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PakMaster XL PLUS

Series
PLUS the new SureLok

Torch!
New SureLok Torch
Technology
New SureLok

Electrode
Design
Ergonomic Torch Handle
PakMaster

50XL PLUS
GENUINE CUT
1
2 (12.7mm)
SEVERANCE CUT
3
4 (19.1mm)
PakMaster

100XL PLUS
GENUINE CUT 1 (25.4mm)
SEVERANCE CUT 1
1
4 (31.8mm)
PakMaster

75XL PLUS
GENUINE CUT
3
4 (19.1mm)
SEVERANCE CUT 1 (25.4mm)
PAK

MASTER XL PLUS
3
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Air Plasma Cutting
Systems
Over 40 Years of Plasma Cutting Innovation
PLASMA CUTTING SERIES
PAK

MASTER XL PLUS
2 THERMAL DYNAMICS w w w . t h e r m a l - d y n a m i c s . c o m T h e r m a l D y n a m i c s C o r p . , 2 0 0 0
SURELOK TORCH
SureLoktorch technology is an innovation in plasma torch
design. Our patented electrode locking mechanism results in
precise tip and electrode positioning and more efficient oper-
ation, resulting in improved consumable life. The electrode is
also easier to install, with no tools required.
SMART LOGIC
This circuit prevents damage to the unit should it be connect-
ed to high line voltage while it is linked for low voltage.
SMART START AUTO PILOT RESTART
Instantly reignites the pilot arc when the cutting arc is inter-
rupted, such as when cutting expanded metal. This feature
keeps the arc on when cutting over holes or moving from
one cut to another without having to restart the torch, an
important feature for maintaining productivity.
TIP SAVER CURRENT FOLD BACK CIRCUIT
Accidental contact between tip and material while cutting
or gouging at higher output levels can be expensive with
some competitive systems. Our Tip Saver
circuit protects consumable parts and
eliminates down time by reducing the
cutting current while the tip is in contact
with the material, saving time and money.
TRIGGER LATCH
Prevents hand fatigue during long cuts by
allowing the torch switch to be released
after the cutting arc is established. The arc
will remain on until the cutting arc is bro-
ken at the edge of the metal or if the torch
is lifted away from the work piece. This feature can be de-
selected by the front panel switch for automated applications
or hand applications where the operator needs to be able to
stop the arc by release of the torch switch.
UNIVERSAL INPUT POWER
By a simple change over procedure and use of the appropriate
input cable/plug, the units can accept input power from 208 to
460 VAC 10%, single or three phase, 50 or 60 hertz. An
optional transformer is available for use on 575 VAC.
IP-23C PROTECTION CERTIFIED
Thermal Dynamics

uses this test to check the units abili-


ty to perform in difficult conditions. Where other manu-
facturers use a simple water drip test, Thermal Dynamics
uses a high pressure spray test to check the units ability to
stand up to outdoor weather.
FLOW THROUGH COOLING DESIGN
All of the semi-conductor devices are mounted on a
heatsink. The cooling air is channeled through the fins on
the opposite side of the heatsink so that dirty environmen-
tal air does not flow directly over the switching devices.
This helps to prevent build up of foreign material which
could otherwise limit duty cycle or component life.
CSA NRTL/C APPROVED
The Canadian Standards Association is recognized world-
wide as a premier testing laboratory. Thermal Dynamics is
proud to comply with the rigorous
standards of CSA 22.2 No. 60 for
electrical equipment.
3 YEAR WARRANTY
PROTECTION
PakMaster XL PLUS units come
with excellent warranty protection
Power supply components are
warranted for 3 years; labor, torch
and leads for 1 full year.
Features and Benefits
PLASMA CUTTING SERIES
PAK

