shield Cup
Catalog No. 9-6004
Drag Cutting Tip
(.031 in)
Catalog No. 9-6001
Gouging Tip
(.046)
Catalog No. 9-6002
Gas Distributor
Catalog No. 9-6007
A-00017
CAUTION
Do not use MaximimLife™ parts (Tips, Gas
Distributor or Electrode) with standard parts.
Shield cup attachment (No. 9-6503) must be
installed over the standard shield cup.
Shield Cup
Catalog No. 9-6503
Standoff
Cutting Tip (.031 in)
Catalog No. 9-6500
Electrode
Catalog No. 9-6506
Cutting Tip (.031 in)
Drag
Catalog No. 9-6501
Gas Distributor
Catalog No. 9-6507
A-00318
Manual 0-2470 79 P ARTS LIST
6.11 TORCH OPTIONS AND ACCESSORIES
Item Qty. Catalog Description
No. Number
1 7-3247 PCH-35 Cutting Guide Kit
1 4-6007 Leads Extension Kit - PCH-35 Hand Torch - 25 ft (7.6 m)
1 4-6008 Leads Extension Kit - PCH-35 Hand Torch - 50 ft (15.2 m)
1 4-6009 Leads Extension Kit - PCM-35 Machine Torch - 25 ft (7.6 m)
1 4-6010 Leads Extension Kit - PCM-35 Machine Torch - 50 ft (15.2 m)
1 1 8-4305 Torch Handle
2 1 8-4304 Torch Handle Boot
3 1 8-4303 Switch Track Closure
4 1 8-4302 Switch Track Insert
5 1 8-4301 Switch Assembly
1 8-5170 Switch Lever Kit - Includes items
6 1 Switch Lever
7 2 Switch Lever Mounting Bracket
1 8-5172 PCH-35 Handle Extension Kit
1 7-3253 Machine Torch Mounting Tube Kit (Metal) - Includes:
8 1 8-4306 Adaptor Tube
9 1 7-3207 Metal Mounting Tube (includes Item 10)
10 1 8-4204 End Cap (Bushing)
11 1 8-4018 Retaining Nut
12 1 7-2827 Pinion Assembly
13 1 7-3291 Circle Cutting Attachment
PARTS LIST 80 Manual0-2470
6
5
7
3
4
2
10
1
12
9
11
8
13
Manual 0-2470 81 P ARTS LIST
6.12 TORCH SPARE PARTS KITS
Qty. Catalog Description
Number
5-6028 Spare Parts Kit - PCH/M-35 MaximimLife™ - Includes:
1 9-6503 MaximimLife™ Shield Cup Attachment (Install Over Standard Cup)
10 9-6500 MaximimLife™ Standoff Cutting Tip
10 9-6501 MaximimLife™ Drag Cutting Tip
15 9-6506 MaximimLife™ Electrode
2 9-6507 MaximimLife™ Gas Distributor
5-6015 Spare Parts Kit - PCH/M-35 Gouging - Includes:
2 9-6003 Shield Cup - Standard
6 9-6002 Tip - Gouging
5 9-6006 Electrode
2 9-6007 Gas Distributor
5-6021 Spare Parts Kit - PCH/M-35 Drag Cutting - Includes:
1 9-6004 Crown Cup Attachment
10 9-6000 Tip - Standoff Cutting
10 9-6001 Tip - Drag Cutting
10 9-6120 Tip - Drag Cutting (Heavy Duty)
15 9-6006 Electrode
2 9-6007 Gas Distributor
PARTS LIST 82 Manual0-2470
This Page Left Blank
Manual 0-2470 83 APPENDIX
APPENDIX I: SYSTEM SCHEMATIC
A-00804
APPENDIX 84 Manual 0-2470
A-00804
Manual 0-2470 85 APPENDIX
APPENDIX 86 Manual 0-2470
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