MASTER XL PLUS
3
The SureLok

Advantage
Thermal Dynamics

SureLok torch technology is used throughout the


PakMaster XL PLUS family. SureLok torches and consumable parts offer
important advantages for hand or mechanized plasma cutting.
Tapered shield cup and small torch head Allow excel-
lent control when beveling and gouging. SureLoks size,
shape and long arc also make PakMaster XL PLUS an
excellent tool for cutting and gouging in tight spaces
where other torches will not fit
Long arc length SureLok torches produce excellent cuts
across a wide range of cutting conditions, from drag cut-
ting with the tip directly on the material, to beveling and
gouging, where the tip must be held further away from
material. SureLoks strong pilot arc and focused cutting
power produce a long arc that gives operators more flexi-
bility and control in demanding situations.
Improved cutting performance - The patented electrode
insertion design results in exact positioning of consum-
able parts, every time, with no special tools. This means
a precise, well-defined cutting arc and more precise cuts.
Improved torch cooling Means longer consumable
parts life and lower operating costs.
Extended tip For maximum visibility and optimum per-
formance in drag cutting. The extended tip provides a
clear view of the cut in stand-off or drag cutting. Drag
cutting with the tip in contact with the metal results in a
narrow kerf, helps eliminate dross and results in greater
precision on sheet metal.
Cut Quality
PakMaster XL PLUS power supplies deliver exceptionally
smooth, powerful cutting current. Combined with the fea-
tures of the SureLok torch, this makes PakMaster XL
PLUS the leader in cut quality.
Sheet Metal PakMaster XL PLUS systems excel at drag
cutting at current levels below 35 amps. The tip directly
touches the metal, resulting in clean cuts, narrow kerf and
a very small Heat Affected Zone (HAZ). This quality can-
not be achieved with torches that have a bulky shield cup
and recessed tip.
Stand-off cutting Hold the torch tip
1
8 -
3
8 inches away
from the work for cutting at higher amperage levels.
PakMaster XL PLUS systems provide a precise, well-
defined arc that results in less top edge rounding, less bevel
along the cut edge and a smoother cut surface. Our Tip
Saver fold-back circuit protects consumable parts from
damage caused by accidental contact with the work.
Gouging PakMaster XL PLUS systems can be used for
precision gouging with a simple change of consumable
parts. With adjustable current settings and the SureLok
torch features, PakMaster XL PLUS systems deliver the
power and control you need for backgouging welds, sepa-
rating welded parts or removing hardfacing metals. Our
Tip Saver fold-back circuit protects your consumable
parts life and makes the torch an easy to use gouging tool.
PakMaster 50 XL PLUS cut on 7 guage mild
steel using the optional cutting guide kit
PAK

MASTER XL PLUS
PLASMA CUTTING SERIES
4
c a l l 1-603-298-5711 f o r m o r e i n f o r m a t i o n
70 Hand Torch 90 Hand Torch 180 Machine Torch
SYSTEM 20 ft. (6.1m) 50 ft. (15.2m) 20 ft. (6.1m) 50 ft. (15.2m) 25 ft. (7.6m) 50 ft. (15.2m)
PakMaster 50XL PLUS 1-5045-V 1-5046-V 1-5047-V 1-5048-V 1-5049-V 1-5050-V
PakMaster 75XL PLUS 1-7565-V 1-7566-V 1-7567-V 1-7568-V 1-7569-V 1-7570-V
PakMaster 100XL PLUS 1-0085-V 1-0086-V 1-0087-V 1-0088-V 1-0089-V 1-0090-V
70 Hand Torch 90 Hand Torch 180 Machine Torch
20 ft. Leads 50 ft. Leads 20 ft. Leads 50 ft. Leads 25 ft. Leads 50 ft. Leads
PCH/M-62 7-6220 7-6221 7-6222 7-6223 7-6224 7-6225
PCH/M-102 7-7530-SL 7-7532-SL 7-7531-SL 7-7533-SL 7-7536-SL 7-7537-SL
System Ordering Information: The standard systems include power supply with 20 work cable and clamp, torch and
leads and spare parts kit. Machine torch systems include phenolic mounting tube and pinch block assembly. Remote
Pendant or CNC Cable are not included with systems, see Remote Options below for ordering information.
V=Voltage Suffix:1 208/230vac 1ph setting with 50 amp input cable and plug 2 460vac 3ph setting No input cable or plug
Torch & Lead Combinations (Included with Systems)
Remote Options:
Computer Control (CNC) Cable: 25 ft (7.6m) 8-5557
50 ft (15.2m) 8-5558
Hand Pendant Control with 25 ft (7.6m) Cable: 7-3114
Extension Cable 25 ft (7.6m) for Hand Pendant Control: 7-7744
Metal Mounting Tube with Pinion Assembly 7-7745
Which PakMaster XL
PLUS System Do I Need?
Several factors should be considered when selecting a
plasma system.
What is the thickest material to be cut?
Genuine cut ratings mean that the system can cut a specific
thickness of mild steel at approximately 10 inches per
minute and achieve excellent cut quality. Severance cut
rating means the system will cut this thickness of mild steel
at a slower rate with some loss in cut quality. Aluminum and
stainless steel generally require more power to cut, and cut
ratings may vary by as much as 25%.
What will I need to pierce?
Pierce ratings should be calculated at 50% of genuine
cut ratings.
How fast do I want to cut?
Operator comfort and control is the real determinant of
cut speed in hand cutting. More cutting power translates
directly to faster cutting speeds. Mechanized system
cutting speeds can be limited by the mechanized posi-
tioner capability.
What voltage input power is available?
PakMaster XL PLUS systems accept 208-460 volts, sin-
gle or 3 phase power.
XL

PLUS IN
PERFORMANCE
PLASMA CUTTING SERIES
5
c a l l 1-603-298-5711 f o r m o r e i n f o r m a t i o n
PakMaster 50XL PLUS PCH/M-62
Spare Parts Kits
Standard VIP
Cat. Number Part Description #5-6203 #5-6205
9-8407 Electrode, Maximum Life 3 25
9-8402 Electrode, General Purpose 0 0
9-8411 Tip, 40 Amp, Drag 2 20
9-8412 Tip, 40 Amp, Stand-off 5 30
9-8416 Tip, 40 Amp, Gouging 0 0
9-8401 Gas Distributor, 40 Amp 0 1
9-8400 Shield Cup, 40 Amp 0 1
8-0532 O-Ring 1 0
9-7501 Coil Spring 1 2
9-8415 Stand-off Cutting Guide 1 1
PAK

MASTER XL PLUS
PakMaster 75XL PLUS PCH/M-102 (60 Amp)
Spare Parts Kits
Standard VIP Gouging
Cat. Number Description #5-7509 #5-7510 #5-0011
9-8407 Electrode, Maximum Life 5 20 10
9-8402 Electrode, General Purpose 0 0 0
8-7503 Tip, 40 Amp, Cutting 2 10 0
9-7726 Tip, 60 Amp, Cutting 5 40 0
8-7506 Tip, Gouging 0 0 15
8-7501 Gas Distributor, Cutting 0 2 0
8-7508 Gas Distributor, Gouging 0 0 2
8-7500 Shield Cup, Cutting 0 1 2
8-0532 O-Ring 1 5 5
9-7501 Coil Spring 1 3 3
8-7575 Stand-off Cutting Guide 1 1 0
8-7507 Shield Cup, Crown 0 1 0
PakMaster 100XL PLUS PCH/M-102 (80 Amp)
Spare Parts Kits
Standard VIP Gouging
Cat. Number Description #5-0009 #5-0010 #5-0011
9-8407 Electrode, Maximum Life 5 20 10
9-8402 Electrode, General Purpose 0 0 0
8-7503 Tip, 40 Amp, Cutting 2 10 0
9-7726 Tip, 60 Amp, Cutting 0 0 0
9-7728 Tip, 80 Amp, Cutting 5 40 0
8-7506 Tip, Gouging 0 0 15
8-7501 Gas Distributor, Cutting 0 2 0
8-7508 Gas Distributor, Gouging 0 0 2
8-7500 Shield Cup, Cutting 0 1 2
8-0532 O-Ring 1 5 5
9-7501 Coil Spring 1 3 3
8-7575 Stand-off Cutting Guide 1 1 0
8-7507 Shield Cup, Crown 0 1 0
SureLok

Plasma Torches
PLASMA CUTTING SERIES
ACCESSORIES
PAKMASTER XL PLUS PRODUCT SPECIFICATIONS
PAKMASTER 50 XL PLUS PAKMASTER 75 XL PLUS PAKMASTER 100 XL PLUS
Cutting System Specification Cutting System Specification Cutting System Specification
Power Supply
Capacity:
1
2 (12.7mm) Genuine
3
4 (19.1mm) Genuine 1 (25.4mm) Genuine
3
4 (19.1mm) Severance 1 (25.4mm) Severance 1
1
4 (31.8mm) Severance
Output: 15-40 Amps - Continuously variable 15-60 Amps - Continuously variable 15-80 Amps - Continuously variable
Input Power: 208-460 VAC (+/-10%) 208-460 VAC (+/-10%) 208-460 VAC (+/-10%)
1/3 Phase, 50/60Hz 1/3 Phase, 50/60Hz 1/3 Phase, 50/60Hz
40/22 Amps 1 Phase 60/30 Amps 1 Phase 91/46 Amps 1 Phase
20/11 Amps 3 Phase 31/16 Amps 3 Phase 48/26 Amps 3 Phase
Duty cycle: 100% @ 40 Amps 65% @ 60 Amps / 100% @ 55 Amps 40% @ 80 Amps / 100% @ 60 Amps
Panel Controls: On/Off Switch On/Off Switch On/Off Switch
RUN/SET/LATCH Switch RUN/SET/LATCH Switch RUN/SET/LATCH Switch
Output Current Potentiometer Output Current Potentiometer Output Current Potentiometer
Panel Indicators: AC Power AC Power AC Power
Temperature Temperature Temperature
Gas Pressure Gas Pressure Gas Pressure
DC Output DC Output DC Output
Dimensions: Height: 16 (406mm) Height: 16 (406mm) Height: 16 (406mm)
Width: 13 (330mm) Width: 13 (330mm) Width: 13 (330mm)
Length: 24.8 (630mm) Length: 24.8 (630mm) Length: 24.8 (630mm)
Weight: 66 lbs. (29.9 Kg) 71 lbs. (32.2 Kg) 75 lbs. (34 Kg)
Work Cable Length: 20 ft (6.1m) 20 ft (6.1m) 20 ft (6.1m)
Torch
Model PCH/M-62 PCH/M-102 PCH/M-102
Gas: Air, Nitrogen Air, Nitrogen Air, Nitrogen
Gas Pressure: 70 PSI ( 4.8 Bar) 60 PSI ( 4.1 Bar) 70 PSI ( 4.8 Bar)
Gas Flow: 200 SCFH / 3.3CFM (95 lpm) 300 SCFH / 5CFM (142 lpm) 400 SCFH / 6.6CFM (190 lpm)
Pilot: CD Start/ Pulsed DC CD Start/ Pulsed DC CD Start/ Pulsed DC
Control: Hand switch Hand switch Hand switch
Remote Pendant Remote Pendant Remote Pendant
CNC Interface Cable CNC Interface Cable CNC Interface Cable
Torch Lead length:
Hand 20 ft (6.1m) 20 ft (6.1m) 20 ft (6.1m)
50 ft (15.2m) 50 ft (15.2m) 50 ft (15.2m)
Machine 25 ft (7.6m) 25 ft (7.6m) 25 ft (7.6m)
50 ft (15.2m) 50 ft (15.2m) 50 ft (15.2m)
575 Volt Power Transformer Cat. No. 9-7500
For use with XL PLUS systems that require 575 Volt 3 ph input power
Air Filter Kit
Cat. No. 7-7507
All Systems
.85 Micron
Particulate
Filter for use on
compressed shop
air systems
Cutting
Guide Kit
Cat. No. 7-8910
All Systems
Easy add-on
attachments to allow
for straight line,circle
cutting and beveling
for all XL PLUS
Systems
Cutting
Guide
Cat. No. 7-7501
All Systems
Manual circle
cutting guide,
2" to 16" circles
Smart Cart
Cat. No. 7-7777
All Systems
Rugged steel cart with
large rubber wheels
to maximize system
portability
International Customer Service Thermadyne Canada Thermadyne UK Thermadyne Asia Sdn. Bhd. Cigweld Australia
Oakville, Ontario, Canada Oakville, Ontario Canada Chorley, England Kuala Lumpur, Malaysia Melbourne, Australia
Ph: (1) 905-827-9777 Ph: (1) 905-827-1111 Ph: (44) 1257-261755 Ph: (603) 6092-2988 Ph: (61) 3-9474-7400
Fax: (1) 905-827-9797 Fax: (1) 905-827-3648 Fax: (44) 1257-224800 Fax: (603) 6092-1085 Fax: (61) 3-9474-7510
Thermadyne do Brasil Thermadyne Middle East Thermadyne de Mexico Thermadyne Japan Thermadyne Europe
Rio de Janeiro, Brazil Dubai, United Arab Emirates Mexico City, Mexico Osaka, Japan Milan, Italy
Ph: (55) 21-485-8859 Ph: (971) 4-332-9060 Ph: (52) 5696-7407 Ph: (81) 6-4809-8411 Ph: (39) 039-204-991
Fax: (55) 21-485-8735 Fax: (971) 4-332-5484 Fax: (52) 5696-7757 Fax: (81) 6-4809-8412 Fax: (39) 039-204-9922
U.S. CUSTOMER SERVICE: Industrial Park #2 West Lebanon, NH 03784
(1) 603-298-5711 FAX (1) 603-298-5720
International Offices
Form No. 63-9901 (1/01) Thermal Dynamics Corp., 2001 www.thermal-dynamics.com Printed in U.S.A.
WORLD HEADQUARTERS: 101 S. Hanley Road St. Louis, MO 63105 314-721-5573 FAX 314-746-2161

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